I just completed my Pro4896 build and having issues with CNC12 and movements. During a “slow” jog I can move the machine freely on all axis, the spindle (AV70S) will start and go to full RPM, everything moves correctly, all servo motor lights are amber at rest, all proximity sensors trigger at the appropriate flag per indicator lights.
When I switch to a “fast” jog any Y movement results in a loud “bang” and the system grinds to a halt within a few inches travel. I get a 9031 Drive Fault error.
When trying to home, same issue.
In either slow, fast, or home when the X axis moves to the left it throws the “fixed” cable track hinges apart (so far I can reconnect them) and slams into the hard stop and I have to manually push it a bit (does not disengage the rack) before I can clear the error. Movement to the right seems fine. Guessing this may just be a need more move the left sensor flag a bit, but per the indicator light the prox sensor IS triggering and it just doesn’t stop. XYZ Prox indicator on VCP is triggered.
Are you only getting a drive fault when you move Y? What about X?
If it’s only one axis then the motors are likely doing their job and throwing a fault because they are jammed somehow… Check for loose cabling as well.
If it’s all axes there’s a chance you may have selected stepper instead of servo in the motor settings…
I get the fault on any fast move on Y. With X it will fast move. Move to the right seems fine, it stops short of hitting the bumped. Move left and it’ll slam into the stops resulting in the same fault, but it will traverse the whole width of the gantry.
I sort of suspect that the Y motors are not perfectly square to one another, I’ve only tested it visually, the motors look to be about the same position. When I am back at the machine I will get under it and count teeth and measure it with my calipers. Would just a tooth or two off square cause a jam on a fast move and not a slow move over just a few inches travel?
Another observation is that I can only manually move the Y axis very slowly, more than a half inch a second or so and it’ll start to stutter and jerk as I push it, if I push too hard it’ll seize up and not move at all unless pressure is halted. An end-end manual move takes over a minute.
The VFD is new from the box, nothing in the documentation suggests it needs to be reprogramed. In fact it seems the opposite, that when purchased together they’re pre-programed?
I did re-run the wizard to verify that I was on servos.
I won’t get back in the shop until Tuesday, so no rush on this. I appreciate the quick reply on a Saturday!
It’s ok if the gantry is a little out of square. When you home it it will square itself:
It shouldn’t
This is normal.
This is correct
This points to a problem with your Y motors. Make sure they’re hooked up correctly, and to the correct motor ports. Also make sure they’re moving in the right direction (not opposite of one another)
You CAN smack them into the bumpers when moving the machine around, this is normal until the machine is homed. At that point it “knows” where it is so it will no longer allow you to hit the end stops.
If that doesn’t yield anything open up a support ticket and we can get you some help. I’m sure it’s something “simple but not obvious” and we’ll get you all sorted out.
I do all my design work in metric, so I switched units to mm. I think at some point in doing that the whole process went sideways and the math got messed up. I’ve reloaded a new profile with all the defaults and not making any changes to units, and the machine is able to home. I’ve got home, TT, and spoil board located. Now I can continue with the video I think!
If you switched to metric while leaving the wizard open this can cause a lot of problems.
If you did that the easiest thing to do is to start a new profile. Before even opening the wizard go into CNC12 and set it to metric. Then proceed with setup.
In reference to earlier response I have just completed my retrofit with servos for my pro. It went fairly smooth accept time. Below I will list issues I am having and have not been able to solve from this forum.
Z axis throws a “fault drive” when the bottom of the moving plate is coplaner with the bottom of the z axis. It also does the same thing when it fast move in the Z+ it gets about 4" inches before it abruptly stops.
The z axis squeals, and from what I read may be from the plastic couple at the top of the ballscrew. Not sure yet
Not sure if the brake is even disengaging. Just moving the spindle up and down cause the Zaxis Servo to get really hot. Not sure how to test if the brake is actually disengaging when it is powered up.
I have a Delta VFD-22EL and the changes on the instructions do match what I had when I followed the instructions. So I am not sure if that is even correctly set up. it was setting on f133 when I started I hit the enter button and got the 00 I moved the up arrow to go to 03 and enter. this is where it is different it is supposed to be 0 but my display had 3.0 not knowing what to do I hit enter and the number 8 was showing up up arrowed to 22 and enter and it saved.
I put the zerts in the z axis bearings but they are so close to the rails you cannot seat a grease coupling on it. Anyone have suggestion for this?
Lastly my x servo sounds like gears grinding when it zeros out from the hard stop it does it for about 2 seconds then backs off. It does not would good.
Currently I am stuck hopefully I can get some help I did submit a ticket but I work all week so its hard to take a support call to fix my machine when at work.
This is what I have done to troubleshoot. Checked all my connections, check machine config to ensure I had servos and the correct spindle. Removed the brake cable and tried no luck, If I had a spare cable I would try running a new cable to ensure the current on is not bad.
You should wait for support to respond, but I may be able to help you a bit here:
When you first move the Z axis you should here a metallic “ting” sound indicating that the brake has been released. If you don’t have the brake plugged in by default the brake is on. The motors have enough power to overcome the brake for a bit, but they will fault out.
Sounds like from the rest of your description that this may be the case. If this is an upgrade you may not have plugged it in?
The other thing this could be is the VFD programming:
Watch this section of the video:
(actually watch the whole video if you haven’t)
What might also be causing the fault is an improperly programmed VFD. The VFD fault line is tied in with the motor fault, so if your VFD is off (or not programmed) then it will send a fault signal to the controller. It intent here is to stop the machine should your VFD turn off or stall.
If you didn’t get the machine and controller and VFD brand new from us at once your VFD will need programming.
They should be reachable with our grease gun
I’d check the spring tension, and check for worn pinions.
Hey Eric Thanks for the response truly appreiate it.
I will have to listen more carefully for the metallic click. I did check the connections at the top of the z axis and the box which it is plugged into the Brake port. The reason I mentioned the brake possibly not disengaging is for one of the possible reasons my z axis faults out and the servo is very hot over a very short period of time.
I actually watched the video 3 times just in case I missed anyting. When I programmed my VFD which is a Delta VFD-22EL A but when I programmed it according to the Instructions I did not have the same display readings the instructions provided, But I do have something set a 22. It looks like the first step is going to the group 3 then enter. and changing the 8 (fault indicator) to 22 (AC Motor drive ready). No whether or not I got the right stuff I dont know because I had an extra display code in my set up then what was in the instructions.
The spring tension was the first thing I check on and tightened. It sould smooth as silk flying back and forth on the x axis but when it does that hard stop and keeps engaged until the other axis complete it just makes me cringe. I would think that the servo would fault out before it would strip any gears.
thanks again Eric hopefully Ill get this figured out soon. I would have upgraded my spindle but I am waiting for the AV40.
You can just bypass the spindle fault by flipping the dip switch on the servo board:
If you flip that switch off (or jumper if that’s what you have)
You can trick the control into thinking the VFD is good no matter what.. that can help rule out any VFD issues.
Are you taking about hitting the hard stop when jogging? Or homing…
If homing then it should gently hit the hard stop. When homing the motors are in a low torque mode. There never should be any grinding when homing. I suspect that’s not what’s happening as you haven’t been able to home yet?
If you’re hitting the hard stops just jogging around before homing you’re in high torque mode. and you’re potentially in a state where the fault signals from an overload are ignored.
Get your VFD situation sorted out (either fix the programming or bypass it for now) and see if that helps. If it doesn’t immediately fix things, listen for that servo brake. The sound is pretty distinct.
After hitting E stop (and releasing it) as soon as you move Z you’ll hear a distinct click.
Ok an update. I think my issue is coming from the z-axis brake. I when ahead and laced a foam block under the spindle. I unplugged the power to the z- Motor and it does not move. I cannot even push it up or down. I guess this would explain the squealing, noise from the plastic coupler as there is a lot of stress on the joint. This would also explain why the z motor gets extensively hot just moving up 8 inches on the z axis before it faults out. So now I need to know if I have an bad brake or the VFD is not programmed correctly.
Thanks for responding Eric. I received the system about March 21st. I finally got time off work to make the change. I do not hear any metallic click when I move the z axis. I do have a short recording of the sound it makes when the z-axis move sand it should like 2 wet rubber pieces rubbing together but amplified in sound. I can send the video to someone with the sound clearly heard with not metallic click. I can tell you that this sound is the same sound the x-axis makes when at the hard stop during homing. I do show my phone at the bottom of the z axis but the sound is actually being generated at the motor and you can feel the vibration if you put your hand on the motor along with the heat being generated even at such small increments. I did check the pins on the Brake port on the box and I could not register 24 volts out any of the pins. It did show less than a volt but not 24 and nothing when the estop was engaged.
Sounds like your brake isn’t disengaging. There will be no voltage on any pins UNLESS the estop is off AND the motor has been given a move command.
If you’re positive that the brake isn’t disengaging then I’d start checking the wiring, especially if you did it in the Z axis, those wires are tiny and can get pinched if you’re not careful
Unfortunately, that is what I am expecting. I did check for voltage at the port, and I also got the same reading. Just so I understand, the brake is disengaged when the system is turned on unless an estop is engaged or limits. Or does it only disengage when the motor is given a move command? I assumed the brake was disengaged when the system had power, and the servos kept the axis in place. So if it only disengages during move command, then that ebrake will engage and disengage possibly thousands of times during a carve? But if it only sends voltage to the brake upon movement, then I will need to check the voltage again while someone moves the z-axis.
I checked voltage output at the controller box while someone moved the z axis and got nothing. Not sure if it loose wire or not connected properly. I did notice a bundle of wires with the ends stripped and bound on the port side of the box between the box wal and the boards. When I got the controller there were probably about 10 screws and 2 stand-offs floating around and the 2 horizontal boards above the servo controllers are kind of just flopping in there.
