Acorn CNC Controller freezing < full of com errors>

[PAI-Dallas]

We are having an issue with a 2 axis router randomly freezing while executing a G-code sequence. There is no consistency, but it seems to happen most often at the very beginning or very end of the G-code while executing several M60/M80 commands to turn on/off auxiliary outputs or during a homing sequence which also uses M26/M91. We discovered that just pressing any button on the VCP will cause it to resume but will ignore the function of that button. For example, pressing the Cycle Stop button during a freeze will actually cause it to resume.

We have already check the firewall settings, then upgraded the ethernet cable, then replaced the entire board, and did everything else we can think of to prevent signal interference, but the problem persists. Any ideas?

[tblough]

Do you have snubbers on the relays that are being controlled by the M60/M80 commands?

[PAI-Dallas]

I believe so, if I understand your question correctly. I have separate power supplies for the auxiliary components switched by the Acorn relay module, so they are not sharing the 24v power feeding the board. I had thought that might be part of the issue, but it doesn't explain why it often freezes during a homing cycle.

[cnckeith]

error log is just full of com errors. amazing it ran at all.

) 12-05-2023 13:31:41 944 MPU requested resend # 58
(1) 12-05-2023 13:31:41 452 Ethernet Communication Error, See Tech Bulletin 270
(4) 12-05-2023 13:31:41 946 PC resending # 1387
(4) 12-05-2023 13:32:05 944 MPU requested resend # 59
(4) 12-05-2023 13:32:05 946 PC resending # 1393
(1) 12-05-2023 13:32:05 452 Ethernet Communication Error, See Tech Bulletin 270
(1) 12-05-2023 13:32:11 407 Y+ limit (#50003) tripped
(1) 12-05-2023 13:32:15 407 X- limit (#50002) tripped
(4) 12-05-2023 13:50:34 944 MPU requested resend # 60
(4) 12-05-2023 13:50:34 946 PC resending # 1396
(1) 12-05-2023 13:50:53 407 Y+ limit (#50003) tripped
(1) 12-05-2023 13:50:58 407 X- limit (#50002) tripped
(1) 12-05-2023 13:51:33 407 Y+ limit (#50003) tripped
(1) 12-05-2023 13:51:37 407 X- limit (#50002) tripped
(4) 12-05-2023 13:51:45 944 MPU requested resend # 61
(1) 12-05-2023 13:51:45 452 Ethernet Communication Error, See Tech Bulletin 270
(1) 12-05-2023 13:51:45 417 Abnormal end of job
(4) 12-05-2023 13:51:45 946 PC resending # 1398
(4) 12-05-2023 13:51:53 944 MPU requested resend # 62
(1) 12-05-2023 13:51:53 452 Ethernet Communication Error, See Tech Bulletin 270
(4) 12-05-2023 13:51:53 946 PC resending # 1401
(1) 12-05-2023 13:52:17 407 Y+ limit (#50003) tripped
(1) 12-05-2023 13:52:21 407 X- limit (#50002) tripped
(1) 12-05-2023 13:52:55 407 Y+ limit (#50003) tripped
(1) 12-05-2023 13:52:59 407 X- limit (#50002) tripped
(4) 12-05-2023 13:53:11 944 MPU requested resend # 63
(4) 12-05-2023 13:53:11 946 PC resending # 1405
(1) 12-05-2023 13:53:11 452 Ethernet Communication Error, See Tech Bulletin 270
(4) 12-05-2023 13:53:41 944 MPU requested resend # 64
(4) 12-05-2023 13:53:41 946 PC resending # 1407
(4) 12-05-2023 13:53:41 944 MPU requested resend # 65
(4) 12-05-2023 13:53:41 946 PC resending # 1420
(1) 12-05-2023 13:53:52 Creating report...

[cnckeith]

did you follow TB 270 guidance?

- run the PC Tuner.
- run the com stress test

review all the details in TB270 https://www.centroidcnc.com/dealersuppo ... ds/270.pdf

and this post.
https://centroidcncforum.com/viewtopic.php?f=61&t=1451

[dpascucci_support]

What kind of computer are you using? Is it a laptop?

[PAI-Dallas]

I thought I went through TB270 months ago when I initially installed the machine, but I've been chasing down other problems which I thought were related to this issue but ended up not being so. I'm actually servicing this machine for a third party so I don't have immediate access to all the relevant information, only what they have given me so far. I'll go back through TB270 just to check everything, but I'll have to wait until they can halt operations.

I'm running off a PC dedicated exclusively to this machine.

[cnckeith]

the com errors exist in the error log going all the back to day one. and appear on every day the machine was on.
it was never right from the begining.

running the com stress test on this machine would have never passed.

need more info from you on the system to help you out.

what does "dedicated pc" mean? what does "upgraded ethernet cable" mean?


(4) 08-18-2023 17:40:12 944 MPU requested resend # 110
(4) 08-18-2023 17:40:12 946 PC resending # 921
(4) 08-18-2023 17:40:20 944 MPU requested resend # 111
(4) 08-18-2023 17:40:20 946 PC resending # 924
(4) 08-18-2023 17:40:24 944 MPU requested resend # 112
(4) 08-18-2023 17:40:24 946 PC resending # 927
(4) 08-18-2023 17:40:25 944 MPU requested resend # 113
(4) 08-18-2023 17:40:25 946 PC resending # 931
(4) 08-18-2023 17:40:26 944 MPU requested resend # 114
(4) 08-18-2023 17:40:27 946 PC resending # 935
(4) 08-18-2023 17:40:29 944 MPU requested resend # 115
(4) 08-18-2023 17:40:29 946 PC resending # 938
(4) 08-18-2023 17:40:30 944 MPU requested resend # 116
(4) 08-18-2023 17:40:30 946 PC resending # 941
(4) 08-18-2023 17:40:33 944 MPU requested resend # 117
(4) 08-18-2023 17:40:33 946 PC resending # 945
(4) 08-18-2023 17:40:40 944 MPU requested resend # 118
(4) 08-18-2023 17:40:40 946 PC resending # 948
(4) 08-18-2023 17:40:40 944 MPU requested resend # 119
(4) 08-18-2023 17:40:40 946 PC resending # 951
(4) 08-18-2023 17:40:41 944 MPU requested resend # 120
(4) 08-18-2023 17:40:41 946 PC resending # 955
(4) 08-18-2023 17:40:42 944 MPU requested resend # 121

[cnckeith]

got any photos of the install?

tell your customer to install Teamviewer (or any other remote access software) so you can log in and run the pc tuner and the stress test.

could be as easy as wrong cable or pc not setup properly. (use the pC tuner)

[PAI-Dallas]

I was finally able to service the machine. I ran the PC tuner, went through all of TB270 and TB309, and periodically ran stress tests. The stress tests failed every time. After completing the tech bulletins I restarted CNC12 and got the error in the attached image. So I shut down and restarted the power to the PC and Acorn board. After that everything work perfectly, the stress test passed perfectly and I ran about a dozen operation back to back with no issue. Two days later it hadn't been used again, so I powered it up just to check and everything was still good. Now a week later they turned it on and got the same error in the attachment, even after repeatedly cycling the power.

Heartbeat is good.
Ping test is good.
Every single thing in TB270/309 is turned off.
The PC is not on another network, it's dedicated exclusively to running this machine.
Snubbers are in place.
Power supply is not shared except with homing sensors.
Ethernet cable is shielded with no bulkhead and away from other power cords.
We have swapped out a new Acorn board.
This is a 2.5 axis router with two Clearpath Motors wired according to the attached schematics.

We have built two other machines exactly like this except with a third Z axis motor and they have been working fine for 2 years.
Our next thing to try is replacing the whole PC. Are there any other ideas?