Snubbers Work!

[frijoli]

Marty, Not sure what happened there. I edited the post.

[cbb1962]

I re-wired the snubbers across the coils. And still got a comm error. Any ideas?

[martyscncgarage]

What kind of machine is it?
Can you please post a high resolution of the control cabinet?
Did you wire it all?

If you have a VFD, turn it off and test again to see if you get the comm error.
If that doesn't do it, and you continue to get comm errors, disconnect these one at a time testing as you disconnect them:
Spindle Analog output
Output connector(s)
One bank of input connectors
Second bank of input connectors

Try and isolate where the noise is coming from.

[cbb1962]

What kind of machine is it? It is a 9 years old NewCNC machine, they imported a heavy-duty Chinese frame and put Yaskawa sigma 2 drives, a delta VFD and a 6HP Chinese ATC spindle, a two PLCs, and spindle break-out board, a PMDX board, and smooth stepper board with Mach3 to drive it all.
Can you please post a high resolution of the control cabinet? I'll try to clean up all the stray wires and get a good picture.
Did you wire it all? No, I replaced the controls with Acorn and kept everything else.

If you have a VFD, turn it off and test again to see if you get the comm error. My original test was without the spindle running and I e-stopped 20-30 times while doing MDI moves and no comm errors, Now the only times it has comm errors is during a job when the spindle is running. The comm errors are MUCH less frequent now though.
If that doesn't do it, and you continue to get comm errors, disconnect these one at a time testing as you disconnect them:
Spindle Analog output
Output connector(s)
One bank of input connectors
Second bank of input connectors

Try and isolate where the noise is coming from.

[martyscncgarage]

Ah, I remember the beastie now....

[cbb1962]

One thing I discovered was that my 24VDC power supply was only outputting 18.5VDC could this contribute to the connection issues?

[tblough]

It's possible. Lower voltages are more susceptible to noise. Can the voltage be adjusted? Is the low voltage being caused by the supply being overloaded? How much noise/ripple is present on the supply lines?

[cbb1962]

It's possible. Lower voltages are more susceptible to noise. Can the voltage be adjusted? Yes I was able to adjust it to 22.5 volts.

Is the low voltage being caused by the supply being overloaded? To be honest I never even checked it. But this system has a fan, solenoid valves, and I am using CNC4PC's C86 RJ45 board that requires DC power. Would that be considered overloaded? I have an industrial 24VDC power supply I could drop in.

How much noise/ripple is present on the supply lines? I don't have a means to check/measure this.

[martyscncgarage]

It's possible. Lower voltages are more susceptible to noise. Can the voltage be adjusted? Yes I was able to adjust it to 22.5 volts.

Is the low voltage being caused by the supply being overloaded? To be honest I never even checked it. But this system has a fan, solenoid valves, and I am using CNC4PC's C86 RJ45 board that requires DC power. Would that be considered overloaded? I have an industrial 24VDC power supply I could drop in.

How much noise/ripple is present on the supply lines? I don't have a means to check/measure this.

Is this a separate power supply? Not Acorn's logic power supply? Good quality? I would replace it. Further you need to connect the commons of the logic power supplies together.
I would put those prox sensors on Acorn's power supply. Get the 24VDC from the input 24VDC input terminal, (the one open) and Common and retest.

[martyscncgarage]

There is a problem with the C86Acorn board, rev2. They just released a rev3. I have not tested it yet.
If your green light is not on, its not working right....contact CNC4PC for a replacement. Yes it appears to work, but it expects ALL enables to come on at the same time and they don't always.