Plasma Stopped working after upgrade to 4.20 <resolved>

[TheKitMill]

On the small plasma/Router i just finished and that was running both the plasma cutter and engraver. See attached photos taken during testing.

Both worked as designed. When plasma Cutting the breaker for the spindle inverter was turned off and when the spindle was turned on the plasma was turned off The Spindle relay is power up at start up and the was was operated manually and automatically from the acorn 0-10 v controlled the speed.

The plasma was was triggered via the NO part of the contactor that also controlled the spindle drive power.

The spindle works as designed but when I turn off the spindle and turn on the plasma the no longer works. Its moves to position above the part and fires as it did before but within a few seconds it faults out the Acorn Board as if the power was turned off. It get a lost connection error.

The only change was upgrade to 4.20 and I used the restore option to restore the 4.18 report that was working. I uninstalled and reinstalled 4.20 And again did a restore report of the known working configuration.

I tried manually firing the plasma with the same results. Its a Thermal Dynamics Power max 100 with a machine torch and cut well during the test cuts. Not sure what changed but the router side of it works perfectly. I have a Hunyang 2.2 K inverter with water cooled spindle.

Attached is last report of today. I will try again tomorrow.

I did update 2 other machines with 4.20 and restore report with no issues.

Any suggestions appreciated

this is the v4.20 report

report_78047348F112-0703192229_2020-01-14_18-47-10.zip

IMG_20200101_153432.jpg

IMG_20191220_170300.jpg

[martyscncgarage]

Go back to 4.18 (you did save a copy of the folder on your C drive before you upgraded didn't you?) And retest.
Do you have snubbers across all contactor coils?
Can you post your last report from 4.18 as well

There were several drive faults followed by the communication error. What caused those?
Marty

[cnckeith]

yeah, just like marty says...lots of comm errors in the error logs.
452 Ethernet Communication Error, CNCPC to controller. See Tech Bulletin 270

make sure you don't have firewall on, or virus software installed, make sure you are using shielded ethernet cable.

also, looking at the timing on all the restore reports in the logs.. looks like you might have forgot to press "write settings to cnc control" in the wizard after restoring the report and power cycle the Acorn?

[TheKitMill]

Thanks Marty and Keith. I did save a report from 4.18 and I can reinstall it. I don't Snubbers but can install them. However everything was working without them. I am rechecking all the wiring this morning. Don't know what else could have changed between 4.18 and 4.20 in the Wizzard but I will recheck

See tech bulletin 270 error happens everything I trigger the Plasma and the drive fault error is a result of the brake not being active after or during the 270 error. All that said i am able to operate the Engraving head with no problems it just when I trigger the plasma via a separate relay that the fault happens. I will post an update in a few hours along with some footage of what its doing.

[martyscncgarage]

Thanks Marty and Keith. I did save a report from 4.18 and I can reinstall it. I don't Snubbers but can install them. However everything was working without them. I am rechecking all the wiring this morning. Don't know what else could have changed between 4.18 and 4.20 in the Wizzard but I will recheck

See tech bulletin 270 error happens everything I trigger the Plasma and the drive fault error is a result of the brake not being active after or during the 270 error. All that said i am able to operate the Engraving head with no problems it just when I trigger the plasma via a separate relay that the fault happens. I will post an update in a few hours along with some footage of what its doing.

So, that is noise probably coming from the Plasma cutter.
But you say it worked fine with 4.18
FYI. When you have a working version of software, just copy the complete directory and rename it, like CNCM 4.18
That way all you have to do to go back is rename the directory CNCM

Looking forward to hear how you make out.
Marty

[TheKitMill]

Thanks Marty. I cut about 10 parts before the upgrade then tested the engraver and when back to test Plasma and it started faulting. I am recheck all wires to see i something came loose. Going back to 4.18 now to do more testing.

Chuck

[TheKitMill]

Update

Re installed cnc 4.18 checked all the wiring and I/O

results:

Spindle working as intended, Fully controlled from within the CNC

Switched Spindle Drive Power off and turned on Plasma and it works with no faults during previous testing just triggering the plasma would result in a 270 Error.

So all appears to work on 4.18 but not on 4.20, Plasma spark is controlled by stand alone relay that is triggered by the Acorn board. I was able to cycle the torch several times with no failure. The sputtering is Air flow issue I had it hooked up to my small compressor as there is over a foot of snow on the ground and I can't get to the shed outside to turn on the Screw Compressor.

Attached is short Video link

[cnckeith]

ok.. will need reports from both 4.18 working and 4.20 just after update to see what the differences are

[TheKitMill]

Follow up attached is the latest report with Plasma Working

cnckeith adds this is the v4.18 report.

[TheKitMill]

Previous report in first post. Thanks