Upgrade Issues. Drive Faults and Jerky behavior-RESOLVED

[Shinosky]

Update:
I believe my issues with noise have been resolved. The fix turned out to be grounding the VFD cable shield at BOTH ends of the cable. At the VFD and at the Motor. This is contrary to conventional shield grounding but is necessary for this type of application according to Beldin Cable.

Photos of the Control Box and Mechanicals: https://photos.app.goo.gl/
CNCPC: I5-2400 @ 3.10GHz , 8Gb Ram, NVIDIA GeForce GTX 1050 Ti, ASUS VT229H 21.5" Touchscreen Monitor, Centroid Wireless MPG
Centroid Acorn System Report: https://www.dropbox.com/s/xhyx9ggbpynig ... 4.zip?dl=0

I have been upgrading my ShopSabre 23 to Acorn and ClearPath servos.

I currently have 2 problems.
The first is noise interference from the spindle.
Here is what I have done to try and mitigate that:
(1) Added 2.2K resistors between Step/Dir and +24V
(2) Added an EMI filter to the line inputs of the VFD
(3) Replaced power cable from VFD to Spindle with a Shielded 16AWG Cable grounding the drain wire at the VFD only
(4) Reduced the step pulse frequency to 100K

The new cable made the biggest improvement but did not eliminate the problem completely.
I will get random DRIVE FAULTS only when the spindle is on. I can aircut a program with the spindle off without having a drive fault. The faults always occur on the Z axis motor. As far as I can tell…
The Motor Setup Program from Clearpath warns of a shut down on that motor due to either a short, noise or step pulse width too small. Only happens with spindle running.
The only thing I have’t tried yet is to reduce the length of the Z-Axis Data Cable. I left it longer than necesarry just in case… It is probably at least 15ft. long

My VFD is not in my control box. It is mounted to the wall away from the control box. Only the power cable runs through my cable chain to the motor.
All the DATA and POWER cables for the motors are purchased directly from Teknic. The data cables pass through the control box directly and are wired directly to the inputs on ACORN according to Centroid schematics.

I have run out of things to try to resolve this problem…

The second issue is also bad. There is terrible Jitter/Jerkiness on the Y-Axis.
I may see a slight amount on X-Axis but it does not compare to what is visible on the Y-Axis
I am running the largest/strongest Nema 23 motors that Clearpath makes. They are replacing the 286 oz/in Nema 23 Steppers that came with the machine. They are direct drive. I saw none of this jerkiness with the steppers. Even on a simple straight line Y-Axis move the jerkiness is evident.
Here is what I have done to try and identify the problem:
(1) in an attempt to localize the problem I swapped the X and Y Motors and ran the AutoTune function again. The problem persists and did not follow the motor to the X axis. Although I do not fully understand the Scope feature on the Clearpath MSP software it showed incredible erratic position errors for that axis compared to the others. I am beginning to suspect some mechanical issue but I can not be sure. It may also be the Auto tune settings. Whatever it is it is unusable. This may require a call to Tecknic’s engineers.

Video of the Jerkiness on Y-Axis:

I also was having connection issues between the CNCPC and Acorn. I had to remove the RJ45 Connector on the control box and run the wire directly through the wall of the control box to connect it directly to the Acorn…..One issue after another

I am ready to slit my wrists………
If I can’t find solutions I may be forced to undo my $3000 upgrade and return to lackluster performance in order to get the machine back on line. I have spent a lot of time and money on this and it’s killing me……

[martyscncgarage]

Your photo link does not work for me. So at least I can't see what you are working with.
UPLOAD the report directly, here.

Make sure you have no mechanical slop in your axis, loose bearings, pulleys, couplers etc.

Follow this post for better help: viewtopic.php?f=20&t=383
When we have a better understanding of what you are working with, we'll try and help.

Is this your first conversion?

Marty

[Shinosky]

Sorry about the link. First time doing it like this.
https://photos.app.goo.gl/tinYboAuzCoWXn2m6

report_0C1C571296E2-0210202962_2020-04-04_14-27-44.zip

(305.41 KiB) Downloaded 121 times

This is not my first rodeo conversion. I built a Mach machine years ago. It is my first Acorn control and use of Servos.
I did manage to make some progress this morning. I shortened the Data cable and rewired it for the Z Axis. I also went down to a 1K resistor . I did not expect this to work but amazingly it has. So far. I have been aircutting a g-code program for over a half hour without a fault.

I still have the terrible jerkiness on the Y axis.

Thanks for looking at this with me.

Andy

[martyscncgarage]

The photo link is working.
You have an awful lot of ethernet errors. You have to find out what is causing this.
Shut everything down, only power up Acorn and the PC. Pull all the plugs on Acorn except for power.
Look at your message log (found under the F7 Utility menu)
It is in the URF.ZIP file in your Report.Zip file as well, but while you are testing, refer to the log.
Resolve this first. If you try and do a software upgrade with it like this, you may "brick" the beaglebone. Make sure the Ethernet drivers are up to date as well on the PC. This is a standard PC correct?

I have no experience with Clearpath motors/tuning. Maybe one of the others can help. But you have to resolve the ethernet communications first.

Here is your log from yesterday:
(1) 04-04-2020 9:27:58 199 CNC Started
(4) 04-04-2020 9:28:03 944 MPU requested resend # 18
(4) 04-04-2020 9:28:03 946 PC resending # 918
(1) 04-04-2020 9:28:05 CNC12 Acorn Mill v4.20 (revision 4.20.1) Jan 17 2020, 09:50:30
(4) 04-04-2020 9:28:05 9033 Reset Initiated, Press Reset to Clear
(4) 04-04-2020 9:28:05 944 MPU requested resend # 20
(4) 04-04-2020 9:28:05 946 PC resending # 971
(4) 04-04-2020 9:28:08 4032 Reset Cleared
(4) 04-04-2020 9:30:28 944 MPU requested resend # 21
(4) 04-04-2020 9:30:28 946 PC resending # 974
(4) 04-04-2020 9:35:42 944 MPU requested resend # 22
(4) 04-04-2020 9:35:42 946 PC resending # 979
(1) 04-04-2020 9:41:39 452 Ethernet Communication Error, CNCPC to controller. See Tech Bulletin 270
(1) 04-04-2020 11:14:09 199 CNC Started
(4) 04-04-2020 11:14:14 944 MPU requested resend # 17
(4) 04-04-2020 11:14:14 946 PC resending # 872
(1) 04-04-2020 11:14:16 CNC12 Acorn Mill v4.20 (revision 4.20.1) Jan 17 2020, 09:50:30
(4) 04-04-2020 11:14:16 9033 Reset Initiated, Press Reset to Clear
(4) 04-04-2020 11:14:16 944 MPU requested resend # 18
(4) 04-04-2020 11:14:16 946 PC resending # 929
(1) 04-04-2020 11:14:26 204 Exiting CNC...Normal Exit (66)
(1) 04-04-2020 12:42:25 199 CNC Started
(4) 04-04-2020 12:42:30 9039 Software Exited, Cycle E-Stop/Reset to Continue
(4) 04-04-2020 12:42:30 944 MPU requested resend # 17
(4) 04-04-2020 12:42:30 946 PC resending # 883
(1) 04-04-2020 12:42:32 CNC12 Acorn Mill v4.20 (revision 4.20.1) Jan 17 2020, 09:50:30
(4) 04-04-2020 12:42:32 9039 Software Exited, Cycle E-Stop/Reset to Continue
(4) 04-04-2020 12:42:32 944 MPU requested resend # 20
(4) 04-04-2020 12:42:32 946 PC resending # 955
(4) 04-04-2020 12:43:00 9033 Reset Initiated, Press Reset to Clear
(4) 04-04-2020 12:43:02 4032 Reset Cleared
(4) 04-04-2020 12:43:36 944 MPU requested resend # 21
(4) 04-04-2020 12:43:37 946 PC resending # 958
(4) 04-04-2020 12:43:45 944 MPU requested resend # 22
(4) 04-04-2020 12:43:45 946 PC resending # 961
(4) 04-04-2020 12:43:55 944 MPU requested resend # 23
(4) 04-04-2020 12:43:55 946 PC resending # 965
(4) 04-04-2020 12:45:16 944 MPU requested resend # 24
(4) 04-04-2020 12:45:17 946 PC resending # 970
(4) 04-04-2020 12:49:57 944 MPU requested resend # 25
(4) 04-04-2020 12:49:57 946 PC resending # 975
(1) 04-04-2020 12:50:16 204 Exiting CNC...Normal Exit (66)
(1) 04-04-2020 12:53:00 199 CNC Started
(4) 04-04-2020 12:53:05 9039 Software Exited, Cycle E-Stop/Reset to Continue
(4) 04-04-2020 12:53:05 944 MPU requested resend # 18
(4) 04-04-2020 12:53:05 946 PC resending # 951
(1) 04-04-2020 12:53:07 CNC12 Acorn Mill v4.20 (revision 4.20.1) Jan 17 2020, 09:50:30
(4) 04-04-2020 12:53:07 9039 Software Exited, Cycle E-Stop/Reset to Continue
(4) 04-04-2020 12:53:11 9033 Reset Initiated, Press Reset to Clear
(4) 04-04-2020 12:53:12 4032 Reset Cleared
(4) 04-04-2020 12:53:45 944 MPU requested resend # 19
(4) 04-04-2020 12:53:45 946 PC resending # 955
(4) 04-04-2020 12:53:48 944 MPU requested resend # 20
(4) 04-04-2020 12:53:48 946 PC resending # 958
(4) 04-04-2020 12:53:49 944 MPU requested resend # 21
(4) 04-04-2020 12:53:49 946 PC resending # 961
(4) 04-04-2020 12:54:00 944 MPU requested resend # 22
(4) 04-04-2020 12:54:00 946 PC resending # 968
(4) 04-04-2020 12:54:04 944 MPU requested resend # 23
(4) 04-04-2020 12:54:04 946 PC resending # 971
(4) 04-04-2020 12:57:03 944 MPU requested resend # 24
(4) 04-04-2020 12:57:03 946 PC resending # 994
(4) 04-04-2020 12:57:03 944 MPU requested resend # 25
(4) 04-04-2020 12:57:03 946 PC resending # 1007
(4) 04-04-2020 12:57:03 944 MPU requested resend # 26
(4) 04-04-2020 12:57:03 946 PC resending # 1013
(4) 04-04-2020 12:57:06 944 MPU requested resend # 27
(4) 04-04-2020 12:57:06 946 PC resending # 1035
(1) 04-04-2020 12:57:31 204 Exiting CNC...Normal Exit (66)
(1) 04-04-2020 12:57:56 199 CNC Started
(4) 04-04-2020 12:58:01 9039 Software Exited, Cycle E-Stop/Reset to Continue
(4) 04-04-2020 12:58:01 944 MPU requested resend # 13
(4) 04-04-2020 12:58:01 946 PC resending # 651
(1) 04-04-2020 12:58:06 CNC12 Acorn Mill v4.20 (revision 4.20.1) Jan 17 2020, 09:50:30
(4) 04-04-2020 12:58:06 9039 Software Exited, Cycle E-Stop/Reset to Continue
(4) 04-04-2020 12:58:06 944 MPU requested resend # 17
(4) 04-04-2020 12:58:06 946 PC resending # 732
(4) 04-04-2020 12:58:11 9033 Reset Initiated, Press Reset to Clear
(4) 04-04-2020 12:58:12 4032 Reset Cleared
(4) 04-04-2020 12:58:45 944 MPU requested resend # 18
(4) 04-04-2020 12:58:45 946 PC resending # 746
(4) 04-04-2020 12:58:53 944 MPU requested resend # 19
(4) 04-04-2020 12:58:53 946 PC resending # 750
(4) 04-04-2020 12:58:54 944 MPU requested resend # 20
(4) 04-04-2020 12:58:54 946 PC resending # 752
(4) 04-04-2020 13:01:29 944 MPU requested resend # 21
(4) 04-04-2020 13:01:29 946 PC resending # 756
(4) 04-04-2020 13:06:01 944 MPU requested resend # 22
(4) 04-04-2020 13:06:01 946 PC resending # 759
(4) 04-04-2020 13:13:48 944 MPU requested resend # 23
(4) 04-04-2020 13:13:48 946 PC resending # 762
(4) 04-04-2020 13:14:17 944 MPU requested resend # 24
(4) 04-04-2020 13:14:17 946 PC resending # 764
(4) 04-04-2020 13:14:21 944 MPU requested resend # 25
(4) 04-04-2020 13:14:21 946 PC resending # 766
(4) 04-04-2020 13:16:00 944 MPU requested resend # 26
(4) 04-04-2020 13:16:00 946 PC resending # 768
(4) 04-04-2020 13:16:57 944 MPU requested resend # 27
(4) 04-04-2020 13:16:57 946 PC resending # 771
(4) 04-04-2020 13:16:59 944 MPU requested resend # 28
(4) 04-04-2020 13:16:59 946 PC resending # 774
(4) 04-04-2020 13:17:13 944 MPU requested resend # 29
(4) 04-04-2020 13:17:13 946 PC resending # 777
(4) 04-04-2020 13:17:13 944 MPU requested resend # 30
(4) 04-04-2020 13:17:13 946 PC resending # 780
(4) 04-04-2020 13:18:13 944 MPU requested resend # 31
(4) 04-04-2020 13:18:13 946 PC resending # 789
(4) 04-04-2020 13:18:13 944 MPU requested resend # 32
(4) 04-04-2020 13:18:13 946 PC resending # 794
(4) 04-04-2020 13:18:13 944 MPU requested resend # 33
(4) 04-04-2020 13:18:13 946 PC resending # 803
(4) 04-04-2020 13:18:13 944 MPU requested resend # 34
(4) 04-04-2020 13:18:13 946 PC resending # 807
(4) 04-04-2020 13:18:13 944 MPU requested resend # 35
(4) 04-04-2020 13:18:13 946 PC resending # 813
(4) 04-04-2020 13:18:32 944 MPU requested resend # 36
(4) 04-04-2020 13:18:32 946 PC resending # 822
(4) 04-04-2020 13:18:37 944 MPU requested resend # 37
(4) 04-04-2020 13:18:37 946 PC resending # 825
(4) 04-04-2020 13:19:08 944 MPU requested resend # 38
(4) 04-04-2020 13:19:08 946 PC resending # 834
(4) 04-04-2020 13:20:26 944 MPU requested resend # 39
(4) 04-04-2020 13:20:26 946 PC resending # 849
(4) 04-04-2020 13:20:32 944 MPU requested resend # 40
(4) 04-04-2020 13:20:32 946 PC resending # 862
(4) 04-04-2020 13:20:47 944 MPU requested resend # 41
(4) 04-04-2020 13:20:47 946 PC resending # 865
(4) 04-04-2020 13:21:23 944 MPU requested resend # 42
(4) 04-04-2020 13:21:23 946 PC resending # 882
(4) 04-04-2020 13:21:27 944 MPU requested resend # 43
(4) 04-04-2020 13:21:27 946 PC resending # 891
(4) 04-04-2020 13:21:51 944 MPU requested resend # 44
(4) 04-04-2020 13:21:51 946 PC resending # 898
(4) 04-04-2020 13:22:01 944 MPU requested resend # 45
(4) 04-04-2020 13:22:01 946 PC resending # 927
(4) 04-04-2020 13:22:01 944 MPU requested resend # 46
(4) 04-04-2020 13:22:01 946 PC resending # 952
(4) 04-04-2020 13:23:03 511 Missing parameter
(4) 04-04-2020 13:24:01 944 MPU requested resend # 47
(4) 04-04-2020 13:24:01 946 PC resending # 954
(4) 04-04-2020 13:25:07 944 MPU requested resend # 48
(4) 04-04-2020 13:25:07 946 PC resending # 962
(4) 04-04-2020 13:25:07 944 MPU requested resend # 49
(4) 04-04-2020 13:25:07 946 PC resending # 973
(4) 04-04-2020 13:25:07 944 MPU requested resend # 50
(4) 04-04-2020 13:25:08 946 PC resending # 980
(4) 04-04-2020 13:25:08 946 PC resending # 982
(4) 04-04-2020 13:25:08 944 MPU requested resend # 51
(4) 04-04-2020 13:25:08 946 PC resending # 1002
(4) 04-04-2020 13:25:08 944 MPU requested resend # 52
(4) 04-04-2020 13:25:08 946 PC resending # 1013
(4) 04-04-2020 13:25:35 944 MPU requested resend # 53
(4) 04-04-2020 13:25:35 946 PC resending # 1016
(4) 04-04-2020 13:26:03 944 MPU requested resend # 54
(4) 04-04-2020 13:26:03 946 PC resending # 1018
(4) 04-04-2020 13:26:22 944 MPU requested resend # 55
(4) 04-04-2020 13:26:22 946 PC resending # 1025
(4) 04-04-2020 13:26:27 944 MPU requested resend # 56
(4) 04-04-2020 13:26:27 946 PC resending # 1035
(4) 04-04-2020 13:27:04 944 MPU requested resend # 57
(4) 04-04-2020 13:27:04 946 PC resending # 1063
(4) 04-04-2020 13:27:19 944 MPU requested resend # 58
(4) 04-04-2020 13:27:19 946 PC resending # 1074
(4) 04-04-2020 13:27:22 9031 DRIVE FAULT!
(1) 04-04-2020 13:28:33 204 Exiting CNC...Normal Exit (66)
(1) 04-04-2020 14:21:00 199 CNC Started
(1) 04-04-2020 14:21:07 CNC12 Acorn Mill v4.20 (revision 4.20.1) Jan 17 2020, 09:50:30
(4) 04-04-2020 14:21:07 9033 Reset Initiated, Press Reset to Clear
(4) 04-04-2020 14:21:10 4032 Reset Cleared
(1) 04-04-2020 14:27:44 Creating report...

[Shinosky]

I saw the ethernet issues but didn't understand if they were normal. I was having problems connecting to Acorn at startup. I finally removed the control box connector and short cable in the case. I then ran the long Ethernet cable directly to the Acorn board. That eliminated the big connectivity issues. I will check to see what the log files show now and try to sort that out.
And as far as I know there is nothing non standard about the machine. I followed your guidelines for setting it up as a CNCPC. Maybe I should revisit that as well.

thanks!

[martyscncgarage]

I saw the ethernet issues but didn't understand if they were normal. I was having problems connecting to Acorn at startup. I finally removed the control box connector and short cable in the case. I then ran the long Ethernet cable directly to the Acorn board. That eliminated the big connectivity issues. I will check to see what the log files show now and try to sort that out.
And as far as I know there is nothing non standard about the machine. I followed your guidelines for setting it up as a CNCPC. Maybe I should revisit that as well.

thanks!

Make sure the cable is shielded (use the one that Centroid provided)
I'm suggesting you make sure all your PC drivers are up to date.
If you are still getting the resend errors, you might do as I suggested and disconnect the Input connectors and the drive connectors to see if the resend issues go away. Basically you are going back to a basic benchtest setup. CNC PC and ACORN only to see if your ethernet issuess resolve.

...and always post a FRESH report, that is, create a new one just before posting to the forum. That way your logs are up to date.

[Shinosky]

Thanks Marty,
I am using the cable provided by Centroid. After reading the one tech bulletin from Centroid concerning communications errors I realized I also had some poor cable management. I have revisited that. I had the Ethernet cable running precipitously close to the Spindle motor power cable. I spent the afternoon cleaning all that up. I ended up getting another drive fault but on a different axis for a change . I went ahead and installed resistors on all axis. I am testing things again. I appreciate all you do to help us poor novices...
I do think I have resolved the communications errors but I am testing it out now to be certain.

Andy

[martyscncgarage]

It is advised to use VFD cable between the motor and the drive.
For example: https://www.automationdirect.com/adc/sh ... /vfd_cable

[Shinosky]

Thanks Marty,
My initial cable was unshielded so I bought a VFD cable from Automation Direct. Made a big difference but didn't solve it completely. I have moved things around inside my control box in order to isolate the Step/Dir from interference as much as I know how. I thought I had the noise issue cleared up but I will still get random Drive fault errors. Sometimes it can run an entire 30 minute program without issue. Other times it's only 10 minutes. I am only testing...not really cutting anything yet. I don't dare try that.
By the way...is there a way to reset the log files and msg cut files? Once I make a change I'd like to start fresh with the reports so I am not seeing old errors.
Thanks

[tblough]

IIRC, you can just delete the two log files when Centroid is not running and Centroid will recreate them the next time it starts.