Yet another way to get 452 communication errors

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cncsnw
Posts: 1605
Joined: Wed Mar 24, 2010 5:48 pm

Yet another way to get 452 communication errors

Post by cncsnw »

Back in September I had two customers with early-2017 controls fighting intermittent "452 PC Receive Data Error" messages.

We went through the obligatory rounds of reseating the ethernet cables, replacing the cables, checking for unwanted Windows software, and looking for noise sources.

To make a long story short, the issues appear to have been interruption of the 5VDC logic power supply, due to inadequate crimping of the spade lugs on the factory-supplied DC logic power harness. I got the power supply and harness back from one of the customers, and made this video:

https://www.youtube.com/watch?v=tcpxXtqJsBE

In this scenario, normal operation will generally not be restored until the operator restarts the control, or at least exits and restarts the CNC11 or CNC12 software.
cncsnw
Posts: 1605
Joined: Wed Mar 24, 2010 5:48 pm

Re: Yet another way to get 452 communication errors

Post by cncsnw »

One system was an Oak, the other was an Allin1DC.

It is noteworthy that both systems ran for 3+ years before the connection became weak enough to start causing problems.

The message log from the Oak system goes back to initial setup in February of 2017, but the first 452 error was in June of 2020. From then, it became increasingly persistent, until they could not run the machine for more than a couple hours without faults.

Code: Select all

(1)   06-16-2020 12:04:08 452 PC Receive Data Error
(1)   07-14-2020 10:28:31 452 PC Receive Data Error
(1)   07-14-2020 10:43:18 452 PC Receive Data Error
(1)   07-20-2020 13:53:45 452 PC Receive Data Error
(1)   07-30-2020 14:02:34 452 PC Receive Data Error
(1)   07-31-2020 11:42:16 452 PC Receive Data Error
(1)   08-05-2020  8:39:40 452 PC Receive Data Error
(1)   08-05-2020  8:47:13 452 PC Receive Data Error
(1)   08-05-2020  8:47:21 452 PC Receive Data Error
(1)   08-05-2020  8:47:29 452 PC Receive Data Error
(1)   08-05-2020  8:47:39 452 PC Receive Data Error
(1)   08-05-2020  9:11:36 452 PC Receive Data Error
(1)   08-11-2020  6:58:32 452 PC Receive Data Error
(1)   08-12-2020  7:27:51 452 PC Receive Data Error
(1)   08-12-2020  7:53:11 452 PC Receive Data Error
(1)   08-12-2020  8:10:30 452 PC Receive Data Error
(1)   08-13-2020  8:55:51 452 PC Receive Data Error
(1)   08-13-2020  9:48:27 452 PC Receive Data Error
(1)   08-13-2020  9:53:57 452 PC Receive Data Error
(1)   08-13-2020  9:54:06 452 PC Receive Data Error
(1)   08-13-2020  9:54:14 452 PC Receive Data Error
(1)   08-13-2020  9:54:23 452 PC Receive Data Error
(1)   08-13-2020  9:55:45 452 PC Receive Data Error
(1)   08-13-2020 10:04:33 452 PC Receive Data Error
(1)   08-13-2020 10:07:46 452 PC Receive Data Error
(1)   08-18-2020 15:45:57 452 PC Receive Data Error
(1)   08-19-2020  8:03:00 452 PC Receive Data Error
(1)   08-19-2020 12:42:41 452 PC Receive Data Error
(1)   08-19-2020 15:06:33 452 PC Receive Data Error
(1)   08-19-2020 15:18:22 452 PC Receive Data Error
(1)   08-19-2020 15:37:01 452 PC Receive Data Error
(1)   08-20-2020  6:42:18 452 PC Receive Data Error
(1)   08-20-2020  6:44:04 452 PC Receive Data Error
(1)   08-20-2020  6:44:17 452 PC Receive Data Error
(1)   08-20-2020  7:01:23 452 PC Receive Data Error
(1)   08-20-2020  9:23:11 452 PC Receive Data Error
(1)   08-20-2020 11:55:44 452 PC Receive Data Error
(1)   08-20-2020 14:26:31 452 PC Receive Data Error
(1)   08-21-2020 11:13:29 452 PC Receive Data Error
(1)   08-21-2020 11:57:44 452 PC Receive Data Error
(1)   08-24-2020  9:13:58 452 PC Receive Data Error
(1)   08-24-2020 11:48:41 452 PC Receive Data Error
BodeRacing
Posts: 55
Joined: Sat May 16, 2020 12:40 pm
Acorn CNC Controller: No
Allin1DC CNC Controller: No
Oak CNC controller: Yes
MPU11 & GPIO4D -w/ 3rd Party Drives: No
DC3IOB: No
CNC12: No
CNC11: Yes
CPU10 or CPU7: No
CNC Control System Serial Number: 102849

Re: Yet another way to get 452 communication errors

Post by BodeRacing »

Those insulated connectors have no place in critical applications. Bare high quality connectors are far more reliable. I have dealt with my fair share of bad crimps in my career in the industrial electrical field. I had at least one on my machine that I found. I disallow the plastic insulated ones in all the industrial specs that I have control over.
cncsnw
Posts: 1605
Joined: Wed Mar 24, 2010 5:48 pm

Re: Yet another way to get 452 communication errors

Post by cncsnw »

Here is a closer look at the terminals.
Attachments
PA270024.JPG
PA270023.JPG
martyscncgarage
Posts: 6686
Joined: Tue Mar 28, 2017 12:01 pm
Acorn CNC Controller: Yes
Allin1DC CNC Controller: Yes
Oak CNC controller: No
MPU11 & GPIO4D -w/ 3rd Party Drives: No
DC3IOB: No
CNC12: Yes
CNC11: Yes
CPU10 or CPU7: Yes
CNC Control System Serial Number: none
Location: Mesa, AZ

Re: Yet another way to get 452 communication errors

Post by martyscncgarage »

Thanks for sharing those Marc. That looks pretty bad. Crimped the insulation instead of the connector itself...
Reminder, for support please follow this post: viewtopic.php?f=20&t=383
We can't "SEE" what you see...
Mesa, AZ
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