X axis gives drive fault (Resolved)

[caskscob]

I installed the ArizonaCNC kit on my PM30 Mill. The Z and Y axis both run without issues. When I try to jog the X axis the motor turns about 1/4 turn then gives a drive fault. In my troubleshooting, I have set the Limits to ±50" to eliminate limit issues. I removed the motor from the machine to eliminate excess torque issues. I swapped the X and Y motors and the X still does the same thing. I swapped the CL86Y stepper driver for the X axis with a new one and the same problem. I even rewired the cables just to be sure and it does the same thing.
It appears I have something in the CNC12 software setup incorrect, however everything that I can see has all the settings pretty much the same.

I attached the report file for the setup.

Any help would be much appreciated.

[martyscncgarage]

Are you saying the problem is following the original X axis drive and motor or is staying with X axis on Acorn?
Does the X axis drive SHOW a fault or does CNC12 give you drive fault or both?

Pictures would be helpful....

You can temporarily disconnect the drive fault input wires from the drives or take drive fault out as an input temporarily...CNC12 will not register a drive fault and fault out, but it will let you try and turn your motors

[caskscob]

I don't understand your question in the first sentence. The problem is with the X axis in Acorn (apparently). The X motor will only turn about a 1/4 turn before CNC12 shows a Drive Fault. That is even with the motor disconnected from the machine physically so there is no load on the motor. If I swap the X and Y motors (still not connected to machine) the Y motor placed on the X drive still does the same thing. That is what prompted me to switch out the Stepper drive module (CL86Y) for a new one. After that it still did the same thing so I believe there is a problem with configuration or something in CNC12. I will try removing the fault sense wire and see what happens.

[Dave_C]

The X motor will only turn about a 1/4 turn before CNC12 shows a Drive Fault

If memory serves me, you are using closed loop stepper or what we call "hybrid steppers"? Yes?

I use those as well and when the motor turns a 1/4 turn and faults out it is not getting the correct encoder signal back to the driver to tell it that it moved the right distance.

So how can that happen? Well I have had encoder cables sent to me that were the wrong pin outs and it took many hours to figure out the issue. I swapped out the cables and the whole setup started working.

Take one of the motors with its cables and put it on the X axis and see if it moves.

I doubt you have a problem in Acorn, it is just too easy to set up right! (But anything is possible)

Edit: Make sure that the encoder cable is wired the same at the controller end as the other two. Also, if you had to add on to the length of the cable you could have an issue there as well. All of the symptoms point to a bad or miss-wired encoder cable.

Dave C.

[caskscob]

Found the problem! Operator error as I suspected. Turns out when I installed the cable I swapped the B+ and B- wires. Then when I replaced the cables I wired them exactly the same way.... doh!!! After that I discovered a retaining screw on the lovejoy connector contacting the motor mount and the motor mount needed a shim also. Weird that it would make a 1/4 turn before fault. I think I'm all set to destroy perfectly good stock now. Thanks all for their input!

[Dave_C]

Weird that it would make a 1/4 turn before fault.

No, not weird at all because the drive has a fault tolerance of so many pulses before it sends out an fault. 1/4 of a turn seems like a lot and it is but that only happens in certain situations. The fault is less if the drive has actually started to move and then has an issue.

So cut away,

Dave C.