M15DRV1 board level troubleshooting

[thelinuxman]

Hi everybody. This is probably a long shot, but...
I have an old M15 controller that just developed a problem stating the Z+ limit is tripped.
I have verified the switch is closed, verified all the way to the console plug.
I have also verified the wiring from the console plug to the solder joint on the M15DRV1 board.
From there, I don't see any visible traces of where that connection goes. Does anyone have a board layout I could follow?

The board is a M15DRV1 REV970801

I am assuming I am headed for an ALLIN1DC upgrade, but if I can get a few more weeks out of this controller to complete an order that would be fantastic.

[cncsnw]

Do the other six limit inputs seem to be working properly (green, on the Alt-i display)?

If you toggle the limit defeater DIP switches (on the end of the board) on (so the switch levers are parallel with the board, and limit inputs are defeated), does that clear the problem input?

I do not have a circuit diagram for the board. I also do not know which side of the input opto-coupler the limit-defeater DIP switches act upon, but I suspect it is on in-board (logic) side.

And a caution: if toggling the limit defeater on clears the problem, then you can theoretically run the machine. However, any limit switch that is defeated with the DIP switches will appear closed (not tripped) at all times. Therefore you cannot home the machine with a home limit defeated.

[thelinuxman]

Old Linux controller, so no Alt-I. No alarms on the other limits though. I can hit those limit switches and they show an alarm and then clear when I let off the switch, so they seem to be working.
Does the M15 have limit defeat switches? I am familiar with those on the ALLIN1DC and OAK, not sure they even exist on this old controller.
My Z homes to Z+ so I can't really defeat it, unless I home down to Z-.

[centroid467]

Yes, M15DRV has limit defeat switches.

[tylerintesting]

The dip switches are in the middle of the end of the board, the end opposite of the fibers and the relays. If you're opening up the M15 from the LCD side, it should be on your left.

[cncsnw]

All Linux (CNC10) software versions have the Alt-i display. It was introduced in the DOS (CNC7) software, in v8.00.

[thelinuxman]

All Linux (CNC10) software versions have the Alt-i display. It was introduced in the DOS (CNC7) software, in v8.00.

Thank you! I am not sure why I thought that didn't exist on the old Linux controllers. I just brought it up on the two that I am still running.
A little closure (for now) on this topic. I put the M15 back together yesterday and it ran all day & started right back up again this morning. Maybe a dirty connection on the plug going into the M15DRV1 board? Maybe a broken wire that I got moved just right during disassembly/reassembly??

[thelinuxman]

A little closure (for now) on this topic. I put the M15 back together yesterday and it ran all day & started right back up again this morning. Maybe a dirty connection on the plug going into the M15DRV1 board? Maybe a broken wire that I got moved just right during disassembly/reassembly??

This machine ran all day an entire week without a hiccup after putting the controller back together.
This week it starts up fine every morning and runs a couple hours and then starts cycling thru Z- OT and clears, Z+ OT and clears, Estop and clears, occasional X OT thrown in. Those overtravel, estop and clear messages cycle about one per second. If I power it down a few hours and back up I can run another hour or two.

I am back to guessing it is the M15DRV1 board, but I'll take any available advice before I trash it and order a new controller.

[tblough]

If it runs for a while, then errors start showing up, I would suspect heat related issues. Is seems to be input related, so I'd check the 24V power supply first, but check all the fans to make sure they are clean and smooth spinning.

[cncsnw]

It could be a power supply issue, but that is a little unlikely because the PLC inputs on this board use the same 5VDC supply that runs the logic circuits and the computer motherboard assembly.

If that supply were going out, you would have system-wide problems (e.g. PC lockups, or at least "401 PLC failure detected").

Nonetheless, if you have an alternate +5/+12 power supply -- either a switching supply of at least 65W, or an AT- or ATX-style computer supply -- it wouldn't hurt to try connecting it.