New DMM Servo install

[Raceman17]

Me-811 mechanical push button switches. The wiring is "temporary". They are all wired in series using input 1 on the acorn.

[Raceman17]

So interesting thing happens... if I home the machine and as soon as it gets done with the homing sequence I can immediately move the axis off the home position and it wont fault out. If I dont move the axis it will fault out. 

[martyscncgarage]

Can you please post a fresh report....

[Raceman17]

Please see the attached report. The machine has been sitting for an hour after I moved the axis off of the home switch locations with ZERO faults.

[martyscncgarage]

Are your revolutions per inch correct? They do NOT seem correct. Measure how many ballscrew threads there are in an inch:
I would imagine you probably have closer to 5 threads per inch on your ballscrews.
Please double check this.
You have the DMM DYN4's set to GEAR and LINE to 2000 correct?
Can you tell us exactly where your home switches are placed on the machine?
It appears:
Z switch trips at the top of Z
X trips at the RIGHT end of the table
Y trips near the column

Marty

Axis Label Motor Encoder Lash Comp. Limit Home Dir Screw
revs/in counts/rev. (inches) - + - + Rev Comp
1 X 1.5835 8000 0.0000 0 0 0 1 Y N
2 Y 1.5835 8000 0.0000 0 0 1 0 N N
3 Z 2.4814 8000 0.0000 0 0 0 1 Y N

Also, do you have your soft limits set correctly?
CNC12 v. 4.20 coordinates file
Axis Minus Plus Return Return Return Return
Limit Limit #1(G28) #2(G30) #3 #4
X -39.0000 0.0000 0.00000 0.00000 0.00000 0.00000
Y 0.0000 19.0000 0.00000 0.00000 0.00000 0.00000
Z -19.0000 0.0000 0.00000 0.00000 0.00000 0.00000

Here is your log file, note a number of X axis exceeded in your logs:
(1) 04-09-2020 15:55:32 199 CNC Started
(4) 04-09-2020 15:55:36 9039 Software Exited, Cycle E-Stop/Reset to Continue
(1) 04-09-2020 15:55:39 CNC12 Acorn Mill v4.20 (revision 4.20.1) Jan 17 2020, 09:50:30
(4) 04-09-2020 15:55:39 9039 Software Exited, Cycle E-Stop/Reset to Continue
(4) 04-09-2020 15:55:41 9033 Reset Initiated, Press Reset to Clear
(4) 04-09-2020 15:55:42 4032 Reset Cleared
(4) 04-09-2020 15:56:29 9031 DRIVE FAULT!
(4) 04-09-2020 15:57:30 9033 Reset Initiated, Press Reset to Clear
(4) 04-09-2020 15:57:31 4032 Reset Cleared
(4) 04-09-2020 15:57:38 9031 DRIVE FAULT!
(4) 04-09-2020 15:58:20 9033 Reset Initiated, Press Reset to Clear
(4) 04-09-2020 15:58:21 4032 Reset Cleared
(4) 04-09-2020 15:58:28 9031 DRIVE FAULT!
(4) 04-09-2020 15:58:57 9033 Reset Initiated, Press Reset to Clear
(4) 04-09-2020 15:58:58 4032 Reset Cleared
(4) 04-09-2020 15:59:01 907 X axis travel exceeded
(4) 04-09-2020 15:59:05 907 X axis travel exceeded
(4) 04-09-2020 15:59:11 907 X axis travel exceeded
(4) 04-09-2020 15:59:31 9031 DRIVE FAULT!
(4) 04-09-2020 16:05:03 9033 Reset Initiated, Press Reset to Clear
(4) 04-09-2020 16:05:04 4032 Reset Cleared
(4) 04-09-2020 16:05:12 9031 DRIVE FAULT!
(4) 04-09-2020 16:06:14 9033 Reset Initiated, Press Reset to Clear
(4) 04-09-2020 16:06:15 4032 Reset Cleared
(4) 04-09-2020 16:06:21 9031 DRIVE FAULT!
(4) 04-09-2020 16:09:40 9033 Reset Initiated, Press Reset to Clear
(4) 04-09-2020 16:09:41 4032 Reset Cleared
(4) 04-09-2020 16:09:49 9031 DRIVE FAULT!
(4) 04-09-2020 16:10:58 9033 Reset Initiated, Press Reset to Clear
(4) 04-09-2020 16:10:59 4032 Reset Cleared
(4) 04-09-2020 16:11:00 907 X axis travel exceeded
(4) 04-09-2020 16:11:02 9033 Reset Initiated, Press Reset to Clear
(4) 04-09-2020 16:11:03 4032 Reset Cleared
(4) 04-09-2020 16:11:04 9031 DRIVE FAULT!
(4) 04-09-2020 16:11:06 9033 Reset Initiated, Press Reset to Clear
(4) 04-09-2020 16:11:07 4032 Reset Cleared
(4) 04-09-2020 16:11:07 907 X axis travel exceeded
(4) 04-09-2020 16:11:35 9033 Reset Initiated, Press Reset to Clear
(4) 04-09-2020 16:11:36 4032 Reset Cleared
(4) 04-09-2020 16:11:37 907 X axis travel exceeded
(4) 04-09-2020 16:11:43 9031 DRIVE FAULT!
(4) 04-09-2020 16:11:46 9033 Reset Initiated, Press Reset to Clear
(4) 04-09-2020 16:11:47 4032 Reset Cleared
(4) 04-09-2020 16:12:15 907 X axis travel exceeded
(4) 04-09-2020 16:12:24 9033 Reset Initiated, Press Reset to Clear
(4) 04-09-2020 16:12:25 4032 Reset Cleared
(4) 04-09-2020 16:12:26 907 X axis travel exceeded
(4) 04-09-2020 16:12:43 9031 DRIVE FAULT!
(4) 04-09-2020 16:13:49 9033 Reset Initiated, Press Reset to Clear
(4) 04-09-2020 16:13:50 4032 Reset Cleared
(4) 04-09-2020 16:13:57 9031 DRIVE FAULT!
(4) 04-09-2020 16:16:47 9033 Reset Initiated, Press Reset to Clear
(4) 04-09-2020 16:16:48 4032 Reset Cleared
(4) 04-09-2020 16:17:43 9031 DRIVE FAULT!
(4) 04-09-2020 16:24:23 9033 Reset Initiated, Press Reset to Clear
(4) 04-09-2020 16:24:24 4032 Reset Cleared
(4) 04-09-2020 16:24:36 907 X axis travel exceeded
(4) 04-09-2020 16:26:23 9031 DRIVE FAULT!
(4) 04-09-2020 16:26:43 9033 Reset Initiated, Press Reset to Clear
(4) 04-09-2020 16:26:44 4032 Reset Cleared
(4) 04-09-2020 16:26:55 907 Y axis travel exceeded
(4) 04-09-2020 16:30:17 9031 DRIVE FAULT!
(4) 04-09-2020 16:30:31 9033 Reset Initiated, Press Reset to Clear
(4) 04-09-2020 16:30:32 4032 Reset Cleared
(4) 04-09-2020 17:23:17 9031 DRIVE FAULT!

[Raceman17]

Yes the revolutions per inch is correct. These ball screws are huge. The x and y screws are 1.76" in diameter and the z is slightly smaller. Both line and gear are set to 2000 in the DMM software. The z axis switch is placed on the upper column so the z axis carriage hits it at the top of the travel. The y axis is placed at the bottom of the z axis colum and the xy saddle hit it when it travels to the back towards the colum. The x axis switch is placed on the xy saddle and a bracket is attached to the table. Once it homes the bracket hits the switch to trip. The xyz soft limits are correct. They are set just slightly less then the machine travel. I cant say why the travel exceeds were showing up but it wasnt because it was hitting any hard limits. I remember in was having an issue with the x axis responding so I was just trying to get it to move. I think i reset acorn and then those stopped.

[martyscncgarage]

Your are saying that in ONE INCH of ballscrew there is only 1.5 threads??
I'd like to see a picture of that...

I am at a loss what to suggest to you next....
Maybe just strip down Acorn to ONE axis, remove all the wiring except power to the X drive and it logic input, no contactor, one limit switch. Turn off Y and Z in the Wizard. Only one DB25 cable from Acorn to X axis DYN4. See if you can get Acorn to home X only and create a small G code program to move X back and forth.

Just posted a video of my FADAL running with Oak and 3 DYN4 drives, 1.3KW servos....no faults, haven't even tuned it yet with DMMDRV....
I really don't have the trouble you guys are having with DYN4s....I'm sorry, I wish I could be of more help. Drop back to basics, ONE axis get it working, the get Y working. Use separate Home inputs. One pair of wire for each Home switch.


Marty

[Raceman17]

I definitely wasnt looking for this much trouble when I started I can assure you that. I've been talking with DMM daily on these issues and they have been giving suggestions. Right now we are looking at the motor monitor in the software and seeing what the torque of the servos are when they are running. This is just a weird problem. It doesnt make sense. As soon as it homes it will fault out within seconds of finishing. If I can beat the fault after it homes and move each axis the fault will not appear. I can run the Box program I have and run the machine tnrough the x and y travels for 45 minutes and it runs fine. Tomorrow I will hook each axisnupnto an input before I tear all the wiring down and start from scratch. I really do appreciate all the help and guidance. Here's a pic of the y axis ball screw.

[martyscncgarage]

Wow. You'd need more torque I would think...
But I don't understand why they would fault just sitting there. Especially X and Y

[Raceman17]

The z axis has the 1.8kw motor and the x and y has the 1.3kw motor. DMM assured me that their servos could handle the size of the machine. I've already had to swap to the 1.8kw motor because their calculations were off on the z axis. Heres a pic of the original machine specifications. The ballscrew info is wrong for some reason. My machine has larger x and y screws. The z is correct.