ClearPath Trouble - Step Input timing error - Resolved!

[cbb1962]

I have installed new ClearPath servos on my machine and it jogs and moves great until I run a program. (a previously run program)

https://youtu.be/A5SISb24WlM

The error I get on the ClearPath software is "Step Input Timing Error." I found this thread viewtopic.php?f=60&t=2913&p=21244&hilit ... ror#p21244 And cnckeith suggested going back to the ClearPath bench test settings. I reset all inputs to the ClearPath defaults and unplugged the output header from the acorn and the motors didn't lock up. I plugged the output header back in and got the "Step Input Timing Error" again.

I rewired my output header to correspond to the default settings and retried and got the same error. I unplugged the output header and no error...
What I have done so far:

• Wired according to the ClearPath multiple motors schematic.

• Verified wiring

• I have not connected HLFB.

• I Tuned the motors with the ClearPath software.

• Set Wizard to ClearPath Defaults unplugged output header- No Lockups

• ClearPath Defaults - plugged in output header- Locked up

• Set Wizard to my input configuration - unplugged output header- No Lockups

• My input configuration - plugged in output header- Locked up

• Jogged machine without issue either setting

I suspect it is something that I am overlooking.

report_38D2695C8301-0122180576_2019-04-25_19-15-17.zip

(251.28 KiB) Downloaded 100 times

ClearPath X-Axis Tuning values.txt

(5.02 KiB) Downloaded 84 times

ClearPath Y-Axis Tuning values.txt

(5.02 KiB) Downloaded 92 times

ClearPath Z-Axis Tuning values.txt

(5.02 KiB) Downloaded 94 times

[Gary Campbell]

Explain how/where you arrived at the "Step Input Timing" message.

Post the schematic that you have used and show a closeup picture of the ClearPath connections on H2/H3

When you tuned the motors, the X for example, how much of the ~23" motion did you use for the tuning process?

What power supply are you using? (tt:)

Are you using Teknic provided wires?

Are you using a Power Hub?

If you are using the OEM 24/5vdc power supply, what items are using 24V? What about 5v?

[cbb1962]

Explain how/where you arrived at the "Step Input Timing" message.

After the Motors kept stopping, I started the ClearPath MSP program. I read that you could run the program to monitor the activity while another program was controlling the motor. I could watch the encoder counts and the RPMs when the motor stopped it displayed this message. The picture shows an input resolution of 2,000, this was later changed back to 6400.

Post the schematic that you have used and show a closeup picture of the ClearPath connections on H2/H3

S14972-ACORN_rev4_MULTIPLE_CLEARPATH_SDSK_SERIES_MOTORS.pdf

(163.49 KiB) Downloaded 90 times

When you tuned the motors, the X for example, how much of the ~23" motion did you use for the tuning process?

Full range of motion, just like the ClearPath video I watched.

What power supply are you using? (tt:)

I am using the IPC-5

Are you using Teknic provided wires?

Yes, the power cables I used the stock power supply cables and bought the pins and connectors and added the cable and connector for the third axis. I used the Clearpath control cables, I had to add a couple of feet for the Z-Axis I used 22ga 8-conductor wire

Are you using a Power Hub?

No

If you are using the OEM 24/5vdc power supply, what items are using 24V? What about 5v?

I am using the OEM 24VDC Power Supply, the recommended Mean Well 24V/5V was defective, I have a replacement coming tomorrow. The only thing other than the Acorn on 24v is a relay board for the spindle and flood outputs. I have the 5V relay board from Centroid but because the 5v PS was toast and the HLFB was an optional connection I didn't connect it at this time.

[Gary Campbell]

What are the Orange Jumpers for on the ENA terminals in your picture?

Where do you have the (control cable ) Black, White & Blue wires connected to?

[cbb1962]

What are the Orange Jumpers for on the ENA terminals in your picture?

I have two NC switches on the e-Stop button -one for the actual e-stop, the other for the enable circuit. I tried to replicate the drawing.

Where do you have the (control cable ) Black, White & Blue wires connected to?

They are connected to +24VDC you can see them in this picture, so I guess my earlier statement I omitted that the Clearpath's were also connected to 24VDC.

[Gary Campbell]

I have two NC switches on the e-Stop button -one for the actual e-stop, the other for the enable circuit. I tried to replicate the drawing.

I don't use the enable terminals as they don't seem to work well with the HLFB when used as an alarm. (when using servo power contactor driven by "OkFault" configured output)

All looks good to me, you might be best served to verify all your signals and then contact Teknic support

[DannyB]

I have installed new ClearPath servos on my machine and it jogs and moves great until I run a program. (a previously run program)

https://youtu.be/A5SISb24WlM

The error I get on the ClearPath software is "Step Input Timing Error." I found this thread viewtopic.php?f=60&t=2913&p=21244&hilit ... ror#p21244 And cnckeith suggested going back to the ClearPath bench test settings. I reset all inputs to the ClearPath defaults and unplugged the output header from the acorn and the motors didn't lock up. I plugged the output header back in and got the "Step Input Timing Error" again.

I rewired my output header to correspond to the default settings and retried and got the same error. I unplugged the output header and no error...
What I have done so far:

• Wired according to the ClearPath multiple motors schematic.

• Verified wiring

• I have not connected HLFB.

• I Tuned the motors with the ClearPath software.

• Set Wizard to ClearPath Defaults unplugged output header- No Lockups

• ClearPath Defaults - plugged in output header- Locked up

• Set Wizard to my input configuration - unplugged output header- No Lockups

• My input configuration - plugged in output header- Locked up

• Jogged machine without issue either setting

I suspect it is something that I am overlooking.
report_38D2695C8301-0122180576_2019-04-25_19-15-17.zip
ClearPath X-Axis Tuning values.txtClearPath Y-Axis Tuning values.txtClearPath Z-Axis Tuning values.txt

Like Gary said, this all looks pretty darn sane at a glance.
I don't remember offhand if the MSP scope can display the step input stream, but that would be really helpful.
(you may need a cheap logic analyzer if it can't).

I've talked with teknic about step input timing errors, and they really should only show up when the input signal is noisy (or something is otherwise broken). The min pulse width the drives can accept is 1us, which is 1,000,000 steps a second. They do some amount of signal filtering, but also note that's a lot of steps/second for a non-differential signal.

It's also like 9400rpm at 6400 steps/rev, so unachievable in practice anyway
In my case, the step signal was floating when the drives were not enabled (This was not on an acorn). This caused pulses greater than the filtering time but less than the minimum step width, which the drive detected.

[Richards]

What happens if the router motor is disconnected when you run an air cut? If jogging works with the router motor off (higher step rates) but normal moves don't workwith router motor on (lower step rates), the problem may be electrical interference from the router motor..

[wellington_tregear]

Try this: run a new step wire and direction wire from the acorn terminal to the clearpath and test.

[cbb1962]

I jogged with the spindle-on and got the error on all axis. It is definitely spindle noise.

I had a lot of extra loose wire running to the step and direction terminals on the Acorn, I trimmed them all shorter and I was able to eliminate the error on the X and Y axis'. I still have the error on the Z.

I can induce the error by turning on the spindle manually at a slow speed 2,000 RPMs and the ClearPath will error out without movement. It takes some Z movement to make it error when the RPMs are at 24,000 RPMs.

I extended the Z-Axis cable, (each wire soldered) but it is also in the closest proximity to the spindle. Is there a way to know where the noise is actually coming from??