Erratic movement on power up that does not stop - [SOLVED]

[billyclaymyers]

I am retro-fitting an AXYZ 4008 machine that I purchased that was running Mach 3, but having an issue with cutting in the corners but seemingly working otherwise.

I purchased an Acorn last year, and have been slowly working to get the machine back up and running. I started with everything in one large enclosure, but was getting this random jerky movement on X and Y (Z not hooked up), and so recently I separated the Power from the Electronics via two enclosures and pass the power into the enclosure with the Acorn.

For Power I am running Meanwell DIN Mount Power Supplies. 2 x SDR-960-48 for the steppers which are KL34H280-55-4A, 1 x EDR-120-24 for the Acorn, 1 x MDR-60-5 5V for the Stepper Drivers.

I am running 4x Gecko Raptor GR214V Stepper Drivers, I have tried them at 2 Micro Steps, 25 Micro Steps, and 32 Micro Steps. at 32 I get the least jerking, but it still occurs. Note that these Micro Step choices were at random, and not diagnostic in any way other than changing things. I have the GR214V set at 5.5 AMP via the dip switches.

This weekend, I hooked everything back up after rebuilding it all. I am using Shielded motor cables to all axes, and to note, the movement is most prevalent on the X Axis, with small jerks in Y, until I unplug X, at which point Y gets the brunt of it. Not sure if that is diagnostic, or simply a result of removing the draw of X and Y being next in line.

X is across the gantry and is the narrow 4 ft axis. Y is paired in Acorn and has one motor reversed. X and Y are Rack and Pinion, but straight cut instead of helical.

All Power comes through a filter, into a Siemens contactor that is wired to power the 48V Power Supplies when the E-Stop is in the NC position. The 24V and 5V Power up immediately and bring the Acorn board online where I get a good heartbeat and can connect to the Acorn from the PC.

I then release the E-Stop bringing the 48V supplies online at which point I get the erratic movement. I can override that with commands from the software or by powering up the remote and moving it with the wheel. When I stop moving, the erratic movement comes back. Not always right away, but within a minute at most. It can be seen with the covers off as the stepper motor jerking one direction, then the other, or maybe many jerks in one direction.

I removed the Step and Direction to isolate the problem to before or after the Raptor's and without the step and direction attached, but all powered, no movement is observed, so I don't believe it to be an issue from the 48V Power out to the motors via the Raptor's.

I was thinking maybe my step and direction wires needed shielding but was told that the Raptor's are good at filtering out the EMI, so to check the Raptor's or the Acorn. 2 of the Raptor's are brand new, and since it affects three of them ( One X, 2 Y) I am less inclined to believe it to be a bad Raptor.

Hoping that maybe someone here has some thoughts on the issue.

NOTE: I have attached an image of the controller enclosure back plate without the stepper wiring output connected.
Blue is +5V
Purple is +48V
Black is a Common Ground between all the power supplies
Yellow is 24V
Green/Yellow is Earth Ground via 4-Wire 220V

Gecko's are wired according the the attached Acorn_Gecko_214V.pdf which is from the official hookup schematics with the optional connections made. The only difference is that I ran the GND from the Raptor to the COM in the DB25 connector using 18-25 since they also tie to COM per the diagram.

Also attached is a breakout showing my wiring colors from the DB25 to the Raptors - Acorn DB25 Pinout.

Thanks in advance,
Billy

[Upnorth]

In my opinion step and direction cables should always be shielded. No exceptions. They are prone to picking up stray electrical noise.

[billyclaymyers]

In my opinion step and direction cables should always be shielded. No exceptions. They are prone to picking up stray electrical noise.

What shielded Step and Direction cables do you recommend?

[cnckeith]

hello. when you say the machine was running with mach3, was mach3 running the raptors?

please post a fresh report.zip

[billyclaymyers]

@CNCKeith The machine was running with Mach3 with the same Motors, different offbrand steppers, which were causing other issues. Acorn has only been configured with the Raptors.

See attached the fresh Report.

Also here is a Google Photos Album with a video showing the Issue. I filmed the X Axis, but the same happens on X and Y and both motors of Y
Warning: Poster, Album not found for https://photos.app.goo.gl/aLcbF6uEF6rreMN5A. Please check the URL by editing the post and try again.

[Upnorth]

The wire I use is Part Number M27500G22SD2T23. It's stuff I get for free that is left over after installing avionics in aircraft so it's good quality. It's twisted pair (or more conductors) and shielded. Teflon insulated so heat and chemical resistant. It can be bought at Aircraft spruce. Look for M27500 wire and then choose the one that suits your needs.

If you live in Canada I can send you a few feet of the wire to get your install done. I have miles of it.

[cnckeith]

@CNCKeith The machine was running with Mach3 with the same Motors, different offbrand steppers, which were causing other issues. Acorn has only been configured with the Raptors.

See attached the fresh Report.

Also here is a Google Photos Album with a video showing the Issue. I filmed the X Axis, but the same happens on X and Y and both motors of Y
Warning: Poster, Album not found for https://photos.app.goo.gl/aLcbF6uEF6rreMN5A. Please check the URL by editing the post and try again.

thanks for the video. that really looks like the phases of the motor are not wired properly.

[cnckeith]

and some what related.
minimum step per rev is 1600. report shows x and z set to 400 which will not produce good results.
see this post for more information. https://centroidcncforum.com/viewtopic.php?f=63&t=1801

[cnckeith]

please create a google photo album and populate with lots of photos of the machine and cabinet etc.. and post link here.

[billyclaymyers]

@cnckeith,

Will go get some photos. As for wiring, the axes move as expected when commanded to move, but when not commanded to move, they sit and jerk like that, so while it is possible the motors are wired incorrectly, It is strange that it moves as expected when commanded to do so.

I will make adjustments to the other axes, but had left them alone since I was trying to get Y working and had actually disconnected Z and also X until today, for taking that video.