Interesting.
On #28 I had a similar failure. But it wasn't heat. Static electricity (I assume) caused the 1st driver port to fail. That machine now has the drivers for the x axis sharing the step output and I flipped the wiring at the driver to keep rotation of the motor correct. Y and z are still solo.

It was the oddest of failures.

Another problem cropped up, I tried to do some motor tuning, more weird thing reveals... I'm using mod.1 24t pinion, direct drive, 10 microstepping, "step per" in theory is 200x10/(24xpi)=26.525 but in this scenario, Mach take 106 which is 4 times the theritical "step per"...

I'm beginning to suspect my intelligence...

I am sure you reloaded Mach. I know this will sound odd, but did you physical move the slider in the motor tuning after entering the number. I found that when I reset the steps field that I had to move the velocity slider for the correct number to take. After that Mach failure

I didn't touch the slider.... a drowning man will move any slider... ;)
Edit,
Update, moved the slider, but still it moved only 1/4 of what it supposed to. eg. g0 x100 yield 25mm movement on x axis.

Try it. Its the weirdest darn thing if it works. Just have to move a tick. I personally think its a buffer issue in Mach , and it is somehow linked to that algorithm on that setting.

ken check your email

Danilo, Max CL mode is checked. If it is unchecked, the motors won't move...

Sean, the slider trick didn't work either...

I'm seriously considering pulling the LPT cable to my running router MM which runs on EMC2 A.K.A LinuxCNC....

It should not be that way,
The native mode for Mach 3 is to provide Step & Direction signals to the stepper controllers for each axis - 2 signals per axis. Maxnc uses "wave drive", presumably for some sort of half or quarter stepping

Your bob might need some sort of "enable" signal beside the charge pump and when in maxnc mode when the pins are automaticaly set it might get it and that is why it works, I had one and just set output in pins&ports enable1 to appropriate lpt pin.


also check units mm/inch , I once had that and after re-tune the motors again.

I'm completely overwhelm by this MaxCL thingy... I have no idea what that is & what it does...

Unit were checked many times I'm mm guy hence no in...

Update again...

Ran a thorough test on the BOB, all the output pins are working properly.

Thanks to Anil's who walked me through the diagnostic test on the BOB

Now most possible problems are eliminate, & it point straight at Mach3...

Posted on Mach support forum & lets wait & see...

Finally, After 2 weeks of hair pulling troubleshooting chore.... while rewiring the control panel, I realized I had my motor pin assigned wrongly, DIR for STEP & vice verse...

All along this time, I knew the problem is gonna be so glaring & right on my face.... Also a simple one to solve... That is IF I can find what was wrong...

All are not lost, something good did came out of my personal blunder, I now know how to monitor parallel port signal, & sending test signal from Mach3 to the BOB... etc etc etc...

It gets confusing, doesn't it!! :D:D

It get's to the point when you swap swapped wires and chaise your tail :)

Hmm, Like you swap wires and also swap signals in mach as well :)

Respect Murphy! :p

Thousand thanks to Anil & Danilo for walking me through all the testing.

Anil even sent me his new drivers.

LOL Ken, Anil was like calling me and was like hitting head on a invisible wall !

finally you figured it out!

Let us know how these work.

Regards
Irfan

Ken most problems are simple ... once solved :)
Before solving though they tend to be significantly more complex and wide ranging.
Well done and a gold star for persistence.

Regards
Ross

...and the persistence of the MM forum prevails again.
Glad to see your up and running Ken!

Surely eye candy is an absolute must

Anil's new & improved BOB & Drivers
Attachment 13558

The cover mount is much improve. & the jumper selector is more reliable than the earlier finger switch.
Attachment 13559

Another view
Attachment 13560

Fresly renovated Control panel looks like this now, Only the motor drivers are connected to BOB.
Attachment 13561

I got paranoid with heat, hence remove the drivers's casing & mount it directly on the external Heat Sink
Attachment 13562

This is how it look from outside.
Attachment 13563

My IR thermometer says the heat sink is 34C, the panel is 36C, the driver boards are around 40C, the transformer remains 50C.
I'm comfortable with these figures :) :)

Funny thing is the fans are 65C...

Ah Ken,

why remove the drive case - I run my tiny's @ 60V DC and at 5 A all the time with no ventilation and mounted on the steel (painted) surface directly ( with heat sink compound) ( I know its not the best way to do it!)- never bothered about them ever!

work horses every day!

Hi Irfan, The spec sheet did mention that it can work with 65C,

The official reason in doing so are, 1) so near the Equator with 32~40C ambient temperature, 2) paranoid... 3)... free up more real estate... 4) what ever... :p

The unofficial (real) reasons are, it looks too cool to resist :D & because I can... :D :D

Ken - from the pics looks like you removed the heatsinks - have you still used the insulated heat pads below the mosfets.?

the fets need to be isolated from eachother.

Yes, I bought some isolation pads for the job & applied heat compound.

FINALLY!!!!!
SPARKS!!! THUNDER!!!

WOOOO HOOOOOO!!!!!

Now I can sleep......

http://www.youtube.com/watch?v=u-s7J...ature=youtu.be

congratulations Ken,
It's a huge machine, I can remember the pile of steel in the corner from your workshop. be careful with all those sparks.

Well done Ken - the video was great to watch.

Regards
Ross

good work ken

Nicely done, félicitation ;)

Ken,
Nicely done - I know the Sparks and fire feeling!

Great job as always.

Ken , try cutting a little lower. it seems you have dross on the upper edge :P

Its ok when the sparks fly parallel to the plane of sheet

Thanks everyone. Its been a nerve wrecking journey, enjoyed it nevertheless.

Couldn't had completed the machine without Danilo#64 tireless guidance on Plasma operation, THC controller, Mach3 THC functions from & Antony#77 on the THC introduction & Anil on the BOB & Drivers trouble shooting.

Danilo, I suspected that too. Still learning the THC & the parameters...
I just inspected the nozzle & it is worn out only after less than 30 minutes of cutting... must be the result of all the wrong settings...

One thing I learnt about the recommended cutting parameters table which came with the operation manual... They are a big pile of crap!!!

The manual stated for 3mm MS plate, when using 60Amp, the feed should be 5060mm/min, cut height 3.8mm & piercing height 4.1mm but after some fiddling, the actual feed speed should be 2200~2400mm/min & cut height is about 2mm... TOTALLY OUT OF EXPECTATION!!!!

I take back this comment, the recommandation is fairly accurate. The error is due to bad cutting height setting... My bad... :o:o

Ken... in three weeks you'll be cutting like a pro (me) :) hehe

Congrats !!! Nice Machine !!!

What torch are you using?

I love post 112 .... "I'd like to thank my ...." just like the awards shows and racing here in the states. :)

:D :D

Thank you thank you... I'll like to thank.... {applause} {Clap clap clap}

Jokes aside, I genuinely appreciate all the help :) :)

Mike, That is a Thermal Dynamics A80 Plasma power source with SL100 machine torch.

Congratulations Ken

It looks as though your control cabinet is on the large size too don't be shy post up the size:D LOL looks like a great build, the way you felt sorting out your wiring is probably the same as I felt for most of my build:o
Hope it brings much happiness to your life.

I have to laugh at how the wheel turns......

When we built the first MechMate (maybe 8 years ago?) everyone tried to build the smallest control cabinet (and had the smallest cellphone). They shook their heads at our "big" control box (without air holes). Today there seems to be a competition for the biggest box (and the biggest cellphone) :D

LOL!!! BIG IS BEAUTIFUL!!!

My boxes are 400(W) x 500(H) x 200 deep. 40 liters each... one for the electronics & the other for the PC. Not as big as I wish... each panel cost about a ready-made PC box, the next size up is nearly double the price...

Tiny in comparison to Duckie‘s double panel 500x600x300 each...

Like I said in my 1st built, a penal this size is TINY in comparison to the actual MM’s actual foot print. What is the good in saving that 10~20 liter ?? & squeezing a PC mother-board in it??? My hand & fingers are just too big for such endeavor...

Gerald, I've seen people actually shouting into 10.4" iPad (as phone) against their favorite side cheek walking on the street.... I can tell they have problem holding it single handed....

Is that what that box is..
Though it was a towel drier for Ken's new swimming pool :D.

Regards
Ross