Calmotion USB wont run whole program

I need some help guys. My new to me 1988 Fadal 4020 has been a work in progress. But I can run a short program from the Calmotion USB but not larger programs.
At first I thought it was my Fusion 360 putting out strange code but I had a professional check it out and he said the code was good.

So basicaly it will stop short then jump back to the beginning of the program and start from the beginning.

Any ideas ?
Baud rate is set correct -9600

CD,8 (enter)
DNC, 1008.txt+

Is how I get the controler to read it.

Looking for suggestions.

Calmotion USB was baught new Oct 2020

Thanks!

...some things are not allowed in Programs when running DNC. Like no SubProgram calls or Looping maybe causing the problem.

Read more Chapter 14.2.4 (page 342)
https://fadalparts.net/content/Fadal...r%20Manual.pdf

MachineHop5,
Thanks for the reply . I made sure I didn't have any sub routines or Looping - I understand they will confuse it.

Quote:

---

Originally Posted by AirChunk

MachineHop5,
Thanks for the reply . I made sure I didn't have any sub routines or Looping - I understand they will confuse it.

---

Post you program just cut and paste the area where there seems to be a problem

Its somewhere around line 2800.
Its part of the engraving portion.
Thanks!

N2725 X-2.3838 Y-0.4161 Z-0.0127
N2730 X-2.3782 Y-0.4117 Z-0.0128
N2735 X-2.3725 Y-0.4065 Z-0.0129
N2740 X-2.3669 Y-0.4006 Z-0.013
N2745 X-2.3614 Y-0.3939 Z-0.0132
N2750 X-2.3562 Y-0.3867 Z-0.0135
N2755 X-2.3513 Y-0.3789 Z-0.0137
N2760 X-2.3469 Y-0.371 Z-0.0139
N2765 X-2.3429 Y-0.3624 Z-0.014
N2770 X-2.3392 Y-0.3531 Z-0.0141
N2775 X-2.3365 Y-0.3447 Z-0.0143
N2780 X-2.3347 Y-0.3379 Z-0.0144
N2785 X-2.3329 Y-0.329
N2790 X-2.3317 Y-0.3198 Z-0.0145
N2795 X-2.331 Y-0.3103
N2800 X-2.3308 Y-0.3002
N2805 X-2.3311 Y-0.2911 Z-0.0144
N2810 X-2.332 Y-0.2823 Z-0.0143
N2815 X-2.3333 Y-0.2743 Z-0.0141
N2820 X-2.3352 Y-0.2666 Z-0.014
N2825 X-2.3371 Y-0.2608 Z-0.0139
N2830 X-2.3399 Y-0.254 Z-0.0138
N2835 X-2.3426 Y-0.2487 Z-0.0137
N2840 X-2.3461 Y-0.2434 Z-0.0136
N2845 X-2.3502 Y-0.2382 Z-0.0134
N2850 X-2.3538 Y-0.2343 Z-0.0133
N2855 X-2.3579 Y-0.2306 Z-0.0131
N2860 X-2.3628 Y-0.2268 Z-0.0129
N2865 X-2.3673 Y-0.224 Z-0.0127
N2870 X-2.3722 Y-0.2216 Z-0.0125
N2875 X-2.3774 Y-0.2195 Z-0.0123
N2880 X-2.3837 Y-0.2176 Z-0.0122
N2885 X-2.3896 Y-0.2164 Z-0.0121
N2890 X-2.3976 Y-0.2153 Z-0.0119
N2895 X-2.4072 Y-0.2146 Z-0.0118
N2900 X-2.4194 Y-0.2142 Z-0.0117
N2905 X-2.423
N2910 X-2.4671
N2915 X-2.4716 Y-0.2146 Z-0.0121
N2920 X-2.4761 Y-0.2157 Z-0.0132
N2925 X-2.4806 Y-0.2174 Z-0.0149
N2930 X-2.4927 Y-0.2025 Z0.
N2935 X-2.4806 Y-0.2174 Z-0.0149
N2940 X-2.4821 Y-0.2212 Z-0.0142
N2945 X-2.4832 Y-0.2251 Z-0.0139
N2950 X-2.5236 Y-0.4183
N2955 X-2.5242 Y-0.4225 Z-0.0142
N2960 Y-0.4268 Z-0.015
N2965 X-2.5238 Y-0.4312 Z-0.0163
N2970 G0 Z0.225
N2975 G1 X-2.2907 Y-0.4475 F100.
N2980 G0 Z0.2
N2985 G1 Z0. F20.
N2990 X-2.2737 Y-0.4336 Z-0.0139
N2995 X-2.2625 Y-0.4475 Z0.
N3000 X-2.2737 Y-0.4336 Z-0.0139
N3005 X-2.2532 Y-0.3356 Z-0.0138
N3010 X-2.252 Y-0.3312 Z-0.0142
N3015 X-2.2501 Y-0.3269 Z-0.0151
N3020 X-2.2475 Y-0.3227 Z-0.0168
N3025 X-2.2482 Y-0.3178 Z-0.0151
N3030 Y-0.3131 Z-0.0141
N3035 X-2.2476 Y-0.3085 Z-0.0138
N3040 X-2.2299 Y-0.2241
N3045 X-2.2289 Y-0.2206 Z-0.014
N3050 X-2.2276 Y-0.2171 Z-0.0146
N3055 X-2.2395 Y-0.2025 Z0.
N3060 X-2.2276 Y-0.2171 Z-0.0146

Quote:

---

Originally Posted by AirChunk

Its somewhere around line 2800.
Its part of the engraving portion.
Thanks!

N2725 X-2.3838 Y-0.4161 Z-0.0127
N2730 X-2.3782 Y-0.4117 Z-0.0128
N2735 X-2.3725 Y-0.4065 Z-0.0129
N2740 X-2.3669 Y-0.4006 Z-0.013
N2745 X-2.3614 Y-0.3939 Z-0.0132
N2750 X-2.3562 Y-0.3867 Z-0.0135
N2755 X-2.3513 Y-0.3789 Z-0.0137
N2760 X-2.3469 Y-0.371 Z-0.0139
N2765 X-2.3429 Y-0.3624 Z-0.014
N2770 X-2.3392 Y-0.3531 Z-0.0141
N2775 X-2.3365 Y-0.3447 Z-0.0143
N2780 X-2.3347 Y-0.3379 Z-0.0144
N2785 X-2.3329 Y-0.329
N2790 X-2.3317 Y-0.3198 Z-0.0145
N2795 X-2.331 Y-0.3103
N2800 X-2.3308 Y-0.3002
N2805 X-2.3311 Y-0.2911 Z-0.0144
N2810 X-2.332 Y-0.2823 Z-0.0143
N2815 X-2.3333 Y-0.2743 Z-0.0141
N2820 X-2.3352 Y-0.2666 Z-0.014
N2825 X-2.3371 Y-0.2608 Z-0.0139
N2830 X-2.3399 Y-0.254 Z-0.0138
N2835 X-2.3426 Y-0.2487 Z-0.0137
N2840 X-2.3461 Y-0.2434 Z-0.0136
N2845 X-2.3502 Y-0.2382 Z-0.0134
N2850 X-2.3538 Y-0.2343 Z-0.0133
N2855 X-2.3579 Y-0.2306 Z-0.0131
N2860 X-2.3628 Y-0.2268 Z-0.0129
N2865 X-2.3673 Y-0.224 Z-0.0127
N2870 X-2.3722 Y-0.2216 Z-0.0125
N2875 X-2.3774 Y-0.2195 Z-0.0123
N2880 X-2.3837 Y-0.2176 Z-0.0122
N2885 X-2.3896 Y-0.2164 Z-0.0121
N2890 X-2.3976 Y-0.2153 Z-0.0119
N2895 X-2.4072 Y-0.2146 Z-0.0118
N2900 X-2.4194 Y-0.2142 Z-0.0117
N2905 X-2.423
N2910 X-2.4671
N2915 X-2.4716 Y-0.2146 Z-0.0121
N2920 X-2.4761 Y-0.2157 Z-0.0132
N2925 X-2.4806 Y-0.2174 Z-0.0149
N2930 X-2.4927 Y-0.2025 Z0.
N2935 X-2.4806 Y-0.2174 Z-0.0149
N2940 X-2.4821 Y-0.2212 Z-0.0142
N2945 X-2.4832 Y-0.2251 Z-0.0139
N2950 X-2.5236 Y-0.4183
N2955 X-2.5242 Y-0.4225 Z-0.0142
N2960 Y-0.4268 Z-0.015
N2965 X-2.5238 Y-0.4312 Z-0.0163
N2970 G0 Z0.225
N2975 G1 X-2.2907 Y-0.4475 F100.
N2980 G0 Z0.2
N2985 G1 Z0. F20.
N2990 X-2.2737 Y-0.4336 Z-0.0139
N2995 X-2.2625 Y-0.4475 Z0.
N3000 X-2.2737 Y-0.4336 Z-0.0139
N3005 X-2.2532 Y-0.3356 Z-0.0138
N3010 X-2.252 Y-0.3312 Z-0.0142
N3015 X-2.2501 Y-0.3269 Z-0.0151
N3020 X-2.2475 Y-0.3227 Z-0.0168
N3025 X-2.2482 Y-0.3178 Z-0.0151
N3030 Y-0.3131 Z-0.0141
N3035 X-2.2476 Y-0.3085 Z-0.0138
N3040 X-2.2299 Y-0.2241
N3045 X-2.2289 Y-0.2206 Z-0.014
N3050 X-2.2276 Y-0.2171 Z-0.0146
N3055 X-2.2395 Y-0.2025 Z0.
N3060 X-2.2276 Y-0.2171 Z-0.0146

---

It might have lost it's Feed rate, should not have, the program looks ok, so you could try by adding some feed rates in that area

Or the program may be to long for the control to run it, if so you may have to break up the program

...If your machine has DNCX try using that command. If not, I would suspect the cable between the Calmo and the RS232 plug. First check the grounding lug on the RS232 plug to Cabinet by removing it and scraping the paint off so there is no questions about good grounding. Also try/check in the parameters (SETP) for Buffering that it is set max 255.
good luck

Thanks man . After talking to Calmotion today they wanted the whole unit I bought from them back . They helped me do some troubleshooting and they think the firmware in the Calmotion black box was corrupted. So I sent it back to them to be fixed .
Ill report back after it returns to see if it works properly.

Quote:

---

Originally Posted by AirChunk

Thanks man . After talking to Calmotion today they wanted the whole unit I bought from them back . They helped me do some troubleshooting and they think the firmware in the Calmotion black box was corrupted. So I sent it back to them to be fixed .

---

...would have been nice if, they just send you a new unit... or better yet personally showed up to fix it. :) we wish

Machinehop5,
Yeah it would of been really good if they would of just exchanged it for a good one.
The lady out there said it would only be a couple of days to fix it. But Now I am at the 2 week mark since they recieved it and I am still waiting .
Grrrrrrr

I have the calmotion and I have not had problems. I recommend it. I generate codes with mastercam. I think you should use the .nc extension it would look like this. cd, 8 dnc.1000.nc + the program should start like this. or 1000;

Still chasing issues - How big/how many lies of program have you ran?

I never had any luck with my Calmotion either. Short or fairly small programs were okay, but larger ones gave me problems. Contacting Calmotion really didn't help in my case and I simply unplugged mine and quit using it. I hope they get you fixed up.

i had this problem before as wel
there is the settings file on the calmotion try to put the baud rate you will be using in there as well that worked for me
now I can run programs with 100k more lines no problem

if you'd like i can share my settings file of my calmotion card

i can now run adaptive programs no problem only very small vast movement then it will struggle a bit but still work

hope this wil help

Check grounding. I had a heck of a time in my previous shop with intermittent problems. All was traced back to bad grounding. In my new shop with new wiring I haven't had a problem.