[Arbo]

I have had my setup/machine for a while. Went out today to turn it on to run a project after it not being on for a couple months.

Now it shows that an estop button has been pressed. I can not clear it. There is no estop button, just a straight wire running where an estop would be. Nothing has changed in my setup, nothing changed on the control setup.

Just curious as to what this might be, and if it may mean I am hosed because the 540 suddenly went bad.

Out of curiosity I reversed the low/high signal for estop in the software, but then the machine does not respond to movements at all.

Paul

[Arbo]

I disconnected all the motors as well. No difference. When mach comes up, I do get the green light on the G540.

[CarveOne]

I had a situation where I was using my G540 laying on the side of the APC UPS case that it is mounted it. When I turned the case right side up it did what you describe. Lay it over on the side again and it would work.

The cause turned out to be the jumper wire on pin 10 that is used when no e-stop switch is installed had a terminal screw that was not quite tight enough against the jumper wire. It felt tight when I originally installed the G540 in the case, but it was not. Try that fix and see if it improves.

CarveOne

[Arbo]

Yeah, I actually moved the case from upright to it's side, didn't make any difference. When I get a chance I'll unhook everything and recheck the connections, but I am doubting that is it.

[Arbo]

I downloaded a new 540.xml from gecko. Set that up for charge pump and estop only. And get the same issue.

This is very odd.

Unfortunately something touched something it shouldn't of touched, and the internal fuse in the 540 blew. Just verified it is open. So just ordered a few from digikey.

I guess when I get that replaced, if that's all that happened and it powers up, I need to try a new parallel cable, and then pull out a spare PC and try it on that... other than that I have no idea.

[Arbo]

I found that on the 'estop' pin, the gecko was sending .8v.... that doesn't seem like it should be a 'on' signal, but when I disconnect that pin, it went away.

Then I learned my Y drive was not driving. Fiddled with it a bit and blew one of the drives in the 540. Then found a loose wire on the y drive.

So the 540 is fixed and being sent back, hopefully that solves everything. Will see when it arrives.

[Arbo]

Well, the machine seems to be working. Some odd stuff going on though. It seems estop and spindle on/off are reversed in terms of signals received. M5 starts the spindle and M3 shuts it off. But the probe seems to be correct.

[ger21]

Is the active low set wrong on the spindle relay pin?

[Arbo]

It doesn't seem to matter if I set it active low or high. Seems to act the same way. It is cutting something now, when it's done I will check again.

I also just set up mach on a spare computer and will hook that up as well to see if it is the port on the one I'm using.

[Arbo]

Well, I tried it normal and active low selected. Same exact outcome. Hooked up the other computer, same exact thing. Also estop is reversed on the other computer.

Not sure where to go from here.

[Arbo]

There were a few different issues, and sending the controller back into the manufacturer took care of all the issues.