[yagodajm]

Good evening, I have had my G540 since 2017 and it has been running great. Yesterday my 48V power supply died. I noticed that all of my steppers were not locking like they usually do. After some troubleshooting, I discovered the bad power supply. I got a new power supply and hooked it up. Once I applied power, the steppers locked as they should. My only problem now is that my router turned on when I turned the system on; this is not normal. I have my router running through a relay controlled by output one on my g540. I checked the voltage from outputs 1 and 2, which had 12v. They both should have 0 since I did not even have my UCCNC software started up. I disconnected the ribbon cable from my UCCNC UC300eth, turned my system back on, and started my router. I am not sure why this is happening. Everything was running great before my power supply went bad. I don't even have the 48v power supply running through those two outputs; I have a separate 12v power supply powering my relays. I checked the diagnostics in my UCCNC software, and M3 was not lit up. When I press M3, the light lights up, but the router stays on. I am not sure what is going on.

Any help would be greatly appreciated.

Thanks,
Justin

[phomann]

Hi Justin,
It sounds like the two FETs that drive the outputs have failed “On”.
It is quite common for FETs when they fail to do so in the “On” state. It is one of the reasons why you should have an Estop that removes the power from the controller, rather than just feeding into the software to action.

My guess is that when the power supply failed it put a surge through the G540 damaging the output FETs.
Do the G540 inputs still work correctly?

You may need to replace the G540 motherboard. You can get them from Geckodrive or a distributor.

https://www.homanndesigns.com/index....roducts_id=281

The FETs could also be replaced, check with Geckodrive.

Sorry, the news is not better.

Cheers

Peter


Sent from my iPhone using Tapatalk Pro

[yagodajm]

Hi Justin,
It sounds like the two FETs that drive the outputs have failed “On”.
It is quite common for FETs when they fail to do so in the “On” state. It is one of the reasons why you should have an Estop that removes the power from the controller, rather than just feeding into the software to action.

My guess is that when the power supply failed it put a surge through the G540 damaging the output FETs.
Do the G540 inputs still work correctly?

You may need to replace the G540 motherboard. You can get them from Geckodrive or a distributor.

https://www.homanndesigns.com/index....roducts_id=281

The FETs could also be replaced, check with Geckodrive.

Sorry, the news is not better.

Cheers

Peter


Sent from my iPhone using Tapatalk Pro

Good morning Peter, I was thinking it would be something along those lines. I do have an estop on my G540, I also have a switch on the A/C side as stated in the G540 Manual. There are no switches on the DC side. Yes, I do have inputs, my touch prode runs through my G540. I tested it lastnight and it is working correctly. I also have 3 limit switches and they are all working correctly also. It is just very odd that it took out those to FET's. I am trying to get in contact with Gecko to see what they can do. If it is just simply replacing them, I may just do that.

Thanks for you help.

Justin

[elephantcnc]

Hi Justin,

It sounds like your G540’s output signals might have been affected during the power supply failure. Let’s troubleshoot step by step:

Steps to Diagnose and Resolve the Issue
Inspect G540 and Wiring:

Double-check all connections, especially between the G540, relays, and the 12V power supply. Ensure nothing is shorted or miswired.
Test Relay Operation:

Disconnect the router from the relay temporarily.
Manually test the relay by sending an M3 (spindle on) and M5 (spindle off) command in UCCNC. Observe whether the relay clicks appropriately.
Measure Output Voltage:

With the G540 powered but no commands sent, measure the voltage at outputs 1 and 2 again. A consistent 12V may indicate a signal or hardware issue.
Inspect Ribbon Cable and UC300ETH:

Since disconnecting the ribbon cable still caused the router to turn on, the issue might be internal to the G540.
Recheck the UC300ETH diagnostics to confirm it’s not inadvertently sending a signal.
Test Outputs Without Load:

Remove the relay and measure the voltage on outputs 1 and 2 with no load. If the outputs still show 12V, the G540 might have a fault in its internal circuitry.
Reset or Reflash the G540:

If your G540 supports a reset, perform it. A corrupted state in its internal logic could cause erratic behavior.
Potential Root Cause
The failure of your 48V power supply might have introduced a transient voltage spike or surge, potentially damaging or altering the behavior of the G540’s output circuitry.

Solutions If Hardware Is Faulty
If the G540 outputs remain stuck, you might need to repair or replace the G540.
Temporarily reroute the relay to a different output, if available, and reconfigure UCCNC to control the new output.
This is our contact information, maybe we can help you:
https://www.elephant-cnc.com/
https://www.cncrouter-shop.com/
Email: [email protected]
Whatsapp/mobile: +86-15064026772

- - - Updated - - -

Hi Justin,

It sounds like your G540’s output signals might have been affected during the power supply failure. Let’s troubleshoot step by step:

Steps to Diagnose and Resolve the Issue
Inspect G540 and Wiring:

Double-check all connections, especially between the G540, relays, and the 12V power supply. Ensure nothing is shorted or miswired.
Test Relay Operation:

Disconnect the router from the relay temporarily.
Manually test the relay by sending an M3 (spindle on) and M5 (spindle off) command in UCCNC. Observe whether the relay clicks appropriately.
Measure Output Voltage:

With the G540 powered but no commands sent, measure the voltage at outputs 1 and 2 again. A consistent 12V may indicate a signal or hardware issue.
Inspect Ribbon Cable and UC300ETH:

Since disconnecting the ribbon cable still caused the router to turn on, the issue might be internal to the G540.
Recheck the UC300ETH diagnostics to confirm it’s not inadvertently sending a signal.
Test Outputs Without Load:

Remove the relay and measure the voltage on outputs 1 and 2 with no load. If the outputs still show 12V, the G540 might have a fault in its internal circuitry.
Reset or Reflash the G540:

If your G540 supports a reset, perform it. A corrupted state in its internal logic could cause erratic behavior.
Potential Root Cause
The failure of your 48V power supply might have introduced a transient voltage spike or surge, potentially damaging or altering the behavior of the G540’s output circuitry.

Solutions If Hardware Is Faulty
If the G540 outputs remain stuck, you might need to repair or replace the G540.
Temporarily reroute the relay to a different output, if available, and reconfigure UCCNC to control the new output.
This is our contact information, maybe we can help you:
https://www.elephant-cnc.com/
https://www.cncrouter-shop.com/
Email: [email protected]
Whatsapp/mobile: +86-15064026772