[CURST991]

Old laptop running Windows XP dedicated to operating CNC only
Smoothstepper ESS
Mach 3

Unfortunately the faults happen when Im 3 hours into a long 3D carving toolpath.

Last year I started getting "smoothstepper lost comms" faults. It was hot in my shop so I put a fan on the controller to keep it cooler. I also cleaned all connections and used a new ethernet cable. It seemed to work.

This year, as in again today, Im getting that fault as well as "failed to communicate properly for extended amount of time." I cycle power and the ESS communicates again.

Ive swapped out the smaootherstepper board last year. Ive had a fan on the controller so heats not the issue.

Are these faults caused by the old laptop or SS board?

The CNC worked great for years. Last year I started getting the faults.

[joeavaerage]

Hi,
I would guess it is the PC.

The ESS has a motion buffer, by default 180ms long. When the PC devotes CPU service to Mach its trajectory planner 'fills up' the motion buffer with the movement data required
to enact the trajectory. The ESS 'consumes' this data, one frame of data per millisecond. It is to be hoped that the PC again devotes some CPU resource to Mach BEFORE the motion buffer runs out.
That is not always the case, and in that event the motion buffer is empty and the ESS has no motion data to execute....usually resulting in tool path failure.

Having a PC that is relatively unencumbered by software and services is the best way to ensure that it devotes sufficient CPU resource to Mach so this does not ocurr.

It is not always plain why a system that has operated OK in the past suddenly fails to do so now, but usually there is some underlying Windows process or service that is hogging CPU time.

My machine is run on a low powered dual core Atom single board PC, with 3G Ram and no graphics card. This is well less than even NFS recommend to run Mach4, but I've been using it with good results for ten years.
I do however have instances where the buffer runs out of data. A recent change in the manner that I generate Gcode for making PCB's has made it worse, so I think I'll be upgrading my PC (i5 or i7, 8G Ram) sometime soon.
My existing solution works, but could be 'smoother' I suspect with a little more processing power and memory.

I think its time you considered upgrading your PC, and I would suggest Mach4 while your about it. I've been using it for ten years and its light years ahead of Mach3. Do be aware if you do change there is a short but steep learning
curve associated with it.

Craig

[CURST991]

Craig,
Thanks for the information.

I bought a different laptop last year, windows 10, but knew it would take some time to learn how to integrate it into my system.

After the issue, I did look at the laptop and saw over 2000 deleted toolpath files in the recycle bin so I cleaned the bin. I have 2 designs to complete.

But the best fix would be to take the time to integrate the laptop and Mach 4 as an upgrade to my machine. Im dreading the issues/debug time I will encounter

[joeavaerage]

Hi,

Im dreading the issues/debug time I will encounter

When I upgraded from Mach3 and two parallel ports to an ESS and Mach4, it took nearly a month, and extremely frustrating it was too. I've come to the conclusion that the people whom most struggle
with Mach4 are those whom are well versed in Mach3. You are wise to allow some time if you wish to upgrade, and patience pills and/or Bourbon are recommended.

Superficially Mach3 and Mach4 look similar, but their internal organisation is quite different. In particular Mach4 is very much more modular and 'engineered' as opposed to Mach3 which sort of 'evolved'.
It is when you come to customise your machine, say adding a button, or LED, or DRO or whatever, then Mach4's structure and scripting environment will really start to impress. Whatever negative impressions
you formed when doing the upgrade will soon be forgotten when you realise just how damned clever mach4 really is.

Craig