Bricked controller?

[ant]

Hi folks,

I purchased a masso g3 3 axis mill controller late last year, have finally gotten around to wiring it up, switched on for the first time last night and again this morning to load the update (updated to v3.47 as the masso did not appear to have any software on it- wouldn't load past a spash screen)

Switched the unit off to address a sensor wiring issue and when I've gone to power it back up, nothing. No LED, monitor goes into standby. Stepper drivers have their own psu and appear to be functional.

Have tested psu 240v in, 12v 1amp out. 1 amp fuse is intact.

Have tested board with a bench psu and no dice either.

Popped into Jaycar and grabbed a new psu and 1 amp fuse just to do an idiot check, still no power.

Any suggestions?

Could the update have caused this?


Edit: Forgot to add, removed cover and there appears to be no obvious damage

 

[tpos]

Hi Ant

I would disconnect every thing off it first did you have the controller powered and running the earlier version of software have you formatted your flash drive fat 32 with the new software i think it needs to have flashdrive inserted upon power up there is a video showing the procedure did you try reloading older software cheers Trev

 

[ant]

Hi Trev,

No I didn't have the controller powered up prior to everything being connected. First time I powered on the controller it loaded a splash screen but wouldn't load beyond that after an hour. Installed the update and loaded withing seconds after install complete.

Flash drive was formatted correctly and installed as per the masso video.

As to rolling back the update, i can try, but I'm not sure as to how to if the controller wont power up?

 

[masso-support]

Hi Ant,

Sorry to hear you are having a problem with your Masso.
I need to start by confirming a couple of things with you.

It sounds like you loaded version 3.47 and after this was complete Masso started normally as you expected.

You mention that when you power up Masso nothing happens. Not even the LED lights show up.
Could i ask you yo please unplug everything from Masso including the Keyboard, monitor, mouse, sensors, drives etc. Only have the power connected.
Remove the cover from Masso and power it up. You should see a green LED within a few seconds followed by a flashing Red LED 5 or so seconds later.
I mention removing the cover because if the LEDS have been moved sideways a little they will not show up through the top cover.

Please use a meter to measure the voltage at the power input to Masso.
Please also measure the voltage between one of the black connectors between inputs 12 & 13 and one of the red connectors between inputs 6 & 7.

Let us know your results.

Cheers Peter

 

[ant]

Thanks mate, will give that a go in the am and let you know

 

[ant]

Ok,

Removed all wires, connected unit to 24v 2.5a meanwell din mount psu (i decided to ditch the original 12v 3a psu). Got solid green light and blinking red.

Voltage at power imput is 23.9v

Voltage at red and black connector (between 6&7 and 12&13) is 23.9v

 

[breezy]

Ant,

Now connect just the keyboard and monitor, then power it up. If that works OK then slowly add back connections and test in between. If it stops then the last thing connected is causing your problem.

Regards,

Arie.

 

[ant]

Okies, Here where I'm at;

have begun rewiring 1 component at a time, powering off each time until i've found my first fault. removed the offending component, switched control back on and it will no longer power on as before. is that normal? does each fault require you entirely disconnect every wire/plug from the board then rewire it?

 

[breezy]

@ant

Ant,

You shouldn't have to disconnect every wire/plug, just to get the unit up and running.

Are powering any else from the PS that is powering MASSO?

We had another case where the sensors were powered from the same PS as the MASSO and a faulty sensor was pulling the voltage down and the MASSO would not start.

When you have the situation where MASSO is not starting do the voltage test that you did with nothing connected and report back.

Regards,

Arie.

 

[ant]

Hi Arie,

I'm using a dedicated power supply to the board, nothing else connected.

The limit switches are being powered by the masso, I'm unsure as to why anyone would have a separate psu for 5v limit switch.

What begs the question is, why when the faulty element is removed does the masso not power up? Is there a reset button i am over looking?

I am unsure of what repeating the voltage test with everything unplugged again will tell us that it didn't the first time

 

[breezy]

Ant,

The limit switches are being powered by the masso, I'm unsure as to why anyone would have a separate psu for 5v limit switch.

Where are you getting the 5v from in the MASSO?

What type of limit switches are you using?

I am unsure of what repeating the voltage test with everything unplugged again will tell us that it didn't the first time

What I wanted here was for you to measure the voltage in the same places as in the first test while it is under the fault condition, with everything still connected, to see if the voltage is being dragged down and preventing MASSO from starting. Something you are doing, that is stopping MASSO from starting. If it is coming alive with nothing connected, you haven't damaged it.

Regards,

Arie.

 

[ant]

my apologies, 6-36 v inductive limit switches, link below

#Aliexpress AU $2.31 15%OFF | LJ12A3-4-Z/BX New Inductive Proximity Sensor Detection Switch NPN DC 6-36V

1.66US $ |LJ12A3 4 Z/BX New Inductive Proximity Sensor Detection Switch NPN DC 6 36V|Sensors| - AliExpress

Smarter Shopping, Better Living! Aliexpress.com

a.aliexpress.com

I must be misunderstanding you, did you want me to unwire the board, power it back on and test or unwire the board, cycle power on/off, rewire up to the fault and then test?

I can test the board with every thing connected up to the fault and in fault condition, but disconecting everything after the fault occurs, then powering back up resets the fault, testing then would produce no new information- at least to my very limited understanding.



That being said, i still don't understand why it wont power on after removing the faulty part, yet by completely removing every component connected it will power on

 

[breezy]

Ant,

being powered by the masso

What do you mean by this comment. I asked in my earlier reply and you haven't answered it.

why anyone would have a separate psu for 5v limit switch.

Because the MASSO is not designed to power high load devices. The power and grounds are intended to be used by simple contact switches connected to MASSO inputs.

Those limit switches require 300ma at 6-36v to operate, assuming you are using a minimum of 4, that is 1200ma or 1.2 AMPS and the installation instructions state to place a 1 AMP fuse in the supply to the MASSO.

The only thing with that supplier, they don't say whether they are NO or NC, you want NC so if you get an O/C in your wiring MASSO will trip hard limit alarm.

Wire as per Homing Sensor just use the black wire in place of the white wire in the documentation.

Regarding the testing, get the unit reset and working with keyboard & monitor connected, without any input / output wiring attached, then add the remaining wiring, testing between each connection, when it fails check the voltage at the two points that we asked you to check at the beginning. We are trying to determine if your wiring is pulling the PS down or causing a problem internally.

Regards,

Arie.

 

[diegocolonnello]

I ordered this ones: https://www.phidgets.com/?tier=3&catid=13&pcid=11&prodid=402

They seem to consume only 5mA....

 

[ant]

Thanks for that mate, will look into them.

Arie, as for what i mean by being powered by the masso, i mean signal wire to input, + wire to the red block between input 6&7, ground to black block between input 12&13.

In fault condition with nothing else connected it is drawing 0.6v at the power in connection on the masso and 0.6 at the red block between 6&7 and black block between 12&13. (See photos)

At this stage, unlike yesterday, the masso will not power on- no LED on and there appears to be no visible signs of damage (see photos)

Edit: on closer inspection, fuse could be suspect, will replace

 

[breezy]

Ant,

Yes the fuse or the wiring back to the PS is suspect.

As I said in an earlier post we had similar situation here on the forum where the power to the MASSO dropped too low for it to start, in your case very low! And that one was a faulty sensor shorting out the power supply. https://www.masso.com.au/forums/topic/dead-controller-2/

In regards to the sensors connect them directly to a power bus that is fused, instead of using MASSO's internal bus. No need to replace them.

Regards,

Arie.

 

[ant]

Ok, here's where I'm at,

Got power and it boots up,

3 Limit switches are connected to their own 12v 3amp power suppy with 2 amp fuse, signal wires are connected x to input 7, y input 8, z imput 9. In the settings all show as low yet when triggered there is no change in status. Thought it could be my wiring, disconnecting the 3 sensors and using a known good sensor connected directly to the psu and input 7 on the masso, sensor lights up when triggered but no change of status in the software....not sure whats going on there. Any thoughts?



Tried hooking up the x axis stepper driver and motor:

TP Series 1 Axis Closed Loop Stepper CNC Kit 12Nm/1700oz.in Nema 34 Motor & Driver - 1-CL86T-P120 STEPPERONLINE

TP Series 1 Axis Closed Loop Stepper CNC Kit 12Nm/1700oz.in Nema 34 Motor & Driver - 1-CL86T-P120 - Closed Loop Stepper Kit - This CNC kit included: 1 x P Series Nema 34 Closed Loop Stepper Motor 12Nm/1700oz.in with Encoder 1000CPR 1 x Closed Loop Ste

www.omc-stepperonline.com

(Same driver in link, cl86t; but the the motors are nema 34 5.8nm on x and y, 11.5nm on z)

However, cannot get it to move, connected as per wiring diagram https://docs.masso.com.au/wiring-an...xis-servo-stepper-examples/leadshine-cs-d1008

Steppers are powered by 1x 24v 20amp power supply, which i now realise is insufficient for these motors, but it should at least rotate the shaft without any load or hum with the power on.

Have ordered 3 x 48v 8.3a power supplies to power them

 

[breezy]

Ant,

Have you connected the negatives of all your PSUs together? You need a return path for the electrons from the sensor to its PSU.

Have you watched Peter's CNCnutz video How to Set up Homing on Masso - Masso Edition 15

When you power up the steppers, can you rotate the shaft? The steppers should "lock" when powered up.

Are your S&D wires connected the right way around, reversed wires will not "light" up the optocouplers.

Again watch Peter's video How to connect your Stepper or Servo drive to Masso - Episode 020

Regards,

Arie.

 

[ant]

Heya, sorry been a busy couple of weeks.

Ok, here's where I'm at,

Definitely got the s&d wired up correctly and when powered on the stepper locks up as it should.

Ordered 3x new 48v 8.4amp power supplies for the steppers and drivers as I'm certain what was originally in there was insufficient.

So, now my setup is 1 x 48v 8.2amp psu per stepper

1 X 12v 3amp psu for 3x3 Limit switch

1x 12 2.4amp psu for masso board.

All ground termials from psus are connected back to a bus bar (star point)

All positive connections run through a fuse box with appropriate fuses, all grounds run to a terminal strip

I've connected up one end switch and can get that to change status on the masso settings page.

Moving on to the x axis, i simply cannot get the motor to turn. It will hum a about 20 seconds after turning the hand wheel or pressing the x- or x+ on the jog screen but that's it.

Thinking it may be the length of the power and signal wires (4 meter) I removed the motor from the mill and plugged it directly into the stepper driver, same result.

I'm running stepper online cl86t drivers and nema 34 closed loop stepper motors, wired in differential connection (s+ to s+, s- to s-, d+ to d+, d- to d-)



Watched peters video a few times and not sure where I'm going wrong. I did see another chap having a similar issue with his closed loop steppers on the forum here to.



Not sure where I'm going wrong, but its got me scratching my head

 

[breezy]

Ant,

Can you provide a link to the driver manual?

Have you got the encoder wires correct?

Is your signal cable shielded, if it is there won't be a problem there.

Is the driver throwing an alarm, connect the alarm output to MASSOs axis alarm input, then you will see if there is problem there.

Have you tuned the motor/driver combination with the driver tuning software, because in there you can move the motor back and forth, which removes MASSO from the situation.

Can't think of anything else.

Regards,

Arie.