Issues with Masso & G540

[nschlee]

Having an installation issue with random faulting with the G540. I have it connected to a Masso controller.

When the Masso sends Z commands to the G540 it causes a fault, sometimes it will work for a few minutes then fault. I ve tried disconnecting the Z motor from the G540 and it still faults the G540 randomly but only when the Masso sends Z commands to the G540. I m using the G540 with the Charge Pump switch set to off and a jumper as stated. When it does fault, I switch the CP switch to on, then off and it lights the G540 green light, it will work for a short time then fault.

The X and Y axis function normally and will operate without faulting the G540. Trying to figure out if it's the controller or G540 causing the issue. I've verified all connections. Am I missing something or can anyone make suggestions?

Tia,

Neal

 

[cnc-maker]

Hi Neal,

I am a total newbie when it comes to Masso ( I dont even have mine yet) so I am zero help there.

But I have run a G540/ Mach3 on a small bench-top router/mill for the last 5 years.

Firstly are the motors connected to an actual machine yet or are you just running the motors on a bench at this stage.

Knowing this would eliminate any possibility of it being caused by actual machine mechanical issues. When we built our first machine we over tightened the thrust bearings on the Y axis. This would overheat the stepper motor after a few minutes and the G540 would randomly go into Fault mode. We loosened the bearings a bees-dick and never had a problem again. So it would be good to know your circumstance.

Its pretty easy to over-load a G540 if you are running biggish motors and have a tight drive train on an axis, especially if you aren't running the heat sink and fan assembly.

 

[nschlee]

Motors are mounted on machine, no binding all turn freely. Weird thing is even with the motors disconnected from the G540, just sending Z commands from the Masso, the G540 will randomly fault, but no faults when running the X & Y axis.

 

[cnc-maker]

Is the G540 brand spanking new, or have you been running it successfully under something like Mach3 with no problems before?

 

[breezy]

Have you tried swapping MASSO Z output with either X or Y, if the fault moves problem in MASSO, if not then 540 is at fault.

Regards,

Arie.

 

[evermech]

Hi @nschlee

there must be a way to know what the fault is that the drive is detecting. I don't use these drives but even the cheapest ones I've bought have a list of faults and usually flashing lights, or light combinations that determine what fault is present. In the meantime I would separate the z drive motor from the mechanical axis, block up or hold up the z axis to a safe place, then run the Gcode and see if it still errors. My suspicion is over voltage, or over torque fault because the motor may be working too hard either moving the load or holding the load. Could be over temperature too.

Guy