Setup: Longboard 30x30 Mk1, Super Long Board, gSender, Vetric VCarve v12, Grbl post processor set in VCarve and gSender.
gSender is running on a i7 Lenovo laptop.
I have three years of experience with the Sienci 30 x 30 Mk1 with the original control board, Vcarve, and gSender. The operation of the original setup was reasonably flawless. I recently swapped out the original control board for the SLB controller. The SLB controller power supply is on a dedicated AC circuit separate from the router & vacuum AC circuit and has an IOT relay controled by the SLB. Each of the AC lines have a balanced EMI filter installed. Each of the I/O lines, including the USB cable from the laptop, have a snap on EMI / RFI filter. The frame of the CNC is grounded to the house master utility ground using 1" tinned copper braid.
Last week, I was running multiple trial carves from known good files that I re-ran through Vcarve v12 with the Grbl post processor set. The CNC x/y/z movement would stop at >random places< in the codes with the “HALT” message appearing on the gSender screen. The IOT would not be triggered into the accessory OFF condition so the router and vacuum would continue running. The console window would show the invalid code message OR no message at all. In either case I could use the resume job function and, in 90% of the time, the job would continue and then HALT again further down the code. 10% of the time that I would use Resume Job the Z axis would drive the tool down into the material without the X & Y axis moving. I checked the continuity of all the SLB I/O lines while wiggling the wires. All were okay. The ES and the three buttons function as intended. The AC line to the router has a HOBBS time recorder and it shows 26 hours on this set of original brushes. I rearranged all of the I/O lines to reduce the possibility of inductive coupling. The strange HALT is still occurring, I am at my wits end. The frustration arises because with the original controller, even the 10-12 hour jobs ran flawlessly. Does anyone have any additional troubleshooting hints?
@jayfmiller would you be able to share what the Halt message looks like by taking a picture? Also you could share the diagnostic file when this happens to you, instructions found here: Problems / Bugs? - gSender Docs
Ultimately, it sounds to me like this issue is frustrating you quickly, so in that case I’d advise sending us a direct ticket where we can help you more quickly: Contact Us | Sienci Labs
Thanks for the response. I ran a series of trial files and discovered the “HALT” message again occurred randomly in the sequence of commands. That appeared to indicate that it may be a hardware problem rather than software. After much additional investigation, I discovered that the “Halt” occurred when there were rapid and abrupt “X” axis changes located at the left side of that axis range limit. I started checking cabling and connectors again. The fault appeared to occur when the “X” axis was on the far left and there were abrupt direction changes during fast moves. The ES switch assembly is mounted very close to the end of the left rail I discovered an intermittent contact fault in the female RJ45 Emergency Stop connector. When I first installed the cable, I thought the fit was a bit “sloppy.” I used a sliver of plastic shim stock to eliminate the movement and nudge the contacts into a stable position. I ran the five trial files again and the “Halt” problem did not occur. I think the intermittent contact must have been producing a very short pulse response. If I had thought about it at the time, I would have set up a video camera with the SLB in frame to see if the associated LEDs flashed. Thanks again for your assistance. I wanted to make sure this situation was resolved before the Sienci spindle kit arrived.
Great to hear Jay, great sleuthing! In hindsight errant Halting is most likely to be caused by loose wiring or faulty components so I’m glad you narrowed it down. Bit odd in my opinion that the RJ jack was loose in the connector and needed to be wedged in - perhaps something I should communicate to the QC team as something to look for on our current batch.
Thanks. Sometimes we do a good first piece and first article inspection routine on parts from an offshore manufacturing vendor and then things slip later. The RJ connection between the cable and the ES is, in fact, a lot less firm than I am accustomed to. The looseness, in this case, is primarily in the vertical axis. I hope this specific instance may be an anomaly.