Machsupport Forum
Mach Discussion => Mach4 General Discussion => Topic started by: Zuxztah on August 26, 2018, 09:17:23 AM
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Hey! have managed to get a problem with my mach4. The program stops in the middle of the cycle, sometimes a few minutes in and sometimes closer to the end of the cycle, and I can not figure out why it does that!
ive tried to start logging to see what it says, but i dont understand the message,
The problem is shown by that line and beyond from that line:
2018-08-26 14: 45: 02,798 - Controller :: RunCanonBuffer called AddStopReportRequest () RunCanon.cpp: 76
It has worked perfectly before? the problem have started just now?
have been thinking about EMI, or if the computer is too slow, I have tried to mount lots of Ferrite cores, but without any results .. any ideas?
the machine uses twisted pairs with shielding grounded to machine chassie (and only in the machine end)
the computer is moved far away from the machine,
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2018-08-26 14:40:47.721 - Loggging Enabled.
2018-08-26 14:40:53.298 - Spindle speed capped by current range!
2018-08-26 14:40:53.299 - Spindle speed capped by current range!
2018-08-26 14:40:53.328 - API: mcToolPathGenerate() called.
2018-08-26 14:41:00.066 - API: mcCntlRewindFile() called.
2018-08-26 14:41:06.362 - API: mcCntlCycleStart() called.
2018-08-26 14:41:06.464 - Attempt transition from "Idle" on event "Cycle Start" MachAPI.cpp:2603
2018-08-26 14:41:06.464 - Signal id 1127, (Jog Enabled), changed from HIGH to LOW.
2018-08-26 14:41:06.465 - S_IDLE_on_exit
2018-08-26 14:41:06.465 - ACTION_start_cycle
2018-08-26 14:41:06.466 - S_FILE_RUNNING_on_entry
2018-08-26 14:41:06.466 - S_FILE_RUNNING2_on_entry
2018-08-26 14:41:06.466 - Signal id 1114, (Gcode Running), changed from LOW to HIGH.
2018-08-26 14:41:06.489 - API: mcSpindleSetDirection(inst = 0, dir = 0) called.
2018-08-26 14:41:06.530 - Signal id 1121, (Tool Change), changed from LOW to HIGH.
2018-08-26 14:41:06.532 - Signal id 1121, (Tool Change), changed from HIGH to LOW.
2018-08-26 14:41:06.535 - API: mcSpindleSetDirection(inst = 0, dir = 1) called.
2018-08-26 14:41:06.535 - Signal id 1142, (Spindle Fwd), changed from LOW to HIGH.
2018-08-26 14:41:06.536 - Signal id 1141, (Spindle On), changed from LOW to HIGH.
<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<
2018-08-26 14:45:02.798 - Controller::RunCanonBuffer called AddStopReportRequest() RunCanon.cpp:76
2018-08-26 14:45:02.798 - Requesting a stopped report for axis 0 motors.
2018-08-26 14:45:02.798 - Requesting a stopped report for motor 0.
2018-08-26 14:45:02.798 - Requesting a stopped report for axis 1 motors.
2018-08-26 14:45:02.798 - ESS: Mach requested MSG_REPORT_MOTOR_STOP Motor 0
2018-08-26 14:45:02.799 - Requesting a stopped report for motor 1.
2018-08-26 14:45:02.799 - Requesting a stopped report for axis 2 motors.
2018-08-26 14:45:02.799 - ESS: Mach requested MSG_REPORT_MOTOR_STOP Motor 1
2018-08-26 14:45:02.799 - Requesting a stopped report for motor 2.
2018-08-26 14:45:02.799 - ESS: Mach requested MSG_REPORT_MOTOR_STOP Motor 2
2018-08-26 14:45:02.799 - Waiting on SetStill...
2018-08-26 14:45:02.974 - ESS: Motor 2 Still
2018-08-26 14:45:02.999 - ESS: Motor 0 Still
2018-08-26 14:45:02.999 - ESS: Motor 1 Still
2018-08-26 14:45:02.999 - All motors marked as still.
2018-08-26 14:45:02.999 - Waiting on SetStill is Done!
2018-08-26 14:45:03.001 - Signal id 1142, (Spindle Fwd), changed from HIGH to LOW.
2018-08-26 14:45:03.001 - Signal id 1141, (Spindle On), changed from HIGH to LOW.
2018-08-26 14:45:03.002 - Waiting 1.500000 seconds for spindle to stop... Spindle.cpp:351
2018-08-26 14:45:04.488 - Done. Spindle.cpp:356
2018-08-26 14:45:04.488 - Waiting for motions to complete: MC_CANON_REWIND. GcodeExec.cpp:745
2018-08-26 14:45:04.499 - Attempt transition from "File Running" on event "Stop" GcodeExec.cpp:765
2018-08-26 14:45:04.499 - S_FILE_RUNNING2_on_exit
2018-08-26 14:45:04.499 - Signal id 1114, (Gcode Running), changed from HIGH to LOW.
2018-08-26 14:45:04.499 - S_FILE_RUNNING_on_exit
2018-08-26 14:45:04.500 - ACTION_stop
2018-08-26 14:45:04.523 - S_IDLE_on_entry
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well you certainty have some event happening. have you tried another program and see if it does the same thing. also can you tell where in the Gcode its happening, you said its random but i am wondering if you are calling for something specific in Gcode that happens before this happens. also check all you wires to limits and estop to make sure they are connected well one loose wire can cause no end to trouble.
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I've rewired every cable in the whole machine and moved the control electronics to their own control cabinet to separate stepper motor drivers and the Ethernet smoothstepper card along with the BOB boards that also are grounded with computer and cabinets, ensuring that there are no ground loops
I'm using only shielded cables that are grounded in the signal end for everything, home switches, VFD USB rs485 communication, motor cables, spindle power cable and so on.
I've upgraded the computer to:
Intel i5 6500 3.2Ghz
16GB 1600MHz Ram
128GB SSD Drive,
Mach 4 is the only thing that is installed on the computer, along with drivers, and other necessary things
I've followed the guide for "how to run mach 4 reliable"
I've tried to change the buffer size and Plugin frequency in ESS plugin Configuration under the "General Tab"
following recommended values.
I can send the gcode file privately. for closer inspection, I use the Fusion 360 and the Postprocessor for mach 3 and have never experienced any problems before? The problem usually occurs at line 17000-19000 as the timeline change says in the log file,
can also see a sudden jump on the line viewing window from line 5000 up to 20000 and back again and when it happens and then the gcode rewinds. spindle still running, is just like the machine stops moving for a second and then moves on but only sometimes, and then that happens again and it locks up, but mach is still operational and I can jog the machine and everything after I reset the E-stop condition
Log file "Try 1" fault occours between 19sec and 36sec
2018-09-07 13:29:32.308 - Loggging Enabled.
2018-09-07 13:29:35.762 - API: mcCntlCycleStart() called.
2018-09-07 13:29:35.863 - Attempt transition from "Idle" on event "Cycle Start" MachAPI.cpp:2603
2018-09-07 13:29:35.863 - S_IDLE_on_exit
2018-09-07 13:29:35.863 - ACTION_start_cycle
2018-09-07 13:29:35.864 - S_FILE_RUNNING_on_entry
2018-09-07 13:29:35.864 - S_FILE_RUNNING2_on_entry
2018-09-07 13:29:35.864 - Signal id 1114, (Gcode Running), changed from LOW to HIGH.
2018-09-07 13:29:42.178 - Controller::RunCanonBuffer called AddStopReportRequest() RunCanon.cpp:76
2018-09-07 13:29:42.178 - Requesting a stopped report for axis 0 motors.
2018-09-07 13:29:42.178 - Requesting a stopped report for motor 0.
2018-09-07 13:29:42.178 - Requesting a stopped report for axis 1 motors.
2018-09-07 13:29:42.178 - Requesting a stopped report for motor 1.
2018-09-07 13:29:42.178 - Requesting a stopped report for axis 2 motors.
2018-09-07 13:29:42.178 - Requesting a stopped report for motor 2.
2018-09-07 13:29:42.178 - Waiting on SetStill...
2018-09-07 13:29:42.586 - All motors marked as still.
2018-09-07 13:29:42.586 - Waiting on SetStill is Done!
2018-09-07 13:29:42.588 - API: mcSpindleSetDirection(inst = 0, dir = 0) called.
2018-09-07 13:29:42.588 -
2018-09-07 13:29:42.588 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:29:42.588 - >>> ESS: Relay Mode - Spindle stopped, 'Spindle Motor Dir' not changed.
2018-09-07 13:29:42.590 - Signal id 1121, (Tool Change), changed from LOW to HIGH.
2018-09-07 13:29:42.590 - >>>>> ESS received a Tool Change Required notification.
2018-09-07 13:29:42.590 - >>>>> ESS received a Tool Change Done notification.
2018-09-07 13:29:42.590 - Signal id 1121, (Tool Change), changed from HIGH to LOW.
2018-09-07 13:29:42.591 - >>>>> ESS received a Tool Change Done notification.
2018-09-07 13:29:42.591 -
2018-09-07 13:29:42.591 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:29:42.591 - >>> ESS: Relay Mode - Spindle stopped, 'Spindle Motor Dir' not changed.
2018-09-07 13:29:42.594 - API: mcSpindleSetDirection(inst = 0, dir = 1) called.
2018-09-07 13:29:42.594 - Signal id 1142, (Spindle Fwd), changed from LOW to HIGH.
2018-09-07 13:29:42.594 -
2018-09-07 13:29:42.594 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:29:42.594 - >>> ESS: Relay Mode - 'Spindle Motor Dir' set to Forward.
2018-09-07 13:29:42.595 - Signal id 1141, (Spindle On), changed from LOW to HIGH.
2018-09-07 13:29:42.610 - All motors marked as still.
2018-09-07 13:29:42.661 -
2018-09-07 13:29:42.661 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:29:42.661 - >>> ESS: Relay Mode - 'Spindle Motor Dir' set to Forward.
2018-09-07 13:36:06.139 - Controller::RunCanonBuffer called AddStopReportRequest() RunCanon.cpp:76
2018-09-07 13:36:06.139 - Requesting a stopped report for axis 0 motors.
2018-09-07 13:36:06.139 - Requesting a stopped report for motor 0.
2018-09-07 13:36:06.139 - Requesting a stopped report for axis 1 motors.
2018-09-07 13:36:06.139 - Requesting a stopped report for motor 1.
2018-09-07 13:36:06.139 - Requesting a stopped report for axis 2 motors.
2018-09-07 13:36:06.139 - Requesting a stopped report for motor 2.
2018-09-07 13:36:06.140 - Waiting on SetStill...
2018-09-07 13:36:06.521 - All motors marked as still.
2018-09-07 13:36:06.521 - Waiting on SetStill is Done!
2018-09-07 13:36:06.522 - Signal id 1142, (Spindle Fwd), changed from HIGH to LOW.
2018-09-07 13:36:06.522 -
2018-09-07 13:36:06.522 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:36:06.522 - >>> ESS: Relay Mode - Spindle stopped, 'Spindle Motor Dir' not changed.
2018-09-07 13:36:06.522 - Signal id 1141, (Spindle On), changed from HIGH to LOW.
2018-09-07 13:36:06.522 - Waiting 1.500000 seconds for spindle to stop... Spindle.cpp:351
2018-09-07 13:36:08.015 - Done. Spindle.cpp:356
2018-09-07 13:36:08.015 - Waiting for motions to complete: MC_CANON_REWIND. GcodeExec.cpp:745
2018-09-07 13:36:08.026 - Attempt transition from "File Running" on event "Stop" GcodeExec.cpp:765
2018-09-07 13:36:08.026 - S_FILE_RUNNING2_on_exit
2018-09-07 13:36:08.026 - Signal id 1114, (Gcode Running), changed from HIGH to LOW.
2018-09-07 13:36:08.026 - S_FILE_RUNNING_on_exit
2018-09-07 13:36:08.026 - ACTION_stop
2018-09-07 13:36:08.042 - S_IDLE_on_entry
............................................................................
Log file "Try 2" With Stop/Emergency button hit. problem occurs between 46sec and 53sec
2018-09-07 13:46:05.722 - Loggging Enabled.
2018-09-07 13:46:14.626 - API: mcCntlCycleStart() called.
2018-09-07 13:46:14.727 - Attempt transition from "Idle" on event "Cycle Start" MachAPI.cpp:2603
2018-09-07 13:46:14.727 - Signal id 1127, (Jog Enabled), changed from HIGH to LOW.
2018-09-07 13:46:14.727 - S_IDLE_on_exit
2018-09-07 13:46:14.727 - ACTION_start_cycle
2018-09-07 13:46:14.728 - S_FILE_RUNNING_on_entry
2018-09-07 13:46:14.728 - S_FILE_RUNNING2_on_entry
2018-09-07 13:46:14.728 - Signal id 1114, (Gcode Running), changed from LOW to HIGH.
2018-09-07 13:46:21.211 - Controller::RunCanonBuffer called AddStopReportRequest() RunCanon.cpp:76
2018-09-07 13:46:21.211 - Requesting a stopped report for axis 0 motors.
2018-09-07 13:46:21.211 - Requesting a stopped report for motor 0.
2018-09-07 13:46:21.211 - Requesting a stopped report for axis 1 motors.
2018-09-07 13:46:21.211 - Requesting a stopped report for motor 1.
2018-09-07 13:46:21.211 - Requesting a stopped report for axis 2 motors.
2018-09-07 13:46:21.211 - Requesting a stopped report for motor 2.
2018-09-07 13:46:21.211 - Waiting on SetStill...
2018-09-07 13:46:21.475 - All motors marked as still.
2018-09-07 13:46:21.475 - Waiting on SetStill is Done!
2018-09-07 13:46:21.476 - API: mcSpindleSetDirection(inst = 0, dir = 0) called.
2018-09-07 13:46:21.476 -
2018-09-07 13:46:21.476 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:46:21.476 - >>> ESS: Relay Mode - Spindle stopped, 'Spindle Motor Dir' not changed.
2018-09-07 13:46:21.512 - All motors marked as still.
2018-09-07 13:46:21.514 - Signal id 1121, (Tool Change), changed from LOW to HIGH.
2018-09-07 13:46:21.514 - >>>>> ESS received a Tool Change Required notification.
2018-09-07 13:46:21.514 - >>>>> ESS received a Tool Change Done notification.
2018-09-07 13:46:21.514 - Signal id 1121, (Tool Change), changed from HIGH to LOW.
2018-09-07 13:46:21.515 - >>>>> ESS received a Tool Change Done notification.
2018-09-07 13:46:21.515 -
2018-09-07 13:46:21.515 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:46:21.515 - >>> ESS: Relay Mode - Spindle stopped, 'Spindle Motor Dir' not changed.
2018-09-07 13:46:21.516 - API: mcSpindleSetDirection(inst = 0, dir = 1) called.
2018-09-07 13:46:21.516 - Signal id 1142, (Spindle Fwd), changed from LOW to HIGH.
2018-09-07 13:46:21.516 -
2018-09-07 13:46:21.516 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:46:21.516 - >>> ESS: Relay Mode - 'Spindle Motor Dir' set to Forward.
2018-09-07 13:46:21.516 - Signal id 1141, (Spindle On), changed from LOW to HIGH.
2018-09-07 13:46:21.613 -
2018-09-07 13:46:21.613 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:46:21.613 - >>> ESS: Relay Mode - 'Spindle Motor Dir' set to Forward.
2018-09-07 13:53:56.933 - Controller::RunCanonBuffer called AddStopReportRequest() RunCanon.cpp:76
2018-09-07 13:53:56.933 - Requesting a stopped report for axis 0 motors.
2018-09-07 13:53:56.933 - Requesting a stopped report for motor 0.
2018-09-07 13:53:56.933 - Requesting a stopped report for axis 1 motors.
2018-09-07 13:53:56.933 - Requesting a stopped report for motor 1.
2018-09-07 13:53:56.933 - Requesting a stopped report for axis 2 motors.
2018-09-07 13:53:56.934 - Requesting a stopped report for motor 2.
2018-09-07 13:53:56.934 - Waiting on SetStill...
2018-09-07 13:53:57.171 - All motors marked as still.
2018-09-07 13:53:57.171 - Waiting on SetStill is Done!
2018-09-07 13:53:57.172 - Signal id 1142, (Spindle Fwd), changed from HIGH to LOW.
2018-09-07 13:53:57.172 -
2018-09-07 13:53:57.172 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:53:57.172 - >>> ESS: Relay Mode - Spindle stopped, 'Spindle Motor Dir' not changed.
2018-09-07 13:53:57.173 - Signal id 1141, (Spindle On), changed from HIGH to LOW.
2018-09-07 13:53:57.173 - Waiting 1.500000 seconds for spindle to stop... Spindle.cpp:351
2018-09-07 13:53:58.669 - Done. Spindle.cpp:356
2018-09-07 13:53:58.670 - Waiting for motions to complete: MC_CANON_REWIND. GcodeExec.cpp:745
2018-09-07 13:53:58.679 - Attempt transition from "File Running" on event "Stop" GcodeExec.cpp:765
2018-09-07 13:53:58.679 - S_FILE_RUNNING2_on_exit
2018-09-07 13:53:58.679 - Signal id 1114, (Gcode Running), changed from HIGH to LOW.
2018-09-07 13:53:58.679 - S_FILE_RUNNING_on_exit
2018-09-07 13:53:58.679 - ACTION_stop
2018-09-07 13:53:58.696 - S_IDLE_on_entry
2018-09-07 13:54:14.554 - API: mcScriptExecute() called. filename "m5.mcs" async 0
2018-09-07 13:54:14.556 - API: mcSpindleSetDirection(inst = 0, dir = 0) called.
2018-09-07 13:54:14.556 -
2018-09-07 13:54:14.556 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:54:14.556 - >>> ESS: Relay Mode - Spindle stopped, 'Spindle Motor Dir' not changed.
2018-09-07 13:54:14.582 - API: mcCntlCycleStop() called.
2018-09-07 13:54:14.585 - API: mcSpindleSetDirection(inst = 0, dir = 0) called.
2018-09-07 13:54:14.586 -
2018-09-07 13:54:14.586 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:54:14.586 - >>> ESS: Relay Mode - Spindle stopped, 'Spindle Motor Dir' not changed.
2018-09-07 13:54:14.586 -
2018-09-07 13:54:14.586 - $$$ ESS: Mach4 had a Cycle Stop - Force Output Stop Sates Now
2018-09-07 13:54:14.586 - $$$ ESS: Finished processing the Stop Event
2018-09-07 13:54:14.586 -
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Hello again! I tried to run the code again and there is no specific line in the gcode that seems to be the problem?
The problem is that it can´t handle more than 6-7 minutes in running state..
Pressed cycle start and waited for the problem to happen and it happened, this time I was able to roughly see what line it stopped working at. close to line 20000 but that´s not always at that line. sometimes it happens at line 17840 and sometimes at line 25123 and every line between so it´s not consistent.
Scrolled down to somewhere around line 14000 and chose to "run from here", and it seemed to work like it should, Runs to the end of the program and then return to Machine Zero.
It´s a very small object with very complex engraving, but shouldn't be too much for the computer/ESS?
something is wrong with mach/windows 10? timing out?
the Ethernet port is not allowed to sleep, HDD/Screen isn't allowed to go to sleep either? mach is prioritized as highest possible
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Is your licence installed correctly ?
That’s the what happens if the licence file is not installed
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Yes it’s licensed as a hobby license, and it’s active. I think the limit of lines is set to 500 when using the demo version
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Ok
Then apart from your pc running short of ram , or a corrupt install of mach4 I cannot help sorry
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Hi,
I think the limit of lines is set to 500 when using the demo version
No, the 500 line limit applies to Mach3 when in Demo mode.
Mach4 will run for six minutes before shutting down in Demo mode. Given the timing of the fault I wondered as Stuart did if your licensing was correct.
Try Help/About just to double check that the license file has not got screwed up.
Craig
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Absolutely, I’ll check soon
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I run another program now, and it just went past 18minutes @37000 lines and the program in total is 100000 lines, it’s not as dense as the other program that I have problem with. I’m gonna wait and see if this program
Makes it,
I don’t know if Mach and my setup is up for the job with that fast running code for that file that I have problem with
and I’m also currently remaking the model and cam processing for the other file to see if something happend in fusion from the beginning? License seems to work anyway,
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A video showing the problem, it happens when I say ”där” pay close attention to the line indicator window: https://youtu.be/-QLr-zM0RMc
The program is far from done.
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Zuxztah,
Mach4 V3481 and V3804 do not have any issues, they can process up to 2 Million lines of G-Code without issue.
Mach4 V3481 and V3804 also do not have any issues with Memory or CPU usage.
I can run Mach4 with many other programs at the same time with the CPU running at 100% all the time without any issues.
I have used it on runs that last over 14hours straight on the CNC Mill with no issues.
Also have run jobs that ran each day for 14days straight with a max of about 14 hours a day.
Mach4 can run on an XP PC with 2GB ram and no Video card with over 1 million lines and not stop.
I use a PC with 8GB Ram and Win10.
So if it is not a licensing issue it must be something else.
Regards,
Mauri.
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You are probably right about that. It should not have any problems, and licensing isn’t a problem either at the moment, there have been issues with the licensing for me earlier. the PCID was constantly changing on my old PC, the new one have survived restart after restart, and that I also was able to run 20k+ lines 20min+ proves that the license is working,
One problem that I’ve never thought of is that I’m currently running version 3233, I’ll try to update to the newest version: 3804 and see what happens
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Updated Mach4 Hobby to 4.2.0.3804.
Fixed the Go To Work Zero problem by removing axis A0 from startup script.
Loaded the new Gcode file and ran it. Everything works like it should now, I don’t really know what the problem was but it fixed itself
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Bet you had a corrupt install and the update fixed it up
Glad you have it sorted
It’s a bit difficult to phrase any licence questions without inferring that you have not got it licence
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As you say that it may be a installation problem, I copied the old mach 4 Hobby folder from my old SSD to the new one and something must have gone wrong, a clean install and only copy over profiles macros and plugins seems to do the job. Super glad that it’s up and running again:)
now I have other problems to solve, and that is to add a mpg wheel and 3stage rotary axis selector switch and maybe a switch to set 0,1 0,01 0,001 jogging.. found a guide with code online: Shane engineer “how to add a generic mpg pendant to Mach 4”
The problem with that code is that it disables “ ref all home” and all jog features on screen.. not how I want it to be. I want to be able to use both