Jeff, Thanks for that excellent explanation. I agree with everything except I'm not sure about the 100 mA limit. I believe the USB port will typically put out more than that and the current limit doesn't go into effect until about 1 amp or so. Under high load the voltage droops considerably like you mentioned. All devices start out at 100 mA or less. After configuration they can bump up to 500 mA if they are a high-power device. I just experimented with the USB port on my development computer. I placed a 6-ohm resistor from Port 3 pin 4 (5V) to ground. I then plugged the USB cable into the board and measured a current of about 700 mA through the resistor. I guess that would equate to a bus voltage of about 4.2V, though I didn't measure that. The SmoothStepper was recognized by the OS without a problem. I think the only reason for keeping track of the current is so that the OS can decide if a device will draw too much total power from all of the USB ports combined. If a high-power device is plugged in, the OS would be able to deny it from bumping up to a higher current. The concern is the risk of loading down the bus and having a bunch of USB devices drop out from the low voltage. There is also a spec that limits a device to 10uF of capacitance for a similar reason. Too much capacitance will suck a ton a current for a brief moment when the device is plugged in, which could reset other USB devices connected to the computer. I made sure the SS conformed to that spec. There is a 100uF cap on the board, but it is only on the external 5V input. One other point is that a device doesn't even need to enumerate to draw power from a port. You can draw more than 500 mA from a port and not even be a USB device. Of course every USB host is different. Some could have current limiting at various levels, but I think most have one level set a bit higher than 500 mA. For what it is worth, I did a web search and found this interesting site that shows some data that a guy compiled on various devices and how the voltage drooped at low and high current levels. I didn't study it much, but here it is:
http://www.girr.org/mac_stuff/usb_stuff.htmlMaddios, Those voltages are very suspicious. I am wondering if your voltmeter is that inaccurate or if you are measuring from a ground that is not the ground of the SS. I am hoping that you are connecting to the ground of the computer or something like that. If so, that would indicate that the ground of the SS and the ground of the PC are not at the same voltage.
It is interesting that you can see a temperature difference in that one chip. I have a feeling that the board will need to be replaced, but I want to spend more time working through this so that if a new board is installed something bad won't happen to it because of some mis-wiring or something like that.
Thanks for taking the time to take those measurements.
Greg