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  1. #76
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    Oh well. Continuing my trend of going the cheapest route I can (he, I have to hit a winner eventually, don't I?) ive ordered a pci parallel card from China, and a used Gforce 8500 GT card from Aus. Hopefully that'll get me 2 working PC's that I can use.

    So, while waiting for those bits to arrive, I can ponder my controller issues. Do i just carry on regardless of the smoke for now, and hope nothing blows up even more? Ill be sure to find a better surge protector to throw on the new PC first before I start.

    Worst case scenario, what's needed to replace this controller box completely? I assume I need a new 4-axis controller kit ($400 from Homann Designs), a new VFD ($140 from ebay china) and then more cables and plugs?(no idea on cost). Should my current motors work with new stuff, or do I have to replace them too? So another $600 - $1000?

    Time for bed. My brain hurts.
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  3. #77
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    I spent some time looking inside the controller box, to see if I could see where the smoke came from. I think I've found it. I'm going to say, it's the transformer on the controller board? (please correct me if I'm wrong). Anyway, here's a couple pictures of the part - the before photo is first, the after is second.

    So my question is, is that likely to be fatal, or has just some plastic melted? If it should still be OK, so I need to do any cleanup?

    Thanks. Russell.
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  4. #78
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    If you power it up again and more smoke comes out then I would say that is a bad sign.

    You could of course unsolder the transformer and do a couple of continuity / resistance tests. That would be a safer indication of the state of the transformer.

    I should probably also add that I think it may be cactus

    I take it you have no desire to rewind this part yourself?

  5. #79
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    Quote Originally Posted by Bob Willson View Post
    I take it you have no desire to rewind this part yourself?
    You take it correctly. As a novice, I don't want to risk playing with high power devices.

    I did start it again briefly after it died, and ran for about 15 seconds, and didn't notice any other smoke or smell, and the water pump was running OK.
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  6. #80
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    old settings ( manufacture ) i think some of the axis pins were pin 16, 17 , ,, were you setting the axis when it smoked ??????

    i disabled the spindle while searching for axis pins , a very low setting will over heat the spindle drive unit

    just saying the maufactrures pin setups were wrong , had pin 16 , and pin 17 ( spindle drive pins) , on axis pins. the spindle has a minimum pulse per minute , if you go under that it will over heat ? , set up to fail by the manufacture ????

    the enamel on the wire should be able to take altleast 160c before turning to crap , the blue heat shrink that has turned to charcoal would be lower , but by how much ???and its pretty well cooked , but the nylon zippy tie looks fine , i think nylon melts at 180c ?


    so id say it fried , put a huge spike down its pin in's from the BOB(Brake out board ) , and fried the BOB , it should have stopped there , but looks like it has fried your motherboard as well , and will do the same to the next mother board you plug it into , the water pump comes off the the transformer before the spindle controller , so is un affected , turns on when you turn the power on , i will defenetly look at changing my BOB ( brake out board ) if yours failed to stop a spike from killing the parallel port

    can you take a photo of the brake out board ( where the 25pin plug go's in ) , its probably missing the tops of the opto couplers , and a few SMD resisters should be cooked

  7. #81
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    Well if you didn't get any smoke are you doing anything differently now from the first time.
    Because if you aren't, then that transformer should start melting again, unless you have blown something else and that part is no longer in circuit.

    Bob Willson

  8. #82
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    just looked up the chip numbers on the BOB , hc244sj , there 8 wire line buffers ,"not opto isolated from the mother board "
    absolutely nothing to stop a spike going through


    74VHC244SJ pdf, 74VHC244SJ description, 74VHC244SJ datasheets, 74VHC244SJ view ::: ALLDATASHEET :::

  9. #83
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    Yes I may have been adjusting the axis settings when it blew.

    I'll have a look at the other parts again tomorrow, but that was the only obvious thing I saw.

    So you're basically saying I'll have to throw away the whole box and start again??
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  10. #84
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    Quote Originally Posted by Bob Willson View Post
    Well if you didn't get any smoke are you doing anything differently now from the first time.
    Because if you aren't, then that transformer should start melting again, unless you have blown something else and that part is no longer in circuit.

    Bob Willson
    That was just powering up the control box. The computer connection was not plugged in at that stage, as it had died.
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  11. #85
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    what pin settings were you running , the set up PDF that came with the machine , or the ones i posted ?






    quote

    So you're basically saying I'll have to throw away the whole box and start again??

    VDF and BOB at least



    ive got one of these , seriously thinking about shoe horning it in http://www.ebay.com.au/itm/CNC-DB25-...ht_3013wt_1396

    but i like the look of this one http://www.ebay.com.au/itm/CNC-Stepp...ht_1951wt_1396

    asking the forum members , whats the best BOB

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  12. #86
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    Quote Originally Posted by SawDustSniffer View Post
    what pin settings were you running , the set up PDF that came with the machine , or the ones i posted ?
    When nothing was happening with your settings, I decided to see what the PDF settings did. At least I think that was the stage I was at.
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  13. #87
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    Quote Originally Posted by BoomerangInfo View Post
    So you're basically saying I'll have to throw away the whole box and start again??
    the only good sign is that the nylon zippy tie still looks perfect , the enamel quite possibly might have survived un cooked , ( "enamel "the painted on insulator on the wire rapped around the transformer )

    to the left of that photo , there are a heap of capacitors and resistors , have a real good look at them for any sign of blackening on the resistors, and warping on the capacitors ( melting ) , and have a good look around the board for some chipped ( cracked , like a glass chip ) tops on the chips , BoB as well

    before connecting to a new mother board , remove the brown and blue wires going into that board ,and isolate them real well , just the brown one will do , that way you can test if the BOB still works , and the motor driver board , still might fry your mother board , and since you don't like High Voltage , get you BIL to help ( free of charge off course )

  14. #88
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    Quote Originally Posted by SawDustSniffer View Post
    the only good sign is that the nylon zippy tie still looks perfect , the enamel quite possibly might have survived un cooked , ( "enamel "the painted on insulator on the wire rapped around the transformer )

    to the left of that photo , there are a heap of capacitors and resistors , have a real good look at them for any sign of blackening on the resistors, and warping on the capacitors ( melting ) , and have a good look around the board for some chipped ( cracked , like a glass chip ) tops on the chips , BoB as well
    Ok thanks for the advice. Tomorrow I'll drag it out into the sunlight and try and get some good shots of everything and see what i can see. I'm more & more think though that maybe I have to bite the bullet and try and replace the lot with something decent. Trouble is, I need something plug & play, and it doesn't seem anyone provides that at the 'hobby' level of CNC. I'll browse around Pete Homann's site and try and get an idea on how difficult it is.

    Will report back on my findings tomorrow.
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  15. #89
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    So here are the detailed pictures of the parts in my controller, after the burn out.

    Note in the first picture, it's showing the bottom of the transformer. The plastic wrap still seems to be fine underneath, so it's only melted on the top. Not sure if that is significant.

    Nothing else I can see has any evidence of burnout, but maybe more experienced eyes can spot something.
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  16. #90
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    you will kill me when you blow up another mother board , pull the spindle plug from the bob , and plug it in

    leave the spindle board connected to 240 , it shouldnt send a spike to the bob if its unpluged from the bob , and if it smokes again your up for a VFD

    see if the LEDs light up on your BOB and stepper driver board for now

    DANGER KEEP YOUR FINGERS OUT SIDE THE BOX WHEN PLUGGED IN , even when its unplugged the spindle board can boot you , there are large capacitors on that board , keep your fingers away from the bare turminals on that board ,unless its been unplugged for 1/2 hour

    with out the PC connected i get 1 LED on the bob , and when you first power up the stepper board , a few LED's turn on , then off again , and 4 sets of 2 LED's stay on , one set is hard to see behind the large capacitors far right corner

    do you get the same

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