Finally got my blackbox-controlled router assembled and going through the first couple calibration steps. Unfortunately, I've ran into three main problems: 1) Power supply and blackbox started up just fine and I was able to connect to Openbuilds Control and begin jogging all 3 axis to ensure proper movement. I turned off the blackbox and power supply to make some adjustments and re-route some cords. When I turned the power supply back on the red switch lights up but the fan does not start. Also, there is no power being delivered to the blackbox. Breakers/gfci/etc are all good. I went through and re-plugged all the connections and tried a different circuit but to no avail. Is this a connection issue within the power supply? 2) When jogging the axis with no load (just the weight of the gantry) the Z and Y steppers all make nice smooth movements and sounds. However, the X axis sounds terrible - grinding and very rough. It is moving, slowly, but I didn't try jogging too much in fear of doing damage to the motor. I disconnected the coupler to the lead screw and the motor still made the same sound. Is this exceeding its torque somehow? Can I adjust the potentiometer on the blackbox for the x-axis to bring this back in line? All wires are wired RBGY per Blackbox/Openbuilds instructions. 3) The Z axis is moving in the wrong direction - I'm assuming this is a simple wiring and/or software setting? Thank you in advance for any advice that can be provided! Cheers, Tom
Hi Tom, 1) Do you have the Openbuilds PSU? make sure the black AC wire is on L, white on N.. and tight Make sure the input selector switch is set to your ac input either 120vac for US or 220vac for most of the rest of the world. The fan only goes on when the temp requires it for the Meanwell. 2) Yes, adjust the X axis pot it increase the current until runs smooth without stalling.. if it wont then you have a wiring issue with the coils not paired correctly or only 3 of the 4 wires making good contact. 3) Yes, you can switch the wires around of any one coil or change the direction on the GRBL setting $3.. below from GRBL Wiki... Make sure to read up on the GRBL Wiki and the Blackbox Docs Cheers Gary
A bit of followup info on the power supply: 1) Fuse inside the PSU is not blown - checked continuity 2) 24V DC @ both sets of DC out pins + at end of power cord running to Blackbox 3) Fuse on Blackbox is not blown either - replaced with new fuse to double check, to no avail. 4) With only the 110v cord plugged into the PSU, the red switch light comes on when powered up + the red openbuilds logo lights up solid. Upon plugging in the powercord to the the blackbox, the red openbuilds light starts blinking. No power can be achieved to the blackbox via the PSU 5) USB power still lights up the appropriate leds on the blackbox.
Hi Tom, so you are measureing 24V? until you put a load on it, aka the blackbox? double check 24v pos to pos and neg to neg, also maybe try a 24v short wire that for sure has no issues.
Hi Gary, Thanks for the prompt response! Correct - I have the Openbuilds PSU bundle. 115v Selector switch is good (made sure before powering on). Also, doubled-checked the AC Line and Neutral wires...good there as well. My confusion is mostly surrounded the fact that it was running just fine and now isn't. -Tom
That's correct - 24V across both sets of pins on the PSU. Cord seems fine (only one I have, came with Blackbox/PSU) - Rechecked connections on the extension connectors. I've got solid continuity through pos-to-pos and neg-to-neg across the length of the cord. One small update - when I have the PSU turned on and try to connect the 24v cord to the blackbox, I hear a slight buzz/crackle and it trips the red openbuilds LED on the PSU. -Tom
This all happened after you re-routed all the wiring so the fault may lay there somewhere. You could try disconnecting all cables from the black box except the PSU, then reconnect the cables, one at a time, 'till something shows up.
@Gary Caruso: PS: In CONTROL we made it even easier, no need for a lookup table: Disconnect everything except power from the BlackBox: perhaps you have a short on one of the other connectors (think limit switch V+ to GND, etc) unplugging them is a quick check The red led on PSU going out tells me there's a short and PSU is shutting itself off to protect itself Almost always wiring related: Either only 3 of the 4 wires are making good contact, or you don't have the coils correctly identified (color codes could be wrong)
Thank you for all of the responses. @Christian James - that was my first thought too, to work backwards from the motors. Unfortunately, the short/ground-fault occurs with only the blackbox and PSU cord at play. @Peter Van Der Walt - I appreciate the further info on the Z-axis direction and stepper motor wiring. I'll follow up with any further concerns on those items. My big concern at this point is the PSU, the Xtension connectors and the power cord running to the blackbox. With the lights dim, I can actually see a small spark/flash at the blackbox powersupply connection when I plug it in. Is it possible that the short is internal to the blackbox (solders, internal connections, etc)? The only thing I can't try are alternate Xtension Connectors for the powersupply (don't have any). I can make a different cord and I've tried it on multiple circuits in my house. As always, I appreciate the insight! Cheers, Tom
You are using our Meanwell PSU correct? Take it apart, and with just Muscle in hand, connect power then turn on, see if you can see any damage, where it sparks, and post some pics
That's correct - Openbuilds' Meanwell PSU w/ Xtension connectors. Just to clarify, I'll take apart the blackbox and remove the Brains Board, connect the powersupply and turn it on? I'll try to snap some photos/video and hopefully it will be insightful! Thanks, Tom
Correct, as power comes into the Muscle board, a visual inspection there may have some clues, before we send you over to [email protected]
I disassembled the blackbox and plugged in only the muscle board and...all seems fine. Green LED comes on on the muscle board and it doesn't trip the PSU. I then reattached the Brains board and plugged it back in. This tripped the power supply. I inspected all of the pins and solder connections and it looks like the solder on one of the 2 pins (V-) for the fan broke off or was missed. Even if the fan isn't plugged in could this cause the short? If this is the case (I'm assuming this should be a soldered joint...) can I repair this pin and give it a go? Thanks, Tom
And here's a second image from the top of the Brains Board with the V- fan pin removed, it slid right out. PSU still trips with the pin removed. All other connections seem solid. The large row of pins connecting the two boards together mesh nicely and all of the solders look great.
Good troubleshooting, would've suspected the Muscle board, so good catch that its one the Brains Yes please if you feel up for trying a repair, go for it It saves you a couple days over doing an RMA if it helps. If it still doesnt work, http://support.openbuilds.com/support/home will still gladly send you a new Brains board too so it's up to you. If you need a replacement, drop them an email, reference this thread, and request a replacement Brains Board please
