Electrical issue

esco_SW · May 10, 2018, 8:08am

Hi.
I recently bought smoothieboard v1.0a X4 to move from Arduino (Mega, old but working, hacked to support 24V).
Hardware that I have:

Smoothieboard x4 v1.0a
24V power supply
3 motors 42byghm809 (1.7A(u) 0.9deg/stp) for x,y,z
1 motor kh4234890006 (1.2A 1.8deg/stp) for extruder
24V 8A heat Bed
24V 3A hotend
3 bare endstops
2 temp reader

What I have done:
0. check cli connectivity over usb

upgrade firmware
make conf file for my delta (wiring do not allows me to plug X tower cable to M1, so I decided to switch pins in config file with extruder).
wire things up (screen attached)
check temp reads, endstops (without 24V PSU on)
power on 24 power supply
move X 10mm to right (nothing happens)
turn off all power (when I touch board to unplug power it was hot at a4982 driver responsible for X movement - marked on attached screen).
unplug everything
after fev min turn board on over usb only to check damages

What newer was tested

Heaters

What is still working:

led (1-5 where 2 and 3 blinks - looks promising)
cli connectivity over USB
temp reads and endstop reads are correct

What is the problem:

stepper driver responsible for X movement (marked on attached screen) gets hot even on USB cable
there is no SD card mounted properly on board (SD card is visible and working over PC adapter), cli log:

> ls
sd/
> pwd
/
> cd /sd/
Could not open directory /sd/
> ls /sd/
Could not open directory /sd/

Questions:

Is there any debug mode for board or any POST logs?
I want to replace stepper driver, what else from power section I need to replace to get rid of powering stepper driver over USB ?
I tried to wipe sd card, format with FAT32, place new firmware on it and re-flash firmware - without success. Board powers on, but SD is unreadable.
Does my config file have any mistakes (maybe to high amps for a4982 drivers)?
Did I wire board correctly ?

Thank you for any help.

My config:

# Smoothieboard configuration file, # NOTE Lines must not exceed 132 characters, and '#' characters mean what follows is ignored ## Robot module configurations : general handling of movement G-codes and slicing into moves Basic motion configuration default_feed_rate 4000 # Default speed (mm/minute) for G1/G2/G3 moves default_seek_rate 4000 # Default speed (mm/minute) for G0 moves mm_per_arc_segment 0.0 # Fixed length for line segments that divide arcs, 0 to disable #mm_per_line_segment 5 # Cut lines into segments this size mm_max_arc_error 0.01 # The maximum error for line segments that divide arcs 0 to disable # note it is invalid for both the above be 0 # if both are used, will use largest segment length based on radius delta_segments_per_second 100 # For deltas only, number of segments per second, set to 0 to disable # and use mm_per_line_segment Arm solution configuration : Cartesian robot. Translates mm positions into stepper positions See alpha_steps_per_mm 200 # Steps per mm for alpha ( X ) stepper and tower beta_steps_per_mm 200 # Steps per mm for beta ( Y ) stepper and tower gamma_steps_per_mm 200 # Steps per mm for gamma ( Z ) stepper and tower Delta configuration See arm_solution linear_delta # Selects the linear delta arm solution arm_length 355.0 # This is the length of an arm from hinge to hinge arm_radius 180.55 # This is the horizontal distance from hinge to hinge when the effector is centered Planner module configuration : Look-ahead and acceleration configuration See acceleration 3000 # Acceleration in mm/second/second. #z_acceleration 500 # Acceleration for Z only moves in mm/s^2, 0 uses acceleration which is the default. DO NOT SET ON A DELTA junction_deviation 0.05 # See #z_junction_deviation 0.0 # For Z only moves, -1 uses junction_deviation, zero disables junction_deviation on z moves DO NOT SET ON A DELTA Cartesian axis speed limits x_axis_max_speed 30000 # Maximum speed in mm/min y_axis_max_speed 30000 # Maximum speed in mm/min z_axis_max_speed 30000 # Maximum speed in mm/min Stepper module configuration Pins are defined as ports, and pin numbers, appending “!” to the number will invert a pin See alpha_step_pin 2.3 # Pin for alpha stepper step signal alpha_dir_pin 0.22 # Pin for alpha stepper direction, add ‘!’ to reverse direction alpha_en_pin 0.21 # Pin for alpha enable pin alpha_current 1.7 # X stepper motor current alpha_max_rate 30000.0 # Maximum rate in mm/min beta_step_pin 2.1 # Pin for beta stepper step signal beta_dir_pin 0.11 # Pin for beta stepper direction, add ‘!’ to reverse direction beta_en_pin 0.10 # Pin for beta enable beta_current 1.7 # Y stepper motor current beta_max_rate 30000.0 # Maxmimum rate in mm/min gamma_step_pin 2.2 # Pin for gamma stepper step signal gamma_dir_pin 0.20 # Pin for gamma stepper direction, add ‘!’ to reverse direction gamma_en_pin 0.19 # Pin for gamma enable gamma_current 1.7 # Z stepper motor current gamma_max_rate 30000.0 # Maximum rate in mm/min Extruder module configuration See extruder.hotend.enable true # Whether to activate the extruder module at all. All configuration is ignored if false extruder.hotend.steps_per_mm 100.2 # Steps per mm for extruder stepper extruder.hotend.default_feed_rate 600 # Default rate ( mm/minute ) for moves where only the extruder moves extruder.hotend.acceleration 500 # Acceleration for the stepper motor mm/sec² extruder.hotend.max_speed 50 # Maximum speed in mm/s extruder.hotend.step_pin 2.0 # Pin for extruder step signal extruder.hotend.dir_pin 0.5 # Pin for extruder dir signal ( add ‘!’ to reverse direction ) extruder.hotend.en_pin 0.4 # Pin for extruder enable signal Extruder offset extruder.hotend.x_offset 0 # X offset from origin in mm extruder.hotend.y_offset 0 # Y offset from origin in mm extruder.hotend.z_offset 0 # Z offset from origin in mm Firmware retract settings when using G10/G11, these are the defaults if not defined, must be defined for each extruder if not using the defaults extruder.hotend.retract_length 3 # Retract length in mm extruder.hotend.retract_feedrate 45 # Retract feedrate in mm/sec extruder.hotend.retract_recover_length 0 # Additional length for recover extruder.hotend.retract_recover_feedrate 8 # Recover feedrate in mm/sec (should be less than retract feedrate) extruder.hotend.retract_zlift_length 0 # Z-lift on retract in mm, 0 disables extruder.hotend.retract_zlift_feedrate 6000 # Z-lift feedrate in mm/min (Note mm/min NOT mm/sec) delta_current 1.2 # First extruder stepper motor current Second extruder module configuration extruder.hotend2.enable true # Whether to activate the extruder module at all. All configuration is ignored if false extruder.hotend2.steps_per_mm 140 # Steps per mm for extruder stepper extruder.hotend2.default_feed_rate 600 # Default rate ( mm/minute ) for moves where only the extruder moves extruder.hotend2.acceleration 500 # Acceleration for the stepper motor, as of 0.6, arbitrary ratio extruder.hotend2.max_speed 50 # mm/s extruder.hotend2.step_pin 2.8 # Pin for extruder step signal extruder.hotend2.dir_pin 2.13 # Pin for extruder dir signal ( add ‘!’ to reverse direction ) extruder.hotend2.en_pin 4.29 # Pin for extruder enable signal extruder.hotend2.x_offset 0 # x offset from origin in mm extruder.hotend2.y_offset 25.0 # y offset from origin in mm extruder.hotend2.z_offset 0 # z offset from origin in mm #epsilon_current 1.5 # Second extruder stepper motor current Laser module configuration See laser_module_enable false # Whether to activate the laser module at all laser_module_pwm_pin 2.5 # This pin will be PWMed to control the laser. # Only pins 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 1.18, 1.20, 1.21, 1.23, 1.24, 1.26, 3.25 and 3.26 # can be used since laser requires hardware PWM, see #laser_module_ttl_pin 1.30 # This pin turns on when the laser turns on, and off when the laser turns off. #laser_module_maximum_power 1.0 # This is the maximum duty cycle that will be applied to the laser #laser_module_minimum_power 0.0 # This is a value just below the minimum duty cycle that keeps the laser # active without actually burning. #laser_module_default_power 0.8 # This is the default laser power that will be used for cuts if a power has not been specified. The value is a scale between # the maximum and minimum power levels specified above #laser_module_pwm_period 20 # This sets the pwm frequency as the period in microseconds Temperature control configuration See First hotend configuration temperature_control.hotend.enable true # Whether to activate this ( “hotend” ) module at all. temperature_control.hotend.thermistor_pin 0.23 # Pin for the thermistor to read temperature_control.hotend.heater_pin 2.5 # Pin that controls the heater, set to nc if a readonly thermistor is being defined temperature_control.hotend.thermistor EPCOS100K # See #temperature_control.hotend.beta 4066 # Or set the beta value temperature_control.hotend.set_m_code 104 # M-code to set the temperature for this module temperature_control.hotend.set_and_wait_m_code 109 # M-code to set-and-wait for this module temperature_control.hotend.designator T # Designator letter for this module temperature_control.hotend.max_temp 300 # Set maximum temperature - Will prevent heating above 300 by default #temperature_control.hotend.min_temp 0 # Set minimum temperature - Will prevent heating below if set Safety control is enabled by default and can be overidden here, the values show the defaults See #temperature_control.hotend.runaway_heating_timeout 900 # How long it can take to heat up, max is 2040 seconds. #temperature_control.hotend.runaway_cooling_timeout 0 # How long it can take to cool down if temp is set lower, max is 2040 seconds #temperature_control.hotend.runaway_range 20 # How far from the set temperature it can wander, max setting is 63°C PID configuration See #temperature_control.hotend.p_factor 13.7 # P ( proportional ) factor #temperature_control.hotend.i_factor 0.097 # I ( integral ) factor #temperature_control.hotend.d_factor 24 # D ( derivative ) factor #temperature_control.hotend.max_pwm 64 # Max pwm, 64 is a good value if driving a 12v resistor with 24v. Second hotend configuration #temperature_control.hotend2.enable true # Whether to activate this ( “hotend” ) module at all. #temperature_control.hotend2.thermistor_pin 0.25 # Pin for the thermistor to read #temperature_control.hotend2.heater_pin 1.23 # Pin that controls the heater #temperature_control.hotend2.thermistor EPCOS100K # See ##temperature_control.hotend2.beta 4066 # or set the beta value #temperature_control.hotend2.set_m_code 104 # M-code to set the temperature for this module #temperature_control.hotend2.set_and_wait_m_code 109 # M-code to set-and-wait for this module #temperature_control.hotend2.designator T1 # Designator letter for this module #temperature_control.hotend2.p_factor 13.7 # P ( proportional ) factor #temperature_control.hotend2.i_factor 0.097 # I ( integral ) factor #temperature_control.hotend2.d_factor 24 # D ( derivative ) factor #temperature_control.hotend2.max_pwm 64 # Max pwm, 64 is a good value if driving a 12v resistor with 24v. temperature_control.bed.enable true # Whether to activate this ( “hotend” ) module at all. temperature_control.bed.thermistor_pin 0.24 # Pin for the thermistor to read temperature_control.bed.heater_pin 2.7 # Pin that controls the heater temperature_control.bed.thermistor EPCOS100K # See #temperature_control.bed.beta 3974 # Or set the beta value temperature_control.bed.set_m_code 140 # M-code to set the temperature for this module temperature_control.bed.set_and_wait_m_code 190 # M-code to set-and-wait for this module temperature_control.bed.designator B # Designator letter for this module Bang-bang ( simplified ) control See #temperature_control.bed.bang_bang false # Set to true to use bang bang control rather than PID #temperature_control.bed.hysteresis 2.0 # Set to the temperature in degrees C to use as hysteresis Switch modules See Switch module for fan control switch.fan.enable true # Enable this module switch.fan.input_on_command M106 # Command that will turn this switch on switch.fan.input_off_command M107 # Command that will turn this switch off switch.fan.output_pin 2.6 # Pin this module controls switch.fan.output_type pwm # PWM output settable with S parameter in the input_on_comand #switch.fan.max_pwm 255 # Set max pwm for the pin default is 255 #switch.misc.enable true # Enable this module #switch.misc.input_on_command M42 # Command that will turn this switch on #switch.misc.input_off_command M43 # Command that will turn this switch off #switch.misc.output_pin 2.4 # Pin this module controls #switch.misc.output_type digital # Digital means this is just an on or off pin Temperatureswitch See Automatically toggle a switch at a specified temperature. Different ones of these may be defined to monitor different temperatures and switch different swithxes Useful to turn on a fan or water pump to cool the hotend #temperatureswitch.hotend.enable true # #temperatureswitch.hotend.designator T # first character of the temperature control designator to use as the temperature sensor to monitor #temperatureswitch.hotend.switch misc # select which switch to use, matches the name of the defined switch #temperatureswitch.hotend.threshold_temp 60.0 # temperature to turn on (if rising) or off the switch #temperatureswitch.hotend.heatup_poll 15 # poll heatup at 15 sec intervals #temperatureswitch.hotend.cooldown_poll 60 # poll cooldown at 60 sec intervals Endstops See endstops_enable true # The endstop module is disabled by default and must be enabled here delta_homing true # Forces all three axis to home a the same time regardless of what is specified in G28 alpha_min_endstop nc # Pin to read min endstop, add a ! to invert if endstop is NO connected to ground alpha_max_endstop 1.25^ # Pin to read max endstop, uncomment this and comment the above if using max endstops alpha_homing_direction home_to_max # Or set to home_to_max and set alpha_max and uncomment the alpha_max_endstop alpha_max 0 # This gets loaded as the current position after homing when home_to_max is set beta_min_endstop nc # Pin to read min endstop, add a ! to invert if endstop is NO connected to ground beta_max_endstop 1.27^ # Pin to read max endstop, uncomment this and comment the above if using max endstops beta_homing_direction home_to_max # Or set to home_to_max and set alpha_max and uncomment the alpha_max_endstop beta_max 0 # This gets loaded as the current position after homing when home_to_max is set gamma_min_endstop nc # Pin to read min endstop, add a ! to invert if endstop is NO connected to ground gamma_max_endstop 1.29^ # Pin to read max endstop, uncomment this and comment the above if using max endstops gamma_homing_direction home_to_max # Or set to home_to_max and set alpha_max and uncomment the alpha_max_endstop gamma_max 275.05 # This gets loaded as the current position after homing when home_to_max is set alpha_max_travel 600 # Max travel in mm for alpha/X axis when homing beta_max_travel 600 # Max travel in mm for beta/Y axis when homing gamma_max_travel 600 # Max travel in mm for gamma/Z axis when homing Endstops home at their fast feedrate first, then once the endstop is found they home again at their slow feedrate for accuracy alpha_fast_homing_rate_mm_s 150 # Alpha tower fast homing feedrate in mm/second alpha_slow_homing_rate_mm_s 20 # Alpha tower slow homing feedrate in mm/second beta_fast_homing_rate_mm_s 150 # Beta tower fast homing feedrate in mm/second beta_slow_homing_rate_mm_s 20 # Beta tower slow homing feedrate in mm/second gamma_fast_homing_rate_mm_s 150 # Gamma tower fast homing feedrate in mm/second gamma_slow_homing_rate_mm_s 20 # Gamma tower slow homing feedrate in mm/second alpha_homing_retract_mm 5 # Distance to retract from the endstop after it is hit for alpha/X beta_homing_retract_mm 5 # Distance to retract from the endstop after it is hit for beta/Y gamma_homing_retract_mm 5 # Distance to retract from the endstop after it is hit for gamma/Z Endstop debouncing options #endstop_debounce_count 100 # Uncomment if you get noise on your endstops, default is 100 #endstop_debounce_ms 1 # Uncomment if you get noise on your endstops, default is 1 millisecond debounce Endstop trim options alpha_trim 0 # Software trim for alpha stepper endstop (in mm) beta_trim 0 # Software trim for beta stepper endstop (in mm) gamma_trim 0 # Software trim for gamma stepper endstop (in mm) End of endstop config Delete the above endstop section and uncomment next line and copy and edit Snippets/abc-endstop.config file to enable endstops for ABC axis #include abc-endstop.config Z-probe See zprobe.enable false # Set to true to enable a zprobe zprobe.probe_pin 1.28!^ # Pin probe is attached to, if NC remove the ! zprobe.slow_feedrate 5 # Mm/sec probe feed rate #zprobe.debounce_ms 1 # Set if noisy zprobe.fast_feedrate 100 # Move feedrate mm/sec zprobe.probe_height 5 # How much above bed to start probe #gamma_min_endstop nc # Normally 1.28. Change to nc to prevent conflict, Levelling strategy Example for the delta calibration strategy #leveling-strategy.delta-calibration.enable true # Enable basic delta calibration #leveling-strategy.delta-calibration.radius 100 # the probe radius Example for the delta grid leveling strategy #leveling-strategy.delta-grid.enable true # Enable grid leveling #leveling-strategy.delta-grid.radius 50 # Grid radius in millimeters #leveling-strategy.delta-grid.size 7 # Grid size, must be an odd number #leveling-strategy.delta-grid.do_home true # Whether to home before calibration #leveling-strategy.delta-grid.save true # Whether to automatically save the grid #leveling-strategy.delta-grid.initial_height 10 # Height at which to start probling Panel See Please find your panel on the wiki and copy/paste the right configuration here panel.enable false # Set to true to enable the panel code Example for reprap discount GLCD on glcd EXP1 is to left and EXP2 is to right, pin 1 is bottom left, pin 2 is top left etc. +5v is EXP1 pin 10, Gnd is EXP1 pin 9 #panel.lcd reprap_discount_glcd # #panel.spi_channel 0 # SPI channel to use ; GLCD EXP1 Pins 3,5 (MOSI, SCLK) #panel.spi_cs_pin 0.16 # SPI chip select ; GLCD EXP1 Pin 4 #panel.encoder_a_pin 3.25!^ # Encoder pin ; GLCD EXP2 Pin 3 #panel.encoder_b_pin 3.26!^ # Encoder pin ; GLCD EXP2 Pin 5 #panel.click_button_pin 1.30!^ # Click button ; GLCD EXP1 Pin 2 #panel.buzz_pin 1.31 # Pin for buzzer ; GLCD EXP1 Pin 1 #panel.back_button_pin 2.11!^ # Back button ; GLCD EXP2 Pin 8 panel.menu_offset 0 # Some panels will need 1 here panel.alpha_jog_feedrate 6000 # X jogging feedrate in mm/min panel.beta_jog_feedrate 6000 # Y jogging feedrate in mm/min panel.gamma_jog_feedrate 200 # Z jogging feedrate in mm/min panel.hotend_temperature 185 # Temp to set hotend when preheat is selected panel.bed_temperature 60 # Temp to set bed when preheat is selected Custom menus : Example of a custom menu entry, which will show up in the Custom entry. NOTE _ gets converted to space in the menu and commands, | is used to separate multiple commands custom_menu.power_on.enable true # custom_menu.power_on.name Power_on # custom_menu.power_on.command M80 # custom_menu.power_off.enable true # custom_menu.power_off.name Power_off # custom_menu.power_off.command M81 # Network settings See network.enable true # Enable the ethernet network services network.webserver.enable true # Enable the webserver network.telnet.enable true # Enable the telnet server #network.ip_address auto # Use dhcp to get ip address Uncomment the 3 below to manually setup ip address network.ip_address 192.168.0.99 # The IP address network.ip_mask 255.255.255.0 # The ip mask network.ip_gateway 192.168.0.254 # The gateway address #network.mac_override xx.xx.xx.xx.xx.xx # Override the mac address, only do this if you have a conflict System configuration Serial communications configuration ( baud rate defaults to 9600 if undefined ) For communication over the UART port, not the USB/Serial port uart0.baud_rate 115200 # Baud rate for the default hardware ( UART ) serial port second_usb_serial_enable false # This enables a second USB serial port #leds_disable true # Disable using leds after config loaded #play_led_disable true # Disable the play led Kill button maybe assigned to a different pin, set to the onboard pin by default See kill_button_enable true # Set to true to enable a kill button kill_button_pin 2.12 # Kill button pin. default is same as pause button 2.12 (2.11 is another good choice) #msd_disable false # Disable the MSD (USB SDCARD), see #dfu_enable false # For linux developers, set to true to enable DFU Only needed on a smoothieboard See

currentcontrol_module_enable true # Control stepper motor current via the configuration file

edit: picture uploaded :

Imported from wikidot

Arthur_Wolf · May 10, 2018, 8:11am

This sounds very much like your entire board was damaged by a short or ESD. If the SD card has issues and the stepper driver gets hot with just USB, you are in big trouble.
You could try replacing the stepper driver and SD card, and maybe you’ll get lucky and that’s all that was damaged, but I can’t say how likely that is. It might be you have only to replace one of the two, or it might be you have to replace both, or you might have to replace both and also the microcontroller …

Edit: I’ve just seen the picture, and you have X on the E driver, etc … they are all the wrong way around. X is M1.

esco_SW · May 10, 2018, 8:36am

Thanks for reply.
I changed pinout in my configuration to use M4 as X and M1 as Extruder, so I think this is not an issue.
I also changed pinout for heatbed and extruder.
Can you look at my config pinouts and current values and tell me if anything is misconfigured?

Arthur_Wolf · May 10, 2018, 8:38am

can you please try with the very latest firmware, very latest delta example config, and see if it works with the default wiring and completely unmofidifed config

esco_SW · May 10, 2018, 8:39am

ok, I’ll try that

esco_SW · May 10, 2018, 1:49pm

Little update.
I desolder M4 stepper driver. Problem with SD card disappears (at least something ).
I have mcp4451 module that is responsible for current adjustment on stepper drivers.
I measured voltage on each stepper driver Vref pin, and I get:
M1 Vref = 0.46 V
M2, M3, M4 Vref = 0.65 V

A4982 have formula for max current:
TripMAX = VREF / (8×RS)
I have R050 (0.05 ohm) resistors for each coil.

The max current for M1 is 0.46/(8*0.05) = 1.15 (it is close enough - in config is 1.2A for extruder).
The max current for M2, M3, M4 is 0.65/(8*0.05) = 1.625 (it is close enough - in config is 1.7A for axis).

From above we can conclude that X and Extrude are properly switched in config.
I have coil grouped correctly (AABB, or BBAA depending from which side are you looking).
Vref have correct values, and max current (2A) limit for stepper driver wasn’t reached.
My wiring was correct, so I’m wondering why one of my stepper drivers burned out ?
Maybe I should add heat sink with fan to cool them down ?

P.S I ordered stepper drivers, but I need to wait about month before they reach to my country, maybe together we figure out what I did wrong, to avoid future mistake.