7i96 card may have bad Module Descriptor 4

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12 Feb 2021 00:04 #198459 by hickory43
My plasmac machine has been operational for several months. Upon startup recently I found that my Z drive motor would not run but the DRO showed movement. I assumed that this might be caused by loose wires in the cabinet so began checking the wiring, continuity, joint tightness, etc, During this process I sparked a few wires. I attempted to bypass the 4th stepper module and use the fifth module without success. I had also changed some of the programing. without dribbling along I am at a point that the attached error message was received

File Attachment:

File Name: errortext.txt
File Size:2 KB

File Attachment:

File Name: RsplasmaC.hal.hal
File Size:7 KB

File Attachment:

File Name: RsplasmaC.ini.ini
File Size:11 KB

File Attachment:

File Name: RsplasmaC_....hal.hal
File Size:3 KB
. Basic question can the card possibly be repaired or do I need a new card? Best case I'm all wet and it is something else.
Thanks for your help in advance. I have a great time pulling my hair out over this conversion from router to plasma and greatly appreciate all that the many of the forum members do!
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12 Feb 2021 00:13 #198460 by PCW
The error is likely because you are using firmware with only
4 stepgens (probably has PWM on the 5th stepgen) and you asked
to enable 5 stepgens.

If the system works as far as showing motion on the screen
and the Z axis is wired properly, its likely an issue with the
drive, drive wiring or 7I96 step/dir output

If its just a bad step/dir output on the 7I96, this is reparable

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12 Feb 2021 00:35 #198463 by tommylight
What wires did spark?

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12 Feb 2021 04:14 #198487 by hickory43
I have tried to change the configuration from 5 steppers to 4 steppers and a PWM but apparently unsuccessfully. In terms of wiring, I believe that I have things wired correctly, but I have a question, the stepper connections only require two wires, one for step and one for direction, is this correct? Is there a way for me to test the integrity of the # 4 module? I appreciate the quick response.

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12 Feb 2021 04:18 #198488 by hickory43
I had the wire from the breakaway switch hanging loose while testing continuity of the motor wires. the two sets made contact making some sparks. Thanks for the quick response.

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12 Feb 2021 04:24 #198489 by hickory43
In terms of the motor driver, yes I did detect some smoke damage across a resister(?) in the motor driver. I replaced the driver but have not been able to test the motor system since I haven't cleared all of the errors.

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12 Feb 2021 15:34 #198542 by PCW

hickory43 wrote: I have tried to change the configuration from 5 steppers to 4 steppers and a PWM but apparently unsuccessfully. In terms of wiring, I believe that I have things wired correctly, but I have a question, the stepper connections only require two wires, one for step and one for direction, is this correct? Is there a way for me to test the integrity of the # 4 module? I appreciate the quick response.


In addition to step and direction you need ground or 5V depending on the drive

The module 4 error means you have a hal file issue where you are asking for more stepgens
than the firmware has available (you probably have a "num_stepgens=5" statement in your
hal file but have firmware loaded tha has only 4 stepgens and a pwmgen)

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