2nd stage of Crusader II retrofit

I reconnected the P4 connector with all wires and that brought up the 15vdc power on the amp cards and all three axis locked up.

Good, so the drives enable. Did the drives not enable when flipping the toggle switch on the back of the box with only the 2 wires coming from the man/auto switch? There is a possibility you may be feeding 120v back into the 801 with the other wires still connected?! (Again, I followed what others have done. You may want to double check a wiring diagram to make sure you're okay with the additional connections on that connector) I'm guessing it powers the other ice cube relays for m functions.

I don't have read-out from any of the axis I am thinking something is not providing power to the scales but not sure what.

Assuming you have 5v going to the encoders, did you set the 7i77 jumpers for single ended? Manual says jumper set to the left hand for single ended.

Wow, it looks like I didn't press submit after writing my last post??

Anyway I have the readouts working since moving all the TB3 jumpers to the right.
Now the problem is Y-axis again. It powers up but dosen't respond to jog commands both the other axis do.

Jim

Edit: yes they don't enable with the switch in manual. And I removed the other wires from P4.

I have the readouts working since moving all the TB3 jumpers to the right.

Good, so just to clarify, you switched the jumper position from the default to the other "right". Left for single ended unless you don't have the stock scales.

Now the problem is Y-axis again. It powers up but dosen't respond to jog commands both the other axis do.

When it powers up, is the Y axis locked? When you try to jog the Y, do you get a joint following error? We are back to the same questions raised before. You ruled out the drive before by swapping with the X. Any chance you have a bad keyboard? Did you try executing a G code Y move in mdi? Anything change in your config and ini files?

OT-CNC

Y-axis "locks up" when the machine is enabled.
Yes the Y-axis errors out when jogged.
The jog is done by mouse on the Axis Interface and the cutter on screen can be seen to move.
Quite a bit has changed in the hal file not much in the ini.

What would happen if I swapped the X Y connections at the 7i77 TB5 drv 0 and 1?

Jim

Lets look at your files first. You risk a runaway when swapping the drv and encoder connections if any of the axis are configured differently in direction.

I am all for the safest course. Here's a copy of my current hal and ini files.

Thanks
Jim

Ini shows ax_velocity instead of max for the Y.

OT-CNC, Tommylight

I corrected the ini file to read MAX_V and tried again. Same problem, Y-axis enables but does not jog continuous or incremental.

I did try probing the TB5 AOUT0 AOUT1 AOUT2 pins at the screw lock downs. X & Z axis show voltage +/- when jogged. Y axis shows nothing.

Not sure what to make of this but... or why there is no voltage.
I tried reading voltage without the wire in the connection and then there is voltage.

Thank you both for your help
Jim