Error,

I did test them one at a time and the results are listed with serial number of the card in that zip file.

The green and red lights are all on they do not flicker.

Hmmm, this is really weird! Now, some of the older DIO boards did not have the readback feature in the firmware, so this result would be expected. But, there is one much later board (SN0041) that should have the latest firmware, so the readback on that one should be working.

When you power up the PPMC motherboard, do all the red lights come on immediately? That should not happen, the red LEDs should all be off, as the board should be in the power-up reset state, and in E-stop.

If you halt the diotest with ctrl/c, are all the red LEDs lit, or do they have some random pattern with some lit, some dark? (The diotest diagnostic sends random patterns to the SSRs and then reads back to see if the values match what it sent.) It goes so fast that the LEDs may appear all lit when the diag is running, but they are actually flickering on and off about 50%, but probably too fast to see.)

Jon

OH, DIO serial # 0019 did report mostly OK tests, it had a few missed values. That is interesting, that 3 boards have no response, but one board mostly responds correctly. Even stranger!

Jon

Your telling me! They are all set to address 6 and in the same slot. When power is applied a red light on the encoder 2 card blinks once and the I/O all has green lights.

When diotest is halted there are random red lights on.

When diotest is halted there are random red lights on.

OK, this all sounds right, then. There may be some noise issues on the parport bus, but it seems to be mostly working. I think, (as others have said) that there is some kind of issue with the lube pump relay that is sparking so brightly in the video. I'd just disconnect that for now, and see if the rest of the system comes up and works properly. If so, then you will need to find out why that relay sparks and fix it, possibly with arc suppressors on the contacts.

Jon

I have already disabled the contact that was sparking. I have also posted about that and that if I comment out the drive ready signal in the code it will not do any of that.

The drive ready signal has been cycling so fast that the machine would home out. That contact is no longer sparking and the machine seems to be locked into E-stop all the time now.

I am going to put everything back in its original positions and see what works or doesn't at this time.