Re: [Emc-users] Had to re-flash Mesa 7i77 twice

[Peter C. W. <pc...@me...>]

On Tue, 25 Apr 2017, Marius Alksnys wrote:

> Date: Tue, 25 Apr 2017 16:35:33 +0200
> From: Marius Alksnys <ma...@ro...>
> Reply-To: "Enhanced Machine Controller (EMC)"
>     <emc...@li...>
> To: emc...@li...
> Subject: Re: [Emc-users] Had to re-flash Mesa 7i77 twice
> 
> The firmware was the same, downloaded a month ago. The cable is provided 
by Mesa, no damage observed.

>Today is even "funnier": the machine started to drift away, like user 
>said, to go to completely different position than commanded in G-code.
>This was observed at least four times. Two of them where going to the 
>material - operator noticed and hit the Emergency button.
>
>I think it is drifting away with the latest analog command DACs received 
>and Enable signal state and all components: LinuxCNC, Mesa cards and 
>servo drives are happy with it, not stopping anything and not issuing an 
>error in a timely fashion.

The only way I can see this (drift) happening (assuming reasonable following 
error settings) is encoder counting issues. If drift was the only issue I 
would be tempted to enable encoder filtering(if not enabled) and perhaps lower 
the encoder sampling rate.

But the drift in addition to the sserial+quadrature errors suggest a 
systemic problem, perhaps 5V power to the 7I77 is marginal, or as I mentioned 
before you have PC power/PCI issues (the list of sserial errors you got is not 
really possible with just a link failure and I think reflects complete loss of 
communication to the 5I25 card so the PCI reads are reading 0xFFFFFFFF and 
therefore all possible hardware errors are reported)



>You can see the videos and pictures by yourself. The user claims it is 
>the same G-code, almost the same time, no HW / SW changes, cables also 
>not touched. Maybe even without LinuxCNC restart:
>https://www.youtube.com/playlist?list=PLMTctt_8ZIjX3eo2pw2IDmmH3Q34qZm83
>
>The pictures of electric cabinet, cables, cards:
>https://drive.google.com/drive/folders/0Bx5r7yxJ8GWDTVdvbnFxVFFyYmc?usp=sharing


04/24/2017 03:23 PM, Peter C. Wallace raÿÿÿÿ:
> On Mon, 24 Apr 2017, Marius Alksnys wrote:
>
>> Date: Mon, 24 Apr 2017 13:52:55 +0200
>> From: Marius Alksnys <ma...@ro...>
>> Reply-To: "Enhanced Machine Controller (EMC)"
>>     <emc...@li...>
>> To: emc...@li...
>> Subject: [Emc-users] Had to re-flash Mesa 7i77 twice
>>
>> A month ago one machine with LinuxCNC and Mesa cards: one 5i25 and one 7i77
>> started bringing errors(1) each time program was started. Then I re-flashed
>> 7i77 using ./update_7i77 script from mesanet page. It fixed the problem..
>> till today. Today I got similar errors(2). And again, reflashing 7i77 fixed
>> the problem.
>
> If the error was not a complaint about the 7I77 firmware version being < 14,
> reflashing the card would not help. I suspect that there is  a signal
> integrity issue perhaps in the 5I25 PCI/system connection, as that set of
> errors looks like bad data at that interface.
>


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Peter Wallace
Mesa Electronics

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