Troubleshooting
Golden rule of finding issues!
we need clear instructions on how to repeat the error at our end, otherwise we are just crystal ball gazing.
If you can't get it to repeat at your end, it might've just been a fluke or an error in your processes, but if you can get it to repeat, then we may have a bug, but it means we can also look at and verify the process to check for errors.
Generally there are two types of issues
- Doing something when it shouldn't be
- Not doing something when it should be
Start with updating all your software!
The bug may have already been solved, so there is no point chasing our tails if you haven't updated the software! Update both Gladius, and the Swordfish Firmware on your machine.
What are you trying to accomplish?
Give accurate detailed instructions on what you have been doing to acheive what you are trying to accomplish.
What are you experiencing?
- Doing something when it shouldn't be
- Not doing something when it should be
Read your Gcode!
Computers, and especially ours, are extemely fast, incredibly accurate but insanely stupid! They will do exactly as they are told and make ZERO assumptions, let's make sure we aren't telling it to do something silly :)
Common Issues:
- Cutting in the wrong place
- Pneumatics not working
- WCS (XYZ) Probe not working
- Tool [setter] Probe not working
- Spindle not turning on or off
- Limit Exception
- Machine Stalling, typically on Y Axis
- Tool Change not Functioning
- Tool Height Incorrect after Tool Change
Cutting in the wrong place
SYMPTOMS:
Cutting in the wrong place
DIAGNOSIS:
Machine has stalled and lost it's poistion
Gladius isn't set to the same work coordinate system as your file, typically G54.0
The WCS (Work Coordinate System) Zero has been set wrong
SOLUTIONS:
Home your Machine
Ensure you are in the correct WCS workspace (i.e G54.0)
Verify your X0Y0, and your Z0 coordinate position is the same as your CAM setup
Pnuematics not working
SYMPTOMS:
Machine halts during tool change
DIAGNOSIS:
Insufficient Air
Water in Air
SOLUTIONS:
Ensure air line is connected (YES! Silly but it happens)
Ensure compressor is up to the task (See machine requirements)
Ensure air has sufficient drainage or dryer is on compressor. If there is moisture in the lines, you will be blowing water directly into the bearings causing rust and damage leading to eventual failure of the spindle.
Work Coordinate Setter (WCS) Probe not working
SYMPTOMS:
Machine drives into base of probe, stalls or snaps tool.
Machine not making contact with probe
Machine not moving (or moving veerrry slowly)
Button is greyed out in Gladius
DIAGNOSIS:
Ensure probe is plugged in and firmly seated.
Red LED on probe should be lit up.
Touch XYZ (WCS) Probe against general mass of earth and visually check that LED goes brighter
Check M119 function for "TRIGGERED" or "OPEN" response while both touching and not touching mass of earth
Corner not selected in software
SOLUTIONS:
Plug Probe in
Probe is damaged and needs replacing
Machine has been set too far away from the probe, relative to it's safe probing distance. Default 10mm.
Machine has been set to probe far too slowly (default 20mm/minute). Can appear like it's not moving. Change to 200mm/min rate in the probing function.
ATC Spindle are supplied with Ceramic bearings, which do not conduct. Use a crocodile clip to go between the machine's general mass of earth, and the tool. I.e clip the top of the tool to a bolt, such as the spindle mount, on the Z axis.
Select the correct corner probe is touching inside gladius and the button should darken and enable.
Tool Setter/Z Probe not working
SYMPTOMS:
Upon Tool change, spindle does not go downwards, only upwards.
May throw a limit exception error
Drives tool into wrong spot on the bed
Tool fails to reach probe
DIAGNOSIS:
M119 to check the status of the probe. Check Z Probe for "TRIGGERED" or "OPEN.
Push and hold probe down while executing another M119 to verify operation
SOLUTIONS:
Probe has been damaged and is stuck in downwards position, will need to be replaced
The work-coordinate location of the probe has been overwritten by the user. Reset position required.
Tool is not protruding sufficiently out of the spindle. Machine has run out of Z travel while probing. Run tool change function again and lower tool slightly.
Spindle not turning on or off
SYMPTOMS:
Error message "TIMED OUT WAITING FOR SPINDLE"
DIAGNOSIS:
Error Message blinking on the VFD Screen.
VFD Toggles Error state when E-Stop is pushed, and does not reset.
SOLUTIONS:
Press the RED "Stop" button on the VFD to clear and reset the VFD
Known bug on earlier firmware to not clear the error state on VFD before restarting, after E-stop, pertaining to DZB312 VFDs. Update to most recent firmware and confirm if bug persists.
Limit Exception
SYMPTOMS:
Machine stops before or during a cut operation
DIAGNOSIS:
"ERROR - Limit Exception" thrown in Console Window relating to X,Y or Z axis.
SOLUTIONS:
READ YOUR GCODE
This error is thrown when the program being run is trying to force the machine outside its work envelope. While the immediate cut will be inside the machine working envelope, the read ahead of the GCode in machine's buffer will cause it to stop.
You will need to change where your workpiece is being zeroed from.
If the error pertains to a Z Axis limit, you may find your cutting too low. Either poke your tool out further, or lift the material up higher on a waste board.
Machine Stalling
This issue is typical of the Y (long) axis on P4, and typically presents when some dirt and debris gets onto the motion system.
SYMPTOMS:
A grinding and a binding noise, followed by the toolhead moving to the wrong spot
DIAGNOSIS:
Ballscrew may be tensioned incorrectly
Ballscrew Tensioner bearing may have failed
Dirt and detritis on Ballscrew
Dirt and detritis on Linear Rail
SOLUTIONS:
Replace Tensioner bearing
Retention Ballscrew
Clean Ballscrew, and apply grease
Clean linear rail, and apply grease
Please note: You may need to grease at multiple points along the rail and ballscrew. It is also good practice to apply some grease directly to the rails and screw with a brush or rag. Grease should be a high-speed lithium grease. Also known as an EP2 or EP3 grease by some brands
GREASE IS CHEAP! Bearings and down time are not! Go wild with the grease, it'll spit out what it doesn't want.
Tool Change not Functioning Correctly (Non-ATC Variants)
SYMPTOMS:
DIAGNOSIS:
SOLUTIONS:
Tool Change not Functioning Correctly (ATC Variants)
SYMPTOMS:
DIAGNOSIS:
SOLUTIONS:
Tool Height Incorrect after Tool Change Operation
SYMPTOMS:
Z not cutting at correct depth, either too high or too low
DIAGNOSIS:
After probing and setting WCS with one tool, the first operation will run at correct height then after a tool change, manual or automatic, the second operation is no longer operating at the expected heights.
SOLUTIONS:
The first tool was not probed correctly, or the tool geometry has meant it has probed off the wrong part of the tool.
For example, Typical of woodworking tools to have spurs on the end to guide, this can offset tool lengths on automatic probing cycles and cause holes to be shallow.
Not probing tools before setting work offsets means the machine loses where it thinks the tool tip is, and still thinks the previous tool and that tools' corresponding offset is still valid! This means that when it changes tools, it applies any distance changes incorrectly and throws out the Z heights.