Anyone ever seen the SSR's burn up like this (see attached photo)? They are on the 1GB board on a C controller. I can enable the motor power but as soon as I try to jog any of the axis it throws error 1504 (position envelop error).

I think it's a 'rite of passage' to anyone tasked with troubleshooting and maintenance to experience a bad day or two at some point. When it happens, it's better being a spectacular moment to remember with lot's of witnesses, then you can look as dumbstruck as anyone else, become famous in your company for turning a 5min job into a major breakdown, blame the pixies, turn around and then :away: Encoder error response errors can easily be proved on Z Series where it's a minor axis related error as they are all mounted in the same vicinity and encoders are available as spare items. The encoder circuit is: Encoder=>1FG=>X3A/X3=>1GB CN2 (As below). So you have a couple of choices but ALWAYS ensure: - Don't rush, and be sequential and logical so that you can retrace your steps. - Note the errors before you start, don't just read, many times people ignore specific error details. - Make an all data file save before you start. - No need to make any mechanical disconnection at this point. - Power down before disconnection/reconnecting any harness. - JTx abnormality errors will occur due to power cycle value comparison differences (ignore/resettable). - Do not try and jog/electrically move any axis. - Carefully read all JTx error messages and compare with your originals. - Misreading could result in you going 'off piste' down a different direction. - All you are doing is checking for encoder comms, actual positional data is irrelevant. Option 1: If you have a spare encoder, you can disconnect the harness and connect the new encoder. - No need to mechanically remove/install at this point. - JTx abnormality error will occur but you can ignore and is resettable. - If the JTx encoder error persists, a disconnection between encoder and 1GB CN2 or 1GB fault is likely. - If the error clears, then the encoder is bad. - If you start receiving new errors, reverse what you have done and get back to where you started. Option 2: If you don't have a spare encoder, then you can swap encoder connections between minor axis. - Making sure to connect both encoders and to not attempt to jog/electrically move any axis. - JTx abnormality error will occur but you can ignore and is resettable. - If the JTx encoder error moves joint, then you have a bad encoder. - If the JTx encoder same JTx, a disconnection between encoder and 1GB CN2 or 1GB fault is likely. - If you start receiving new errors, reverse what you have done and get back to where you started. Obviously, this all carries risks and I cannot accept any liability. If you make an all data file save first, as you are not mechanically removing anything, then as long as you return everything to as it was, then you all data file save could be used to restore any settings you may have changed during.....but as you can see, nothing above involves changing any data. You are just checking for encoder comms remember, so no data should change in the controller. Hope this helps......... :top:

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1GB Board Burnt UP SSR's

Lantz
September 17, 2021 at 3:19 PM
Thread is Unresolved

kwakisaki
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September 27, 2021 at 6:57 PM
- #21
You're welcome, that's excellent news bringing her back into action.
Good idea about swapping at 1FG end, whilst it's out it makes it easier.....
Glad the information helped, you did all the work my friend and thanks for letting us know the outcome.
You've earned a few jars too...........
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