OK, this is interesting

[dlcw]

Machine:

Windows 7 64-bit home edition
Shopbot 6.44
All software and services configured exactly like they were at end of last session (no computer configuration changes, no auto updates, no internet access)

Last week (Thursday) I cut 12 pieces of plywood into cabinet parts with 0 problem. After cutting was done, I parked spindle at end of table like I always do, turned machine off and it has been sitting since then.

This morning I empty the dedicated dust collector, put a new garbage bag on it, put it back in to place with all hoses and grounding hookups (exact hookup as it always is). Go to start cutting a SBLink file and I can't get more then 2 or 3 cuts into the file and the machine gets a comm error. Even with the bit embedded into the wood the machine acts like it hit proximity switches and comes to a dead stop (no ramp down) and just sits there (bit spinning in the wood). I then get that dreaded yellow dialog saying it just puked with the Quit and shut down option. Do that and the spindle keeps running with the bit buried in the wood. Start Control back up and spindle gets shut down.

It stops in a different spot each time. No pattern to anything.

Trouble shooting steps so far:

1. Shut down control software, restart it, re-zero X,Y,Z and try again (stops dead after a couple of cuts). I've tried this 4 times with same results of comm error part way into file
2. Shut down control software, turn Shopbot off, turn computer off. Unplug all USB cables between Shopbot, spindle and computer. Restart everything, re-zero X,Y,Z (tried this a couple of times). Same results of dead stop and comm error after a couple of cuts)
3. Shut down control software, turn Shopbot off, turn computer off, unplug ALL power cords from outlets (110vac and 220vac), unplug all USB cables between Shopbot and computer. Wait 10 minutes, plug everything back in, turn on computer, turn on Shopbot. Load up Shopbot control, re-zero X,Y,Z and try cutting again and get the same full stop and the dreaded yellow dialog box after a couple of cuts.

I've checked all my cables and everything is firmly connected. All cabling is off the floor so there hasn't been any walking on cables. The only thing that changed between last week and this was to empty the dust collector bag (Harbor Freight DC). I tried running the machine with no dust collection running or even hooked up. Same lost comm problems.

Anyone got any ideas what might be wrong? Could this be hardware going bad?

[kevin]

Don if you haven't already tried a different computer try the easy fix first

I FEEL YOUR PAIN

[jerry_stanek]

I would try the UR command and then reload your firmware.

[jTr]

Same scenario for me last week. Checked location of USB cable in relation to 220V main cables - too close and too parallel for comfort. Moved them and had no further issues. If they must cross over, keep intersection @ 90 degrees.
A bit unnerving when that bit just sits there cooking...

[toy1]

I had the same issue it all points to the grounds I would make sure all the ground are making contact re-scrap the surfaces and then reattach the grounds. Once I did this the problem went away unfortunate this is the weak point in the shop bot design. I spent a day trying to understand what was going wrong I went back and read all of the post on grounding, my problem occured when I diconnected the dust foot and it did not make sense but once I did the ground check it worked fine.

hope this helps

[dlcw]

Kevin,

The computer I put on the system is brand new as of a month ago. The hole system has worked flawlessly, on the new computer, for month up until this morning when I emptied the DC bag, turned on the machine, started cutting a file and got the dreaded lost comm dialog with the Quit and Close option only. The last files I cut successfully were last Thursday around midday. Turned everything off, turned it back on this morning and it puked.

I'm working with Frank at support on this issue. It makes no sense to me. He told me my mistake was replacing the DC bag that had the hole in it. Now the gremlins can't get out of the bag. Also, I must be playing the wrong kind of music on the computer....:)

Jeff, the power cables are about 3.5 feet from the USB cables and have been since I installed the machine about 3 years ago.

Carl, thanks for the ideas. The first thing I checked was the loss of a ground somewhere. All grounds are good and clean and securely fastened. As a communications and LORAN electronics technician in the US Coast Guard for 23 years, one thing I learned VERY WELL was how to properly ground things. On a ship, you could here a rusty chain rattling in a high frequency receiver if the chain wasn't properly grounded. It sounded a lot like lightning in an AM radio.

[frank134]

Don I had the same kind of problem. Only mine just sat for two weeks. New computer with windows7 an usb2 ports. I try everything. Still keep getting the same com era. I talk to frank did what he said and still had the same problem. Try another computer. It did the same thing. Them I read something Gary wrote about the new computer he builds with an usb3 port. So I ask my son if I could use his gaming computer with usb3 and it water cool. That was almost three mouths ago. I have tried everything to get it to give me a fail com. even took the ground off. I run great. I think the usb3 port our better. Don't know if this would help you or not. It did for me. You don't have to buy a new computer just get a card with an usb3 port and try it. That what I did with mine.
I hope this help.

[harryball]

Did updates run on the system? I keep hearing "it's a new system..." often it can take weeks for all the updates to automatically download and apply unless you sit and do them yourself. There is a potential bug in the USB drivers of W7 SP1 than can downgrade USB 2.0 devices to 1.1 after your updates.

http://support.microsoft.com/kb/2529073

I know the article says it occurs right after you apply SP1, but I've seen this bug crop up seemingly randomly as well as appear on systems configured from a W7SP1 installation disks.

Long shot, but worth checking.

/RB

[dlcw]

Interesting RB.

I checked and SP1 was installed on my system the day after I booted it up for the first time. Before ever installing the Shopbot software, I made sure the latest updates were already installed on the computer. Then I did the Shopbobt install. The Shopbot has run flawlessly since then up until yesterday. I run it on average about 30 to 35 hours a week. The computer is not connected to the internet so automatics updates can't happen. On my previous computer, WIndows XP Pro, I would connect it to the internet once a month to get critical updates to the OS then remove the internet connection. My SOP is to do the same thing with the new computer.

Since the new computer was brought on line, and all the updates to the OS installed, it has cut over 100 sheets of plywood, cut mortises (in hardwood) on several legs for tables, carved 15 signs, and has carved several 3D models for customers. It wasn't till yesterday that I got this weird behavior.

I just wonder if the spindle or the VFD has started failing. I've been using the Shopbot for over 3 years now. Maybe it's time? :(

[paul_z]

Don,

This is a longshot but is it possible that you pluged the USB cable into a different port on your computer. If so, it creates a new "instance" of the device.

Paul Z

[dlcw]

Gary Campbell suggested that and I might try it.

[dlcw]

Update this morning.

Turned everything on after it was turned off all night. Ran my test file to exercise the machine and it worked perfectly (5 times without a problem). :)

Maybe it needed a night of rest?

Yesterday the exact same program wouldn't move the spindle more then 1.5 ft before I would get the comm error. :eek:

Ordered a new controller board from Shopbot. Hopefully that will make the machine less susceptible to these kinds of problems.

Anyone know of problems that the spindles will start to have after a few years of operation? I've got the 2.2HP spindle.

[ron_moorehead]

Hi Don,

Fellow Washington ShopBoter , how old is your shopbot, mine is a early 2007 with the usb to serial interface and controller card. I just wanted to let you know I bought a new version 205 controller card about a year ago understanding that with the new direct usb plug it would help maybe reduce the number of com losses I was getting and have better through put, I installed the new card and had worse problems with com loss than with the old card. When I could get it to talk to the PC I would get a speed of only 75 in the speed test, with my old card I could get 85. I just tried the new version 205 card last week with the new beta software and was getting the same speed rating as before, but it worked a little better only would loss com 4 times that days as with the old card maybe once a month. If your replacing the old style I hope you have better luck than I did, I make you a good deal on a version 205 control card that does me no good as I went back to the old one and have run 7 days now with no com loss. I have come to the conclusion that if it not broken don't fix it or upgrade it.

[dlcw]

Hi Ron,

Thanks for the update on your board experience.

Mine Shopbot is a 2009. If the new board upgrade doesn't work as advertised, I will send it back for a refund. I'm certainly not going to keep an expensive board anchor around.