One stepper driver overheating after plugging in Jackpot controller

Joebus · November 27, 2023, 7:03pm

I’ve just converted from LR2 to LR3 using all the same stepper motors as before. I have upgraded to the Jackpot CNC controller. I have one Driver getting extremely hot at startup when motors are locked. I have not checked if it cools down when motors are freed. It gets too hot too quickly to find where to turn them off. I can smell it and it burned my finger.

Is it possible I just have a bad driver or the Pot got bumped?? Is there something else I can look at?

-Version 1.1 6/2023
-TMC 2209s that came with the jackpot board

-Driver stays cool with no motor plugged in.
-Plugged in another known working motor and the same overheating issue.
-Moving the driver to a different axis on the controller makes no difference.
-Haven’t touched the potentiometer on the driver or changed any amp settings.

vicious1 · November 27, 2023, 7:24pm

Can you put up a picture of your board and esp please.

When you boot can you run a $SS in the terminal and paste the results here (with the steppers plugged in).

vicious1 · November 27, 2023, 7:25pm

We found at some point some of the boards boot wrong with the steppers plugged in. The new ones have a fix but if this is the cause we have options. Yours seems a little off previously they have all booted under powered (your pots might come into play here might be a backup boot system). To be safe you can turn all the pots down to make sure nothing melts.

Joebus · November 27, 2023, 8:00pm

Here is the logfile with motor NOT plugged in
(Not related but I noticed Low Memory warnings here. The controller had been running for about an hour with no motor plugged in vs just a few mins (bottom log file).

> $G
> [MSG:WARN: Low memory: 13328 bytes]
> [MSG:WARN: Low memory: 9836 bytes]
> <Idle|MPos:0.000,-50.000,0.000|FS:0,0|Pn:Y>
> <Idle|MPos:0.000,-50.000,0.000|FS:0,0|Pn:Y>
> <Idle|MPos:0.000,-50.000,0.000|FS:0,0|Pn:Y>
> $SS
> [MSG:INFO: FluidNC v3.7.8]
> [MSG:INFO: Compiled with ESP32 SDK:v4.4.4]
> [MSG:INFO: Local filesystem type is littlefs]
> [MSG:INFO: Configuration file:config.yaml]
> [MSG:INFO: Machine LowRider]
> [MSG:INFO: Board Jackpot TMC2209]
> [MSG:INFO: UART1 Tx:gpio.0 Rx:gpio.4 RTS:NO_PIN Baud:115200]
> [MSG:INFO: I2SO BCK:gpio.22 WS:gpio.17 DATA:gpio.21]
> [MSG:INFO: SPI SCK:gpio.18 MOSI:gpio.23 MISO:gpio.19]
> [MSG:INFO: SD Card cs_pin:gpio.5 detect:NO_PIN freq:20000000]
> [MSG:INFO: Stepping:I2S_static Pulse:4us Dsbl Delay:0us Dir Delay:1us Idle Delay:255ms]
> [MSG:INFO: User Digital Output:0 on Pin:gpio.26]
> [MSG:INFO: User Digital Output:1 on Pin:gpio.27]
> [MSG:INFO: Axis count 3]
> [MSG:INFO: Axis X (0.000,1220.000)]
> [MSG:INFO:   Motor0]
> [MSG:INFO:     tmc_2209 UART1 Addr:0 CS:NO_PIN Step:I2SO.2 Dir:I2SO.1 Disable:I2SO.0 R:0.110]
> [MSG:INFO:  X Neg Limit gpio.25]
> [MSG:INFO: Axis Y (0.000,2440.000)]
> [MSG:INFO:   Motor0]
> [MSG:INFO:     tmc_2209 UART1 Addr:1 CS:NO_PIN Step:I2SO.5 Dir:I2SO.4 Disable:I2SO.7 R:0.110]
> [MSG:INFO:  Y Neg Limit gpio.33]
> [MSG:INFO:   Motor1]
> [MSG:INFO:     tmc_2209 UART1 Addr:3 CS:I2SO.14 Step:I2SO.13 Dir:I2SO.12 Disable:I2SO.15 R:0.110]
> [MSG:INFO:  Y2 Neg Limit gpio.35]
> [MSG:INFO: Axis Z (-300.000,0.000)]
> [MSG:INFO:   Motor0]
> [MSG:INFO:     tmc_2209 UART1 Addr:2 CS:NO_PIN Step:I2SO.10 Dir:I2SO.9 Disable:I2SO.8 R:0.110]
> [MSG:INFO:  Z Pos Limit gpio.32]
> [MSG:INFO:   Motor1]
> [MSG:INFO:     tmc_2209 UART1 Addr:3 CS:I2SO.19 Step:I2SO.18 Dir:I2SO.17 Disable:I2SO.16 R:0.110]
> [MSG:INFO:  Z2 Pos Limit gpio.34]
> [MSG:INFO: X Axis driver test passed]
> [MSG:INFO: Y Axis driver test passed]
> [MSG:INFO: Y2 Axis driver test passed]
> [MSG:INFO: Z Axis driver test passed]
> [MSG:ERR: Z2 Axis TMC driver not detected - expected 0x21 got 0x0]
> [MSG:INFO: Kinematic system: Cartesian]
> [MSG:INFO: Using spindle NoSpindle]
> [MSG:INFO: Flood coolant gpio.2]
> [MSG:INFO: Mist coolant gpio.16]
> [MSG:INFO: Probe Pin: gpio.36:low]
> [MSG:INFO: STA SSID is not set]
> [MSG:INFO: AP SSID FluidNC IP 192.168.0.1 mask 255.255.255.0 channel 1]
> [MSG:INFO: AP started]
> [MSG:INFO: WiFi on]
> [MSG:INFO: Captive Portal Started]
> [MSG:INFO: HTTP started on port 80]
> [MSG:INFO: Telnet started on port 23]
> ok

With MOTOR PLUGGED IN:

> $G
> [GC:G0 G54 G17 G21 G90 G94 M5 M9 T0 F0 S0]
> ok
> <Idle|MPos:0.000,0.000,0.000|FS:0,0|Pn:Y|WCO:0.000,0.000,0.000>
> <Idle|MPos:0.000,0.000,0.000|FS:0,0|Pn:Y|Ov:100,100,100>
> $SS
> [MSG:INFO: FluidNC v3.7.8]
> [MSG:INFO: Compiled with ESP32 SDK:v4.4.4]
> [MSG:INFO: Local filesystem type is littlefs]
> [MSG:INFO: Configuration file:config.yaml]
> [MSG:INFO: Machine LowRider]
> [MSG:INFO: Board Jackpot TMC2209]
> [MSG:INFO: UART1 Tx:gpio.0 Rx:gpio.4 RTS:NO_PIN Baud:115200]
> [MSG:INFO: I2SO BCK:gpio.22 WS:gpio.17 DATA:gpio.21]
> [MSG:INFO: SPI SCK:gpio.18 MOSI:gpio.23 MISO:gpio.19]
> [MSG:INFO: SD Card cs_pin:gpio.5 detect:NO_PIN freq:20000000]
> [MSG:INFO: Stepping:I2S_static Pulse:4us Dsbl Delay:0us Dir Delay:1us Idle Delay:255ms]
> [MSG:INFO: User Digital Output:0 on Pin:gpio.26]
> [MSG:INFO: User Digital Output:1 on Pin:gpio.27]
> [MSG:INFO: Axis count 3]
> [MSG:INFO: Axis X (0.000,1220.000)]
> [MSG:INFO:   Motor0]
> [MSG:INFO:     tmc_2209 UART1 Addr:0 CS:NO_PIN Step:I2SO.2 Dir:I2SO.1 Disable:I2SO.0 R:0.110]
> [MSG:INFO:  X Neg Limit gpio.25]
> [MSG:INFO: Axis Y (0.000,2440.000)]
> [MSG:INFO:   Motor0]
> [MSG:INFO:     tmc_2209 UART1 Addr:1 CS:NO_PIN Step:I2SO.5 Dir:I2SO.4 Disable:I2SO.7 R:0.110]
> [MSG:INFO:  Y Neg Limit gpio.33]
> [MSG:INFO:   Motor1]
> [MSG:INFO:     tmc_2209 UART1 Addr:3 CS:I2SO.14 Step:I2SO.13 Dir:I2SO.12 Disable:I2SO.15 R:0.110]
> [MSG:INFO:  Y2 Neg Limit gpio.35]
> [MSG:INFO: Axis Z (-300.000,0.000)]
> [MSG:INFO:   Motor0]
> [MSG:INFO:     tmc_2209 UART1 Addr:2 CS:NO_PIN Step:I2SO.10 Dir:I2SO.9 Disable:I2SO.8 R:0.110]
> [MSG:INFO:  Z Pos Limit gpio.32]
> [MSG:INFO:   Motor1]
> [MSG:INFO:     tmc_2209 UART1 Addr:3 CS:I2SO.19 Step:I2SO.18 Dir:I2SO.17 Disable:I2SO.16 R:0.110]
> [MSG:INFO:  Z2 Pos Limit gpio.34]
> [MSG:INFO: X Axis driver test passed]
> [MSG:INFO: Y Axis driver test passed]
> [MSG:INFO: Y2 Axis driver test passed]
> [MSG:INFO: Z Axis driver test passed]
> [MSG:ERR: Z2 Axis TMC driver not detected - expected 0x21 got 0x0]
> [MSG:INFO: Kinematic system: Cartesian]
> [MSG:INFO: Using spindle NoSpindle]
> [MSG:INFO: Flood coolant gpio.2]
> [MSG:INFO: Mist coolant gpio.16]
> [MSG:INFO: Probe Pin: gpio.36:low]
> [MSG:INFO: STA SSID is not set]
> [MSG:INFO: AP SSID FluidNC IP 192.168.0.1 mask 255.255.255.0 channel 1]
> [MSG:INFO: AP started]
> [MSG:INFO: WiFi on]
> [MSG:INFO: Captive Portal Started]
> [MSG:INFO: HTTP started on port 80]
> [MSG:INFO: Telnet started on port 23]
> ok

vicious1 · November 27, 2023, 8:23pm

Something is going on with your Z2 driver.

Can you swap the first and last drivers, make sure all the pins are in and run it again?

vicious1 · November 27, 2023, 8:25pm

Is this just dust or is something shorting these pins?

Joebus · November 27, 2023, 8:27pm

Yes. I will swap X and Z2 drivers and test. Should I turn the Pot all the way down on the troubled driver first?

Just to note that the trouble drive was originally plugged into Y2 and I swapped with Z2 for testing before making this thread. I will still run this test and pull the log file and edit this post.

vicious1 · November 27, 2023, 8:28pm

On both boot runs it is showing Z2 error, so it is not the issue we know about. You either have a bad connection, bad driver, or that stuff in the pins.

Joebus · November 27, 2023, 8:32pm

I’ve cleaned out the specs on the IC. I’m going to swap X and Z2 driver and pull the log file. 1 min.

Thanks for the quick help!! Looking forward to getting this fully running

Joebus · November 27, 2023, 8:34pm

Sorry for the confusion. Both boot runs were done with the driver in Z2. The only difference was the motor plugged in and not plugged in.

Joebus · November 27, 2023, 8:48pm

I’m trying to do this but I’m unable to connect all of a sudden for some reason. Keeps saying incorrect password when trying to logon to the AP. Been working fine.

And now I’m out of time. Gah!
I need to leave work now but can continue this in the morning time.

vicious1 · November 27, 2023, 8:54pm

Yes understood, but both boots show a Z2 error.

No worries I will be around. If all else fails, you can reload the firmware (chrome broswer https://installer.fluidnc.com/).

Joebus · November 27, 2023, 8:59pm

Thanks again!!

I was able to log back in. I swapped the “Trouble” driver from Z2 to X and vice versa. I also turned the POT all the way down. It no longer gets hot.

Here are the logs:

> $G
> <Idle|MPos:0.000,0.000,0.000|FS:0,0|WCO:0.000,0.000,0.000>
> <Idle|MPos:0.000,0.000,0.000|FS:0,0|Ov:100,100,100>
> $SS
> [MSG:INFO: FluidNC v3.7.8]
> [MSG:INFO: Compiled with ESP32 SDK:v4.4.4]
> [MSG:INFO: Local filesystem type is littlefs]
> [MSG:INFO: Configuration file:config.yaml]
> [MSG:INFO: Machine LowRider]
> [MSG:INFO: Board Jackpot TMC2209]
> [MSG:INFO: UART1 Tx:gpio.0 Rx:gpio.4 RTS:NO_PIN Baud:115200]
> [MSG:INFO: I2SO BCK:gpio.22 WS:gpio.17 DATA:gpio.21]
> [MSG:INFO: User Digital Output:0 on Pin:gpio.26]
> [MSG:INFO: User Digital Output:1 on Pin:gpio.27]
> [MSG:INFO: Axis count 3]
> [MSG:INFO: Axis X (0.000,1220.000)]
> [MSG:INFO:   Motor0]
> [MSG:INFO:     tmc_2209 UART1 Addr:0 CS:NO_PIN Step:I2SO.2 Dir:I2SO.1 Disable:I2SO.0 R:0.110]
> [MSG:INFO:  X Neg Limit gpio.25]
> [MSG:INFO: Axis Y (0.000,2440.000)]
> [MSG:INFO:   Motor0]
> [MSG:INFO:     tmc_2209 UART1 Addr:1 CS:NO_PIN Step:I2SO.5 Dir:I2SO.4 Disable:I2SO.7 R:0.110]
> [MSG:INFO:  Y Neg Limit gpio.33]
> [MSG:INFO:   Motor1]
> [MSG:INFO:     tmc_2209 UART1 Addr:3 CS:I2SO.14 Step:I2SO.13 Dir:I2SO.12 Disable:I2SO.15 R:0.110]
> [MSG:INFO:  Y2 Neg Limit gpio.35]
> [MSG:INFO: Axis Z (-300.000,0.000)]
> [MSG:INFO:   Motor0]
> [MSG:INFO:     tmc_2209 UART1 Addr:2 CS:NO_PIN Step:I2SO.10 Dir:I2SO.9 Disable:I2SO.8 R:0.110]
> [MSG:INFO:  Z Pos Limit gpio.32]
> [MSG:INFO:   Motor1]
> [MSG:INFO:     tmc_2209 UART1 Addr:3 CS:I2SO.19 Step:I2SO.18 Dir:I2SO.17 Disable:I2SO.16 R:0.110]
> [MSG:INFO:  Z2 Pos Limit gpio.34]
> [MSG:INFO: X Axis driver test passed]
> [MSG:INFO: Y Axis driver test passed]
> [MSG:INFO: Y2 Axis driver test passed]
> [MSG:INFO: Z Axis driver test passed]
> [MSG:INFO: Z2 Axis driver test passed]
> [MSG:INFO: Kinematic system: Cartesian]
> [MSG:INFO: Using spindle NoSpindle]
> [MSG:INFO: Flood coolant gpio.2]
> [MSG:INFO: Mist coolant gpio.16]
> [MSG:INFO: Probe Pin: gpio.36:low]
> [MSG:INFO: STA SSID is not set]
> [MSG:INFO: AP SSID FluidNC IP 192.168.0.1 mask 255.255.255.0 channel 1]
> [MSG:INFO: AP started]
> [MSG:INFO: WiFi on]
> [MSG:INFO: Captive Portal Started]
> [MSG:INFO: HTTP started on port 80]
> [MSG:INFO: Telnet started on port 23]
> ok

vicious1 · November 27, 2023, 9:13pm

All tests passed so it must have been a missed pin or something. It should work now.

Joebus · November 27, 2023, 10:33pm

Is it ok to leave the pot turned all the way down? All the Vref stuff is handled by the firmware?

vicious1 · November 27, 2023, 11:06pm

Yes, and yes.

deaglebingo · July 31, 2024, 3:01pm

the vref is really handled by the firmware? i have an intermittent issue where the z motor on one side or another is skipping steps depending on which side has more weight at the time. only ever seems to happen on z homing. no physical binding present that i could feel. was going to ask about setting vref like i have on my printers but maybe i’m thinking about it wrong based on what i’m reading in this thread

vicious1 · July 31, 2024, 3:15pm

Yes, one version of the firmware has the Homing Vref set wrong. Best to update to 3.8.0 and that should be fine.