Z-axis losing steps

Spindle/VFD (Aftermarket/Unsupported)
1

I have the 1F Elite foreman with a ATC system.

I’m having a problem with lost z steps during long carves. After a 3 hour carve, when I move the z-axis to max height I get a hard limit z alarm.

I have spoken with 1F tech support and they made a couple of suggestions (the use of ferrites and check connections, moving the power cable from the drag chain ) which I have done. I still get the error.

I have an after market larger drag chain and I have removed the spindle power cables from the chain. They hang from the ceiling and away from the z motor.

I can’t be the only one who is having this lost z step issues.

Does anyone else have similar issues?

2

You did not say but do you also have the braking Z Stepper? I think that is important.
If you do then I would check you cable connections. One issue I had was a intermittent cable connection.
I took each cable connection and with a screw driver made sure each connection was good and tight. Did this right after I got my Elite foreman about 8 months ago and NO more issues, Working 100% for 8 months now. and I have been doing long 3hour+ carves. I have my spindle power cable in the stock drag chain and I do have ferrites on my spindle power cable.

When I say good and tight connection I mean I take the female side of the connection and make the hole a little smaller so the male side is good and tight going into the female side of the connector

3

I do have the z braking stepper. I will check those connections again. Thanks!

4

PROBLEM SOLVED (I think)

The problem EMI is my cheap Amazon LED lights. I have 10 foot ceilings and 3 rows of 5 LED bars from Amazon. Shop is nice and bright.

I have tested the 1F twice with the lights off. Two different files, both past the 3 hour carve and no hard alarms. I’ve run both my CNCs at the same time with the lights off and no hard alarms. I’m convinced its those lights.

5

Phew! That would be incredibly hard for tech support to solve!

6

I installed new led lights on the ceiling and ran a test for 4 1/2 hours. Z hard limit alarm. Damn!

I’ll test the same carve and timing again with the lights out. If I don’t get an alarm maybe I’ll
Just wear a headlamp in my shop :person_shrugging:t3:.

I wonder if fluorescent lights would create more or less emi??

Feeling defeated but will forge on.

7

Hey Peter,

serious machines have cables that are shielded and the machine must be correctly grounded.

Shielded stepper cables:

To make your own cables, you can use shielded LAPP® or IGUS chainflex® cables. See Cable Connectors Used on the Onefinity (all machines).

Grounding the machine:

8

It seems I’m still having issues. Installed different lights and I’m getting the z-alarm hard limit again.

Is there a chance that my z-motor with the internal brake could be causing problems?

Should I test with the z-motor that came with the 1F?

Thanks,
Peter

10

I’ve run the 3+ hour carve multiple times with and without the LED ceiling lights over the CNC machine.

100% of the time without the lights on I get no hard z limit alarms.

100% of the time with the lights on I get the hard z limit alarms.

11

So, one thing to watch out for is the bright light coming down onto the homing sensors.
Try to cover the z homing sensor with some black tape.

12

I should have updated this post a while ago, sorry.

There was interference between the braking Zmotor and the ATC system I have. Once I replaced the braking Zmotor with the original the machine stopped losing steps. 1F even sent me another braking Zmotor but it continued to lose steps.