Odd update or something threw everything off

CrossFire ® Troubleshooting
1

Hey everyone, it’s been a while since I needed help here. My setup has been so plug-and-play that I never really took the time to learn Mach3 beyond the basics. Here’s what’s going on:

I’ve been using Fusion to post-process into Mach3 for 6 years without any issues. Now, when I opened my computer, Mach3 looks different. The buttons are bigger and some things seem off, but it’s not an entirely new program.

The problem: when I load any old or new G-code, Mach3 sees the code as a massive file. The table view only shows less than 1/3 of the actual G-code. Also, the G-code displays as a shaded box with no design lines.

That’s one issue. Another is that my feed rate defaults to 0.24. I can override it and push it to 0.50, but that only applies to micro-movements, not the typical 19-39 IPM I’m used to.

My jog speed had the same issue, but I fixed that by adjusting the motor tuning. However, the feed rate still defaults to 0.24.

I found a forum that mentioned the 0.24 feed rate issue, but the thread ended with someone saying it must be in the G-code. My feed speed settings are correct in the post-process, so I’m not sure what’s causing it.

Since everything worked fine before, I uninstalled Mach3, downloaded a fresh copy, and reinstalled it along with the CrossFire profiles like a first-time setup. Now, the feed rate seems okay, but the file still shows up as a huge shadowed box with no lines in the display.

For example, I have a file with four 2” tabs and 1/2” holes nested together. When I ran it, instead of cutting a 1/2” hole, it created a 12” hole.

I know I should probably upgrade to the FireControl system and be done with Mach3, but I need to make parts to afford the $750 upgrade.

Does anyone know Mach3 well enough to figure out what I’m missing? There’s got to be some settings I’ve overlooked. Any help would be greatly appreciated!

2

I might be able to take a look at this tomorrow morning (ET).

Some tips until then.

  1. You need to isolate the source of the problem:
    a. Controller ?
    b. Mach 3 installation or setup?
    c. Fusion configuration?
    You need to do this in a proper order.
    Don’t cut anything until you know the answer to 1. Do you know how to use the MDI tab? Use this to issue basic G-Code commands to confirm proper movement in both axis, both distance and speeds.
    Example: G91 G0 X1
    This SHOULD move the Gantry +1.000 inches in X direction at Rapid speed
    G91 G1 X1 F50
    This SHOULD move the Gantry +1.000 inches in X direction at 50 IPM
    Change X to Y to move the Y direction.
    Change ‘1’ to ‘-1’ to move in the opposite direction.
    Change F50 to F100 to move 100 IPM.

If those work, then MANUALLY create a G-Code file to move in a 4 inch square. Confirm the movement in both directions.

N0010 (Filename: FourInSquare.tap)
N0020 (Post processor: Manual)
N0030 (Date: 9/28/2019)
N0040 G20 (Units: Inches)
N0050 G53 G90 G91.1 G40
N0060 G54
N0070 G91 G0 X0 Y0 (shouldn't move at all)
N0080 G1 X4 F50
N0090 G1 Y4
N0100 G1 X-4
N0110 G1 Y-4
N0120 M05 M30

Let us know the results of this and then we can move on…

2 Likes
3

Thanks so much for the explanation on this. I’m assuming we’re checking the controller first? The control from MDI tab is spot on! I’m not too sure how the manual code works though. I’m I putting it into notepad and then pulling it up like any other code load, or is that being done in the MDI tab still?

4

Load the GCode file like any other file and run it. That should move in a 4x4 square pattern.

Once that works, then you’ll have tested the Controller and Mach3 most of the way. The only thing remaining is to cut something, but maybe we’ll test your Fusion set up next.

I recommend something simple. Draw a 4x4 inch square in Fusion. Post process for whatever stock you have, as you normally would. Upload the resulting G-Code here and we’ll take a look at it.

2 Likes
5

Alright got the manual program to load and shows the cut line in the display as well. I hit run and the program in Mach ran fine. Then I realized the switch was not on for the table. Turned it on and now when I run it gets to line 4 and says (cannot use g53 incremental , Block = N0050 G53 G90 G91.1 G40)

6

Just ran this and it ran just fine loaded the display, ran with its correct feed rate. However the file is a 4"x4" but the table moves looks like 18"x18".

N10 G90
N15 G70

(2D Profile1)
N20 G0 X2.2048 Y0.1384
N25 M3
N30 G4 P1.
N35 G1 X2.0344 Y0.04 F23.
N40 G2 X2. Y0.0056 I-0.0344 J0.
N45 G1 X-2.
N50 G2 X-2.0344 Y0.04 I0. J0.0344
N55 G1 Y4.04
N60 G2 X-2. Y4.0744 I0.0344 J0.
N65 G1 X2.
N70 G2 X2.0344 Y4.04 I0. J-0.0344
N75 G1 Y0.04
N80 G1 X2.2048 Y-0.0584
N85 M5

N90 M30

7

Just loaded one of my old parts and its again larger and loads a feed rate of 180 when its set for 32IPM?

N10 G90
N15 G70

(2D Profile2)
N20 G0 X-1.1043 Y1.0437
N25 M3
N30 G4 P1.
N35 G1 X-0.9338 Y1.1422 F32.
N40 G3 X-1.4784 I-0.2723 J0.
N45 G3 X-0.9338 I0.2723 J0.
N50 M5

N55 G1 X-0.8389 F300.
N60 G1 X-0.0853 Y0.0445
N65 M3
N70 G4 P1.
N75 G1 X-0.2603 Y0.1346 F32.
N80 G2 X-0.4952 Y0.0656 I-0.2349 J0.3654
N85 G1 X-1.4064
N90 G2 X-1.8408 Y0.5 I0. J0.4344
N95 G1 Y1.7
N100 G2 X-1.4064 Y2.1344 I0.4344 J0.
N105 G1 X-0.4936
N110 G2 X-0.0592 Y1.6994 I0. J-0.4344
N115 G1 X-0.0601 Y1.0316
N120 G1 X-0.0608 Y0.4994
N125 G2 X-0.2603 Y0.1346 I-0.4344 J0.0006
N130 M5

N135 G1 X-0.2582 Y0.0268 F300.
N140 G1 X-0.1288 Y-0.0399
N145 G3 X0.0015 Y0.0062 I0.0435 J0.0843
N150 G1 X0.5524 Y1.1486
N155 M3
N160 G4 P1.
N165 G1 X0.4897 Y0.962 F32.
N170 G3 X0.9662 Y1.1422 I0.2042 J0.1801
N175 G3 X0.4216 I-0.2723 J0.
N180 G3 X0.4897 Y0.962 I0.2723 J0.
N185 M5

N190 G1 X0.4185 Y0.8992 F300.
N195 G1 X0.4276 Y0.8893
N200 G3 X0.5006 Y0.83 I0.2662 J0.2529
N205 G1 X1.8082 Y0.0387
N210 M3
N215 G4 P1.
N220 G1 X1.6345 Y0.1314 F32.
N225 G2 X1.4048 Y0.0656 I-0.2297 J0.3686
N230 G1 X0.4936
N235 G2 X0.0592 Y0.5 I0. J0.4344
N240 G1 Y1.7
N245 G2 X0.4936 Y2.1344 I0.4344 J0.
N250 G1 X1.4064
N255 G2 X1.8408 Y1.6994 I0. J-0.4344
N260 G1 X1.8392 Y0.4994
N265 G2 X1.6345 Y0.1314 I-0.4344 J0.0006
N270 M5

N275 G1 X1.6351 Y0.0235 F300.
N280 G1 X0.6799 Y-0.9169
N285 M3
N290 G4 P1.
N295 G1 X0.4862 Y-0.8817 F32.
N300 G3 X0.4216 Y-1.0578 I0.2077 J-0.1761
N305 G3 X0.9662 I0.2723 J0.
N310 G3 X0.4862 Y-0.8817 I-0.2723 J0.
N315 M5

N320 G1 X0.4138 Y-0.8204 F300.
N325 G1 X0.4052 Y-0.8309
N330 G3 X0.329 Y-1.0171 I0.2887 J-0.2269
N335 G1 X0.1875 Y-2.2309
N340 M3
N345 G4 P1.
N350 G1 X0.219 Y-2.0365 F32.
N355 G2 X0.0592 Y-1.7 I0.2746 J0.3365
N360 G1 Y-0.9262
N365 G1 Y-0.5
N370 G2 X0.4936 Y-0.0656 I0.4344 J0.
N375 G1 X1.4064
N380 G2 X1.8408 Y-0.5006 I0. J-0.4344
N385 G1 X1.8392 Y-1.7006
N390 G2 X1.4048 Y-2.1344 I-0.4344 J0.0006
N395 G1 X0.4936
N400 G2 X0.219 Y-2.0365 I0. J0.4344
N405 M5

N410 G1 X0.1171 Y-2.072 F300.
N415 G1 X-1.0947 Y-1.1452
N420 M3
N425 G4 P1.
N430 G1 X-0.9353 Y-1.0296 F32.
N435 G3 X-1.4784 Y-1.0578 I-0.2708 J-0.0282
N440 G3 X-0.9338 I0.2723 J0.
N445 G3 X-0.9353 Y-1.0296 I-0.2723 J0.
N450 M5

N455 G1 X-0.8409 Y-1.0198 F300.
N460 G1 X-0.1468 Y-2.2041
N465 M3
N470 G4 P1.
N475 G1 X-0.3088 Y-2.0924 F32.
N480 G2 X-0.4952 Y-2.1344 I-0.1864 J0.3924
N485 G1 X-1.4064
N490 G2 X-1.8408 Y-1.7 I0. J0.4344
N495 G1 Y-0.5
N500 G2 X-1.4064 Y-0.0656 I0.4344 J0.
N505 G1 X-0.4936
N510 G2 X-0.0592 Y-0.5006 I0. J-0.4344
N515 G1 X-0.0608 Y-1.7006
N520 G2 X-0.3088 Y-2.0924 I-0.4344 J0.0006
N525 M5

N530 M30

8

Remove the G53 from the command sequence. I’m not sure why it’s there…

You said that the gantry moved 4 inches when you used the MDI commands. Is this true?
If so then I don’t understand how the last code you posted would move 18 inches.

Either your Mach3 configuration (Motor Tuning) is wrong, or your Stepper Drivers switches are not set correctly.

2 Likes
9

Yea your correct on the G53 that fixed it, but the actual movement is 16"x16" got a tape measure this time.

Double checked commands in MDI and that is on par with what your saying. G91 G0 X1 Moves 4" Then G91 G0 X-1 moves it right back.

1 Like
10

So weird now when I load files its back to doing that .24 feed rate default. Seems like something changes every time i close and reopen Mach3.

11

Was something about this sentence that didn’t make sense? It says the movement should be 1.000 inches. Now you’re telling me that it actually moved 4 inches.

I believe your Mach3 Crossfire profile is not installed correctly. Please repeat the installation steps in the Crossfire documentation.
https://www.langmuirsystems.com/downloads/legacy

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12

I know absolutely nothing about Mach3. But if, for some reason, it was set to MM. 100. mm = 3.937 inches. Like I said, it’s just a qoinkie dink that an entry of 1 moves 4 inches.

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13

If there were native units of dm (Decimeter) then I would agree that’s possible. However, the only choices are mm or inches so the ratio is actually 0.03937:1

EDIT: Corrected units :flushed:

2 Likes
14

Haha yea sorry my brain must have thought four and I ran with it when the machine matched haha.

Thank you for the worm hole options to explore. Finally got into the motor tuning specifics and found that issue. Seems the jog, feedrate and part size is all changed with that setting being tweaked.

Measured out the set steps per unit and got it figured out. Now its running what looks like much more accurate.

1 Like
15

Think that was a huge player in the issue. Some how I mixed up MM and inch. That was my thinking with the sizing issue but had no clue where thats set haha. Motor tuning seems to be a good start!

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16

Im guessing this would change for the type of motor used? Idk im just crash course learning all this, but for this Crossfire 2x2 504 steps per seems to be working.

17

A proper CrossFire profile has 12800 steps per. Did you install and load the correct profile?

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18

As far as I can tell its using the correct profile. I followed the same setup. There’s a 40% chance I still screwed it up, but seems to be the crossfire profile and preset.

However this setting seems to work great. Already burning parts I need for tomorrow morning, and will address this issue once it pops its head up again. Thanks for entertaining my tech incompetency throughout your weekend! I owe you a beer Tom, Cheers!

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