Need help troubleshooting - Stronghold Pro + new Blackbox x32

Hi all,

i have lots of issues going on, and I can't resolve them myself.
I have Stronghold Pro 1000x1000, Blackbox X32 and watercooled spindle.
I had issues with my first Blackbox X32 when it started stalling, and I managed to break plastic voltage adjustment trim pot. Everything else was working well. So I bought a new Blackbox X32.
I reconnected everything to new X32, loaded my GRBL settings from backup and it looked ok except I had to invert some Axis directions, not sure why but ok.
All the wiring was as before, nothing touched.
I started experiencing lots of issues from then:

1. The biggest problem - when I turn on the spindle in Openbuilds Control, and click on Run Job, 8 out of 10 times the connection fails - the spindle turns on full speed, but doesn't start the movement, can't turn in off in Control, can't abort. After 10-15 seconds it loses USB connection and the spindle turns off by itself. I tried changing USB ports, tried changing USB power management settings in Windows, didn't help. I thought it might be EMI, even though i never had these issues on old X32, so I moved away power cables from other cables for steppers and triggers. Didn't help. I have to re-home and jog after each try and it is really frustrating.

2. When working only in Control (without running from GRBL file, just jogging from Control commands), I noticed that when I try to adjust Feed rate slider from 100% to 110% (for example from 2500mm/min), it also "glitches" - the machine will not jog anymore and instead od showing increased speed it starts showing some abnormal numbers - I can make a screenshot tomorrow if needed). I tried resetting/reinstalling everything I could on X32, tried uninstalling Control and installing it again. Didn't help.

3. I generate codes in Fusion 360. I have one longer bit (100mm) and when I run the job it raises Z axis until it hits the limit switch and stops. I have some 35mm of travel between stock top and the bottom of the tool. I set my heights in Fusion only a few mms from stock top but the Control still goes beyond those heights and I just can't start the job because of that. I tried adjusting Safe Retracts in Post Process settings in Fusion, but nothing. If I choose "Clearance height" (as I understand) it shoould use heights I chose in operation setup, but when I start the job it stayes on Z zero, and it moves without retraction until it reaches the point where it has to plunge. If I choose "G28" same thing. If I choose "G53" which is default and it should be the right one, it retracts more than it should, until it hits the switch. It all worked before, I used the same tool on few similar projects, no problem. As solution I also tried to remove one layer of spoilboard MDF (lowered 18mm), and raising the spindle in the bracket as much as I could. I got some 30mm more travel but still didn't help).

4. Spindle speed doesn't go up to max 24000 rpm, but up to approx 23200 on 100%. Didn't bother me much because other problems are more important to solve to me. I know about fine adjusting the 0-10V but didn't do it yet, I don't think it could have anything to do with other issues I'm experiencing, but I'll try tomorrow.

I would appreciate any help, I can't move on with anything until I resolve these issues. I don't see what's wrong, everything was working on the first X32 so I know it is doable. I always do similar projects (electric guitars) so I'm not doing anything that I didn't do before, I'm using same tools, same wiring, same machine, same laptop, same GRBL settings. Only difference is new X32 instead of the one I broke.

My settings are:

$0=10.0 ; Step pulse time, microseconds
$1=255 ; Step idle delay, milliseconds
$2=0 ; Step pulse invert, mask
$3=5 ; Step direction invert, mask
$4=0 ; Invert step enable pin, boolean
$5=0 ; Invert limit pins, boolean/mask
$6=1 ; Invert probe pin, boolean
$8=0 ; Ganged axes direction invert as bitfield
$9=1 ; PWM Spindle as bitfield where setting bit 0 enables the rest
$10=511 ; Status report options, mask
$11=0.010 ; Junction deviation, millimeters
$12=0.002 ; Arc tolerance, millimeters
$13=0 ; Report in inches, boolean
$14=0 ; Limit pins invert, mask
$15=0 ; Coolant pins invert, mask
$16=0 ; Spindle pins invert, mask
$17=0 ; Control pins pullup disable, mask
$18=0 ; Limit pins pullup disable, mask
$19=0 ; Probe pin pullup disable, boolean
$20=0 ; Soft limits enable, boolean
$21=1 ; Hard limits enable, boolean
$22=1 ; Homing cycle enable, boolean (Grbl) / mask (GrblHAL)
$23=1 ; Homing direction invert, mask
$24=100.0 ; Homing locate feed rate, mm/min
$25=1500.0 ; Homing search seek rate, mm/min
$26=20 ; Homing switch debounce delay, milliseconds
$27=5.000 ; Homing switch pull-off distance, millimeters
$28=0.100 ; G73 retract distance, in mm
$29=0.0 ; Step pulse delay (ms)
$30=24000.000 ; Maximum spindle speed, RPM
$31=0.000 ; Minimum spindle speed, RPM
$32=0 ; Laser-mode enable, boolean
$33=400.0 ; Spindle PWM frequency
$34=0.0 ; Spindle off Value
$35=0.0 ; Spindle min value
$36=100.0 ; Spindle max value
$37=0 ; Stepper deenergize mask
$39=1 ; Enable printable realtime command characters, boolean
$40=0 ; Apply soft limits for jog commands, boolean
$43=1 ; Homing passes
$44=4 ; Homing cycle 1
$45=3 ; Homing cycle 2
$46=0 ; Homing cycle 3
$62=0 ; Sleep Enable
$63=3 ; Feed Hold Actions
$64=0 ; Force Init Alarm
$65=0 ; Require homing sequence to be executed at startup
$70=7 ; Network Services
$73=1 ; Wifi Mode
$74= ; Wifi network SSID
$75= ; Wifi network PSK
$100=160.000 ; X-axis steps per millimeter
$101=160.000 ; Y-axis steps per millimeter
$102=400.000 ; Z-axis steps per millimeter
$110=2000.000 ; X-axis maximum rate, mm/min
$111=2000.000 ; Y-axis maximum rate, mm/min
$112=1500.000 ; Z-axis maximum rate, mm/min
$120=80.000 ; X-axis acceleration, mm/sec^2
$121=80.000 ; Y-axis acceleration, mm/sec^2
$122=80.000 ; Z-axis acceleration, mm/sec^2
$130=990.000 ; X-axis maximum travel, millimeters
$131=990.000 ; Y-axis maximum travel, millimeters
$132=125.000 ; Z-axis maximum travel, millimeters
$320=grblHAL ; Hostname, max: 64
$322=192.168.5.1 ; IP Address
$323=192.168.5.1 ; Gateway
$324=255.255.255.0 ; Netmask
$325=23 ; Telnet port
$326=80 ; HTTP port
$327=81 ; Websocket port
$341=0 ; Tool Change Mode
$342=30.0 ; Tool Change probing distance
$343=25.0 ; Tool Change Locate Feed rate
$344=200.0 ; Tool Change Search Seek rate
$345=200.0 ; Tool Change Probe Pull Off rate
$346=1 ; Restore position after M6 as boolean
$370=0 ; Invert I/O Port Inputs (mask)
$384=0 ; Disable G92 Persistence
$396=30 ; WebUI timeout in minutes
$397=0 ; WebUI auto report interval in milliseconds
$398=35 ; Planner buffer blocks
$481=0 ; Autoreport interval in ms
$I=custom

 

Hi all,
as I can say so far, this solved all the issues mentioned above.
I tried maybe 10 jobs so far and no crashes, no disconections, everything seems to work well...

I did have error notifications a while ago with post processing with Openbuilds post processor, so I just switched to GRBL for the menu and forgot about it.
I downloaded fresh one from your link and it works!

Thank you guys for quick responses, you are great help as always!