[Resolved] Need help with the XYZ Probe Plus / Grbl Error 9 - Alarm: 4

Hello thank you for your welcome, I hope I am in the right place for this message, I do not speak English well (I am Swiss-French and I use Google Translate to communicate)

I would like to submit a problem that has never happened. I use my CNC with the configuration mentioned below without technical problem since June 2023.

On Thursday, December 7, I start my CNC to make parts and I encounter a problem with the XYZ Plus Probe, it is impossible to carry out the operation and an error message is displayed:

*GRBL ERROR 9 - G -CODE LOCKED OUT DURING ALARM OR JOG State [G4 P0.4]
This error may just be a symptom of an earlier event:
Alarm: 4 - Probe fail. The Probe is not in the expected initial state before starting probe cycle, where g38.2 and g38.3 Ins not triggered and g38.4 and g38.5 is triggered.*

When I prepare the probe plate on the part and connect the magnet to the nut to launch the alignment procedure The green light lights up before the calibration.

I have traveled a lot of messages on the forum on subjects that talk about electro-magnetism and other subjects about VFD with mass buckles before asking for help but I do not arrive at a conclusion on The fact that this problem has arrived today while the machine in its current configuration of the machine, the wiring has not been changed since June 2023 and all the features were perfect until today.

Below I present to you the machine settings to give you an idea of the problem on the investigation, to carry out tests to resolve this malfunction. I would perfectly respect your instructions.

If you need additional information or photos tell me what I can do to test and guide you in the investigation, sorry if the translation is not perfect.

Thank you very much for your precious help/time and your very useful forum.

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Hardware Configuration
Genmitsu Proverxl 6060 (with original end stop X,Y,Z disabled in Control)
Blackbox X32 USB connected / XYZ Probe Plus / 1.5 kW air cooled spindle / VFD A2-8015 series
Computer Minix Neo J51-C8 Max
ASUS VT168HR 15 " touch screen

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WebGL Support found! success: this application will work optimally on this device!
Bidirectional Websocket Interface Started Succesfully
Checking for Updates
You are already running OpenBuilds CONTROL 1.0.370
PORT INFO: Port is now open: COM4 - Attempting to detect Firmware
Checking for firmware on COM4
Detecting Firmware: Method 1 (Autoreset)
ok

Detecting Firmware: Method 2 (Ctrl+X)

[VER:1.1f.20230501:custom]
[OPT:VNSL+2,35,1024,3,0]
[AXS:3:XYZ]
[NEWOPT:ENUMS,RT+,HOME,REBOOT,TC,SED,RTC,WIFI,SD]
[FIRMWARE:grblHAL]
[NVS STORAGE:*FLASH]
[DRIVER:ESP32]
[DRIVER VERSION:230501]
[DRIVER OPTIONS:4.3.1]
[BOARD:BlackBox X32]
[AUX IO:1,0,0,0]
[WIFI MAC:94:b5:55:1c:f5:c8]
[IP:0.0.0.0]
[PLUGIN:WebUI v0.17]
[PLUGIN:SDCARD v1.09]
ok
[GC:G0 G54 G17 G21 G90 G94 G49 G98 G50 M5 M9 T0 F0 S0.]
ok

Firmware Detected: grbl version 1.1f on COM4

$0=10.0 ;Step pulse time, microseconds
$1=25 ;Step idle delay, milliseconds
$2=0 ;Step pulse invert, mask
$3=7 ;Step direction invert, mask
$4=0 ;Invert step enable pin, boolean
$5=7 ;Invert limit pins, boolean/mask
$6=0 ;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=1 ;Soft limits enable, boolean
$21=0 ;Hard limits enable, boolean
$22=1 ;Homing cycle enable, boolean (Grbl) / mask (GrblHAL)
$23=0 ;Homing direction invert, mask
$24=100.0 ;Homing locate feed rate, mm/min
$25=1500.0 ;Homing search seek rate, mm/min
$26=250 ;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=5000.0 ;Spindle PWM frequency
$34=0.0 ;Spindle off Value
$35=0.0 ;Spindle min value
$36=100.0 ;Spindle max value
$37=1 ;Stepper deenergize mask
$39=1 ;Enable printable realtime command characters, boolean
$40=0 ;Apply soft limits for jog commands, boolean
$41=0 ;Parking cycle as bitfield where setting bit 0 enables the rest
$42=2 ;Parking axis
$43=1 ;Homing passes
$44=4 ;Homing cycle 1
$45=3 ;Homing cycle 2
$46=0 ;Homing cycle 3
$56=5.0 ;Parking pull-out distance in mm
$57=100.0 ;Parking pull-out rate in mm/min
$58=-5.0 ;Parking target in mm
$59=500.0 ;Parking fast rate in mm/min
$60=0 ;Restore overrides
$61=0 ;Safety door options as bitfield
$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=NaN ;Wifi network SSID
$75=xxxxxxxx ;Wifi network PSK
$100=160.000 ;X-axis steps per millimeter
$101=160.000 ;Y-axis steps per millimeter
$102=160.000 ;Z-axis steps per millimeter
$110=2500.000 ;X-axis maximum rate, mm/min
$111=2500.000 ;Y-axis maximum rate, mm/min
$112=2500.000 ;Z-axis maximum rate, mm/min
$120=150.000 ;X-axis acceleration, mm/sec^2
$121=150.000 ;Y-axis acceleration, mm/sec^2
$122=150.000 ;Z-axis acceleration, mm/sec^2
$130=578.000 ;X-axis maximum travel, millimeters
$131=625.000 ;Y-axis maximum travel, millimeters
$132=100.000 ;Z-axis maximum travel, millimeters
$320=NaN ;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
$392=4.0 ;Spindle on delay in s
$393=1.0 ;Coolant on delay in s
$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
ok

 

Hi misterg thank you very much for this track and your time
For precision: the insulators have never been dismantled or modified on this machine, everything is original and it has always worked.
I am looking for solutions everywhere on the forum but it is very large with a lot of messages to examine. In addition all the machines are built with different characteristics, which makes it difficult.
Thank you to the link on the thread, I will add your information in my test protocol, I hope to quickly solve this problem.
I would put this online protocol as soon as the problem is solved.

 

Thank you Peter for your help
Yes absolutely, I carry out domestic electrical installations but I do not know the topology of the X32 !!! And do not mix both at the risk of burning everything one day

Can you tell me what are the elements of the testing in the machine which should not be linked when I test with my multimeter !?
I already have @Misterg information for end-stops to put in my test protocol, in addition to your information I could eliminate step by step.

Thanks in advance.

 

Unfortunately I cannot put doubt on the components such as the PC or the wiring or other components because the machine has not been modified since its general upgrade in April 2023, this is where my problem is in this investigation.
A possibility would be a defective component.
I will apply the test protocol on the basis of the information I received from you and @Peter Van Der Walt.
Thank you very much, I would come back with news

 

Thanks Peter,
I know Meanwell, however, I bought all the components by Conucon Germany which distributed your equipment in March 2023. I hope this company provides good reliable equipment.
The CNC has been operational with this configuration since April 2023.
Here is the psu 350W Netzteil mit 24V und maximal 14,58 A mit 230V Netzstecker (Schukostecker) und Kabel (1,5m) | CONUCON

 

I will initially apply the protocol to investigate a possible short circuit throughout the system and control individually if there is no leakage tension on the PSU circuit.

QUESTION @Peter Van Der Walt : Is it possible to order components directly in your shop and receive them in Switzerland ?

 

Thank you Alex for this information,
I will soon contact OpenBuilds and take information on the shipment of goods and transport costs.
For customs and import taxes I already have the necessary information because the origin of my equipment comes 80% from the outside of Switzerland.
In terms of technical equipment in this field in Switzerland we are poor children
Good evening.

 

No change has been made on the equipment or its topology, no work or defect on the electricity network in the house I suppose a component defect ...
As soon as the tests are carried out I could consider the continuation

 

• I do online or offline tests?
• Machine on or off?

THANKS

 

YES thanks a lot

 

@Peter Van Der Walt @Misterg @Alex Chambers I'm really sorry for that, my apologies

 

?I did not have the idea of activating the inversion of the famous Probe pin.

Tomorrow I will work at the workshop all day, and therefore I will start by testing first "$ 6 = 1", and all the other 17 test points that I identified and registered on a list during our discussions .

This morning I did shopping !!!
1 × Interface CNC Touch Blackbox X32
1 × 24V Meanwell Power Supply Bundle
3 × Xtension Limit Switch Kit
10 x Feet Xtension Wire 3 Conductor

For what ? Because I made people waste time who helped me ... ok ... we exchanged and I learned with you, but now it's time to do the rest in a serious way by making a level with material that corresponds.
Thanks A LOT
(I would come back to you with the results of the tests that I would do tomorrow).

 

@Peter Van Der Walt @Misterg @Alex Chambers

Hi the team,

PROBLEM SOLVED without having to do all the control tests, I would put more details later because I am in the workshop and I am never quiet with all the work I have to finish before the Christmas holidays.

Info:

• There was a loop between the earth and the NO circuit of the Limit Switches
• A loop between EARTH and Probe plate and magnet
• Disconnected and reconnected all Limit Switches
• Disconnected the USB connection> PC (Wifi connection working well)
• Reset Blackbox to factory settings
• Installing latest firmware
• Restore machine settings from June 2023

Now that everything works I will be able to install the new components that I received yesterday from Openbuilds.

1 × CNC Touch Blackbox X32 interface
2 × MOUNTING KIT interface
1 × 24V Meanwell Power Supply Bundle
6 × Xtension Limit Switch Kit
1 × Router/Spindle LED Light Ring
50 Feet Xtension Wire 3 Conductors
( I'm still waiting for delivery for ferrite cores ordered in China )

The news concerning problem solving will follow soon.

Big thank you to the people who put me on all these tracks for helping to solve the problem !!!

See you later soon

 

@Peter Van Der Walt @Misterg @Alex Chambers

Hi all,
Here the work is progressing well, I assembled the PSU, configured the interface and carefully finished the connections so here is the rest of this step.

Problem encountered during tests with the new interface

Interface is completely crazy with the steppes control when the Spindle starts (the Spindle cable is in the chain). EMI may go up in the interface circuit via the Blackbox and the stepper cables.
I have to take out the spindle supply cable from the chain and place it on a dedicated outside arm, I must also put the VFD in the special box connected to the earth.

I dismantled the Spindle and unplugged the VFD, I did a new interface test which is OK then I normally handled X.Y.Z without anomaly, ok on this side.

My opinion: I ordered two boxes with special insulation for electronic components which will be connected to Earth Ground (1 box for the VFD & 1 box for blackbox + psu), because even if a larger box is divided into different spaces with Additional aluminum sheet protection There will always be a risk of general radiation due to the fact that all the elements will be confined in the same space.

Today I'm waiting for the delivery of complementary openbuilds equipment:
3 Additional switch limit to set up in series
40 feet switch limit cable 3 wires
1 LED light for Spindle
2 interface mounting kit

While waiting for the special boxes and the kilo of ferrites I will make an aluminum arm to support the Spindle cable above the machine.

Following this stage I would have questions on the final topology of the wiring (Ferrites & Ground Earth)
Thank you for your attention and take care of yourself.

See you soon