Motor 3 Driver Issues

Hi folks.
I’m having an issue specifically with the motor 3 driver on my new TinyG v8. I’m running an OX CNC with dual Y axis NEMA 23 Steppers. The problem is it stutters, runs rough, makes crunching sounds, skips steps, jitters, etc… while the other Y axis motor runs very smoothly.

Before doing any of the following I detached the pulleys from the belts. I checked that the pulleys are secure and tight on the posts. I checked that all of my wiring is correct and that I’m getting good mechanical contact at the terminals. And also eyeballed the solder joints under the board and didn’t see anything obvious.

– I have done the suggested tuning procedures a bunch of times with no luck. The best I’ve results I’ve gotten is making the stutter go to crunching. It doesn’t resemble the performance of the other 3 drivers at all. It’s still very jittery and seems to have very little torque.
– I’ve tried swapping the y- axis motors to their opposite drivers (ie Y-Left stepper from Motor 2 Driver to motor 3 driver and Y-Right Stepper from motor 3 driver to motor 2 driver). The symptoms just move to other motor, so I don’t think it’s an issue with a bad stepper motor.
– For the first time this morning the tinyg reset itself while idling after I had been putting it through some light testing. The motor 3 driver chip was a bit hotter than the other 3.
– Also, I updated to the newest firmware build 440.20 before all of this. I forget what version was originally on it, but I had the same symptoms with that version as well.

I don’t know….. I’ve spent a lot of time trying to figure this one out. I’ll post the dump of the settings. The settings are for the most part the same as Thomas Shue in this link http://pastebin.com/VsUnxgHd in his videos here https://youtu.be/h0bkr2P7rTw . I’m running the exact same machine that I bought as a kit from SMW3D.

If any of you guys have any suggestions, I would greatly appreciate them.

Another question/concern: If this turns out to be a hardware issue, am I out of luck getting my TinyG replaced or repaired if I bought it back in November of 2015? This is the first time I’m attempting to get the machine running, and I simply haven’t had the free time to complete the build until now. According to the websites, Synthetos says to go to vendor I bought it from, and SMW3D says they don’t do returns (basically) unless the item is unused, original packaging, etc.

Best Regards,
–Mike

$$
 {"ej":""}
[fb]  firmware build            440.20
[fv]  firmware version            0.97
[hp]  hardware platform           1.00
[hv]  hardware version            8.00
[id]  TinyG ID                    3X2204-R2G
[ja]  junction acceleration 1000000 mm
[ct]  chordal tolerance           0.0100 mm
[sl]  soft limit enable           1
[st]  switch type                 1 [0=NO,1=NC]
[mt]  motor idle timeout         60.00 Sec
[ej]  enable json mode            0 [0=text,1=JSON]
[jv]  json verbosity              4 [0=silent,1=footer,2=messages,3=configs,4=linenum,5=verbose]
[js]  json serialize style        1 [0=relaxed,1=strict]
[tv]  text verbosity              1 [0=silent,1=verbose]
[qv]  queue report verbosity      1 [0=off,1=single,2=triple]
[sv]  status report verbosity     1 [0=off,1=filtered,2=verbose]
[si]  status interval           250 ms
[ec]  expand LF to CRLF on TX     0 [0=off,1=on]
[ee]  enable echo                 0 [0=off,1=on]
[ex]  enable flow control         2 [0=off,1=XON/XOFF, 2=RTS/CTS]
[baud] USB baud rate              5 [1=9600,2=19200,3=38400,4=57600,5=115200,6=230400]
[net] network mode                0 [0=master]
[gpl] default gcode plane         0 [0=G17,1=G18,2=G19]
[gun] default gcode units mode    1 [0=G20,1=G21]
[gco] default gcode coord system  1 [1-6 (G54-G59)]
[gpa] default gcode path control  2 [0=G61,1=G61.1,2=G64]
[gdi] default gcode distance mode 0 [0=G90,1=G91]
[1ma] m1 map to axis              0 [0=X,1=Y,2=Z...]
[1sa] m1 step angle               1.800 deg
[1tr] m1 travel per revolution   60.0000 mm
[1mi] m1 microsteps               8 [1,2,4,8]
[1po] m1 polarity                 1 [0=normal,1=reverse]
[1pm] m1 power management         3 [0=disabled,1=always on,2=in cycle,3=when moving]
[2ma] m2 map to axis              1 [0=X,1=Y,2=Z...]
[2sa] m2 step angle               1.800 deg
[2tr] m2 travel per revolution   60.0000 mm
[2mi] m2 microsteps               8 [1,2,4,8]
[2po] m2 polarity                 0 [0=normal,1=reverse]
[2pm] m2 power management         3 [0=disabled,1=always on,2=in cycle,3=when moving]
[3ma] m3 map to axis              1 [0=X,1=Y,2=Z...]
[3sa] m3 step angle               1.800 deg
[3tr] m3 travel per revolution   60.0000 mm
[3mi] m3 microsteps               8 [1,2,4,8]
[3po] m3 polarity                 1 [0=normal,1=reverse]
[3pm] m3 power management         3 [0=disabled,1=always on,2=in cycle,3=when moving]
[4ma] m4 map to axis              2 [0=X,1=Y,2=Z...]
[4sa] m4 step angle               1.800 deg
[4tr] m4 travel per revolution    8.0000 mm
[4mi] m4 microsteps               4 [1,2,4,8]
[4po] m4 polarity                 1 [0=normal,1=reverse]
[4pm] m4 power management         3 [0=disabled,1=always on,2=in cycle,3=when moving]
[xam] x axis mode                 1 [standard]
[xvm] x velocity maximum      16000 mm/min
[xfr] x feedrate maximum      16000 mm/min
[xtn] x travel minimum            0.000 mm
[xtm] x travel maximum          550.000 mm
[xjm] x jerk maximum           5000 mm/min^3 * 1 million
[xjh] x jerk homing           10000 mm/min^3 * 1 million
[xjd] x junction deviation        0.0100 mm (larger is faster)
[xsn] x switch min                1 [0=off,1=homing,2=limit,3=limit+homing]
[xsx] x switch max                0 [0=off,1=homing,2=limit,3=limit+homing]
[xsv] x search velocity        3000 mm/min
[xlv] x latch velocity          100 mm/min
[xlb] x latch backoff            20.000 mm
[xzb] x zero backoff              3.000 mm
[yam] y axis mode                 1 [standard]
[yvm] y velocity maximum       5000 mm/min
[yfr] y feedrate maximum       5000 mm/min
[ytn] y travel minimum            0.000 mm
[ytm] y travel maximum          760.000 mm
[yjm] y jerk maximum           5000 mm/min^3 * 1 million
[yjh] y jerk homing           10000 mm/min^3 * 1 million
[yjd] y junction deviation        0.0200 mm (larger is faster)
[ysn] y switch min                1 [0=off,1=homing,2=limit,3=limit+homing]
[ysx] y switch max                0 [0=off,1=homing,2=limit,3=limit+homing]
[ysv] y search velocity        3000 mm/min
[ylv] y latch velocity          100 mm/min
[ylb] y latch backoff            10.000 mm
[yzb] y zero backoff              3.000 mm
[zam] z axis mode                 1 [standard]
[zvm] z velocity maximum        800 mm/min
[zfr] z feedrate maximum        800 mm/min
[ztn] z travel minimum            0.000 mm
[ztm] z travel maximum           40.000 mm
[zjm] z jerk maximum             50 mm/min^3 * 1 million
[zjh] z jerk homing            1000 mm/min^3 * 1 million
[zjd] z junction deviation        0.0100 mm (larger is faster)
[zsn] z switch min                0 [0=off,1=homing,2=limit,3=limit+homing]
[zsx] z switch max                3 [0=off,1=homing,2=limit,3=limit+homing]
[zsv] z search velocity        3000 mm/min
[zlv] z latch velocity          100 mm/min
[zlb] z latch backoff            20.000 mm
[zzb] z zero backoff              3.000 mm
[aam] a axis mode                 3 [radius]
[avm] a velocity maximum      25920 deg/min
[afr] a feedrate maximum      12960 deg/min
[atn] a travel minimum           -1.000 deg
[atm] a travel maximum           -1.000 deg
[ajm] a jerk maximum         324000 deg/min^3 * 1 million
[ajh] a jerk homing          324000 deg/min^3 * 1 million
[ajd] a junction deviation        0.1000 deg (larger is faster)
[ara] a radius value              5.3050 deg
[asn] a switch min                1 [0=off,1=homing,2=limit,3=limit+homing]
[asx] a switch max                0 [0=off,1=homing,2=limit,3=limit+homing]
[asv] a search velocity        2000 deg/min
[alv] a latch velocity         2000 deg/min
[alb] a latch backoff             5.000 deg
[azb] a zero backoff              2.000 deg
[bam] b axis mode                 0 [disabled]
[bvm] b velocity maximum       3600 deg/min
[bfr] b feedrate maximum       3600 deg/min
[btn] b travel minimum           -1.000 deg
[btm] b travel maximum           -1.000 deg
[bjm] b jerk maximum             20 deg/min^3 * 1 million
[bjd] b junction deviation        0.0100 deg (larger is faster)
[bra] b radius value              1.0000 deg
[cam] c axis mode                 0 [disabled]
[cvm] c velocity maximum       3600 deg/min
[cfr] c feedrate maximum       3600 deg/min
[ctn] c travel minimum           -1.000 deg
[ctm] c travel maximum           -1.000 deg
[cjm] c jerk maximum             20 deg/min^3 * 1 million
[cjd] c junction deviation        0.0100 deg (larger is faster)
[cra] c radius value              1.0000 deg
[p1frq] pwm frequency              5000 Hz
[p1csl] pwm cw speed lo               0 RPM
[p1csh] pwm cw speed hi           10000 RPM
[p1cpl] pwm cw phase lo           0.000 [0..1]
[p1cph] pwm cw phase hi           1.000 [0..1]
[p1wsl] pwm ccw speed lo           1000 RPM
[p1wsh] pwm ccw speed hi           2000 RPM
[p1wpl] pwm ccw phase lo          0.125 [0..1]
[p1wph] pwm ccw phase hi          0.200 [0..1]
[p1pof] pwm phase off             0.000 [0..1]
[g54x] g54 x offset               7.504 mm
[g54y] g54 y offset              28.534 mm
[g54z] g54 z offset              -7.030 mm
[g54a] g54 a offset               0.000 deg
[g54b] g54 b offset               0.000 deg
[g54c] g54 c offset               0.000 deg
[g55x] g55 x offset              75.000 mm
[g55y] g55 y offset              75.000 mm
[g55z] g55 z offset               0.000 mm
[g55a] g55 a offset               0.000 deg
[g55b] g55 b offset               0.000 deg
[g55c] g55 c offset               0.000 deg
[g56x] g56 x offset               0.000 mm
[g56y] g56 y offset               0.000 mm
[g56z] g56 z offset               0.000 mm
[g56a] g56 a offset               0.000 deg
[g56b] g56 b offset               0.000 deg
[g56c] g56 c offset               0.000 deg
[g57x] g57 x offset               0.000 mm
[g57y] g57 y offset               0.000 mm
[g57z] g57 z offset               0.000 mm
[g57a] g57 a offset               0.000 deg
[g57b] g57 b offset               0.000 deg
[g57c] g57 c offset               0.000 deg
[g58x] g58 x offset               0.000 mm
[g58y] g58 y offset               0.000 mm
[g58z] g58 z offset               0.000 mm
[g58a] g58 a offset               0.000 deg
[g58b] g58 b offset               0.000 deg
[g58c] g58 c offset               0.000 deg
[g59x] g59 x offset               0.000 mm
[g59y] g59 y offset               0.000 mm
[g59z] g59 z offset               0.000 mm
[g59a] g59 a offset               0.000 deg
[g59b] g59 b offset               0.000 deg
[g59c] g59 c offset               0.000 deg
[g92x] g92 x offset               0.000 mm
[g92y] g92 y offset               0.000 mm
[g92z] g92 z offset               0.000 mm
[g92a] g92 a offset               0.000 deg
[g92b] g92 b offset               0.000 deg
[g92c] g92 c offset               0.000 deg
[g28x] g28 x position             0.000 mm
[g28y] g28 y position             0.000 mm
[g28z] g28 z position             0.000 mm
[g28a] g28 a position             0.000 deg
[g28b] g28 b position             0.000 deg
[g28c] g28 c position             0.000 deg
[g30x] g30 x position             0.000 mm
[g30y] g30 y position             0.000 mm
[g30z] g30 z position             0.000 mm
[g30a] g30 a position             0.000 deg
[g30b] g30 b position             0.000 deg
[g30c] g30 c position             0.000 deg
tinyg [mm] ok>