Please Close Cover notification (not the usual reason)

[traumfanger]

Hello,
It all started with the Y-Axis Stall error. With inspection I found I needed a new bearing. To make things easier in order to "drill out" the locked in screws, I removed the entire Y assembly from the machine, big mistake. All connectors on the Head Termination Electronics Board Assembly(HTEBA) were factory glued, male to female in such a way as to reveal naked pins on the HTEBA as each connection was force ably pulled out. OK, I replaced the bearings and properly assembled the unit. Regarding the connections to HTEBA, I was somewhat careless and mis-pinned the close cover/probe connector to the naked pins on the HTEBA, not knowing this, I fired up the machine and got the "please close cover" readout. Checking things out, I found my incorrect connection and fixed it, checked it and got the same error reading. Ordered a new HTEBA card, new wire assembly for cover switch/probe. Same problem. OK, so now I removed the cover and shorted out the motor cut off connection and the close cover pins on the HTEBA. Same problem...... "please close cover" The only thing I can think of is I may have trashed a logic circuit when I mis pinned the cover switch/probe connector to the HTEBA. Any ideas? Please note that I have absolutely eliminated the possibility of the HTEBA receiving a signal that the cover is open (shorted the correct (far left) pins) and additionally shorted the motor bullet connectors.

If it is the system controller assembly, is their a fix other than $300+ replacement. Note that prior to getting the close cover notification, the machine readout panel performs correctly and accepts my input. For testing purpose I've asked to measure a board, after which I get the close cover reading.

Thanks in advance for your help

Neil

[bergerud]

Al has reported that plugging in the cover connector upside down gives the close cover message. The white wire should be towards the cut motor.

There are other reasons for the message. Grounding of the board sensor wire in the y truck for example.

[traumfanger]

Thanks for responding. The far left pins on the top horizontal connector on the HTEBA are for the cover switch. The other pins are for the probe functions. I've tried two different switch cable assemblies as well as directly shorting the two far left pins, same result. Checking out the schematic, it appears that the HTEBA board feeds the controller assembly (brains). If I had previously mis pinned on my earlier attempts, I may have caused damage to the assembly. What is confusing is the fact that input and output on the display function works up to the point of execution (measure board) prior to the message of close cover. This tells me that the assembly (brains) has not been damaged. Cables to and from the assembly are good.

[bergerud]

The problem may be elsewhere. Check the FFC ribbon condition and its connections.

[Digitalwoodshop]

And just to say it a second time to be sure, "The white wire is on the cut motor side of the connector?" You were not clear you understood this. Wonder if you have a old 18 pin system?

And it is possible you have the circuit board guide, that little plastic guide stuck on the end of the cable from the cover switch and you are stacking the covers on when pushing the plug on with no electrical connection? Another words... Is the plug clean of the old guide cover?

Still have a problem... Power off then UN PLUG the board sensor on TOP then try the machine again. If it fixes then you have a shorted wire in the board sensor cable.

And since you joined in 2008 and have all the serious glue problems years later... It makes me wonder if you have a old 18 pin system... And changing the one board makes things worst.... If you mix the boards and FFC Cables you can have serious problems....

Look at the pictures and decide if you have the old 18 pin boards or the new 14 pin boards, the A907 kit... Look at the board you replaced and the one you removed if they are different... UN PLUG the machine before you damage more of the machine.... The A907 kit includes the two 14 pin boards and a 14 pin FFC Cable. Plug a Wide Pin FFC Cable in a old 18 pin jack and you can short out the $300.00 computer....

I call the 18 pin a 16 pin in some of the pictures, it's 18.

AL

[bergerud]

I believe there is 24V across two of these pins for the probe. It is conceivable that some damage could result from having the plug shifted on the pins.

[henry1]

were the plug in pin are check very closely if there not a bent pin

[bergerud]

What you could do is, while looking at the cover sensor data, wiggle wires and plugs around.

[traumfanger]

Thanks for responding.
Attached, you'll see the boards, they are of the new variety. Note the one with bare pins due to the male connection plastic enclosure coming up with the female plug. On the "glue" picture, notice the yellow stuff holding the parts together which caused the pins to become bare. For future reference, the glue comes off completely by using "goof off". After this operation and with the new board I could make a complete and correct connection. All is well.....except, I still get the close cover notification. As per my original post, after trying two sets of controller cut off switch and cable assemblies without positive result, I resorted to shorting the close cover pins on the board(far left pins on top horizontal male connector, the pins away from the display and close to the motor) I still get the close cover argument. I had previously mis connected the female close cover/probe connector to the bare pins on the male portion. This I was able to do because the plastic guide cover on the male portion was missing and the connection was off by an entire row. In any case unexpected signals were sent to the controller and may have fried some logic.

Any other thoughts would be greatly appreciated.

Thanks again for your kind and quick response. If all else fails, I will send the controller assembly back for rehab.

Neil7873378735

[traumfanger]

This is probably exactly what happened as I did make a connection and was off by an entire row. Perhaps fried a portion of the controller. Thanks

[bergerud]

The second pin from the keypad side on the top is the 24 volt one. That is far from the cover switch pins. (The 24v is not actually used for the probe so I wonder why it is there.) I assume that damage could only be caused by the closed cover switch shorting the wrong pins. All of the other wires on the plug would be open. The only way the cover switch could have shorted the 24V with the pin below it was if the plug was upside down and shifted.

Try it with the the FFC ribbon unplugged from the board. We know that grounding through the ribbon can cause the open cover message. If you still get the open cover message with the cover pins shorted and the FFC ribbon off, it will not be looking good. Try it with both boards.

[Digitalwoodshop]

With the head cranked down on a board with a piece of copy paper on it.... What is the Board Sensor Reading?

Even with the open cover you should still be able to read sensor data on the board sensor. A Perfect reading with white paper is 156. A Zero and you need to look at the FFC Cable and the 4 conductor cable to the board sensor.
:roll:
Did you ever try the close cover test with the top board sensor cable un plugged?

AL

[traumfanger]

Wow, you guys are good! I'll try both suggestions. Interesting, regarding the 24V pin. As I recall, the J1 pinout, I had placed the female 1-9 over the male 2-10. Per the location of the 24V pin, it should not have caused harm.

[traumfanger]

Problem solved!!:p
Pulled the FFC, no close cover notification, "Z Axis Stall Err 06-0313" comes up. Why on earth the FFC has anything to do with "close cover" is beyond me. In any case after checking things out, I found the motor end of the FFC was not entirely seated. Must have loosened it while moving boards and cables. Not noticeable as the cable is deep seated within a boot on the motor end. Tightened things up and all is well. Thanks so much as I was contemplating sending in the controller for replacement, $300:-(

Have a great day,

Neil

[fwharris]

Problem solved!!:p
Pulled the FFC, no close cover notification, "Z Axis Stall Err 06-0313" comes up. Why on earth the FFC has anything to do with "close cover" is beyond me. In any case after checking things out, I found the motor end of the FFC was not entirely seated. Must have loosened it while moving boards and cables. Not noticeable as the cable is deep seated within a boot on the motor end. Tightened things up and all is well. Thanks so much as I was contemplating sending in the controller for replacement, $300:-(

Have a great day,

Neil
The data is carried through the FFC cable to the controller.

[bergerud]

Problem solved!!:p
Neil

Well, that is great.

Thanks to Al for originally discovering that problems on the other side of the FFC ribbon cause the close cover message.

Now we can add poor FFC connection to the shorted board sensor wire as another cause of the false close cover message.

[Digitalwoodshop]

Well, that is great.

Thanks to Al for originally discovering that problems on the other side of the FFC ribbon cause the close cover message.

Now we can add poor FFC connection to the shorted board sensor wire as another cause of the false close cover message.

Thanks Bergerud.

So it was likely a short to ground due to a skewed FFC cable shorting contacts. Similar in effect to a pinched wire on the board sensor wire. It takes out the 5 volt logic voltage so the computer see's a 0 rather than a 1 in binary logic. 0 = Open Cover. Binary 1 or 5 volts = Closed Cover

I found this when my first 2 machines had constant open cover because I pulled the Board Sensor wire down and it slid along the metal track pinching to ground taking out the 5 volts. That is why I asked you to remove the Upper Board Sensor cable.

So a question to Neil? The Servo Motor side of the FFC Cable has a little black cap that the FFC Cable fits through adding SUPPORT to keep the cable from DROOPING. Is is installed? Way back in 2008 I failed to install it after a motor replacement and the DROOPING FFC Cable snagged on something like the Y Servo Fins pulling it out under power. It shorted out the Z Motor.... SO... If you have not installed the little black cable cap, do so.... I learned the hard way.

The more we understand the machine, the easier it is to fix.

AL