Originally Posted by
fasto
You could try the following but it's VERY DANGEROUS you could badly crash the machine.
Swap the X and Z connectors on the dual-axis cards, ie, plug X into Z and Z into X.
Power up the machine. DO NOT CALIBRATE IT (INITIALIZE, ZERO, HOME, I FORGOT WHAT ULTIMAX CALLS IT) OR IT WILL CRASH. Power up your servos BUT DO NOT CALIBRATE THE MACHINE. See if you get a fault on X now. If so, the Z/Spin dual-axis board is OK and the fault lies further down the system. If you get a fault on Z still, the Z/Spin dual axis board is the likely culprit.
You can jog the machine, remembering the X and Z axes are swapped, but be very careful! You're far better off if you don't even try to jog it. The limit switches might not work which is why it could crash.
Reconnect the wiring properly.
Assuming you now get an error on X, I would work my way through the machine, exchanging X and Z at the CRP board, then at the servo drives, then the servo drive outputs, and so on, repeating the test after each exchange, and replacing the wiring properly after each test. When doing these tests remember that the limit switches might not work (because they're connected to the wrong axis), so DON"T CALIBRATE THE MACHINE! You might get a motion error, too, if the control expects X and Z to move in different directions (the control expects one axis reversed on the BMC-20, I think it's the Y axis, that's why I said exchange X and Z).
I'm sorry about the shouting. I really don't want you to wreck your machine troubleshooting it. I would, and did, do all of this and more on my machine. Please be very careful if you try this, and fully understand what's going on before you do anything. If you're near Worcester, MA I'd be happy to help.