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Thursday, August 14, 2025

Sherline CNC Controller Failure

The slightly obsolete Sherline CNC controller has an annoying problem. It tends to blow fuses if you hot-plug the cable to the motor.  Yes, just remember to turn the controller off first.  But who remembers that?  Maybe I need a reminder on the plug.  

The fuses are not expensive.   They are just a nuisance to replace.   The leads are pretty soft so getting them into the sockets usually requires you hold the end of the lead with needle-nose pliers.   And you have to disconnect cables to open up the case.

Reading Sherline's troubleshooting guide, it mentions that a broken cable from controller to motor can also blow the fuse.  I pulled the last leg of the cable which goes from DIN to a Molex-type connector, to test connectivity.  

I taped the Molex end to the table so that I could effortlessly (almost) touch each contact.  There was no similarly easy way to do the DIN end.  If I had a connector that brought out the leads to wires, it would have been easier.   Nonetheless, I was able to verify that some wires lack connectivity  
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Yes, I have a spare believed to be operational replacement. I am going to test it before hooking it up.  I am also going to test the fuse for resistance before completing reassembly.

Yes.  I can test the fuses in situ and the Z axis fuse is definitely blown.  No continuity while all the rest are.
It still does not work.  I guess I will send controller and cable to Sherline and go back to manual operation. 

UPDATE: Manual operation is just so painfully slow.  I need to move cutting tool 1.75" to the left.  Instead of G1 X-1.75 F25, I calculate the number of handwheel turns.  1.75"/.050=35 turns.  Some distances become x turns and turning the handwheel 15 lines.  

Also, specifying feed rate is so much more precise than calculating how many rpm to turn the handwheel.   In theory, you should get a feel for whether you are cutting tool fast.  I am not confident that I am there.

It can be done, but waiting for the controller to return makes more sense.

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