SuperPID failure, anybody else experienced this?

(Griff Carpenter) #1

Hey all, I was facing some Al yesterday when my DW611 suddenly accelerated to full speed which somehow crashed the 1 1/2 inch flycutter into the workpiece causing a bit of damage. I hit the E stop as soon as I heard the router spool up but not fast enough.

Anyway, I now find that the on/off switch I have wired into the SuperPID has no effect. The router comes on at full speed immediately when plugged in. The switch built into the router works. As you might imagine, the speed pot for the Super PID has no effect either.

I’ve messaged the SuperPID folks. Just thought I’d ask here.

(Dan Nelson) #2

Check to see if the optical sensor on your router has come loose or is not connected properly. If the sensor cannot sense the speed of the router it will continue to speed up trying to get to the set speed. I had this happen. Turn it on without the “run” switch turned on and manually turn the router, you’ll see on the SuperPID screen if it’s working.


(Dan Nelson) #3

Oh and turn off mains power when you do this obviously.

My SuperPID has been bulletproof in the year or so that I’ve had it, with the exception of when I’ve done something wrong:slight_smile:


(Griff Carpenter) #4

Hey Dan, yeah, since the failure I’ve pulled the sensor, cleaned, and reset.

Now, the router doesn’t spool up upon plug in. It doesn’t spool up at all. The on/off switch in the SP circuit does sort of work now. When OFF, shows the expected “many bars” “few bars” when the spindle is turned manually, but when ON, I get continuous START, FAILED TO START messages.

Will try my spare router tomorrow.

(Dan Nelson) #5

Huhm, that’s odd, yea maybe some issue with the router itself and since you have a spare that’s a good way to start. When mine croaked the sensor had come loose and was intermittently working as it slid in/out of the tube. It also rubbed a bit of the white paint off my commutator, so while I had it apart I repainted. I only know when it lost optical contact it took off at full speed trying to catch up with itself. You already know this, but check all connections and such that you made during initial install, things come loose.

A couple years ago I did an ECU update on one of my motorcycles (Yamaha R6). I had the ECU reflashed, added an aftermarket fuel control module, did a full exhaust mod, intake mods, ditched all the emissions junk, etc… It was a real beast! I was working with the guy who did the ECU flash to get my fuel maps all sorted out and all of the sudden one day, in heavy traffic of course, the bike just quit. Pushed it off to the side of the road, cycled the ignition, it started right up. This happened several more times, to the point that I didn’t want to ride it. The guy working with me on the ECU suggested I remove the O2 sensor and autotune module from my bike. I did so and never had another problem. Looking at the removed sensor and autotune module a few days later I noticed one wire wasn’t properly secured to the module(it’s like 6 wires into terminals and I didn’t tighten one). So basically I’d be blasting down the road, bike would vibrate a bit, and quit. I had sworn up and down that the install was good and there must be something else wrong with the map or ECU flash, I had to eat crow on that one. As has been said before, “Learning has occurred!”


(Griff Carpenter) #6

I hear you. I looked pretty hard at the connections, no obvious issues.

BTW, the router does work when connected to a separate circuit. And, as you can see from the pic above, at an insane 37,900 rpm!! Can you imagine that big old 1 1/2” flycutter spinning that fast? Scary stuff.

I’ve pulled it from the machine for now. I’ve been wanting to redo the case and mount for a while now. This is a good opportunity. I’ve got a Prusa Mk3 3D printer on the way, one of its first jobs may be a SuperPID case,