Quoted from Peak-Pin:I believe that I have found the basic problem [...]
Excellent sleuthing!
My Node 10 journey seems to support your hypothesis. The original board went up in smoke after about 300 plays. Stern Support sends out a replacement, and that one made it approx 200 plays before failing. I tell them how the clock occasionally stops working until the next machine boot. They thought a bad clock motor might be the culprit, so they send out a Node 10 board AND a replacement clock motor with the 4-pin 0.100" connector already attached (the one that fits the header on the Node 10 board).
That was right around the time when the leading "root cause" theory was the gorilla with the zip-tie gun, and my ramp motor was definitely a victim of said gorilla... the insulation was mashed on the black and red wires so badly, it nearly severed them. Rather than counting the games until the third board went up in flames, I decide to order an OEM motor from the manufacturer (Lin Engineering) with the "flying leads" option, crimp my own pins onto it, and run it straight to the Node 10 board to ensure that it remained untouched by the zip-tie gorilla.
Replacement clock motor arrived with black zip-ties instead of the former white, but they were much more loose... I could even slide them across the wires to inspect the insulation beneath. Just to be safe, I removed them and substituted a few short pieces of heat shrink tubing in lieu of the zip-ties. When the new ramp motor arrived from Lin Engineering, I did the same thing. Both motors are now directly connected to the Node 10 board with the OEM leads, using the correct pins, and free from the guerilla gorilla's handiwork (see pic).
2 months and about 500 games later, and board number 3 is still performing like a champ! The ramp wires are a little too short to route through the existing path, but I'll take dangling wires any day, if it means this stupid issue is finally resolved!
One additional bit of info: I did open up the old ramp motor to see if the conductors could be easily replaced with 22ga leads, and they cannot. There is no chance in hell that I would attempt it, at least. It would involve disassembling the innards of the stepper, and from the way everything is packed in there with tight tolerance, the prospect of getting it all back together would likely be daunting (and unsuccessful). I would advise against opening the motors, period.
Final observation: The weird "clock stops working until next boot" issue has also gone away! So either the clock motor WAS bad, or maybe they fixed the issue with a subsequent code update... but either way, my clock and ramp are both rock solid as of today, and I'm a happy Rush camper again.
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