Retrofitting a 1986 Maho MH400E

Hello, once make the ladder for one speed then to make the logic for the rest is relative easy. You can test the ladder logic on the pc-mesa without connect the actual machine, just use a breadboard and simulating the position of the cams with cables and switches on the breadboard.
You are right the forth cam is not connected to the controller, if 11k3 is enabled than once the forth cam is on, then the NC contact (11S4, 11S9 or 11S14) in series to the motors open and the motor gets lower voltage in series with the resistors 11r1,11r2 or 11r3

I can send you all the files I have now, (I will post it once I debug on the machine) but you have to experiment with the timings, and for sure your gear box is reversed compered to mine so the left and right to the motors is reversed.
The biggest problem I had to deal with ladder is that when you enable a subroutine SR1, SR2… once you disable it (when the cam is at position), then the outputs stay on the last position they were the moment the subroutine is disabled. End when you enabled them again the items on the subroutine (timers, ext.) behave like there was no off period. I don’t know if is bug or is made to behave like this. So after a cam is at position SR8 is enabled for brief time to disable all the outputs before the next cam start to rotate.

I didnt pick up that SR stood for subroutine. Thanks for clarifying that Drimaropoylos. Thanks also for the explanation of the fourth CAM logic and the resisters along the top of the relay board.

I just packed up my Linux PC to bring it into a room with a LAN connection, and I will try and make a bootable LinuixCNC USB stick under linux. Once I get a more recent LinuxCNC installed (I think 2.3 is currently on it) then I can work on installing and configuring the MESA 5i25 and its two daughter boards. and start defining the HAL pins to interface with the MAHO systems. I am not yet up to the point of working on the ladder logic, but would really appreciate a copy of your files, as this logic is lot more complicated that the examples in the Ladder help files I read, so it is helpful to learn with a practical example, directly applicable to this machine. Also a copy of your HAL would really help, as I could keep the same naming convention you use.

I did some more troubleshooting on the actual machine, and for the first time noticed that all the 24V relays have a manual test button. Everyone else probably already knew that, but it was a helpful discovery for me. After using a wooden wedge to hold 19K1 on, simulating the controller ready output, I could go through and test each system. Hydraulic pump, coolant, main spindle, twitching and gearbox all seem to work. As far as I can tell so far, the only failed components in this machine are in the Phillips 432 and monitor.

Are you also using a MESA 5i25/7i77/7i84 setup, or something different? Do you have any pictures of your machine, and how you packed the replacement electronics into the electrical cabinet? Since I am going to reuse the Heindenhain EXE board, it is tempting to put the ITX motherboard, and the 7i77 onto slide in carriers, and reuse the Phillips housing. The 7i84 is going on the cabinet door, as it is only interfacing the two MAHO relay board ribbon cables (unless I run out of I/O on the 7i77).
Mark

Tomorrow after work, I will make a copy and post it. I constantly make changes and there are bugs and missing things. For testing on the machine disconnect everything from the mesa and keep only what you testing. The previews owners of my machine had a runaway of the servo on the Y axis, and crash it at the end of travel. The ball screw lost a lot off balls and he sold me the machine for half the price of one indramat servo.
I am using MESA 5i25/7i77
John

Thanks John. Are you getting the ballscrew rebuilt or replacing it?

Do you have any Phillips 432/10 manuals? I only have the instructors examples. The one thing which I would like to know for the retrofit is what all the signals on the I/O boards 37 pin connectors 28X1 and 28X2 (The ribbon cables) are. The MAHO wiring diagram details most of the control signals which they feed to and from the Phillips, but not all.

For example, OPC1-1 (28X1-1) loops out to screw connection 208, an then back in to IPC1-2 (28X2) as "NC Start". I was just going to connect the 28x2-2 to the MESA as an output, and leave 28x1-1 disconnected.

Do you know what the BCD Zahlen {1,2,4,8,10,20,40,80} on pins OPC1-25 thru 32 are used for?
Mark

Hi, apparently some changes I have made on the ladder file from the windows machine conflict with the rest of the configuration and crashes. You can download the ladder for windows from here sites.google.com/site/classicladder/home/downloads to test the logic until I find the conflict and post a working configuration. You can read the files with notepad, notepad++ from windows. But don’t use the configuration file I post, I have make them for testing and is not well organized. Once installation off linuxcnc completes make a fresh start with PNCconf from the menu/linuxcnc/PNCconf linuxcnc.org/docs/html/config/pncconf.html and then make the ladder file from the start (coping the logic not the actuals values from my files).or if you complete the wiring drawing to the mesa-machine I will make the a new configuration file for our machines and post it in few days helping others in the future with complete instructions for the retrofit with drawings and configuration files.