Retrofitting a 1986 Maho MH400E

Once again, many thanks!

Thanks to the parceled information, I was able to go over all the lines for each component (estop and machine is on) and check them in the documentation pdf. It turns out my problems were related to the ini file, rahter than hal config.

The behavior of the machine is now changed. When 3SH1 is pressed, the Z axis brake no longer releases. External estop recognizes the state of 3SH1 correctly, and ties it with what the GUI displays.
When 3SH1 is pressed in LinuxCNC, the machine can be "turned on" in the control panel.

The next problem is that when I do press the machine on button, the brake releases, I get a following error and the machine estops again.In a proper config, what should happen is that the drives energize and this prevents the Z axis from moving after the brake is released. Is this a correct assumption? If so, I have to look at the configuration of the drive enable signals.

Here's a Mesa question that I think might be important. To get the 7i74 working with the 7i84 I use the hal command PCW specified: "sserial_port_1=00000000"

Does this mean that the connected 7i84 operates in Mode 0? Because that means it only does I/O and doesn't provide field power, which might be important for starting the drives and I should change it to 1.

The 7i74 doesn't have any modes in the manual, so I'm guessing the above is correct? There should be some output voltage sent to the machine rather than just an I/O signal I think. How do I change it to 1? =10000000, or 100xxx, or something else?

How does that work with a setup that doesn't have a 7i74, like Mark has? Does his choice of wiring specify the operating mode in the absence of the hal command?

EDIT: I have the 7i84 on channel 5 and a 7i73 on 4.

Well, I changed the mode to 1 and the machine behaviour is still the same, so I guess I have to search for another cause.

In a proper config, what should happen is that the drives energize and this prevents the Z axis from moving after the brake is released. Is this a correct assumption? If so, I have to look at the configuration of the drive enable signals.

That is correct. Plus I am pretty sure on mine that the brake goes off with the second button push, not the first, so something seems reversed between your and my configurations. I need to look at the 19K2 wiring, but will be out this evening sorry.

I had a conversation about this with John early on in this thread. Try reading forward from about this point...
forum.linuxcnc.org/12-milling/33035-retr...h400e?start=50#99449

I never looked into the MESA mode and channel stuff. I just wired the 7i84 and it worked. If you have already wired 7i84 outputs to MAHO control relays you can see whether the 7184 is working by commanding one of the relays. You should hear the relays click, and can see the witness marks, even if the bus with their muscle power is not energised.
Mark

Good news that the following error is e-stopping the machine. That is an important behaviour.

I got the motors to energize by actually connecting the ground from the Indramat to the 7i77 TB2-6 pin (TB-7, as you suggest in your schematic was already connected to the 19k2 relay). I had previously connected all the original grounds to a terminal on the cabinet (Picard facepalm.jpg),

Now I get a Y following error and the machine estops. Z and X don't seem to move (looking at either motor with the cover off, or on the DRO). If I increase the allowed error, it just moves more before it estops. I remember that with the original wiring, the drives would turn left and right when idle, producing a hum but maintaining position. This is different and it might be hard to troubleshoot for a newb like me.

Possible problem areas are: PID, encoder noise caused by poor wiring, or some config parameters in one of the files.

You have a~50% chance of having axis "runaway" when first setup since you may have the feedback reversed

Basically you need to

1. Get drive enables working
2. Get encoders working in the correct directions and correct scale
3. Get feedback direction correct (you may need to invert the analog output scale)

Expect runaways!

JT has a nice velocity mode servo tutorial here:

gnipsel.com/linuxcnc/tuning/servo.html