CINCINATTI MILACRON ARROW 500 (BDS4 + VFS5) WITH MESA 7i77 + 6i25 WITH LINUXCNC

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07 Mar 2025 07:20 #323407 by UrKibin
Hi,

Good day. Newbie here. Would just like to crowdsource and steer us to the right direction with regards to retrofitting a milacron arrow with BDS4 axis servo controllers and VFS5 spindle servo controllers.

Any inputs and directions will be greatly appreciated.

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07 Mar 2025 20:12 #323462 by andypugh
What command and feedback method do the drives and axes require/provide?

You might want to look at the "HD" cards too, such as the 6i24 as those have rather more pins. For example 6i24 + 7i36. The 7i36 can connect one smart-serial board for GPIO, and then you could add a 7i44 if one sserial board isn't enough.
Look at the 7i43 to simplify the control panel wiring too.
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08 Mar 2025 01:45 #323482 by UrKibin
Hi Andy,

Good day. From what i have gathered in the user manuals available in the internet and checking the existing connection from the servo controllers to the non-functioning acramatic 2100 controller,

each servo controller (X, Y, Z, and Spindle) has
1) +-10V inputs (i assume to drive the servo motors)
2) An A & /A, B & /B, and Z & /Z encoder outputs.

I was thinking of connecting the +-10V servo inputs to the 7i77 by its TB5 outputs namely, ENA0+-, ENA1+-, ENA2+-, and ENA3+-.

Then connecting the servo encoder outputs to the 7i77 by its TB3-TB4 inputs namely, QA0 & /QA0, QB0 & /QB0, IDX0 & /IDX0, for all axes and the spindle.

If that is correct, my only problem now would be the configuration under linuxcnc which I have no idea where to begin.

As I have already purchased the Plug-N-Go Kit (7i77 + 6i25) from Mesa, I would like to use them. But will look into your suggestion since they have more pins. Also, it would be generally hard for me to purchase additional boards since I am from the Philippines.

Thank you very much for your assistance.

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08 Mar 2025 02:24 - 08 Mar 2025 02:31 #323485 by PCW
Normally the basic configuration is created by one of the two configuration utilities:
pncconf or MesaCT. These are GUI programs where you enter the intended interface hardware and
basic machine specifications (dimensions, encoder scaling etc) and I/O connections
(limit/home switches spindle controls etc)

Note that the analog out pins are AOUTn. The ENAn+ and ENAn- pins are a switch to enable the
drives (on when enabled)
 
Last edit: 08 Mar 2025 02:31 by PCW.
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08 Mar 2025 02:58 #323487 by andypugh

As I have already purchased the Plug-N-Go Kit (7i77 + 6i25) from Mesa, I would like to use them.


If you already have the cards, then definitely stick with them, they will work fine.

You can expand to really rather a lot of IO by adding smart serial cards, if you need to.
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08 Mar 2025 03:15 #323488 by UrKibin
Hi PCW,

Noted. Will look to the pncconf in depth next week. I tried the pncconf yesterday. I got to the point where you choose which mesa boards I am using. From gathering in the internet, i should be using the 5i25 since 6i25 is not in linuxcnc and 7i77 x 2 i guess...

As for the Analog I/O thank you for the clarification. So instead of ENAn+ and ENAn-, I should connect the servo drives to the 7i77's AOUTn and respective GND.

Thank you for your assistance.

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08 Mar 2025 03:24 #323490 by UrKibin
Will keep the smart serial cards in mind in the future. Thank you Andy.

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13 Mar 2025 09:52 #323814 by UrKibin
I tried using MesaCT to generae the ini and hal files but upon loading in linuxcnc, it produces an error.

Debug file information:
Note: Using POSIX realtime
./main.hal:31: Pin 'hm2_5i25.0.7i77.0.4.analogena' does not exist
2243
Stopping realtime threads
Unloading hal components
RTAPI_PCI: Unmapped 65536 bytes at 0x7f0b2d806000
Note: Using POSIX realtime

I do not know how to proceed. Kindly advise.

For information purposes,
Drive 0 - x axis
Drive 1 - y axis
Drive 2 - z axis
Drive 5 - Spindle

Regards,
Kelvin
 

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13 Mar 2025 13:54 #323836 by tommylight
Upload the hal and ini files here so we can have a look

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13 Mar 2025 17:04 #323851 by PCW
What tommylight said.

main.hal:31: Pin 'hm2_5i25.0.7i77.0.4.analogena' does not exist

The channel 4 above makes no sense (on a basic 7I77 configuration the analog channel would be 1)
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