KiCAD schematic Anilam Crusader M Conversion

I'm glad you got it to work!

OT-CNC wrote: Did you add an additional fly back diode to protect the 7i77? I assume the diode on K3 is sufficient?

I did not use an additional fly back diode to protect the 7i77. Somewhere in the 7i77 manual it says that you don't need a diode for a small relay (with a coil) due to the 7i77 circuitry, so I didn't add one and you shouldn't have to.

OT-CNC wrote: If I wanted to use K4 for any reason, would I remove the 220 ohm resistor?

I looked at the schematic that I sent you and only saw two 220ohm resistors and they are on the upper right side and didn't seem to be tied to K4 in any way?? Can you describe or tell me where the 220 ohm resistor is that you're talking about?

If you want to use K4, you would either tie P3 Pin 6 to ground or put in jumper JW6 to tie those to ground. Also, the 'triggering' of the relays would come from the 7i77 on P3 Pin 1 which means K3 and K4 would be actuated at the same time.

One thing I noticed that could be a problem on my setup is that I'm driving that Output from the 7i77 'too hard.' My output turns on K3 and then powers up the RESET light bulb, although that light bulb is only 2.4W (that's not much), so that shouldn't hurt it... Hmm, I did notice that my reset light bulb wasn't working. Need to investigate.

OT-CNC wrote: My machine being an older crusader, does not seem to have any line conditioners built in! I see your schematics shows 2. One 5A and a 20A. Anything I need to know when sourcing those? I have a couple rated for different voltages. Can one rated for 250v ac 6A work the same on 120v?

I'm not entirely sure if the 250Vac one will have any issues, but I think it'd work. I don't think you want to put a line filter rated for 120Vac on a 240Vac line, but the other way around should be fine.

I will add, my machine is a noise machine!! I have an Automation Direct GS2 VFD to run my spindle and that thing must be generating noise as well as the bridge rectifier for converting 80Vac to 80Vdc. When I upgraded to the brand new LinuxCNC 2.7.0 release about a year and half ago, my machine wouldn't work! It turned out that, Yes, my system has a ton of noise, but the 2.6.x and previous versions had some 'ignoring' code to ignore bad and noise induced communications within the mesa 5i25/7i77. The programmers changed something around 2.7.4 and now my system should work, but I haven't gotten around to changing from 2.6.12.

Part of why I say this is that I have line filters, but I also have a ton of noise. Not sure how much the line filters will help you, so try the 250Vac ones and see if it works.

Mark

The resistors are shown on the original anilam schematic near jumper jw8 and jw9. (A)(B )(C)(D). I didn't look for them on the pcb. They are on K1 and K3 not K4 as I stated, sorry. If I'm using K4 it's irrelevant.

My initial running of the x and y did not show any obvious issues with noise even without line conditioners but I'll definitely will add them.
Things may look differently with noise once I start tuning and look at signals in hal scope. I also don't have a VFD yet on this machine. I'm running current release 2.7.8. and the 7i77 is not in the main electrical box as that one is too small.

Yes - I agree w/ everything you say about the resistors, that's what I saw as well. My guess is that if we followed the schematic further, those connections/wires led to other components or back to one of the main anilam control boards and were there to keep from dead-shorting the contact. But, what they do or what they're used for, I don't know and don't really care...

Glad you don't have any obvious noise issues. Version 2.7.8 should be just perfect and separating the 7i77 from everthing probably helps. My 7i77 is about 6 inches from my VFD and that VFD is grounded to the backpanel so there's probably noise there. I did it that way because the wires from teh original anilam all 'settled there' for the PCB803 (I think it was 803) and I didn't have to re-wire any of htose leads. They all 'just fit.' But, I might have gotten noise.

Anyway, you're on the right track - Good luck,
Mark