Emco PC turn 55 upgrade..

The control pin table was attached above.

I figured out that the 5.2V reference is actually 5.2 above the reference ground of 3.5V, so if I used them as a pair I could get 5.2V. (comes back from lathe)When I hooked up the 24V input to the VFD the ground went to zero and that issue may have gone away.

I can move a dip switch to change it from 0-10 to 0-5, which seems to be the most convenient solution.

So the new pinout?
Spindle- to 7 GND
Spindle Out to 8 Analog Input
Spindle+ to +5VP on 7I76 or 5.2V on VFD
NC
Spindle Ena- to 28 Controller inhibit 1=enable
Spindle Ena+ to 24V
Spindle Dir- to E4 CW0/CCW1
Spindle Dir+ 24V

If 5.2V is available on the VFD, I would use it (and spindle GND) instead of the 7I76s 5V and GND.
VFDs tend to be quite noisy so it best to maintain the 7I76s spindle control isolation if possible

The more difficult issue looks to be the tool changer. I built the toolerator 3000, but after trying to match up wires it looks like that's not the answer, since my encoder has two less wires and runs on 5V and not 24. So now I need to figure out how to get the 7I76 to control it using the original turret controller. The three relevant wires are Sync, Strobe and Change.

My enable pin now goes high when I click enable amp in pncconfig. My spindle dir- is high all of the time, which is bad. I'm still not getting any movement out of the spindle or voltage out of the spindle out pin. I'm wondering if I needed to do something back in the I/03 page.

In pncconfig I've got the spindle moving forward at the correct speed. It took me hours to realize that the gear ratios in the calculator are upside down and backwards. I also had to change the max voltage to 10 to give me the full 0-5v. It must assume that your going to give the 7i76 10v and cut it in half if you select 5.

The problem now is that when I turn the spindle on in axis it just goes to full speed. If I turn it on in mdi with "s500 m03" it still just goes 4000rpm and it does it nearly instantaneously. The plus and minus buttons in manual don't do anything, but if I move the slider below 100% it will slow it down. I also can't get the spindle to run in reverse, although I'll probably never need it to.

If you immediately get full spindle speed from low commanded speeds it indicates
that the spindle analog output scaling is wrong

Can you post your INI and HAL files here? the error should be easy to spot

..

from the hal file:

net spindle-vel-cmd-rpm-abs => hm2_5i25.0.7i76.0.0.spinout
net spindle-vel-cmd-rpm-abs <= motion.spindle-speed-out-abs

These mean that the spindle speed command is sent directly to the 7I76
so if you set S500 , the value 500 will be sent to the hm2_5i25.0.7i76.0.0.spinout pin

From the ini file

# Spindle
#********************
[SPINDLE_9]
P = 1.0
I = 0.0
D = 0.0
FF0 = 1.0
FF1 = 0.0
FF2 = 0.0
BIAS = 0.0
DEADBAND = 0.0
MAX_OUTPUT = 4085.71428571
ENCODER_SCALE = -100.0
OUTPUT_SCALE = 1
OUTPUT_MIN_LIMIT = 0
OUTPUT_MAX_LIMIT = 1

Output scale of 1 means that any number equal to or greater than 1
will result in a full scale output

Ignoring the gear setting (which are unconnected in the hal file), for a simple
4000 RPM full speed spindle you would want:

OUTPUT_SCALE = 4000
OUTPUT_MIN_LIMIT = 0
OUTPUT_MAX_LIMIT = 4000

Is there any reason to use the spindle speed output from the VFD since I've got an encoder? How can I limit my spindle acceleration?

No reason to use output from the VFD, the spindle encoder will be the most accurate.

Limiting spindle acceleration should be done by putting a lowpass or limit HAL component between motion.spindle-speed-out and whatever sends the analog voltage to the VFD.

Jon