Mill setup troubles and questions (Speed display, at speed signal, coolant pump)

Good day hivemind.

I've been struggling with getting my mill up and running. It's running from an Mesa 5i25 / 7i76 (par port) controller, Leadshine HBS86H driver / 86HBM80C-1000 motor (closed-loop) at 70VDC; 1000PpR. And a BEST FC300-2.2G-S2-B4 VFD.
Attached is a zip with the config files.
Eventually i got it mostly functioning.
I got my homing to work.
Got my pendant (old XHC HB04) to work and operate the axis/spindle/feed.
I reserved a few inputs to add limit switches (at end of stroke). Might want to add extra past-home limits too to prevent overshoots. Setting the homing sensors to act as home and limit (PNCConf option) just gave errors when running LinuxCNC( can't start, limit switch active or something along those lines).

What is left:
Speed!. we want it....
I have a high speed spindle on a VFD (0-10v input, no feedback (jet?)). 24000rpm@400hz. No problems there.
When i turn the spindle on, the speed on screen reads as 300rpm at 100% and the VFD runs up to it's 400Hz max. Turning down to 50%, the VFD goes to 200hz and 12000RPM. But the screen reeds 150rpm.
The speed bar under the speed and % reeds " 0                0                  6000"
And the "at speed" dot doesn't turn green. I do have that output from the VFD connected to the board.

How do I get the display to show the true RPM?
Can the 0-10v output from the VFD be connected to the 7i76 as speed feedback?
*****************
Next question:
I also have a relay on TB6-output2 to which the spindle coolant pump is wired. How do I get that 'programed' to turn it on when the spindle is running? (and perhaps add a function to the pendent to manually turn it on/off too?).

TIA,
Niels

If you want the coolant on al the time the spindle is on, add:

net spindle-enable => hm2_5i25.0.7i76.0.0.output-02

If you want the normal gcode controlled coolant, add:

net coolant-flood  => hm2_5i25.0.7i76.0.0.output-02

or

net coolant-mist   => hm2_5i25.0.7i76.0.0.output-02


As far as the spindle scaling goes, OUTPUT_SCALE must be 24000
If that does not work, the are errors elsewhere that must be fixed.

Hi, Thanks for that.
It appears that just manually turning the spindle on isn't what you're supposed to do. When i give an M03 S2000 command in the MDI, it does turn on, and show 2000 on screen.
Actual speed seems to vary quite a bit.
Getting the 0-10 output from the VFD into the 7i67 and LinuxCNC for the feedback would be a win. But would that go to one of the ports labeled as mpg1a/b 2a/b? (that's where i currently have my homing switches)

So stuff seems to work.
Next up is probing.
I have a tool setter on the bed..and an edge finder for in the spindle.
The 2 macro's work (should have copied them so I could include them here).
I mount the probe and touch it off on the tool setter. Then I manually direct the spindle to the workpiece corner and do the probe.
The workpiece corner is about x450 y400 z-23
When I then do a
G54
G1 x20 y20 f150
The spindle moves towards the machine home zero. Instead of 20x20 relative to the workpiece corner.
In the tool table G54 has coords like X25.645 Y62.956 and Z at 3.457
How?

Getting the 0-10 output from the VFD into the 7i67 and LinuxCNC for the feedback would be a win. But would that go to one of the ports labeled as mpg1a/b 2a/b? (that's where i currently have my homing switches)

The 7I76 has 4 analog inputs (on field inputs 1,2,3,4), but typically its better to use encoder feedback
 

Unfortunately the spindle doesn't have an encoder. And adding one might proof difficult.

Absolute spindle speed accuracy may not be terribly important
anyway for actual machining.
 

Hi,

So i finally have the tool probe and workpoint figured out (i think*).
Running the code i got from Inventor CAM, with the default LinuxCNC post I run into issues.
I attached the Z-probe and workpiece subroutines as well as the Inventor cam generated code.
It stops on the T1 M6 line (N25). But i can't seem to get it to go beyond that. Pressing the start/pause on the HB04 doesn't do a thing.
Commenting out this line moves the program up to line N60 and throws up error messages about the Z-axis running out (it wants to go to high).
To me it looks like the code has a different idea of where the tool tip is (in Z) than what it gets set at with the Z-probe routine.
Work order:
{The z-probe / toolsetter is fixed to the bed}
Mount the probe. (that's the XYZ probe)
Run the Z-probe to set it's tip.
manually move the spindle/probe to within the bounds of the workpiece probe routine. (The vice for now)
Run the workpiece probe routine (finally got it to set it's coords correctly and it moves perfectly above the corner.)
Then i manually move the spinde to a comfortable place to change out the probe for the tool (round paper lollypop stick for now).
I placed a piece of plastic on the tool probe to create extra Z offset for initial safety so the lollypop stick doesn't plunge into the workpiece (the vice).
Then i load the 19.091 cgode file and "press play".
It moves from the probe XY to a place that is NOT the coords of line N55
Then it runs line N60 and error's out on a Z-axis out of bounds. 13mm above the workpiece is well withing that actual range of my machine with the tool probed as is with the extra spacer. I checked this with the spacer on the vice and the tool touching it (simulating the tool touching Z0 on the workpiece /G54. And then move up 13mm and then i still have plenty of headroom before I run into the Z home/limit switch.

So the 2 issues:
Getting past the M6 on line N25
Correctly using the tool length (?).

* probing the workpiece often fails when i comment out the message and M0 commands, claiming the probe is in contact during rapid movement. Adding the M0 'pause' solves that. But that is not how things should be.
Also, i would like to be able to position the probe during the routine
lines:
(MSG, Plaats probe boven werkstuk\n Hou de probe ong. 5mm binnen de hoek\n en druk daarna op start)
M0                        ; Wacht op bevestiging
The M0 hold doesn't allow moving the spindle about.

Also... Here is the LinuxCNC post processor from Inventor.

I've been away on sick leave for a bit.
Just getting back to work on ' trail' basis.

What i find is that there are some issues with the Z settings.
My machine is setup as 600x900x-200mm Home is 0,0,0 of course.

Procedure:
Home the machine.
Move the spindle and put the 3D probe in the ER collet.
Then run the Toolsetter macro. To my knowledge this sets the tip at 39.2mm above the bed.
Then I probe the work piece corner (werkstuk_tasten...) This should set G54 to the offsets from machine home, right?
Then I replace the probe with a mill (actually a lollypop stick for testing purposes). And run the toolsetter routine. I remove the workpiece to mill air while getting the bugs sorted out.
Then I load a program. The Touchy GUI shows the program movements etc on the screen. What i see is that it is correctly positioned in the X and Y but that the Z is to high up in the machine volume (red box on the screen).
Running the program errors out on that it runs out of Z distance wanting to go higher than is available.

So my question is on how to set the height coming out of the toolsetter routine.
The distance from Z-home (0) to the bed is unknown to enough of a certain height to be useable, right?
Or is there some other issue at hand?