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andresgodinho wrote:

Hey guys,
First ever post here and first ever linuxcnc retrofit.
Just got a Chiron FZ12S Rapid CNC machine with a Siemens Sinumeric 810M controller and Siemens Simodrive 611 for all axis and spindle.
Sinumerik 810M is dead.

Started converting to Linuxcnc, got a Mesa 7i92 + 7i77 + 7i74 + 7i70 + 7i71.
Got the basics running. Home switches, XYZ motors running fine, drive enables, a few inputs conected and a few outputs conected (to allow for proper drive and machine start, it requires a complex sequence of relays and input feedback for the safety relays to activate)

Now i am facing the first issue. Basically i got the encoder feedback from the spindle going to the spindle drive and then to mesa 7i77 encoder 5 input.
I comand M3 S200 --> spindle rotates in right direction and at 200 rpm.
I then comand S1000 --> spindle drives jumps to 1000 rpm
If i comand M4 --> spindle rotates in the right direction and at the comanded speed.

Now the problem:
Up until 3900 rpm (spindle is 10500 rpm max) everything works perfect. If i comand S4000, encoder feedback seems to desapear and the drive goes to max rpm... It seems that the Siemens drive is disabling the encoder output to linuxcnc...
Drives uses +-10V and is in velocity control. 
Is there any way to say to linuxcnc that up to 3900 rpm it should use encoder feedback and after 3900 just use the index pulse from the encoder to control the rpm?

Thanks a lot guys and i will be posting pictures soon.



 

Hi, I'm Brazilian and I'm trying to do what you did, use the Sinumerik 611 driver on an 810m using Linux CNC, could you tell me more about what it was like to do this integration? Did you use the +-10v command to activate it or instead of step-dir?

Tommylight thanks for this, I had completely forgotten that the 7i96s has an output of 0-10v cw or ccw, it depends on how the motor phases are connected mechanically... on the lathe that I plan to retrofit, the main spindle is an Ac servo and the factory of course has cw ccw.. my question is whether in that case I will be able to set the counter direction with some magic in the hal
i mean m3-M4 ,or via some relay that would change the motor phases or a third option to find the input pin for changing the direction on the Simodrive itself? there is another option to take the analog output from the 7i77 because I planned it for x and z control. In the case that PhilipMe has, I have the same servo driver on my diy lathe and it can work in both modes, position and velocity also and torque over 25 13 analog inputs on the driver. in the manual there is a possibility to change the direction...PhilipMe check which parameter is responsible for that, it was a long time ago and I forgot.

PCW wrote:

The 7I96/7I96S are step/dir controllers. The 7I96S has a one channel 0 to 10V
output for spindle control. I think tommylight suggested the 7I96S as it gives
you some step/dir outputs for added drives.

For an analog  servo system you need multi channel analog outputs and
multiple encoder inputs. You can add these to the 7I96S either by adding a 7I77
or a 7I85 and 7I83.

A 7I84 just adds more digital I/O say if you have a tool changer.

Sourcing means for example an output device that supplies +24V to a load with a negative common
 

Sinking means for example an output device that grounds its outputs to drive loads with a +24V common

so now I'm a little more confused.  I just read about the 7i77, which seems like doing the 7i96s plus 7i77 would get me where I want to be, but then I looked at the much cheaper 7i83, which appears to do the same thing?  

and you said pair the 7i96 with a 7i77 or 7i85 and 7i83, so why would I need the 85 and 83 together?  So is a 7i77 essentially like a 7i85 and 7i83 put together on one board?

I'm sorry for my complete ignorance, but so many of these cards seem to do the same thing, especially to someone like me who has no clue about things...

The 7I96/7I96S are step/dir controllers. The 7I96S has a one channel 0 to 10V
output for spindle control. I think tommylight suggested the 7I96S as it gives
you some step/dir outputs for added drives.

For an analog  servo system you need multi channel analog outputs and
multiple encoder inputs. You can add these to the 7I96S either by adding a 7I77
or a 7I85 and 7I83.

A 7I84 just adds more digital I/O say if you have a tool changer.

Sourcing means for example an output device that supplies +24V to a load with a negative common

Sinking means for example an output device that grounds its outputs to drive loads with a +24V common

 

my friend just repaired the 7i77 that I had and broke it with a short circuit (he says it's a dc-dc converter), in case it's successful, I'll try to connect it with the 7i96s...my question is, in that case, can I use the spindle output and encoder from  7i96s plus mpg and I/o, and with the 7i77 also use the I/O plus analog signals for the drivers (siemens amplifiers)?

So after the crucial tip from pcw I got the outputs working and configured the lube system. As for the hydraulic draw bar I repurposed the former cycle start button from our very simple hand held. After looking at the code for the central lubrication, I modified it a bit to fit the drawbar application and loaded it as drawbar component, which will only release the drawbar, if the spindle is not running.
It connects via Hal similar to the central lubrication component (wiki.linuxcnc.org/cgi-bin/wiki.pl?CentralizedLubricator).

Hi All,My brother and I recently purchased an old MAHO MH600T with the intention of retrofitting it using LinuxCNC, a 7i77, a 7i84, and the GmoccaPy interface. We began our project by following Mark's thread, which provided invaluable information—without it, we would have been lost. The machine originally came with an old Heidenhain 332 CNC controller, but unfortunately, the video output seems to be broken. Since this compact module also contained the EXE interfaces, we had to replace them with three EXE602 modules to read the linear scales.This is working fine (we are currently ignoring the c-axis...) and the cable cabinet still had a convenient place for its three new members. 

At this stage, we have successfully set up the endstop chain and the linear motion system (encoders and the Indramat drives for X, Y, and Z axes), using conservative values for the PID controller and homing. Our next step is to get the "accessories" working, such as flood coolant, the tool holder, and basic spindle control (including potentially allowing for manual gear changes). While the machine behaves as expected when we press the test buttons on the relay board, we are facing difficulties controlling these functions via LinuxCNC. I have a few questions about this (apologies if they seem basic, but I am new to LinuxCNC and HAL).

1. I wired the 2K2 relay for the coolant pump to output-15 of my 7i84, with field power supplied by the 24V line. The pump operates correctly when I test the relay using its test button, but attempting to activate the relay from the Mesa card causes the machine to go into an emergency stop. Even connecting the relay to my field power alone triggers a shutdown. I've double-checked the wiring (I have a connection from output 15 to the test lead MP12 and to the relay), swapped the relay with a known working one (19K1, machine on), and tested the output without anything connected (it pulls up and down correctly). I initially thought it might be an issue with using a different 24V line, but the "machine on" relay is functioning. I'm currently suspecting a short circuit, but there is no error message displayed by the controller—just the fact that the machine goes into E-Stop. Is there a hidden log or extended error message that might provide more information?

 
 
2. The spindle: For a first test, I wanted to have the spindle on/off working, which just should be the three relays 1K8, 1K9, 1K10, connected to output 12, 13, and 14 on the 7i84. but with the following hal code, nothing happens, when pressing spindle start, and the pins of the 7i84 are floating at roughly 13V. So it seems the pins are not connected in the hal. Is there something I am overlooking, do I need to use the halui pins?:3. The gearbox. The good news is that our machine is equipped with an 18-speed gearbox, similar to Mark's, but the sensing configuration is slightly different. While the outputs are the same, we only have nine inputs, which means we're missing the "Links-Mitte" switch that indicates whether the gear motor should turn left or right. Has anyone modified the gearbox component for the MH400E to accommodate this configuration, or has a working original MAHO with this arrangment and could share, how the gearshift is done there? I somehow hope, that it is just an easy modification, but my C is a bit rusty, so we will se how this goes.
 

Kind regards

Sebastian

Sami wrote:

"""
Remove the lathe power plug, try again.
"""
We have started linuxcnc without lathe hw plugged in and it start until error of
missing I/O-information about door etc. When lathe hw is connected to 6i25 pc reboot
at line addf hm2_5i25.0.read servo-thread.

 

That points to a bad wiring issue with outputs or inputs, or power issues, or different potential between Mesa/lathe electronic/drives/spindle drive.
Remove all the input and output plugs from the Mesa 7i77, power on everything and start LinuxCNC.
If that works, power off the machine, plug one of the connectors, turn on the machine, test connectors one by one.
When you find a connector that causes issues, start removing wires from it and test.
Do not remove wires or plugs while the machine is on.

Question 1:
Is there an output pin for an external Estop/reset safety circuit to read the status of 7i77 WDT? If not, would it be feasible to use one of the existing pin outputs by Keeping this output pin ON while the watchdog timer has NOT bit. Here where the catch 22 comes into play, when the WDT bites, the hostmot2 driver disables the digital outputs therefore my external hardwired circuit will not be able to determine the WDT output pin status (see diagram Highlighted in RED). One way I can think of to solve this puzzle is to restrict the WDT from internally disabling the digital outputs, and have WDT just set a flag and let the hardwired safety circuit take care of disabling the power to the digital outputs.       Or I am out to lunch?Question 2:
7i77 field terminal block has several terminals I am hoping to be able to keep the field power OFF to the digital outputs until the safety lockout circuit is reset and the field digital inputs and VIN powered while the ESTOP circuit is active. If you look at the wiring diagram, I need the numbers of the terminal blocks marked with question mark (highlited in green). Nomenclature:
CR# – CONTROL RELAY
MCR - MASTER CONTROL RELAY
F# - FUSE
DI – DIGITAL INPUT
DO – DIGITAL OUTPUT
PB – PUSH BUTTON
WDT – WATCH DOG TIMER
L1 - MAIN SUPPLY LINE 120 VAC
N - MAIN SUPPLY NEUTRAL
PL- Pilot Light A brief explanation to what this hardwired circuit does follows this diagram.
  The wiring circuit diagram below  is a hardwired circuit that will allow power to be removed from digital outputs, servos and spindle. The circuit achieves the following:

• If power is lost during operation the machine will not restart when power is re-established.
• If an Estop is activated or a fault occurs during operation, the circuit will inhibit (prevent) power to digital outputs, servos and spindle. The rest of the machine control circuit will stay in the ON state; this will enable you to troubleshoot and resume operation without major reinitialization of the machine.
• Machine will not restart until all faults are corrected and operator presses reset button.

This hardwired circuit is the equivalent of safety relay without guided contacts.

I've got a 5' x 10' CNC router with a failed Mach 3 control. It has Yaskawa Servos (SGMGH-09ACA61) and was set up for step/dir with an ethernet smooth stepper. It was "open loop" with that control. It has four motors for the 3 main axis and a 5th motor for a rotary axis. I might not use the 5th axis but I do have a crazy idea for an automated dust collection "axis" that would probably use stepper motors. 

I have a Mesa 7I76e that I bought several years ago for another machine that has yet to be completed and I think this would be my fastest/easiest control to drop in but would still leave me open loop to the control. Instead I've been thinking of running with analog servo signals and the encoder feedback into LinuxCNC using a 7I92TF with a 7I77 or a single 7I97T. It seems the 7I97T might be a bit light on general I/O since the machine has an ATC spindle and several other pneumatics that need to be controlled and sensed so I'm leaning towards the former combo. 

Any suggestions wrt to Mesa card availability and the advantage of using analog vs step/dir in this application? 

 

Why a 7i96 and a 7i77? Can't the VFD be set up to accept an analog speed command, and therefore controlled by one of the free axis on the 7i77? These are both FPGA cards, so you end up with a lot of reduntant processing, and also a lot of unused features on the 7i96.

Are all your outputs on the same voltage? I ended up short of 24V outputs, as I had to put one rail of the 7i84 on 5V.
Good choice on a 7i73 in the user interface panel is a huge time saving in wiring reducing the wiring from the User interface down to the electrical panel to a single Cat 5E, plus one discrete for the E Stop.
Are you not using encoders for Jog/spindle/feed overides? These are slow enough to use normal pins and software encoder.

Have you considered 7i97/7i84/7i73?

Another option is the way I did it on my lathe. I split up all the functions with:
7i92 for the FPGA, plugged straight into:
7i85 interfacing the axis and spindle encoders, and providing 5 channels of RS-485 SSfor:
7i84 I/O (I might need to add a second one)
7/83 Analog servos
7/73 User control panel.
That leaves two spare RS-485 SS ports, so it will be easy to connect in the second 7i84 (once I find space for it in the electrical cabinet), and maybe a second 7i84 for jog wheels down on the apron.
 

Hello,

I am in the process of ordering the necessary components to retrofit my CNC mill. I just worked my way through the mesa selection guide and worked with the configuration tool. Now I would like your help verifying my selection so that as a beginner I don't make a costly mistake that could have been avoided.
The requirements are as follows:
3 analog servo drives with feedback from glass scales
1 Spindle vfd
3 mpg handwheels
34 digital inputs
18 digital outputs

At some point I would like to add physical buttons to the operators console, which would be realised with an 7i73 in the console.

The PC is in the operators console as well, and can only be connected to the mesa cards via ethernet.

In another post tommylight suggested I use the 7i97t, which can support my servomotors and the mpgs as well as a few inputs. Ideally i would expand this with a 7i76, however that is not available for me in europe.

Following the guide I came up with a different setup. As FPGA card I could use 7i96s and then connect 7i77 with the 25 pin connector. That leaves the smart serial connection for later use with the 7i73.
7i96s: Main FPGA board, controls spindle, 3 MPGs(6 inputs), 5 inputs, 6 outputs
7i77: controls the servo motors, takes the feedback from linear scales, 32 inputs, 16 outputs
7i73: keys and encoders on the operator control

so that should have me covered, or am I missing something?
 

Hey guys

just a quick update here.

we worked out the original diagrams of the machine and connected up a lot of  the hydraulics to allow basic operation of the machine

first we connected up the hydraulic pump and checked it was rotating the correct direction.  for those that don't know if a three phase motor is going backwards just swap any 2 of the 3 wires and it will reverse

so we swapped the 2 wires on the main line in and then repowered up the machine

halcmd -fk is your friend here

just type it into the terminal  and then you get auto complete of all the loaded pins on the machine and signals etc.  It is a seriously awesome tool

just to be crystal clear.  "quote marks" mean that this is a Hal command

also i am guessing at the actual pin names just to be clear they are probably not correct..

so the command "setp" turns a pin on or off
 setp hm2-7i92.0.7i77.output.00 1  (this will turn the first output on the mesa 7i77 card which will turn a relay on which will then turn on my hydraulic part.

we did this for all the hydraulics and got to a stage where we could remove the tool in spindle
spindle is hydraulic which is nice and easy

next plan of attack was to get the pallet changer going

current status is all hydraulics are working.  just need to get the motor working to rotate the pallets and swap them and it should be working

I will code a few things in classic ladder just to make it automatic.  and then i need to go through and setup timouts just in case there are other issues and i am not watching.

and thats it for now

hopefully next week i get more time to work on it and get some videos going etc

cheers 

andrew

The issue with a 7I96S+7I74 is that there's nowhere to add the second encoder
(well you could have strange 7I96S+7I74 firmware that puts one differential encoder
on the RX lines of 3 of the 7I74s RJ45 connectors)

Edit: you need three encoders: X, Z, Spindle.

You could use a 7I96S+7I85+7I83 but a 7I96S+7I77 might make more sense

Hi,

I'm configuring a kind of lathe with one 5i25 and two 7i77 and I'm facing the same problem : in the spindle tab of Mesa CT, I can't select anything; all buttons are greyed out.
Where does it come from ?

Jôrg, did you terminate the configuration by hand or with Mesa CT? You did'nt explained what's wrong with your spindle tab.

I've another problem with analog outputs but I just saw Peter's answer (forum.linuxcnc.org/24-hal-components/528...how-and-is-not-found) so it should be ok. In case it would be related... I would try it tomorrow.