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I am using a optocoupler (from amazon) between my 7i77D output and a solenoid valve for a spindle break in the sinking configuration, the output is over-temperature faulting for some reason.
using TB8 OUTPUT0. Field voltage is 24Vdc and driving the relay with the same 24 power supply. 
I set up the opto relay on the bench and it only draws 2.2ma on the input in low position.
I'm kind of at a loss, the manual says the outputs can take up to 350ma.

Please advise
John V.
 

I've ended up fighting the hal loader.

#

---

# M19 ORIENT – single driver / multi‑sink form
#

---

loadrt orient count=1
addf orient.0 servo-thread

loadrt pid names=pid.o
addf pid.o.do-pid-calcs servo-thread

loadrt mux2 count=1
addf mux2.0 servo-thread
loadrt or2 count=1
addf or2.0 servo-thread

# --- Orient PID tuning ---
setp pid.o.Pgain 0.05
setp pid.o.Igain 0.0005
setp pid.o.Dgain 0.0002
setp pid.o.maxoutput 60
setp pid.o.error-previous-target true
setp orient.0.tolerance 0.05
setp orient.0.angle 0

# --- One signal name, declared once and fanned out ---
net orient-bit spindle.0.orient => orient.0.enable
net orient-bit => or2.0.in1
net orient-bit => mux2.0.sel
# separate signal drives the encoder’s index enable input
net orient-arm-index orient-bit => hm2_7i92.0.encoder.05.index-enable

# --- Run enable OR gate ---
net run-enable or2.0.out => hm2_7i92.0.7i77.0.1.spinena
net spindle-enable => or2.0.in0

# --- Orient angle / feedback wiring ---
net orient-angle spindle.0.orient-angle => orient.0.angle
net spindle-revs hm2_7i92.0.encoder.05.position => orient.0.position

# --- Orient PID loop ---
net orient-cmd orient.0.command => pid.o.command
net orient-fb hm2_7i92.0.encoder.05.velocity-rpm => pid.o.feedback
net orient-out pid.o.output => mux2.0.in1

# --- Normal spindle path and output switch ---
net spindle-output pid.s.output => mux2.0.in0
net spindle-vfd-out mux2.0.out => hm2_7i92.0.7i77.0.1.analogout5

# --- Completion flag back to controller ---
net orient-done orient.0.is-oriented => spindle.0.is-oriented

#Error in file ./spindlecontrol.hal:
# Pin 'orient-bit' does not exist
#Shutting down and cleaning up LinuxCNC…

I replaced the spindle motor VFD, three phase outpout and the speed signal is 0-10v.
I notice that the speed varies in a random way and at say 1000 rpm, I get steps of 15 to 30 plus and minus.
The fuzzy line is an oscilloscope trace of the analogout5 pin on the 7i77.
The lower halscope trace is the same pin also nominally at 1000, offset and magnified to show what I can hear.
I have started the spindle using MDI with M3 S1000.
Any ideas what maye be going on?

I am trying to configure the spindle as a C-axis, but I am having a problem and cannot find a solution.
Could someone please take a look at my configuration and the video and give me some advice?
I was not able to post this in the original lathe thread.





#########################
# AXIS C JOINT 2
#########################

setp  pid.c.Pgain     [JOINT_2](P)
setp  pid.c.Igain     [JOINT_2](I)
setp  pid.c.Dgain     [JOINT_2](D)
setp  pid.c.bias      [JOINT_2](BIAS)
setp  pid.c.FF0       [JOINT_2](FF0)
setp  pid.c.FF1       [JOINT_2](FF1)
setp  pid.c.FF2       [JOINT_2](FF2)
setp  pid.c.deadband  [JOINT_2](DEADBAND)
setp  pid.c.maxoutput [JOINT_2](MAX_OUTPUT)
setp  pid.c.error-previous-target true

net c-index-enable    =>  pid.c.index-enable
net c-enable          =>  pid.c.enable
net c-pos-cmd         =>  pid.c.command
net c-spindle-pos-fb  =>  pid.c.feedback
net c-output          <=  pid.c.output 

# ---PWM Generator signals/setup---

268 net c-output            =>  hm2_7i98.0.pwmgen.00.value
269 net c-pos-cmd           <=  joint.2.motor-pos-cmd
270 net c-enable            <=  joint.2.amp-enable-out
271 # enable _all_ sserial pwmgens
272 #net c-enable            =>  hm2_7i92.0.7i77.0.1.analogen

276 net c-spindle-pos-fb    <=  hm2_7i98.0.encoder.02.position
277 net c-spindle-vel-fb    <=  hm2_7i98.0.encoder.02.velocity
278 net c-spindle-pos-fb    =>  joint.2.motor-pos-fb
279 #net c-index-enable     joint.0.index-enable <=> hm2_7i92.0.encoder.06.index-enable
280 net c-pos-rawcounts     <=  hm2_7i98.0.encoder.02.rawcounts

282 # ---setup home / limit switch signals---

284 net c-home-sw           =>  joint.2.home-sw-in
285 net c-neg-limit         =>  joint.2.neg-lim-sw-in
286 net c-pos-limit         =>  joint.2.pos-lim-sw-in


[AXIS_C]
MAX_VELOCITY     = 360
MAX_ACCELERATION = 500
MIN_LIMIT        = -900.0
MAX_LIMIT        = 900.0

[JOINT_2]
TYPE             = ANGULAR
HOME             = 0.0
FERROR           = 1000.0
MIN_FERROR       = 500.0
MAX_VELOCITY     = 360
MAX_ACCELERATION = 500

P        = 0.0000001
I        = 0.
D        = 0.
FF0      = 0.98
FF1      = 0
FF2      = 0
BIAS     = 0
DEADBAND = 0.1
MAX_OUTPUT = 10

ENCODER_SCALE    = -40
OUTPUT_SCALE     = 10
OUTPUT_MIN_LIMIT = -10
OUTPUT_MAX_LIMIT = 10

MIN_LIMIT = -1000
MAX_LIMIT = 1000

HOME_OFFSET   = 0.0
HOME_SEQUENCE = 1

No, Mesa 7i80 does not go with 7i77 and 7i85, the Mesa 7i92TM goes with those. 7i80 is 50 pin, 7i92 is 25/26pin.
There are other options also, the 7i77 is hard to find so a bit more searching is needed, on the 50 pin stuff i can not help, but for 25 pin stuff i used a lot, here are some options:
-7i97T it is roughly the same as 7i92TM with 7i77, with 7i85 or even better with 7i74 as this needs plain LAN cables to wire the 7i70 (48 inputs) and/or 7i71/7i72 (48 outputs sinking or sourcing), or 7i84 (32 in and 16 out)
-7i92TM (notice the M, makes it directly plugable into 7i77 so no need for IDC26 to DB25 cable and adapter), with 7i85 OR 7i74
-7i96S (step/dir and spindle) with 7i83 (analog outputs) and 7i85 (encoder and SSerial) for 7i70/7i71/7i72/7i84
-
I think there is also 7i93 IRC should have 3 of IDC26 headers, but not sure, should be same as 7i92 with more IO. Again, do double check this.

The original contoller (in the control cabinet) has 56 Inputs and 92 Outputs. 
I am going to ned an analog Output for the servos and a sin/cos (1 Vpp)u Input for the linear encoders. The servos also have some encoders on them, but these are only for the velocity.
Later i am going to need another analog Output for the spindle.

In my mind i am going to use a mesa 7i80HDT as a base for the daugthercards. For the spindle and the servos a 7i77 and for the linear encoders a 7i85, because that one can read the 1 Vss signal.
For the other I/Os i would use some 7i70‘s and 7i71‘s.

Please correct me, if i am going to make a mistake?

Hello all

I installed a 0-10v signal from my MESA 7i77 board to the vfd to control rpm and my XHC-W04B-6 pendant will enable the spindle but wont tell the spindle to turn at default spindle speed set in the ini file .  Any help would be appreciated.

Regards 
James 

This is the only thing that works smoothly for me.
# --- FEED SPEED RAPID POTENTIOMETER'S ---
#BIT direct value
setp halui.spindle.0.override.direct-value 1
setp halui.rapid-override.direct-value 1
setp halui.feed-override.direct-value 1
# SCALE
setp halui.spindle.0.override.scale 0.01
setp halui.rapid-override.scale 0.01
setp halui.feed-override.scale 0.01
# scalemax
setp hm2_7i96s.0.7i77.0.0.analogin1-scalemax 100 # spindle
setp hm2_7i96s.0.7i77.0.0.analogin2-scalemax 100 # rapid
setp hm2_7i96s.0.7i77.0.0.analogin0-scalemax 200 # feed
loadrt conv_float_s32 count=2
addf conv-float-s32.0 servo-thread
addf conv-float-s32.1 servo-thread
addf conv-float-s32.2 servo-thread
net analogin1 conv-float-s32.0.in <= hm2_7i96s.0.7i77.0.0.analogin1
net analogin2 conv-float-s32.1.in <= hm2_7i96s.0.7i77.0.0.analogin2
net analogin0 conv-float-s32.2.in <= hm2_7i96s.0.7i77.0.0.analogin0
net analogout0 conv-float-s32.0.out => halui.spindle.0.override.counts
net analogout1 conv-float-s32.1.out => halui.rapid-override.counts
net analogout2 conv-float-s32.2.out => halui.feed-override.counts

Ahh, well, so it goes. I've ordered a 7I76U because I think that the D models were actually going to be more difficult to wire anyways, as I'd like some sourcing outputs.  I'll see about getting an RMA for the 7I77D I have, and can function test the existing 7I76D when I get the new 7I92TM.  5 axis + spindle and 48 I/O pins should be plenty to get this mill up and running, and that leaves me some boards to experiment with in the future

Thanks for the quick replies, nice to keep momentum up on the project!

of course here are my files, I tried one configuration with fb that works but I still don't know in practice if it works well, definitely try it if you are able to see why this one doesn't work. thank you very much




# --- FEED SPEED POTENTIOMETER'S ---
[url=https://www.facebook.com/hashtag/bit?__eep__=6&__cft__[0]#BIT direct value
setp halui.spindle.0.override.direct-value 1
setp halui.feed-override.direct-value 1
# SCALE
setp halui.spindle.0.override.scale 0.01
setp halui.feed-override.scale 0.01
# scalemax
setp hm2_7i96s.0.7i77.0.0.analogin1-scalemax 150 # spindle
setp hm2_7i96s.0.7i77.0.0.analogin0-scalemax 120 # feed
loadrt conv_float_s32 count=2
addf conv-float-s32.0 servo-thread
addf conv-float-s32.1 servo-thread
net analogin0 conv-float-s32.0.in <= hm2_7i96s.0.7i77.0.0.analogin0
net analogin1 conv-float-s32.1.in <= hm2_7i96s.0.7i77.0.0.analogin1
net analogout0 conv-float-s32.0.out => halui.spindle.0.override.counts
net analogout1 conv-float-s32.1.out => halui.feed-override.counts


youtube.com/shorts/Htwi7ruTzAQ?si=xwU-Dm2b8Pwv2qeN 


 [/url]

Non-existant user wrote:

PCW wrote:

First, is the a 7I92M or 7I92TM?
 
This is old machine, so it's probably an old board, so it's probably a 7i92M (sans "T").

Just for future reference, the age of machine will have no bearing on whether it's a T or sans T. It will depend on the period the card was bought. History will show the the Spartan 6 FPGA was hard to get at one stage, hence the switch to the Trion device.

In real life, despite what the "maker community" will tell you, a capacitor isn't the end all and be all. Also you'll really need to know the load current,ripple and frequency for determining the capacitor reqired, which will differ from application to application, just mentioning this as a PSA.
What is the best option is a quality PSU, yep a bench PSU is great for testing, a genuine Meanwell or Weidmüller (depending on where you are not as easy to get hold of and a little more $$$) supply wont let you down once installed, I only mention these as these are the ones I've been using for eons, all DIN rail mount. I usually switch the computer PSU on, then the MESA boards PSUs, then the stepper power and finally the servo driver for the spindle. To tell the truth with all the relays (self latching) and stuff the PSU wiring was way more complicated than maybe what is should have been. But each circuit controlling the mains is independently controlled.
Regarding powering the 7i77/7i776 or any other DB-25 daughter I've been powering mine(7i76/7i74/7i73/7i83)by the DB-25 connector, found it to be a simple and solid solution. The 7i73 & 7i83 are also powered by the smart serial cable via the 7i74.

I will try today the potentiometers for feed and spindle, I noticed when I opened the panel that this is not ``mpg'' but the same potentiometer:)..its power supply is connected to the power supply of the potentiometer for feed and speed and its mass is connected to the physical buttons jog+ and jog-..it probably had some logic in the plc of the old controller, I will have to replace it with a class mpg of 100ppr it seems:)

thank you very much, I will try this tomorrow related to hal file, this is an example for a spindle, I believe it is similar for feed? I also need information on where this file should be located, in which Linux folder ``hist.comp``? and do I need to add any line to the ini, except halfile=...

  #SE USAN CON LOS POTENCIMETROS DE OVERRIDE PARA QUE AL ENCENDER LA MAQUINA MUESTRE EL VALOR CORRECTO DE LA POSICION DEL POTENCIOMETRO

loadrt hyst names=hyst.feedpot,hyst.SPDLpot
loadrt mux_generic config=fs2,fs2

#SE USAN CON LOS POTENCIMETROS DE OVERRIDE PARA QUE AL ENCENDER LA MAQUINA MUESTRE EL VALOR CORRECTO DE LA POSICION DEL POTENCIOMETRO

addf mux-gen.00 servo-thread
addf mux-gen.01 servo-thread
addf hyst.feedpot servo-thread
addf hyst.SPDLpot servo-thread

# --- OVERRIDE SIGNALS ---

# --- ANULAR VELOCIDAD DE AVANCE Y DEL SPINDLE ---
# ----BIT DIRECT VALUE

setp halui.feed-override.direct-value true
setp halui.spindle.0.override.direct-value true

# ESTABLECER ESCALA DE CAMBIOS DE LA ANULACION DE AVANCE Y SPINDLE

setp halui.feed-override.scale 0.01
setp halui.spindle.0.override.scale 0.01

#

---

OVERRIDE AVANCE

---

setp hyst.feedpot.gain 0.05
setp hyst.feedpot.deadband 0.7
setp hyst.feedpot.step 1
setp mux-gen.00.in-float-00 100

setp scale.1.gain 60.61 # ESCALAR LA ENTRADA ANALOGA DE AVANCE OVERRIDE, VALOR ANALOGO 200/3 VOLTIOS = 60.61
setp mux-gen.00.in-float-00 100 # ESTABLECER EL VALOR DE AVANCE OVERRIDE EN 100% CUANDO SE APAGA LA MAQUINA

net analogin0 scale.1.in <= hm2_7i92.0.7i73.0.0.analogin0
net feedpot-raw scale.1.out

net feedpot-raw hyst.feedpot.in
net feedpot-hyst hyst.feedpot.out mux-gen.00.in-float-01
net machine-is-on mux-gen.00.sel-bit-00
net feedpot-mux mux-gen.00.out-s32 halui.feed-override.counts

#

---

FIN OVERRIDE AVANCE

---

#

---

OVERRIDE VELOCIDAD SPINDLE----

setp hyst.SPDLpot.gain 0.05
setp hyst.SPDLpot.deadband 0.7
setp hyst.SPDLpot.step 1

setp scale.2.gain 60.61 # ESCALAR LA ENTRADA ANALOGA DEL SPINDLE OVERRIDE, VALOR ANALOGO 200/3 VOLTIOS = 60.61
setp mux-gen.01.in-float-00 100 # ESTABLECER EL VALOR DE SPINDLE OVERRIDE EN 100% CUANDO SE APAGA LA MAQUINA

net analogin1 scale.2.in <= hm2_7i92.0.7i73.0.0.analogin1
net SPDLpot-raw scale.2.out

net SPDLpot-raw hyst.SPDLpot.in
net SPDLpot-hyst hyst.SPDLpot.out mux-gen.01.in-float-01
net machine-is-on mux-gen.01.sel-bit-00
net SPDLpot-mux mux-gen.01.out-s32 halui.spindle.0.override.counts

I think the tricky part  with feed override and spindle speed override
is to get along with the GUI