So, I did think a bit and decided to actually go on with a change to LinuxCNC. Thanks for the replies helping me to decide in that way.

I think I will try to leave the cabling in the machine mostly untouched, but completely remake everything in the electrical cabinet.

For many of the open questions I will probably stick closely to what Rotary did, as most of the design decisions were considered by this whole forum, and the pros and cons have been carefully considered. With that, I don’t see much of a point in redoing this myself.

I will update here now and again, but only with stuff specific to my project.

With this I will definitely change the Z-axis motor and driver. I do have a Chinese AASD driver from an old project that never happened.
It’s a 1 kW motor, so definitely overkill — but it is already there, so it will work.

One other thing: in the toolholders I got with the machine there was one that does not fit the machine. See picture.
If anyone has a machine that needs this style of toolholder, or knows someone who does, I would be happy to give it away.


 

Hi

This morning I was running v2.9-238.315 and later tested with v2.10-009.072. The issue was present on both versions.

I continued testing and the problem only occurs with o=1 and o=2 magic comments.
o=0 was always working correctly and did not cause any issue.

With o=1 and o=2, the material was written to the *_material.cfg* file, but QtPlasmaC showed a parameter error and did not update the material list. A restart of QtPlasmaC was required for the new material to appear.

I found the cause inside the function rewrite_material_file() in qtplasmac_gcode.
The code checks material_reload like this: But on my installation, this command returns: Since TRUE cannot be converted to int(), a ValueError exception is raised.
This stops the reload process, which leads to the UI not updating and to the misleading “parameter missing” message.

I applied a workaround that accepts both 0/1 and TRUE/FALSE strings:
After this fix:

* o=1 and o=2 now correctly create or update materials
* the UI refreshes immediately
* no more incorrect popup message
* no restart of QtPlasmaC required
* o=0 continues to work as before

I also added a local improvement: after a new material is created, it is automatically selected as the current active material.

If needed, I can provide a clean patch and test G-code examples.
I am also available to run additional tests if required.

I have attached to this post the NGC file I have been using since this morning.
The temporary example file was not working either, except when using o=0

Thanks

So it's a mystery, Your hal/ini files work for me.
(after changing to 10.10.10.10 IP address because that's how my test PC is setup)

Do you always get this error:

hm2_eth: ERROR: Could not retrieve hardware address (MAC) of 192.168.1.121: Resource temporarily unavailable

That happens before any joint/axis ini settings are processed and is only related to low level communications.

You can sometimes get this error after power cycling if the network link is not established yet, so could happen in testing
but is not in anyway related to the number of axis.

 

That is just a list of error codes produced by the Fanuc control. I have a working converter for the 4-wire, low speed (1.024 mbit/second) encoders. I am now trying to decipher the 2-wire, 2.73 mbit/sec encoders. I have been able to trick an encoder to start responding by flipping switches on a pulse generator. But, I tried to set up an FPGA to get the encoder to respond, and I get NOTHING!
So, these encoders apparently need a different command to select the mode before it will respond.
Jon

Those are the thermal overheat switch, which with that wiring will cut power to the main VFD in the case that the brake module overheats. To test it, that connection is not necessary.

One thing I didn't notice in the vid or the thread discussion is that there is a separate manual for the braking module.  It's referenced on page viii (Part G - 11) of the VFD manual.

The braking module manual shows a "T1" and "T2" connection on the module.. but those aren't shown in the main VFD manual.

Based on the diagram, I suspect those need mains power to 'activate' the braking module.

I'm sure there are some parameters to change as well, but this might be a possibility.  Maybe have a look?

And yes...dogshit manuals.

 

You can direct connect to via the AC Servos via a special cable through USB and their software: www.dmm-tech.com/resource-center

The 7I92 does connect via eithernet. I believe the reason for purchasing the dual board setup was to make sure there were enough axis controllers available for eventual expansion via rotary tables and things like that, as well as the appropriate spindle control for the mill.

It is a 7I92M as per the screen printing on the board and the sticker on the back.

I did check the 5v power and it appears to be getting a very solid 5v, but I will power it independently to double check in case there is some form of low voltage immediately at power on.

Appreciate the help, I'll start the RMA process with Mesa.

Edit: Oh, and I'm assuming I should be able to configure the 7I76 / 7I77D appropriately to be powered via direct 5v and look at the lights to confirm those boards function as well? The manual is a little sparse on what the different LED patterns indicate.  

Not, it's the same

Is the card IP address different in the 5 Axis configuration?

First, is the a 7I92M or 7I92TM? these need different firmware and recovery is
done differently.

On a 7I92M, what is expected to happen at power up is that both red LEDs will
turn on briefly and then go out. If the /INIT light never goes out (even for a fraction of a second)
at power up, its likely an issue with the 5V power so first check the 5V power.

Also on a 7I92M, if the /INIT light blinks of briefly at power up and then re-illuminates,
this  suggests corrupted firmware or some other card issue which probably requires
returning the card to Mesa for analysis/repair/replacement.

 

Hallo,
ich brauche mal einen Tip bezüglich der custom postgui hall.
Ich möchte die Maschinenspindel extern über einen Taster ein bzw. wieder aus schalten. Im Moment mache ich das mit zwei Tastern. Einen für EIN und einen für AUS. Dabei wird ein MDI Befehl auf der Axis Oberfläche angestoßen. Ich weiß das es mit der Funktion Toggle möglich ist, nur einen Taster zum EIN und AUS schalten zu benötigen. Funktioniert das auch bei MDI Befehlen?
Gruß Andreas

Pick your excuse :
1/ That requires more effort than my inherent laziness allows
Everything is already in there.

2/ I don't see a deal like that. The best deal offered here for a 5KW servo and driver from AliExpress is at least €1000, so will cost more like €1500 delivered, with tax and customs.

3/ I only have 16A feed at 400V. The required supply varies, but those 5KW servo drivers seem to require supplies which can peak above 20A.

But it is basically what Schaublin did on the follow on 125-CCN model. Since my collet closer limits the spindle to 3000rpm, a 1:2 reduction to the spindle would work, as those servos seem to be 6000rpm.

thank you very much, I really appreciate it