Machsupport Forum

Mach Discussion => General Mach Discussion => Topic started by: bingart on January 04, 2012, 08:50:11 PM

Title: Newbie needs help with Z-axis error codes
Post by: bingart on January 04, 2012, 08:50:11 PM
I'm new to the world of router tables and I just recently purchased a used 6 X 10 Precix Router table. The controller had just been replaced with an Ajax ALLIN1DC and the software is Mach3. The guy I bought it from had just replaced the ball screw because of a crash that he had in trying to set up this new controller and software. After waiting months for the part he lost interest and sold the thing to me as a project. I've been able to get everything fired up and working but had some issue I need your help with. I was able to get everything moving on the X, Y and Z axes briefly but when trying the Z everything stopped working and the error code "Axis Z Encoder Error" came up. I hit "Clear" and then "Reset" and was able to get the Z to move again briefly and then the same error message came up but this time I was no longer able to clear the error and get things to restart. I also have a scrolling error near the Reset button that says "Press Reset...Emergency Mode Active". Also I have a flashing yellow button that says "Abnormal Condition" and when I click on it the message comes up saying "One or More Axis enabled or disabled". I have no doubt these are all related and pointing to something. I just need your help to get this resolved. Thanks in advance for your input!
Title: Re: Newbie needs help with Z-axis error codes
Post by: Hood on January 05, 2012, 03:10:47 AM
It all seems to stem from the Ajax control throwing an encoder state error, what exactly that means I am not sure, it could be noise on the encoder lines giving bad feedback, could be the encoder is not being seen at all, could be just your tuning of the motors.
Really you need to talk to Ajax as the message re encoder is generated by their plugin so hopefully they can point you in the right direction.
I d seem to recall someone else with a similar message, from an Ajax setup, posted a year or so ago, cant remember what the outcome was but maybe a search of the forum would find something.
Hood
Title: Re: Newbie needs help with Z-axis error codes
Post by: bw on January 05, 2012, 05:22:45 PM
"Press Reset...Emergency Mode Active" usually comes on when the e stop or reset is hit.  "Abnormal Condition" pops up from time to time when a config change has been made, no big deal just ignore it or reset it.  As for you encoder error, as hood said noise, motor tuning, not wired right, things like that could cause it.  You might want to try going in to the Ajax plug in config and "turn off the stop on encoder error" until you get it dialed in.  You might also try switching the encoders with another axis and see if it faults there too.  The chances of getting any prompt (if any) reply from Ajax are almost impossible, the Ajax forum does have some good info on it you may also want to read.

Good luck!
Title: Re: Newbie needs help with Z-axis error codes
Post by: bingart on January 06, 2012, 05:55:38 PM
Thanks for all your help. I've turned off the "stop on encoder error" and have the axes moving again, although they are moving very slowly. Do you have any direction you can give me on what might cause them to do that? Should I just continue on with motor tuning and see what that resolves? Thanks again (hood & bw) for your input!
Title: Re: Newbie needs help with Z-axis error codes
Post by: Hood on January 06, 2012, 06:19:04 PM
Have a look at this thread, I did a search as I was sure a similar problem had been posted before. Maybe it will help http://www.machsupport.com/forum/index.php/topic,13968.10.html

Hood
Title: Re: Newbie needs help with Z-axis error codes
Post by: bingart on January 06, 2012, 06:24:57 PM
Thanks Hood, I contacted KiloOne and he sent me the file mentioned in his post. I'm now trying to figure out how to install the thing. It's a .rar file and I'm not familiar with how to proceed. Any help would be much appreciated.
Title: Re: Newbie needs help with Z-axis error codes
Post by: Hood on January 06, 2012, 06:27:16 PM
rar files are just like zips. I think you can download winrar free, at least you used to be able to.
Hood
Title: Re: Newbie needs help with Z-axis error codes
Post by: bw on January 07, 2012, 06:51:09 AM
Check your velocity and acceleration settings in motor tuning.  Also check the LED status on the allin1dc, there are several that may help you to determine what the issue might be.
Title: Re: Newbie needs help with Z-axis error codes
Post by: bingart on January 07, 2012, 09:52:33 AM
Thanks bw, Is there a standard or recommended velocity and acceleration setting to use? I was going to go into the motor tuning this afternoon and take a look at that. On the allin1dc the led1 is the number "1" and it is not flashing. What might that mean?

Thanks, bingart
Title: Re: Newbie needs help with Z-axis error codes
Post by: Hood on January 07, 2012, 10:21:38 AM
Velocity in Mach for a servo system is a known quantity (assuming motors are sized correctly) as you know the max rpm of the motors for the voltage you are supplying them and you also know the amount of revolutions of the motor to 1 unit (Inch or mm)

Acceleration is a case of trial and error as it will depend on the setup you have, axis weight, motor power/torque, gearing etc.

With servos you really need to tune the motors/drives first though before you start setting up the settings in Mach, your drives normally have software to allow you to do that although older hardware it was done via trimmers on the drive/Amplifier.
Hood
Title: Re: Newbie needs help with Z-axis error codes
Post by: bingart on January 07, 2012, 03:14:58 PM
Thanks Hood, I do have a servo system. Where do I find the motor size, voltage and rpm info? These are probably stupid questions but I'm new to all of this so please bear with me!
Title: Re: Newbie needs help with Z-axis error codes
Post by: Hood on January 07, 2012, 04:42:49 PM
You should get all that info on the motors plate or the manual you got with it (if any)
Hood
Title: Re: Newbie needs help with Z-axis error codes
Post by: bw on January 07, 2012, 06:20:59 PM
When tuning with the ajax system and mach you want to set the velocity at 120 and the acceleration at 10, also make sure your encoder steps per are entered correct  Once you start getting them dialed in you can change the velocity and acceleration as needed.
Title: Re: Newbie needs help with Z-axis error codes
Post by: bingart on January 09, 2012, 10:32:28 PM
Thanks Guys,
  I was able to spend some time on motor tuning and have had some success. I have all axes moving well at slow jog but am unable to get the fast jog to work. I've spent a bunch of time searching the forum and have found some similar issues but haven't read any clear resolution to the problem. My shift key is not overriding the slow jog. When I use the shift key and press any of the arrow keys nothing moves, as soon as I release it the slow jog starts right up. Is there something in my setup that I'm overlooking that is making this not work. What things do I need to setup to make this work? Thanks again for your help!
Title: Re: Newbie needs help with Z-axis error codes
Post by: bw on January 10, 2012, 06:41:07 AM
Hate to tell you this but fast jog does not work with Ajax.  There have been many posts about on the Ajax forum, fixes that are supposed to work but don't and as far as I know nobody has had any success.  I wouldn't hold my breath on them doing anything about it either.

If you have your motors tuned set your velocity and acceleration where they need to be and when you jog just cut the speed down in Mach with the % on the mpg screen.  It's a PIA to do every time but it will work.
Title: Re: Newbie needs help with Z-axis error codes
Post by: Hood on January 10, 2012, 06:50:23 AM
Do MPGs work with the Ajax? If so I would highly recommend. Wouldnt be without them on my machines, wind fast and it jogs axis fast, wind slow it jogs slow, change to multi step mode and it will move precisely per click.
I never use the jog keys on an of my machines.
Hood
Title: Re: Newbie needs help with Z-axis error codes
Post by: bw on January 10, 2012, 08:12:37 AM
Not sure Hood, I don't use one.  I know Ajax sells them but the prices are crazy. I have thought about trying one of the less expensive versions I have read about on this site but have yet to get around to it.  With the lack of support from Ajax it's hard to get motivated to add anything.  Perhaps there are others on this forum who have added one and can chime in.
Title: Re: Newbie needs help with Z-axis error codes
Post by: Hood on January 10, 2012, 08:16:12 AM
I am meaning a MPG rather than a pendant, just in case thats what you were thinking as often people call pendants MPGs.
There are quite a few places sell the MPGs, normally 60mm or 80mm dia, my preference is the 80.
Hood
Title: Re: Newbie needs help with Z-axis error codes
Post by: bingart on January 10, 2012, 11:09:51 AM
Thanks for the input, I'll try that today and see how it works!
Title: Re: Newbie needs help with Z-axis error codes
Post by: bingart on January 13, 2012, 02:24:25 PM
Ok guys, I'm coming around the learning curve and boy is it a tough one to maneuver. I've at least learned that I probably need to save my old xml file before making changes or at least taking notes! Here's what I now need help with (And please remember I'm new to all of this so I need it explained the best you can):

1. What value should I use for my Safe Z? (I have 5" of travel from top to bottom if that helps)

2. I'm now getting the following error message when I hit the limit switches on each axis "Axis Position Error". I've checked each switch on the Diagnostic Page and when I click each switch by hand the yellow light comes on. For X it is the M1--, for Y it is the M2++ & for Z it is the M3++. I changed some of my Max & Min Soft limit settings and no doubt that's were most of my problems lie. I'm trying to set up a 50" X 100" table area so any input on all of those settings would be much appreciated.

3. I'm still getting the blinking yellow "Abnormal Condition" on the main page. Can you help me with this? I'm attaching my xml file so that you can see what my setting are.

Thanks again in advance for your help!!!
Title: Re: Newbie needs help with Z-axis error codes
Post by: Hood on January 13, 2012, 03:08:56 PM
I use machine coords for my safe Z and usually set it at zero or close to it, maybe -5mm.

The limits are likely correct, it will just depends on what you have set up, X is M2, Y M2, Z M3 so it doesnt really matter that you are seeing + on some and - on others.

Softlimits would normally be set as X and Y min and Z max as Zero  X and Y Max would be the travel of each axis so in your example above 50 and 100. Z Min is the travel of the Z in a negative value.

If you home to the fully positive ends of your travel put a Home Off value equal to the distance the axis is away from the fully negative travel.

Abnormal condition LEDs are a PITA, its a warning telling you somethingis not what you normally have, it may well still be correct so click on the LED and see what it says, if you think its correct tell Mach it is by double clicking on it and saying OK to reset.

Hood
Title: Re: Newbie needs help with Z-axis error codes
Post by: bingart on January 13, 2012, 03:20:23 PM
Man, that was fast! Thanks for the info. I'll try making those adjustments this evening and let you know how it goes.

Bingart
Title: Re: Newbie needs help with Z-axis error codes
Post by: Hood on January 13, 2012, 04:20:28 PM
Should have also said if you home in the fully negative values then there is no need for a Home Off value.
Hood
Title: Re: Newbie needs help with Z-axis error codes
Post by: bingart on January 14, 2012, 10:35:56 PM
Ok, I'm close to making chips I can almost taste it! Thanks to all of the help that I've been receiving I'm almost there. I've searched this forum and the manual and haven't been able to find an understandable answer to help with setting up Mach3 to control my spindle. That doesn't mean it's not out there, I just need to be able to understand it.

I have a Perske 3 phase 3 HP spindle that is powered through a MagnaTek GPD333 control and I would like to be able to control speed and CW CCW rotation of my spindle through Mach. Is there anyone that can help me with this?

Thanks again for all of the support!

Bingart