Machsupport Forum

Mach Discussion => General Mach Discussion => Topic started by: coachm on February 10, 2016, 01:07:34 PM

Title: Reference Home Error
Post by: coachm on February 10, 2016, 01:07:34 PM
We unfortunately lost a colleague who was the brains behind all our automation in our district's technology education labs and need assistance.  We had a phantom limit switch triggered during our milling process and looked for information to fix this issues.  We went ahead and wired in ceramic caps where the inputs meet the BoB. 

The problem: The machine will not recognize the limit switches when we reference home.  They do not even illuminate when manually jogged to the/past the position.
Title: Re: Reference Home Error
Post by: robertspark on February 10, 2016, 01:20:57 PM
why don't you post your XML profile file, which can be found normally in c:/Mach3/profiles/ then select the folder that matches the profile name listed on the screenset when you start mach.

You will need to call the XML file something unique or it will not upload like coachm.xml

What sort of a breakout board is it?

What pins have you wired the limit switches to on the BoB?


Did it all work before the installation of the ceramic caps (except for the phantom limit switch trigger)?

That being the case are your sure the caps have been installed correctly? 

Did you try changing the debounce setting?

Do you have a motion controller or does the BoB connect directly to the PC via the parallel port?

If you provide as much information as is possible then someone can have a go at diagnosing the issue.... I've yet to hear the complaint of providing too much information....

pictures?

Title: Re: Reference Home Error
Post by: coachm on February 16, 2016, 03:03:37 PM
How can I access the XML file?  I went into the C drive and into my Mach folder but I cannot find anything aside from a basic TXT doc that says profile.  When I open that it just says CNC Mill in it. 

Title: Re: Reference Home Error
Post by: robertspark on February 16, 2016, 03:09:19 PM
If you go into the C:\mach3\ folder,  .... Select show folder contents details, sort by filetype, down the bottom of the list should be the XML.files.... One of which should correspond to your profile name.
Title: Re: Reference Home Error
Post by: coachm on February 16, 2016, 03:15:51 PM
The XML is now attached. 

Other answers from questions that had been asked:

Breakout board is a parallel port board c10 is on it.  No motion control, direct to PC.

12, 13, 15 are the pins for the limit switches on the BoB.

We are looking into the debounce settings now since we now have our limit switches showing activation but will not stop the axis.

Prior to the ceramic caps we only had a phantom limit switch and everything was working.
Title: Re: Reference Home Error
Post by: Overloaded on February 16, 2016, 03:55:00 PM
Hi Coach,
  Are the caps 0.1 mF as recommended ?

Your XML also shows an ESS. Is that configured ?
Title: Re: Reference Home Error
Post by: geh7552 on February 16, 2016, 04:55:55 PM
The XML is configured for a ESS and Gecko 540.  You say you are using a C10 directly to PC PP. Something isn't right.
Title: Re: Reference Home Error
Post by: coachm on February 17, 2016, 08:14:55 AM
Hello,

We removed the CAPs which were .01 but and put the debounce setting at 5000 which ran the program.  We varied the range from 5000-8000 because we could not successfully run the program more than two times in a row without the phantom limit switch.  We then tried to isolate which limit switch was sending the signal by turning off the pins in Mach3.  However, it was sporadic on which one triggered it.  The program runs when all of the limit switches are taken off.  I also grounded all of the shielding from the input wires to try and eliminate any rogue signal from that. 

As far as the ESS and Gecko XML, the Middle School runs a Gecko and we are using the C10 directly to PC.  That has not helped in our troubleshooting situation.  Unfortunately the guy who built the CNC in the Middle School and rewired/worked on this one in the High School is no longer available. 

Title: Re: Reference Home Error
Post by: Overloaded on February 17, 2016, 02:02:13 PM
We removed the CAPs which were .01

I've only seen 0.1 mF recommended.
Not sure if 0.01 would be adequate.

You might check the routing of the conductors as well as the physical condition of each switch.
Vibration can trigger a faulty switch. You can simulate with gentle tapping.
Run a file "in air" with the spindle off to see if there is noise from the hi voltage and/or inverter if so equipped.

Just stuff to try.
Title: Re: Reference Home Error
Post by: geh7552 on February 17, 2016, 09:16:21 PM
It's not a question of who set it up and he's not there anymore excuse. You seem to be stuck on who to blame and NOT addressing how to correct the issue. Can't run a xml setup for an ESS and Gecko in place for a C10 and expect it to work properly. Not going to happen pal....    
Title: Re: Reference Home Error
Post by: coachm on February 19, 2016, 01:06:26 PM
Overloaded- Thanks for the troubleshooting suggestions.  We have had repeated success by turning the spindle off during the "in air" run.  No phantom limit switch errors when the spindle is off. 

Do you think switching out the proximity sensors for a physical switch would solve the problem?  Is there something else we can do instead of having to change those out?

I appreciate the ideas!
Title: Re: Reference Home Error
Post by: Overloaded on February 19, 2016, 02:00:39 PM
Is there an inverter/VFD ?

You mentioned 0.01mF caps. were installed.
I'd reinstall 0.1mF caps, check/reroute the limit wires well away from any high voltage lines, connect the shields only at one end (in the control box), make sure the enclosure and machine is properly grounded.
Noise can be a pickle to track down/isolate.
Checking motor housing and frame members to a good ground with a meter while running will sometimes surprise you (me).
Title: Re: Reference Home Error
Post by: coachm on February 19, 2016, 02:05:58 PM
We do have a VFD
Title: Re: Reference Home Error
Post by: Overloaded on February 19, 2016, 02:16:24 PM
Noisy buggers they are, most of em'.
Title: Re: Reference Home Error
Post by: coachm on February 22, 2016, 11:42:11 AM
I wired the .1mF caps in there.  When reffing home the proximity sensors will light up but not stop the jogging.  I tried to run a simple program anyhow but the phantom limit switch still triggered.  

Definitely noise somewhere so we will be continuing on the list of ideas that are in here.
Title: Re: Reference Home Error
Post by: Overloaded on February 22, 2016, 01:50:30 PM
Hi Coach,
  You mention "Limit Switches" and "Proximity Sensors".

Which do you have .... and where ?

The indicator on a prox. does not necessarily  mean that it is seen by Mach3.
Trigger all of your switches/sensors while observing their associated leds in the Diagnostics screen.
Title: Re: Reference Home Error
Post by: coachm on March 16, 2016, 01:36:15 PM
We tested all of the motors and grounds for the machine which have continuity.  The CAP's are removed now and the limit switches work.  We are still experiencing a "limit switch triggered" almost half way through the program. 
Title: Re: Reference Home Error
Post by: coachm on March 16, 2016, 02:13:12 PM
We detached the proximity sensors from the machine and tried to run the program to see if vibrations were causing the limit switches to be triggered, it did not work.  The "limit switch triggered" message came up again during the process. 
Title: Re: Reference Home Error
Post by: Tweakie.CNC on March 17, 2016, 10:52:10 AM
This discussion has now moved here http://www.machsupport.com/forum/index.php/topic,32178.0.html

Tweakie.