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1

Galil / Phantom Limits, Galil error 22

« on: March 05, 2012, 07:57:21 PM »

Please help me.  I'm so close. 
I'm having problems with phantom error switches.  I have only three limits switches.  One per each (X,Y,Z) axis, the positive (+)limit switches.  I've checked these boxes to set up Mach3:
1)to use limits as homes
2)Disable amplifiers when in E-Stop
3)Config Galil Limits active low
The limits mounted are NC switches that one end is attached to the neg/ground (-) of a 5.0VDC power supply, the other end is connected to FLSn (n=a,b,c,d) , pins #36,37,38,39 of the Galil  I/O (A-D)breakout board (BOB).  The power supply’s positive (+) terminal is connected to the LSCOM (pin #6) of the same Galil I/O (A-D) BOB.
Tripping any of the switches or disconnecting any of the wires from the BOB (FLSn, LSCOM) or from the 5.0VDC power supply gives me a limit switch error.  The RESET “LED” in Mach3 flashes… the alarm goes off every 4 seconds or so…and the Status line says Limit Switch Triggered.   Hitting the history button indicates the same “Limit Switch Triggered” 9 times per second until the switch is released or the wire is connected.   This, to me, seems correct.
I don’t have a clue what I’m supposed to do with ports and pins in Mach3 and have left everything there blank.
Jogging any of the motors (X,Y,Z) in the positive (+) direction works fine, unless/until I hit an actual switch.  They could be smoother but I haven’t tuned them yet.  The DRO also indicates the correct direction and amount of movement.
I am unable to jog any of the motors (X,Y,Z) in the negative (-) direction at all because of the phantom switches.  The motors don’t move a bit.  Touching any of the negative jog (-X,-Y, or -Z) buttons causes a Galil Error 22: Begin not possible due to limit switch.  “Emergency mode Active”.  The error doesn’t sound an alarm like the physical switches nor does the history repeat anything nine times a second just the one line… Galil Error 22: begin not possible due to limit switch.  It’s as if there is(are) a negative limit switch(es) present and triggered.
Does anybody know how to tell either or both the Galil DMC4040 and Mach3 that there are NO neg (-) limit switches.  At this time the soft limits are set at 100 and -100 for all axes.
I would post the debug file if someone would tell me where it’s hidden. 
Thank you for any suggestions.

2

Galil / Three stupid questions

« on: February 20, 2012, 12:50:40 PM »

Hello all,

Please help if you can.

I'm trying to get a DMC-4040 with integrated amps and Mach3 and my mill to play nice together.  A month ago I gave up on the power supply and amps that I was hoping to reuse and sent my control back to Galil to have amps installed and firmware updated.  At that time the encoders worked and the limits notified me if I hit them, but no motor action at all.  Basically a manual mill with DRO.

I've been through a month of eBay hell but now have the power supply mounted and ready for action.  The DMC-4040 is ready as well.  I've turned it on and some things work and others don't.  It seems like my motors go the wrong way but weird also do my encoders now (they didn't before) and I'm getting error 22 which is a limit fault but I'm no where near any of them.  The motors cage but not strongly as I would like.

So hear goes with the questions:
1)  Where is the debug file hidden?
2)  Should I tune it now or wait until I resolved a few issues.  I've never tuned a servo before and have no idea whatsoever is involved.  I've read that the first step I supposs ed to do is tune the dc servos.  This seems wrong to me as I have errors go off as soon as its turned on.
3)  Does Mach3 have a screen or window or command line I'm supposed to use to set certain Galil parameters?  I've been using the Galil tools lite thus far for setting  things like motor peak amps.

3

Galil / Galil dmc-4040 3-axis and/or 4th axis

« on: February 02, 2012, 01:46:56 PM »

Hello all,

I have what should be easy questions for somebody.  I want to... in the near enough future add a horizontal rotary table as the 4th axis but it will only get used very, very infrequently.  I have a table that still needs converting so I really don't know yet for sure what kind of amp or motor yet.  When I do have it ready I don't intend to leave it "hooked up".  All I have is the one bed mill with one computer (Win 7) and one Galil.  Should/Can I set up just one "profile" to include the 4th axis or  should I set up two Mach 3 profiles, one with 3 axis's and one with 4 axis's?  If its set up for 4 axis and the 4th axis isn't there (unplugged), does Mach3 and Galil still work like a normal 3 axis or does it error out?  If I do need to set up a second "profile" how do I do it?  To be more specific, I have a DMC-4040 motion controller with built in amplifiers.  I need to tell the Galil what axis's are brushed or brushless, Amp Gain, Peak Torque, continuous Torque, etc.  etc. etc.  If I do it through Galil Tools I think it sets the board itself one way and only one way.  Is there a way to set these parameters differently through the Mach3/Galil plug-in for each "profile"?  I would strongly favor not having to leave the rotary table connected or having to reset the parameters each time I change back and forth even though it would be very infrequent.  

4

Galil / Galil DMC-4040 Anilam analog amps and DC servos

« on: December 09, 2011, 11:18:23 AM »

Hi guys, I’m sorry for the length.  Please read and help if you can.  Please tell me if this is the right place to post this as well.  It might be more of a general question.

I’m converting a Fryer MB11 bed mill with a dead Anilam 1100M control to Mach3.  I was considering updating it to Mach3 prior to it dying anyways.  Then it died unexpectantly and I was not able to map out the wiring and what makes it tick while it was working.   I’m reusing as much as possible.  So that means DC servos and Anilam’s amp boards.  I bought a Galil DMC-4040 Accerera motion control off of eBay.  The Galil is connected via Ethernet port to an almost new touchscreen computer running Windows 7 64bit. Basically a computer built onto the back of a monitor.   I’ve loaded the software and add-on and seem to have that worked out.  I might/probably need to do some configuring yet.  The limits and the encoders work.  I have what amounts to a manual mill with DRO.  I can’t “turn on” the servos then yet “move” them.     I don’t know what the conventional terms are, so… before the Anilam died when I reset the servos they would power up in a way that held the axis’s stationary.  I’m going to call that “turn on” IF after that, it received a movement command THEN it moved.  I’m going to call that “move” ” or “moving”. 
The parts that were reused are a relay board, a power supply, three Anilam analog amp boards, and three Anilam 37000117 DC servos.  I know I have something wrong with the wiring and or the configuring and or the operation of Mach3.  The power supply is just a bridge rectifier (BR) connected to a big capacitor,  Two wires (115VAC) feeds the BR then two wires feed the capacitor and then out of the capacitor comes 12  thinner wires to feed the  amp boards.  Six wires come out of each of the two screws on the capacitor, two positive and two negative wires to each amp board.   All amps and motors are wired the same.   In addition to the DC “in” wires the amps each have four thin (2 of each) DC “out” wires going to the motors from the same amp wire plug/harness (J4).  Also there are five wires to the (J1) plug/harness.   Two thick wires (white and light green) go to the motor, two more (red and black) for what I think are the +-10VDC  that used to go to the Anilam motion control board that now go to the Galil.  The last wire (blue) is jumpered to all three amps and back to the relay board.  None of this wiring other than the two I think/hope are +-10VDC have changed.  There were no wires added or removed from the amp board or the servo.  A couple of wires from the relay board to the old Anilam motion control board were removed however.  This might be where my problem lies as well.  The blue wire that is in series to all three amps goes to ground unless the relay is powered up and its normally closed contact is opened.  The same 24VDC power that opens this contact also activates another relay which in turn sends the 115VAC to the bridge rectifier that feeds the amp.  This 24VDC for the relay is where I was planning to use a eStop switch.   When I supply power (115VAC) direct to the power supply (BR and capacitor) all three amp board’s error LED light up instantly.  When I supply power to the power supply and disconnect the ground that normally faults the amps (blue wire) on the amp board by applying 24VDC to the relay board something weird happens.  The output from the relay board which should be 115VAC as well as the DC into the amp board varies.  It gets so far and “resets”.  When nothing is connected the out  from the activated relay board is 115VAC.  When everything is connected the output is "reduced” to around 22VAC and then climbs to around 38.3VAC, ramping up fast at first and slowing down as it goes up.  When it reaches 38.3 it resets back to 22 and starts all over again.  It might go all the way to zero but it climbs real fast at first and the first readout on the meter I can read is 22VAC.  It’s the same thing on the DC side of the power supply only with DC.  At 38.3vDC  I see the fault LED on the amp card flash then it resets back to 22 (again it might go all the way to zero) and climbs back up to 38.3VDC and resets again.  Clearly, the fault is what is causing the reset.  Don't know why or what to do yet.  I also don't know if I have everything setup right in Mach3.  It doesn’t seem to be putting out any kind of signal.   On the wires that should be putting out +-10VDC.  Another very possible reason may just be my operation of Mach3.  I reset, hit the tab button bringing up the jog screen and hit the +X,Y,orZ.  It should move 1.0”.   Other buttons pressed after that say something like “can’t perform during move”.  The Galil has firmware 1.0A.  I did a master reset on it last night just to make sure the memory was clean.  Has anybody reused Anilam amp boards and DC servos and made theirs work?  How does one get the servos to “turn on”?  “Move”?  Is the output supposed to vary?  Any suggestions would be great.  I’ve run out of possible reasons. 

5

Galil / Galil plugin configuring

« on: December 08, 2011, 05:24:22 PM »

Hi all,

The worst part so far has been trying to get my computer and Galil DMC-4040 to communicate with each other.  After that questions and minor problems but nothing much.  Presently Mach 3 recognizes the limits and encoders so in effect I have a manual mill with DRO.  I can't seem to get the servos to turn on or move.  I think I may have the Plugin configured wrong, or not at all.  I went through the manual and remember setting things the first time but might not have hit apply or save.  I can't find the any of the screens that are in the manual.  I especially want to see what kind of motor Mach3 "thinks" I have.  I think that's where my problem lies.  I usually don't have problems installing programs and getting stuff to communicate but really dread uninstalling anything after the nightmare I went through the first time.  Do I need to uninstall and then  install everything again or is there an easy way?

6

Galil / Wiring Limits

« on: October 06, 2011, 02:42:53 PM »

Can someone please clear up a few questions I have dealing with wiring and configuring the Limit switches?  Hi, I'm new to this stuff in all ways possible.  I'm usually pretty good on this sort of thing but find myself confused right at the beginning.  I'm converting a Fryer bed mill from an Anilam control to Mach 3.  I have a Galil DMC-4040 Accelera controller.  I'm currently trying to hook everything up.  I am trying to reuse as much as possible and while more bells and whistles are nice and some are very possibly future additions, I only right now need a pretty basic setup.  It’s a three axis bed mill with all three axis's having identical servos, amps, encoders, and limit switches.  I have everything mounted and now have to wire the limits.  Galil allows the power for the switches to come from either the controller itself or from an external source.  The question is why is it suggested to use an external source?  It seems to be just another thing that can go bad.  I have a power supply handy and can mount and wire it but why should I?  It seems greatly simplified just to use the onboard Galil +5v.  Currently I have only one limit switch per axis, the forward (+) limit.  There is a box to check for configuring of the Galil Plugin for Mach 3 that allows using the Limits for Homes.  So the second dumb question is which Limit switch does it choose for the home?  I think I can assume it’ll choose the forward (+) switch as that is probably convention but I would like to confirm that as I don’t have reverse (-) Limit switches.  This leads me to another question…if I don’t have a reverse (-) Limit switch what do I do?  The switches are normally closed so if it thinks I have a reverse Limit switch it would think it’s tripped and fault, right?  Do I just jump the RLSx to the ground or is there a way to tell Galil and Mach 3 there isn’t a switch in the first place?  My final question of the day involves what might be just wiring vs. configuring.  For wiring I was going to wire the pos (+) wire from whichever source to the LSCOM (#6), the ground likewise from whatever source to one end of the switch, and finally the other end of the switch to FLSx(#36,37,38,39).  But in the manual All use port #1:  X +limit = pin #1, Y +limit = pin #2, and Z +limit = pin #3.  What is this about?  I’m still in the wiring stage and it may just be a configuring (ie later) step.

Thanks to anyone that can shed some light on any or some or all of these questions.

7

Galil / get a Galil DMC-4040 to "talk" to the computer

« on: September 04, 2011, 08:12:31 PM »

I guess I'm not very computer literate.  I though this was going to be easy.  Please help me get a DMC-4040 to communicate with the computer.  I believe that's the first step.  I have a Windows 7 64bit computer that I want to run Mach 3 on, via Ethernet to the Galil DMC-4040.  I'm converting a Fryer MB11 bed mill that the Anilam control died on, to Mach 3.   I would rather not use a router or switch or whatnot, just one computer, one crossover cable, and one Galil.  The computer is only for the mill and will remain attached to it.  It has wireless connection for internet, so the RJ45/Ethernet port/jack is for the Galil and only for the Galil.  I have the DMC-4040 connected to the computer with a crossover cable and powered up.  The Link/ACT and power LEDs are solid and the error lite is off.  The computer 'knows' something is attached but has it as an unidentified network.  When I start Mach 3 an error comes up as "Galil card not connected".   Galil's Smart Term gives this error message "DMCShell error, error code=-3.  Controller could not be found in Windows Registry".  When I try the Galil lite program and hit the connection button sometimes there are two choices, sometimes 3 choices.  When the third choice comes up, its light grey and I don't know if that the color its supposed to be or if its indicating a bad link.  The first two choices are wrong but usually only after clicking on either of them does the third choice show up.  Sometimes its there from the start.  Clicking on either of the first two choices gives this response: 

1011 TIMEOUT ERROR. Galil::command("") took longer than 500 ms to read : response.
OFFLINE: 

Once the third choice shows up (192.168.0.2) and I click on it, it gives this response:

5004 OPEN ERROR. Galil::Galil() failed to open Ethernet host 192.168.0.2
OFFLINE:

What am I doing wrong?  I know I'm not Mr. Computer but I didn't think I would be clueless.  Can someone talk me though the steps to connect a Galil DMC-4040 to a Win 7 64 computer.  I am totally willing to uninstall everything and start over.  I have only dial up for the next 3 days though.

8

FAQs / convert retofit Fryer MB11 with Anilam 1100M

« on: August 12, 2011, 01:18:00 AM »

Hello,

I'm just a DIY'er, not a business or anything like that, so my (or that of would be employee(s)) life and/or livelihood doesn't depend on quick or even unquestionable opinions...just what's left of my hair and my sanity.   I have 2 broken mills; the second just died last week.  I bought the second in response to the first dying and was kicking around the idea of either selling it as a manual machine or converting it to mach 3 which I thought might take some time and considerable effort.  I found a decent machine at a reasonable price and bought it.  I used it a few times and winter comes, so my shop (garage) gets crunched down and in effect becomes all but unusable until late spring so I can park my truck inside.  The “extra” mill didn’t help any.  I use it a few more times and it dies to.  The mills are in good shape but lack working/operational CNC.  So... buying a CNC machine and having the controls die and thus considering selling it for a loss on eBay (or what not) as a manual milling machine would be a hit to say the least; but it wouldn't be the end of the world.  Two machines however, are unacceptable.  So, at the very least: the time to learn, mistakes, headaches, etc. are now divided by two machines.  What little research I've done points me to Mach 3.  The servos work and would like to reuse them if possible/practical.  I already have a computer to use.  I'm currently heehawing between the Galil 41x3 and the DSPMC for the motion control card.  I haven’t completely ruled out others and am very open to suggestions.  I believe that a working CNC machine far out values a non-operational and thus manual machine, so much that if done correctly would be cost beneficial.  The “extra” machine in my shop would sell faster and for more.   I don’t think I would make much if any but that by far out ways losing money on it.  As far as the one I keep for myself, it would just be the better.  I’m not against saving money but if I’m going to do it I want to do it right, within reason of course.  If the servos need to be replaced then they will.  But for simplicity and cost I would prefer to use them.  This last winter I’ve been a regular “guest” here and as such have seen some really good advice offered.  So here I am looking for some advice as well.  The first fork in the road is controller with the servos being the major factor.  The servos in question are Anilam model 37000117 DC servos.  Torque 31.25 in. lbs.,  Max volt: 200,  Peak amp: 30.8,  Cur.A.: 6.18,  Res. Ohms: 1.5,  Ind.min.: 6.8,  SEMF-V/1000rpms: 60.0,  Nax rpm: 2400,  Tach-V/1000rpm: 9.56,   JA-LB-in-sec2: 0.000063.  Ant advice would be greatly appreciated.  If I use the existing servos, which motion control board do I choose?  If I go with different servos then which MC do I choose?  What amp is best?  I want to use servos and control them via Ethernet.  Thank you in advance!