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Messages - truckeic

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I have searched and read several post regarding this issue. Most have VFD in play which I don't. I have the stock DC motor on my X2 converted mill. I created a Index sensor using a hall effect and magnet. I am using just one magnet. I get a Index reading in MACH3 and I can get my spindle to turn on using MACH. My calibration however is bad.  My first question would be can I trust the INDEX reading. I have ordered a handheld TACH to get a second opinion but it has not gotten here yet. Peter had a good write up on how he got his calibration and I understand the pulley settings and how it gets the analog voltage from that ratio. So i followed this procedure:
1. Initially let the spindle warm up for 10 minutes running at around 50%
2. Initially set the Max pulley speed to 1000rpm
3. In Mach3 set the speed to 1000rpm and measure the actual speed. (say 3145rpm)
4. Enter 3145  into the Max speed pulley setting
5. Set the speed to around 50%, say 1500rpm and measure the actual speed. It will probably be low.
6. If the actual speed is low, increase the  Max speed pulley setting and repeat steps 5 & 6 until the actual speed matches
But my speeds were higher not lower and could never get this too be correct.

any thoughts?

General Mach Discussion / Re: spindle calibration
« on: June 18, 2019, 07:59:50 PM »
Sorted! almost as soon as I made my last post, I found the official instruction:

"Hi Guys:

This proceedure is not in the Doc's, the reason being its likely to change at some point. What I really
woudl liek to know i show linear YOUR system is using this as the speed setting for it. The setitngs are
highly misunderstood, and many run a linearity run when it isnt necessary, and it badly affects their results.


A VFD takes an output from Mach3 to control its speed. Initially, Mach3 supposes a 1:1 linearty of the result,
which is pretty close to most vfd's in reality, they have allot of electronics in them to do this on their own. BUT
if the output is not right or not linear as output , then the result is obviously goign to be off. So the
following steps will do it right, and Id be very interested in any posts of the results.

Step 1)
Delete the linearity.dat file in your mach3 installation. The system will recreate it on next startup with 1:1
as the table. Also set the config/pulleys to pulley number 1, with a max speed of 1000, and a min speed of 0.
This means the range of commandis now S0 to S1000. ( Doesnt matter what the real speed of your spindle is, use
these numbers to start with.

Step 2)
We now need to know the max speed of the VFD's input, this is the place most get it wrong. VFDs respond,
as do frequency/analogue convertors to only a specific range typically of input vs output. SO lets figure out the top
speed expectation of a VFD..

In config/motor tuning, set the spindle axis steps/unit to 60. This means the velocity slider will now display in hz..
What we need to find out here is both the max frequency of the spindle and the clip frequency of the VFD.
To do this we now set the velocity slider to max. Youll notice it now reads the kernal frequency your using. 25000
in 25Khz for example. Apply the settings and exit the dialog.

- Turn on the spindle and set a S1000 as the speed. Measure the true spindle speed.
- Set a Speed of S950.. then S900, then S850..etc until the spindle actually slows. What will
happen on many systems is you will still get maximum speed until you lower the speed to some number..say S750..
or it may happen that the speed instantly start to slow slightly at S950..
Whenever it occurs that the spindle starts to run slower, note the S speed just prior to the slowdown.

For example, at S1000 I get a true RPM of 3000. SO the following occurs as I do the series..

S1000 -- 3324RPM
S950 --- 3324 RPM
S900 -- 3324 RPM
S850 -- 3156 RPM

SO the magic number here is S900, the last value where the spindle was at max RPM.
This shows us that using 90% of the max frequency tells the VFD to go full out.

So in motor tuning, set the velocity slider down to 90% of the max setting or current setting in Hz. ( Speed / 10 in % ).

Step 3)

Command a S1000 again, the max speed should still result. ( For higher accuracy and linearity you can repeat step 2
and vary the velocity slider to the % of the current slider position if you wish, the more you do step 2, the less change you
shoudl have to make each time. For example if it was at 21600 at this point , another run through step 2 might make you change it
to 21250.. each time the change will be less and less. )
Note the current S1000 speed and enter it in the config/pulleys as the max speed, leave the min speed to 0.

Step 4)

Turn on the spindle and seta speed of S1 . Note the speed you get and eneter it in the config/pulleys as minimum speed
for that pulley.

OK, so now we have properly set the VFD clip frequency, and the pulley min and max values. They now take into accoutn the expectation
of the VFD, and the resultant speeds at low and high end to be expected. The linearity is now considered to be 1:1 for that VFD/freq->analogue conversion.

If you have done this, please post a report of the following run..

Take max speed and divide by 10. Say max speed in pulley max is 2500, so the increment will be 250. Post for me 10 speeds..

S1 actual RPM: ???
S250 ""
S500 ""
S750 ""
S1000 ""

Using this proceedure takes allot fo the guesswork out of setting up a spindle, forces you to take into
account the VFD clipping limits, forces the setup to show you the outgoing frequency in hz of the output and should
show us a quantifiable spindle vs command relationship as a result.

Take note, this is for step output spindles, PWM is another matter, this will still work, but since the number of steps
in speed is dependent on the PWM settings, the end results may be off in a stepwie fashion if using PWM.

Non-linearity can coem from several directions, frequency->analogue conversion can be way off a linear scale,
most vfd's will be pretty close to linear if clipping is taken into accoutn as above. For my part Id appreciate any feedback
on the speed test results after a fresh setup of spindle speed using the above proceedure. Some may find their max speed
is now higher using this technique, others will find a much more linear resultant spindle speed, it shoudlnt negatively affect
anyone if done right.

Thanks, and good luck..

From here http://www.machsupport.com/forum/index.php?topic=30685.0;wap2

I followed it exactly and now have an accurate spindle running at variable speeds again :)

Will this work for a DC motor as well?

General Mach Discussion / Re: Z-axis Auto zero wiring
« on: June 02, 2019, 09:22:48 PM »
This post is quite old but wanted to see if anyone here has a idea for a touch plate that would be good for X an y axis. I have on of the cheap probes round circle type. But this thin sucks trying to use as X or y. The plate has to not be conductive on the part side. Just wondered if anyone has a good idea?

General Mach Discussion / Re: Hall Effect or Slotted Opto?
« on: May 31, 2019, 07:58:04 AM »
How accurate are these

G-Code, CAD, and CAM discussions / Newbie here GCODE 101 Help
« on: May 28, 2019, 11:55:45 AM »
Ok I am just now getting my Harbor Freight DIY CNC machine running and I have MACH3 running the machine, I loaded my first G Code file in Saturday and ran a test. It all seemed to work. I would like to know more about the G code. I have viewed many videos and understand the basics. Using MACH3 how does G52,53,54,55,56,57,58,59 work?
Fusion is putting in a G28 and I am reading this is not used anymore. What is G28 and why?

If there is a video or article that really explains this please share the link or if you can school me sure would be great.


All this, I think, goes to highlight the benefits of our forum dwelling. We all learn from each other (sometimes from the mistakes and sometimes from the explanations) and the vast pool of knowledge we have all helped to create here has made our forum what it is today.

Keep up the good work guys.


Tweakie Have read many post from you and always appreciate the input. I thought maybe you could either point me or teach me a couple things.

I am running MACH3 and right now just using Parallel port the CNC4PC C11G rev.9 board. Having issue on spindle control. I have it all working but when the BOB is not in Green status one of the Relays (relay 2) chatters and is on. This is an issue cause I am using that relay to control spindle light.
Artuo says its an ground loop, which I agree. I can disconnect my analog 12 volts from the BOB or from the aviation connector which feeds my speed control. I have a HF mill the speed board is the FC350BJ. Any Ideas?

Also, I stumbled across this post and I am having limit switch and estop false triggers. Would it be better to ground the lines from these switches to chassis or use the .1uF cap plan?

Thanks in advance

General Mach Discussion / Re: ReConfguration EStop
« on: April 18, 2019, 09:17:17 AM »
Is there any message displayed in the status bar ?
Are your limits all wired NC ?
Are you sure that an axis is not sitting on a limit ?

Well here's a weird one. I run Screenset 2010 instead of the standard Mach3 Screen (have for years). In an effort to answer your questions I Loaded the default Mach3 Screen, when it came up a pressed the Reset button and BINGO it worked. So now I'm thinking I have a corrupt Screenset 2010 screen file. Just for grins I reloaded the Screenset 2010 file and it's working fine!
I have no idea what the heck happened, but I'm up and running.

To answer your questions, yes I checked all the limit switches and non of them were active, if I pressed one of the limit switches the Diagnostic lights come on.

Anyway thanks for the help and suggestions. I'm off to make something.

Mach3 works in mysterious ways..LOL

General Mach Discussion / Re: ReConfguration EStop
« on: April 17, 2019, 03:08:06 PM »
When you go to the diagnostic page do you see the light for estop coming on/off when you push or reset the estop.

Sieg Machines / Re: C11G board wiring on KX1
« on: April 10, 2019, 11:55:44 AM »
So what motor control board are you getting. the same one on a x2 mill?

General Mach Discussion / Re: Another C11G spindle Control issue..
« on: March 28, 2019, 11:02:41 AM »
Yea thats the issue. I am getting like 30 mv out which ain't going to drive the motor. But Artuio says the light on pin 14 should get dimmer as speed goes down and get brighter as speed goes up. This is working so looks like I got the software correct. Just no DC voltage.

Please download the manual for C11G.

If you can get Mach3 to change analogue voltage from 0 to 10,
using M3 SNNNN command, you can wire the 0 to 10 volts between the ground and the wiper of the Potentiometer - if you already have a speed controller with Potentiometer.

e.g. M3 S24000 gives 10V
M3 S0 gives 0V

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