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Messages - bbutcher

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Galil / Re: No DRO readings with Mach 3 and GALIL DMC-1740
« on: September 10, 2018, 11:04:59 AM »
If you are still having problems, to get the DROs calibrated just go to the config menu and select motor tuning. At the lower left corner enter in the Steps per box the correct number of encoder counts per inch (or mm if in metric). Also set the maximum velocity you want (this becomes the rapid move velocity), and an acceleration value, and be sure to click SAVE AXIS SETTINGS button or the changes will not be saved. On my machine I use 20000 counts per step, 150 for velocity, and 100 for acceleration, your results may vary. You can also set the duration of step and dir pulses between 1-5 usec if you are using this type input for your motor amplifiers.

Then select the Y Axis button and repeat, then Z axis, etc. It is a good idea to make an actual move and measure the distance with a dial indicator or separate DRO if you have one on the mill. You can fine tune the steps per value as needed.

Galil / Re: Configure Plugins>>Galil.... then mach3 freezes
« on: September 10, 2018, 10:51:06 AM »
I can create a new profile in Mach3 and get the Galil-ST plugin to configure one time. It is bit of a pain to have to configure all the motor and input settings, but that is one solution to the problem. When I want to run SmartTerminal, I just close Mach3. Likewise after I burn the info I want to keep into SmartTerminal, I close it and open Mach3.

Galil / Re: Plugin problems and licence for mach3
« on: September 10, 2018, 10:46:38 AM »
My understanding is that the Mach3 license can be used on as many machines as you wish. Just copy the file Mach1lic.dat into the Mach3 folder on your new machine. Mach4 licenses must be purchased for each machine. I have had problems configuring the Galil-ST plugin, I seem to be able to configure it on a new profile one time, but then cannot configure it again, Mach3 locks up.

Galil / Re: Gross loss of position using servos and encoders with Galil
« on: September 10, 2018, 09:58:05 AM »
Please note that these servo motors are not being driven by step and dir signals. The motor amps use a +/- 10V signal for motor drive.

Galil / Re: Gross loss of position using servos and encoders with Galil
« on: September 10, 2018, 12:37:24 AM »
I also uninstalled Mach3, deleted everything with Mach3 from the registry, and re-installed it. Same result.

Galil / Re: Gross loss of position using servos and encoders with Galil
« on: September 09, 2018, 12:37:12 PM »
I just verified that the DP counter in Galil is being incremented as the motors are being turned manually. I also verified that the DROs are not being incremented or updated when high voltage is turned off to the motors whether Mach3 is reset or not. Note that the old profile only has 3 axes and the new profile has 4 axes, although I have not activated the motor for the 4th axis in Mach3 Motor Output since the actual motor and encoder is not connected at this time.

Galil / Gross loss of position using servos and encoders with Galil
« on: September 09, 2018, 01:57:07 AM »
I have a weird problem. I am running a DMC 1750 Galil controller with servo motors and US Digital encoders. I have two Mach 3 profiles that I can use, and in one profile the DROs update while manually turning the motors. In the second profile, the DROs do not update while manually turning the motors. The DROs work correctly in both profiles when the motors are being driven.  With motors off, I can move one or two inches and restart the motors with the DRO now updating from the old position (a loss of position of 1-2 inches, i.e. 20000 to 40000 encoder counts in my system).

This is with the two profiles operating on the same hardware with no changes other than opening a different profile. Both profiles are configured to disable the motor amplifiers on E-stop.

I still seem to be communicating with the Galil controller since I can activate a limit switch and see the change on the diagnostic page, both with and without motors activated.

Galil / Re: Limit Switch Connection question
« on: September 09, 2018, 01:21:36 AM »
I think I resolved the limit switch problem. One switch on the Z axis was mechanically broken which was giving some weird results. Replacing it has solved some of my problems. It does require a rather weird configuration scheme however. For what it is worth, the voltage on the ICM 1900 FLSX, FLRX, etc changed from 5 volts to zero volts when the limit switch opens, which I assume means it is "active". When I get GalilSt to config, which is only one time after creating and opening a new profile in Mach3, I have to configure the limit switches as Active low in GalilSt . If I set them to Active High, it changes the value of the SmartTerminal CN operand from 1 to -1, with the Galil controller stopping motion when the switches are not activated.

Then I have to set up limit switches in Mach3 Ports & Pins, Inputs screen. In that screen I have to configure the limit swithces as Active High in order to get Mach3 to allow motion.
I now have the motors all running the correct direction, and the limit switches stopping motion toward the switch when activated. Not quite sure why Mach3 thinks it is active high, but at least it works.

Now my problem is with the DRO boxes in Mach3. I assume these DROs get their value from reading the DP value stored by Galil as the quadrature encoders are rotated by the motors, and converting to inches. What is strange is that in my old Mach3 profile, the DRO values continued to change if I stopped the motors by clicking Reset and then rotated the lead screws (and motors) manually. The DP counter in SmartTerminal continues tracking the encoders, so it always contains the current position regardless of how the encoder is rotated. In the past 10 or so new profiles I had to create to get to this point, the DRO values freeze when the Reset button is clicked and do not change with manual motor rotations. When Reset is clicked again to restore power to the motors, the DRO thinks it is still at the location where it was reset. This is true for all three axes presently being used. I will post this as a separate topic.

Galil / Limit Switch Connection question
« on: September 08, 2018, 09:38:45 AM »
I had my 3 axis system connected and running fine, but decided to add a 4th axis and rewire my controller to make room for the additional motor amp (all motor amps are Copely 306A). These motor amps take a +/- 10V signal for the input rather than a step and direction signal. I had my limit switches connected only to the motor amps in the old system, and therefore Mach3 was not aware they existed. If any axis hit a limit, the motor would stop for that axis only until it was commanded to move away from the limit, but Mach3 would continue running the program as if nothing was wrong. This led to some interesting shaped parts at times but not exactly what I wanted of course.

My revised controller now connects the limit switches to the Galil ICM 1900 break-out board, and uses the AMPEN(x,y,z) pin to enable the motor amp. The motors, encoders, and limit switches were set up using SmartTerminal to get all motors running the correct direction, not running away, and stopping when they hit a limit switch. I only have limit switches connected to the X,Y,&Z axis. I did discover that I got an error22 in SmartTerminal when the unused limit switch connections were not grounded for the FLSW and RLSW pins on ICM 1900. Do I need to ground other unused limit switch pins?

I then set up Mach 3 and the Galil plugin to match the configuration, but was not sure if my limit switches are active high or active low. I mapped them to the appropriate Mach3 pins per the instructions in the GalilPlugIn.pdf file. When I look at the Mach3 diagnostic screen, I see the limit switches all activated if I configure them as active low in the Ports & Pins setup screen, and not activated if I use Active high.

In either active high or active low, when I reset the controller and try to move a motor, I get an error message about limits and the motor does not move. The motors come on and lock in position when I perform the reset, just no motion. I may have selected the wrong limit switch condition when configuring the Galil plugin, but am unable to run configure a second time without locking up Mach3.

A simplified schematic showing the old and new limit switch connections and the ICM to motor amp connections is attached, along with the limit switch mapping for the GalilPlugIn.

Galil / Re: Configure Plugins>>Galil.... then mach3 freezes
« on: September 08, 2018, 07:45:44 AM »
Regarding having SmartTerminal open in the background, I would expect a conflict of some kind since both are trying to connect to the same controller.

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