Messages

21

Galil / Re: Galil Communication Failure - Restart Program

« on: March 08, 2013, 11:50:39 AM »

It has DMC Smart Terminal (version 6.1.7.0) and Servo Design Kit (version 5.21) installed on it.

Mark

22

Galil / Re: Galil Communication Failure - Restart Program

« on: March 08, 2013, 10:43:12 AM »

It already had WSDK32 as well as a Terminal program which I believe is SmartTerm but it may have been called something else.  I'll check in a few minutes when I get a chance to run up to the shop.

Mark

23

Galil / Re: Galil Communication Failure - Restart Program

« on: March 08, 2013, 08:52:13 AM »

Yes, I downloaded the plug-in and followed the install instructions.  I configured the plug-and and it was 'found' in the general Galil controller window of the setup.

Mark

24

Galil / Galil Communication Failure - Restart Program

« on: March 07, 2013, 10:19:04 PM »

Got everything working with my 1842/1900 and WinGCNC.  Now trying to port over to Mach3.  Downloaded installed and configured version 4.4 of the plug-in.  When I start Mach3 I get a Galil Communication Error in the status window in the bottom left of the screen.  Mach3 also typically becomes unresponsive and locks up.

I can close Mach3 and then run WinGCNC and everything operates fine under that control system.  I'm assuming all the Galil registration stuff is already done since the other software (WinGCNC) that it came with works.

Suggestions?  I'm considering taking another computer and moving everything over to it as it is a better machine.  I intend to do that anyway but wanted to go this route first as this machine already has the PCI card, drivers, registration, config..... in it and WinGCNC works fine so I have less 'variables' to deal with for my initial setup.  Once I get this up and running and understand all the parts/pieces better I'll move it over.

Thanks,

Mark

25

Galil / Galil support

« on: March 07, 2013, 01:04:33 PM »

I recently acquired a CNC retrofit mill with a Galil 1842 and 1900.  The electrician did a horrible job of labeling/identifying wiring during disassembly and shipping.  Working with the documentation I got the axis all working correctly but was having problems with the relays for motor forward, motor reverse, coolant on/off....  The documentation covers many models and there are different options so I called support to see if I had opto-isolation and better understand how it should work and be wired.
I've read that these are awesome boards and the support is great but my experience was different.  First keep in mind they were apparently at a trade show so were short staffed (one guy).  As I called through the day I was told he was out to lunch, it appears for about 2 hours, then later he was apparently on a break for about an hour and half.  As I neared the end of the day he asked for the serial number and I said I'd have to run to the shop to get that (5 minutes).  I asked if they were east coast or west coast to see when they might be closing and he said they were west coast to which I replied, "oh, so you'll be open for a bit longer" as it was about 4:15PST.  I ran up and got it then immediately called back and the receptionist said he was gone for the day.  He knew I was calling back in 5 minutes or less and didn't indicate that he was leaving or end of shift...so I emailed the serial number.  All that, eh, a pain but nothing I can't work through.

This morning when I called he asked where I had bought the board and I said it came with the mill I purchased from a commercial machine shop.  He said it was sold to CamSoft and I'd have to ask them my questions.  I was asking a very specific Galil question.  Motor reverse doesn't work which is output 2 on the Galil board.  I verified in the CNC software that the bit is changing states, using the Galil terminal I verified the bit is changing states (_OP returns a 2, that is Output 2) and I moved the wire to another Output on the 1900, flipped that outputs state, and the motor runs in reverse just fine.  This would all seem to indicate that the Galil Output 2 is bad and I was just calling to verify that.  It's not a big deal as I'm only using 3 of the 8 outputs and I can move it.  I just wanted to know the true result of my findings as it related to the direct query and use of the Galil board.  He repeated evaded my questions saying I'd have to contact CamSoft although I told him the machine doesn't run CamSoft and I was working directly with the Galil components.

So, with all that said...when I bought this I thought about scrapping all of the parts/pieces and doing new retrofit.  This seems to work and seems to work pretty well.  However, I definitely got the impression the company doesn't want to work with you unless they sold you the hardware.  Although I'm a 'hobby' user I'm not interested in running a system that has hardware the manufacturer won't support unless you are the original purchaser.

Thoughts or suggestions?

Thanks,

Mark

26

Galil / New (to me) Galil system, many questions

« on: March 03, 2013, 08:48:17 PM »

Where to start....
I picked up a used Wells-Index 883 with a Galil 18x2 4 axis controller (currently using 3 axis) and ICM-1900 interconnect module.  It is a retrofit as the 883 actually came from the factory as an NC system in 1979 so I'm trying to reverse engineer what they did in the retrofit.  The CNC software is WinGCNC.  My end goal is to try and get this operational with Mach as I'm much more familiar with it.  I've been using it on my Sherline for many years, basically just want the same interface on a bigger machine.

So, I wired it all up as he had labeled the wires and found my X and Z drive would 'run away' to the limit switches where they would stop.  MT -1,1,1 would fix the X but every time I rebooted the computer it was back to MT 1,1,1   Appears the limit switches are connected to the NC104 solid state servo controllers so it would just run up against the limit switch and stop.  Starting with the X I tried everything in the Galil instruction book, reverse A+ and A-, reverse channel A and B and finally reversing the motor leads.  The last was a mistake as it looks like each limit switch feeds a positive and negative 'clamp' on the servo controller.  Took me about 2 hours to disassemble the mill enough to 'un bury' the axis due to severe binding and repair the limit switch.  I'm guessing that limit switch was sending the signal to stop the servo but in the opposite direction it was now going.
After trying everything my last effort was to open the servo and check the pin outs on the encoder then ohm everything back to the controller.  How they had this working is beyond me.  The wires are in pairs and they had A+ paired with Index- and so on.  I'm guessing they just moved wires until it worked then left the labels (now incorrect) on the wires.....anyway, I finally got X working right.  Moved on to Z.  Z would run away to the limit switch then stop. If I gave it a MT 1,1,-1 it would just run away in the other direction to the other limit switch.  I opened the encoder and it appeared right but I took all the leads off the encoder and started ohm'ing/connecting again.  I'm not sure but I think they had the +5 and ground backwards.  After putting it all back together again it seemed to work fine however, after rebooting I find I now have to enter an MT 1,1,-1 every time to make it work.  I know the encoder is now wired correctly.  I did each wire separately and double checked my work.  I'm ok with just giving it an MT 1,1,-1 but can't seem to figure out how to make it 'stick' as it defaults back to MT 1,1,1 at every reboot.  This is my first experience with Galil so I'm sure there is a way....
So now, once I enter the MT 1,1,-1 all axis move and the WinGCNC software can be used.  It's been many months since I was able to mess with my Sherline but I'm almost certain the X and Y axis are backwards.  Z negative moves the cutter down, that seems right.  Jogging X negative moves the table left and negative Y moves the table toward the operator.  I could swear those are backwards as direction is supposed to be in reference to the cutter, am I wrong or does something need tweaked/changed.
Next I moved on to the inputs and outputs.  It has one input coming from what looks like the either 'motor on' or 'tool change'.  I'm having a bear of a time figuring out the original electrician schematics on this thing.  They are much different than electronics schematics.  I notice in the Galil book under the inputs section it says something about connecting an external power supply to the 1900 at pin INCOM but the description of that pin says Input Common, No Connection.  Not sure what to do here as I've got axis movement but can't get the motor to turn on.  I'm guessing that line is now coming from the switch used to turn the motor on that is on the mill head but I can't make Input 1 change states (constant zero volts).
On the outputs I've got Out 1 and Out 2 (motor forward and motor reverse) wired and can change their states with M8, M9, M10, M11 but the motor doesn't turn on.  I'm guessing that Input 1 has to change states first and I'm lost on how to make that happen.  Is there a way to get in the Galil config and see what that input is used for so I might be able to figure out where I should be looking?
Once all that's done it's just the migration to Mach and I've got a couple questions there.  First can/should it be done.  Anyone know if my parts/pieces will work well with Mach3. 
And last, just out of curiosity I see where I could probably use the ENA pins on the Galil system for the limit switches/servo drivers.  That would have been handy to use when troubleshooting as there are commands to stop run away servos.  Am I better to leave them connected directly to the drivers or is there value in moving them?  Another thing I've found is once the limit switch is tripped I can't seem to drive the servo in either direction.  I have to manually (no handwheels) move it off the limit switch.  Seems I should be able to 'drive' it in the direction that is off the limit switch.

Long and a lot of buried questions, sorry about that...I'm new to Galil.

Thanks,

Mark

27

General Mach Discussion / Re: Mach3 on older factory CNC mill

« on: October 25, 2012, 04:26:09 PM »

And it just keeps getting better.  More digging around then research on the Internet.....It has a Galil DMC-18x2 in the computer and a Galil ICM1900.  Appears the 18x2 is the controller and the 1900 is a breakout box for the 100 pin connector on the 18x2 card.  Further research seems to indicate there is a Mach3 plug in for Galil and several people are successfully using it.

28

General Mach Discussion / Re: Mach3 on older factory CNC mill

« on: October 25, 2012, 03:21:26 PM »

This is starting to get a lot less intimidating. 

Climbing around the parts and realized the 2.5 foot square cabinet is likely gutted of it's original contents and now only houses a power supply, computer, and 3 solid state DC servo controllers (NC100 series made by Control Systems Research).  A quick check on the Internet  finds they are obsolete as well as the computer from the looks of it but they really are nothing more than larger pieces of what I put together for the Sherline.  I suspect all of the circuitry in the box on the back of the mill is the mill controls, automatic oiler controls.....so this huge cabinet is just the CNC components.

Mark

29

General Mach Discussion / Re: Mach3 on older factory CNC mill

« on: October 25, 2012, 02:34:11 PM »

Servo.  Just went up and got info from them.

Electo Craft Corp
Permanent Magnet Servo Motor-Tach
Part Number 0703-02-072

I'm pretty sure it is closed loop (doesn't it have to be with Servo's?).  I haven't found the 'feedback' hardware yet.  I suspect it is Incremental Optical Encoders as there is a bunch of literature in the documentation pile I recieved on them and some in the spare parts boxes.

Mark

30

General Mach Discussion / Mach3 on older factory CNC mill

« on: October 25, 2012, 02:08:38 PM »

I been running Alibre, CamBam, and Mach3 for years and am very happy with them on my Sherline mill.  I just bought a full size mill that was sold new in 1979 as a factory built (Wells Index) CNC knee milling machine.  It has been upgraded over the years so no longer runs the same controller software (the documentation boasts the original came with 120 feet of tape for storage!).  It currently has WinGCNC installed but I'd like to run Mach3 as I'm familiar with it already.  This machine has a cabinet on the back with lots of wiring/circuit boards filling about 2 square feet of space and another cabinet off to the side that is about 2.5 feet on each dimension also full of wiring/circuit boards.  Is there any hope that I can 'plug n play' Mach3 to this or is it more likely a complete rebuild of the electronics to convert it to something Mach3 compatible?

I'm really excited that this was a factory CNC machine as it's less likely that it was something that was cobbled together in someones garage but not too excited about vintage electronics/controls.  Especially if they start breaking and need replaced.

Thanks,

Mark