Messages

91

General Mach Discussion / Re: Safer connection from Mach3 to X200 VFD?

« on: February 17, 2015, 08:58:50 PM »

Ok... now getting more info as to the REAL problem. The ESS running out of data and losing position fault message is not a Mach 3 problem. It's a result of the ESS not configured correctly.

First... make sure you have the latest ESS plugin from the Warp 9 site.

1) Go to the ESS config page and change the Data Rate (upper left hand side) from the default 4Khz to 1Khz or 2Khz.
2) Calculate the ESS motor step frequency (right under the data rate box) and set for lowest frequency equal to or just above the calculated value. The Warp9 website has the procedure to figure this number. Or set the motor step freq number to the lowest one which I believe is 32khz.  
3) In Mach 3 set the kernel rate for 25Khz. The ESS does all the step calculations independent of Mach 3 so setting the kernel above 25khz just wastes PC CPU time and resources and adds absolutely nothing.  Also... it's been reported setting the kernel higher than 25Khz can result in Mach 3 calculation, DRO and trajectory errors with ESS.
4) Use Mach 3 ver 0.62. This version works with ESS and is recommend by Warp9. Do NOT, repeat NOT use V0.66... it has problems and should be avoided.
5) Set Mach 3 Look Ahead to 200.
6) Set CV to ON and turn off all other CV settings such as CV Dist, CV Speed, CV Stop angle. CV speed and dist is broken in Mach 3 anyway.

The Ess "Running out of data fault" is caused because the ESS buffer is running out of data (make sense right?)... the PC can't supply it fast enough. If you are still getting the fault change the ESS data rate to 1Khz. BTW... if you are wondering, increasing the Mach 3 kernel rate and the look ahead will NOT fix this problem.  

Now... run a G-code program and hit Mach 3 "Stop"... I bet the machine stops dead, G-code stops, Z axis goes up to home, VFD shuts off and no ESS error messages. Do NOT use Feed Hold. Then use Run From Here command... the program will start right where the Stop command was issued.

The Feed Hold function doesn't really work as one would assume unless you are running a very small look ahead buffer like 5... but this just creates other problems.

I have a ESS and run Mach 3 V0.62 with a VFD and it works good. I was getting running out of data faults after running 25 or 30 lines of code. Once I configured the ESS correctly... no more problems.    



  

92

General Mach Discussion / Re: Safer connection from Mach3 to X200 VFD?

« on: February 17, 2015, 10:24:34 AM »

Pressing STOP in Mach3 should STOP the axis dead in their tracks NO movement.

(;-)TP

That's the way mine works.... pressing "STOP" kills any axis movement and raises the Z axis to home position. If your axis is still moving something is wrong or maybe you are using "Feed Hold" which will continue movement until the buffer is empty. I use "Stop" and "Run From Here" instead of "Feed Hold" to prevent tool crashing.

93

General Mach Discussion / Re: Safer connection from Mach3 to X200 VFD?

« on: February 15, 2015, 06:04:30 PM »

Good point BR549.  If this setup is being used in a commercial or industrial application then personnel safety is #1. E-stops can not be a function of a PLC or PC and must be hard wired to be fail safe to remove sources of energy. Only Siemens PLC's has recently been certified to to perform e-stop functions. Siemens fail safe logic is very complex.
 

94

General Mach Discussion / Re: Safer connection from Mach3 to X200 VFD?

« on: February 15, 2015, 05:58:04 PM »

First... you are getting WAY over paranoid about the "What If's" especially with item #3. Years ago I had a boss that was overly paranoid and analyzed everything to death. I called it "Analysis Paralysis"...  

If you were using a PLC all the concerns you have could be fairly easily addressed. But now we are talking system design and integration on a much different level.

Most, if not all, VFD's have two programmable output contact (relays) that can be setup to monitor drive functions such as "drive running", "at speed", "Drive faulted", etc. and probably a couple of dozen drive parameters.... as well as programmable digital inputs. And most are Modbus compatible which expands the options. I'm not sure about the older X200 VFD but this stuff has been around since the early 80's. Nothing new here.

You could have the drive monitor the charge pump enable and Mach 3 monitor the drive status via the E-stop input wired in series with the drive relay contact... probably a half dozen ways to make it work. Just figure out the logic to make it happen.      

95

General Mach Discussion / Re: Mach3 Windows 7 64bit with UC100- NEED HELP!!!

« on: February 13, 2015, 08:23:43 AM »

Contact UCCNC they have great customer service.

96

General Mach Discussion / Re: spindle problem

« on: February 12, 2015, 01:57:43 PM »

Smooth stepper Ethernet the way to go. The USB version tends to be problematic. Using USB for motion control is tricky and more affected by electrical noise. I use the Ethernet version and have had zero problems.

97

Mach3 under Vista / Re: Mach 3 R3.043.066 and Windows 7 problems.

« on: February 12, 2015, 01:48:27 PM »

There are plenty of XP computers available on Ebay or Craigslist cheap some less than $50. XP is probably the best OS ever built and now it's history. However, ArtSoft is out of touch with the customer's needs and get a workable Mach 3 - Windows 7 product. Until the issues with Mach 4 are resolved, which doesn't appear to be happening anytime in the near future, I don't see a huge migration away from Mach 3.

I would try 0.062 and see if that works any better. V0.066 has allot of issues and should be avoided.

98

General Mach Discussion / Re: My spindle keeps shutting off randomly.

« on: February 12, 2015, 09:26:44 AM »

I have no idea why you were told to use L1 & L3. Teco (Westinghouse), Toshiba G3, G4, Automation Direct and almost all single phase VFD's including the cheap Chinese junk VFD's are electrical the same use L1 & L2.  I have a Automation Direct GS-2, 2hp, 240V drive wired to L1 & L2... runs great.  I don't think the drive is damaged unless it faults out on "OC" when powering it up. If you get a "OC".... the drive's power section has failed.  

Again... NEVER use a circuit breaker as a on/off switch unless it's rated for switching. If it is, it will be marked "SDR", "SWR" or "SW" on the case. Buy a separate 2 pole power switch instead which is allot cheaper than replacing a 2 pole 20A or 30A breaker.

One thing to consider is the incoming power wire size and distance from the circuit breaker panel... a 3hp motor and VFD, 200V-240V should have no less than #12 AWG with #10 AWG being the preferred to prevent voltage drop and overheating the conductors.    

Let me know how you make out.

99

General Mach Discussion / Re: My spindle keeps shutting off randomly.

« on: February 11, 2015, 04:37:07 PM »

Teco's FM50 user manual clear shows L1 &L2 for single phase 200V - 240V. Ask Teco why the breaker gets hot and trips when using L1 & L3. I'm curious for their answer. 

100

General Mach Discussion / Re: My spindle keeps shutting off randomly.

« on: February 11, 2015, 08:45:13 AM »

Measure the voltage at the drive terminals L1 &L2 with the drive off then measure again with the drive running and compare the readings. Should be the same with no voltage drop. If you have a 208V system it should be 208V or a little higher. If it's a 240V system it should be around 240V. In any case it shouldn't be less than 200VAC.

The electrician should have tested the voltage... that's pretty basic troubleshooting. I'm running out of ideas.... it's difficult to problem solve without actually seeing the problem.