Messages

3101

Mach4 General Discussion / Re: Setting up Spindle/VFD control Issues

« on: February 08, 2019, 07:21:33 PM »

Hi,

also has a Analog output which you can configure to output between 0-10v!

that output is NOT A SUPPLY for the PWM circuit!

Its meant to be a signal output, probably less than 10mA. Depending on how you program the drive the output
might be an analogue representation of the VFD ouptut power, or output current, or output frequency, or temperature of
the IGBT's, or whatever.....It meant so you can monitor the VFD or motor it drives.

3102

Mach4 General Discussion / Re: Setting up Spindle/VFD control Issues

« on: February 08, 2019, 07:16:46 PM »

Hi,
yes you could use a simple voltage divider but you can't be sure how much current the G540 will draw and whether it will
be constant. The output voltage of the voltage divider will vary with the current drawn.

The attached is a simple Zener diode regulator with just a diode and a resistor. I'm going to guess that the G540 will draw
10 mA or so. Zener diodes come in a variety of sizes, 500mW being the common small size. You can get 1W and 3W Zeners
as well. I would recommend 1W or 3W if you can find one locally. The resistor should be 1/2W or thereabouts.

You can use an adjustable regulator, the LM317 is very common, its like an asshole....everyones got one!
It would require a 317 reg, a 100mA TO92 size would be plenty big enough. Two resistors, or better one
resistor and an adjustable resistor would allow you to adjust it perfectly. The only draw back is the dropout voltage.
A linear regulator like this lets say has an output voltage of 10V. The device requires, according to the LM317 spec,
an input voltage of at least 2.5V MORE than the output voltage. So our reg will require 12.5V minimum. If the input
voltage drops below 12.5V then the output voltage may no longer get to the required 10V output, in fact it might stop
altogether. That is called the 'dropout voltage'. With 13.2V from the VFD you are awfully close to the minimum required
input voltage.

There are regulators which have lower than normal dropout voltages, called LDO regulators. They tend to be a little more
specialized and you are less likely to fin one in your local electronics shop.

I would try the Zener reg to start with, I'm 99% confident it will work for you. If not Then we start looking at slightly more
sophisticated designs.

Lastly why does the VFD have a 12V (13V) output when its analog inputs only work with 0-10v :S

I suspect that the VFD manufacturer sees the 12V nominal output as a purely auxillary supply and did not waste any resources
on its design, a standard off the shelf IC and that is that. The manufacturer might reasonably assume that the PWM
can handle the extra.

Geckos have an excellent reputation for robustness and it surprises me that they have specified such a close tolerance between
the expected max output (10V) and an input supply (12V). Without being privy to the circuit diagram I can't say for sure
why that is or if indeed 13.2V would cause damage. For the sake of a Zener and a resistor why risk it?

Craig

3103

FAQs / Re: I should buy new controller.

« on: February 08, 2019, 03:09:11 PM »

Hi,
that looks like Chinese made controller. China might as well be another planet as far as getting repair or service info,
it seems the Chinese manufacturers don't care what happens to you once they've got your money.

Those three big ICs are the stepper drivers ICs and are prone to failure. If one blows up you have to buy another board
if you can't unsolder the faulty IC and replace it.

Gecko, a US company, have a very good reputation for making robust stepper drivers. One of their most popular
products is the G540. It is a parallel port breakout board and 4 axis stepper drivers combined. The maximum voltage
of the stepper drivers is 50V, not spectacular but useful.

https://www.geckodrive.com/g540-4-axis-digital-stepper-drive.html

Gecko also make individual stepper drives with maximum voltages of 72V.  The G213 is an example. You would need
three units AND a breakout board so at $150 a unit quality doesn't come cheap. The good news is you will have them
for years and if you ever need help Gecko is only a phonecall or email away.

https://www.geckodrive.com/g213v-digital-stepper-drive.html

A somewhat cheaper alternative is Leadshine AM882. It has a very useful, in fact class leading, 80V input at up to 8.2A.
I have seen them on Ebay for as low as $66 each, but $75-$85 is more normal. Leadshine has a pretty good reputation
for quality. If you were to go this way you would want one unit for each axis AND a breakout board.

http://www.leadshine.com/productdetail.aspx?type=products&category=stepper-products&producttype=stepper-drives&series=AM&model=AM882

If you need a breakout board there are plenty of good ones. I like and use the MB-02-V6 from Homann Designs in Austrailia.
I live in New Zealand so is pretty close to local to me.

https://www.homanndesigns.com/index.php?main_page=product_info&cPath=54_22&products_id=59&zenid=m9hqu4ek9oinoasvdev8usfov5

One thing that you should look out for if buying a breakout board, make sure it has LEDs on all the outputs. You can see at a glance
what outputs are working. A Godsend when you are trying to set up.

Craig

3104

Mach4 General Discussion / Re: Is there any way to home a single axis?

« on: February 08, 2019, 02:35:18 PM »

Hi,
yes you can use a script which uses the API:

LUA Syntax:
rc = mc.mcAxisHome(
   number mInst,
   number axisId)

Description:
Used to start an axis homing.


Or you can use the Ref Z axis (or Ref X, Ref Y) on the machine diagnostics page.

Craig

3105

Mach4 General Discussion / Re: Setting up Spindle/VFD control Issues

« on: February 08, 2019, 05:12:05 AM »

Hi,

Maybe thats why they say not to connect it to over 12v as it cant reduce anything over 12v down to 10volts?

Not quite. The G540 can reduce the input voltage in a range of 0% to 100%. If you call for the spindle to go to maximum
speed it will output 100% of the supply voltage it is given. If it is given 13V then at 100% the output voltage will be 13V.

The problem I'm guessing is that Gecko believe that an input voltage of more than 12V will stress the internals of the G540.

Next problem is I setup Output 2 as Spindle On And the output is working (testing with multimeter) but the VFD only activates the X1 terminal when X1 and Comm terminal (on the vfd) are connected. and Output 2 on the g540 doesnt seem to have continuity to Comm on vfd so im not sure what to do there. Maybe run a wire from the Comm terminal on the VFD to the pin12 on the GeckoG540 (power supply ground)

Sounds like the VFD Enable is active low. If you reverse the sense of the Gecko output, when it goes low it should turn the
VFD on. It may be as you say that the Com terminal is isolated from pin12, the power supply ground. Try in the first instance
the reversal of the signal, done in the ESS plugin Pins Config page. It may be necessary to hook pin 12 of the G540 to the Com
of the VFD.

Craig

3106

General Mach Discussion / Re: Mach3 Breakout Board Inputs

« on: February 08, 2019, 02:39:59 AM »

Hi,
when I was still using Mach3 (now on Mach4) I used two breakout boards from Homann Designs in Auatrailia:

https://www.homanndesigns.com/index.php?main_page=product_info&cPath=54_22&products_id=59&zenid=d57t79b1cg7ac4l2676v12okd5

Of course I live in New Zealand so close to local for me. Been great. I still use them now that I have a Smoothstepper.

Really that's your choice....just get a breakout board and stick with a parallel port (and its limitations) or get yourself
an external motion controller like a SmoothStepper or a UC300 or similar.

DONT BUY CHINESE JUNK!
Cheap is about the only thing you'll like about them.....and really, are they that cheap when you have to throw them out
because they don't work?

Craig

3107

Mach4 General Discussion / Re: Setting up Spindle/VFD control Issues

« on: February 08, 2019, 12:48:20 AM »

Hi,

The VFD does have a “12v” out but while I was checking things I happened to probe between this post and the comm post and it was showing 13.2volts. I do remember reading somewhere in the gecko manual not to let this be over 12v. Is this a problem?

Yes, it may be. Its quite common for a 'nominal 12V' supply to be somewhat more, as in your case 13.2V.
As you know 12V is the common output voltage of an automotive 6 cell flooded lead acid battery. In fact when absolutely
fully charged you might expect 2.2V per cell for a total output voltage of 12.6V. When in automotive service when the engine runs
the generator (old school)/altenator will elevate the voltage to charge the battery. A modest charge rate could be secured by
charging at 13.2V. A more aggressive charge rate as is the norm for modern cars is 14.2V to 14.5V.

With the long history of 12V use in automotive service then '12V' can be a bit flexible.

I don't recall seeing anything in the G540 manual, but I take your word that it is there, the recommendation not to exceed 12V.
If that is the recommendation I would stick to it. It is worth an email to Gecko to get a little more info.
The simplest solution I can think of would be to drop the voltage slightly with a 9.1V Zener diode and a resistor. That would
mean that the variable output voltage of the G540 would be  0 to 9.1V, slightly less than spec but close enough. 9.1V is a
standard Zener voltage. You might enquire from Gecko about the expected G540 current draw from the nominal 10V supply,
it maybe that a Zener will get a bit hot and bothered.

Another alternative is to use a low dropout voltage regulator. You might get away with a very common and dirt cheap LM317.
It would require two resistors to set the voltage but you can set it very accurately.

Let me know if you need some help to regulate the 13.2V output of your VFD. Electronics is 'my thing'.

Craig

3108

FAQs / Re: Problem with X axis

« on: February 07, 2019, 05:03:50 AM »

Hi,
the most likely explanation is a faulty driver IC which is very likely to be one of the Toshiba driver ICs which are
commonly used in Chinese made controllers. The Toshiba ICs are a bit prone to failing

Are you able to unsolder the existing IC and fit a new one?

Craig

3109

Mach4 General Discussion / Re: Setting up Spindle/VFD control Issues

« on: February 07, 2019, 04:56:01 AM »

Hi,

Gecko G540 Pin 7 (VFD Ground) --> Comm Terminal on VFD

Correct

Gecko G540 Pin 8 (VFD Out) --> X1 Terminal on VFD (Spindle FWD Input)

Incorrect. Pin8 of the G540
is a variable output voltage between 0 and 10V. It needs to be hooked to the AIN input of your VFD

Gecko G540 Pin 9 (VFD 10V) --> AIN1 (Analog Input 1)

Incorrect. The G540 is expecting a constant 10V input supply, from the VFD if it has one or an external 10V supply
if it doesn't. The G540 will take this 10V supply and 'modulate' it to the required (variable) output. Does you VFD have
a 10-12V supply for this purpose?.

Spindle: Type = PWM
Frequency Hz = 400z (im not actually sure about this one? how do you know the base hz, I just choose the max hz

Correct although the G540 is expecting a base frequency of 50Hz, probably good idea to provide the signal
that the G540 is designed for, ie 50Hz

Pins Config:
Port 1 - Pin8 - Out - Active High - Spindle PWM
Port 1 - Pin9 - Out - Active High - Spindle FWD

Incorrect. The ESS pins will hook to the DB25 input of the G540.

Thus Port1 -Pin14 Active High Spindle PWM

You have a problem now. It is common to have a signal to turn the spindle ON/OFF.
If you want to be able to go both directions you'll want a FWD/REV signal as well.

There are two uncommitted outputs on the G540, OUTPUT1 and OUTPUT2. They are driven by two G540 DB25
input pins.

Port1 -Pin1 OUTPUT2
Port1 -Pin17 OUTPUT1

You need to decide whether you want ON/OFF AND direction control OR just plain ON/OFF control.

Mach 4 Config:
Output Signals:
Spindle FWD - Enabled - Device = ESS - Output Name Spindle FWD

You shouldn't touch this setting. You make the output settings in the ESS plugin and that AUTOMATICALLY populates
the Mach4 Config.

Until you decide the direction/ON/OFF question the ESS outputs are undecided.

Craig

3110

Mach4 General Discussion / Re: Can I safely downgrade Mach4 to an older version without loosing settings?

« on: February 06, 2019, 03:18:21 AM »

Hi,
if your profile and screenset are named appropriately you don't have to do anything. All the other files get replaced
but not your ones.

Yes you can package your profile but if is not uniquely named it will get overwritten. Likewise the screenset. Make sure it
is uniquely named.

Craig