The error may also be because of running flat out with no load on the motor maybe?

Shouldn't be, can run servos flat out at insane accelerations with no loads.

You could possibly try from the drives front panel to jog at 100% and see if it causes any issues., if it does run fine that way then likely it is needing tuned a bit better in the IP-A.
If however the tuning in the drive itself is not great but the drive has a large following error then it may run fine in the drive but you may have problems getting tight tuning in the IP-A because of that.

Hopefully you will get some info on what options there are for tuning etc.
Hood

Will have a play tomorrow, thanks

Couple of build q's...

What size fuse should i use for servo with a 750w motor ?

The PC - strip and build into the operator panel? strip and build into control cabinet? Leave as-is and stick it somewhere

Looks like the main cab will have to be cut and fabricated as it needs to be pretty big to fit all the bits in and big cabs cost ££££. Also sketching up ideas for the operator panel, probably suspended from the side of the main body somewhere so i still have the ability to use both ends of the ram if needed.

Just whatever the drives max input current  is I suppose, not sure if the manual says or not?


I like to have my motherboards in the control panel as it means keyboard and monitor leads are short. On the Chiron I also had the MPG module there so that the buttons, switches and pots had short wiring and I only had to run the CanBus cable back to the IP-A in the electrical cabinet.

If your cabinet is on the side of the mill then possibly have an arm coming from it.

Hood

Can't see a max current listed, hence the question

Well the AB DSD drives say nominal current for 0.5Kw drive is 5amp and for 1 Kw is 9amp, so probably somewhere in between.

Hood

I used 6A type B circuit breakers for my servos, however I've got no idea where I got that spec from.

Just had a look in the manual, and it says 15A fuse for 750W motors, however the drive input current is listed as 5.5A (largest motor the drives will do is 750W). I'm guessing the fuse rating is for a quick blow (standard) fuse to give a bit surge tolerance, which normal circuit breakers will give anyway.

Ok, thanks, 6A B type should do it then.

Sketching out my wiring diagram,

Safety:-

A - Use the CSMIO HV O/p to control power to the drives - this drops out when Mach goes into reset
B - Have a totally separate safety circuit with main reset button which drops out power to the drives - this circuit would control Machs' E-Stop system

A would have the drives killed every time Mach went into reset - limits etc
B would only kill the drives if an E-Stop button was pressed - a genuine E-Stop situation

you should have it drop the power to the controller killing the power to the motor may course back current

Explain please, my terminology....

Controller - CSMIO
Drive - the servo amplifier units
Motor - the servo motor itself