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Taking the CNC Plunge

Discussion in 'PRECISION-MATTHEWS' started by TomS, Aug 6, 2014.

  1. TomS

    TomS Active User H-M Supporter-Premium

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    Thanks for the encouragement and no magic smoke escaped. Thank God! My conversion is moving along but at a slow pace. These gremlins keep popping up but the instructions that came with the electronics/software are lacking in details. I've been using the trial and error method but that doesn't always work. If it wasn't for the support I've received from forum members I wouldn't be this far along.

    Tom S
     
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  2. jbolt

    jbolt United States Active User H-M Supporter-Premium

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    I'm not familiar with your BOB. Do you have a link to a manual for your BOB? Does the BOB have dedicated terminals for an e-stop? What type of switch are you using for the e-stop?
     
  3. TomS

    TomS Active User H-M Supporter-Premium

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    Here's the manual I found on-line for my BoB. I'm using the switch that came with my mill and I haven't changed any of the e-stop wiring.

    As a side note I've done some more reading on the internet about UC100 issues. From what I read interference is a big issue on low voltage systems and may be the cause of the UC100 losing connection. One of the sources of interference may be the flouresent lights in my shop. I'll test the system with the lights off and see what effect that has. I'm going to set debounce interval to 2000 and work down from there. If I can get the number low enough I may be OK. Another suggestion is to get a double shielded UC100/USB cable. May do this anyway just to reduce/eliminate interference problems.

    Tom S
     

    Attached Files:

  4. jbolt

    jbolt United States Active User H-M Supporter-Premium

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    Okay your BOB does not have a dedicated e-stop. Are your limit switches in series or parallel? What pin #(s) are you using for the limit switches?

    My BOB is different and has a dedicated e-stop terminal so I am pulling this from memory when I was first setting up my mill with a different BOB. Hopefully someone will correct me if I am giving you bad info.

    If you have the LS's in series then put the e-stop switch in that chain, wire the e-stop switch to the NC terminals and set the active low to the same as the LS's. I believe Mach3 uses pin #10 as the default e-stop pin so I would use that.

    If in parallel put the e-stop on pin 10 and X,Y & Z would then be on pins 11, 12 & 13
     
  5. TomS

    TomS Active User H-M Supporter-Premium

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    Leaving the shop lights off and setting the debounce to 2000 didn't have any effect. What I did do was unbolt and set the BoB as far away from the Z axis power supply/driver (about 8") as I could. I started Mach 3 with no 220v power to the power supplies. I was able to reset the e-stop without getting a UC100 error. As soon as I plugged in 220v power and the PS started up I got the error message. This points to electrical interference. Question is how far away from the power supplies does the BoB need to be? Will double shielded USB cables be sufficient?

    Tom S
     
  6. TomS

    TomS Active User H-M Supporter-Premium

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    My limit switches are wired in series and are connected to Pin #12 (input #3 on the BoB) and have the e-stop set to Pin #12. I'll look at my e-stop switch but isn't it already wired as NC? In any case I'm assuming when you say "wire the e-stop switch to the NC terminals" you mean the NC terminals on the e-stop. Is this correct?

    The more I thought about it (see post below) I don't think electrical interference is the culprit. I'm saying this so anyone reading this thread will be clear on what we are doing and why we are doing it. I'm learning and I want others to learn from what we are doing.

    Tom S
     
  7. jbolt

    jbolt United States Active User H-M Supporter-Premium

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    If you are using the e-stop switch that came with the machine and it is the same as mine then it is only NC.

    Here is a typical e-stop with both configurations.

    e-stop001.gif e-stop003.gif e-stop004.gif
     
  8. jbolt

    jbolt United States Active User H-M Supporter-Premium

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    Check this link for limit/home e-stop wiring and mach3 config. Starts about half way down the page.
     
  9. TomS

    TomS Active User H-M Supporter-Premium

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    Thanks for the link. Seems simple enough to wire the switch into the limit switch circuit. Need to figure out how to wire it so the spindle also shuts down.

    Thanks for the help.

    Tom S
     
  10. jbolt

    jbolt United States Active User H-M Supporter-Premium

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    Are you planning on turning the spindle on and off with mach3?

    You can do that with one of the contactors and a SSR. An e-stop or limit trip would stop the spindle.
     
  11. TomS

    TomS Active User H-M Supporter-Premium

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    Not going to turn the spindle on and off with Mach 3 at this time. Maybe later once the mill is up and running with a few hours on it. I would like to wire the e-stop so that it stops axis movement and spindle rotation when activated. The spindle motor circuit wiring is as it came from the factory; the 24vdc transformer latches the spindle contactor (KM1).

    Tom S
     
  12. jbolt

    jbolt United States Active User H-M Supporter-Premium

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    If you want to stop the spindle with only the e-stop button you could do that by switching the spindle motor contactor with an e-stop switch with 2 NC contacts, 1 for the limit circuit and one for the contactor coil circuit. This would not stop the spindle on a limit trip. A switch like this with an extra NC contact block would do the trick.

    To stop the spindle on an e-stop and limit trip you need to trip the contactor with a relay. Your BOB has a low volt relay that could control an SSR that would then control the contactor coil. At that point you are controlling the spindle with mach3.

    Before I did the VFD conversion I had my spindle wired to run from mach3 or manualy using a 3 position switch. In position 1, mach3 would turn on a SSR to energize the contactor. Position 2 was all off. Position 3 would bypass the SSR and energize the contactor directly. I found this useful for doing manual work or using edge finders.

    Having used the mill for over a year I am now comfortable using mach3 to do what I used to do manually.

    Jay

    Also, I have my system wired with 2 e-stops. One is through the BOB and stops the axis and spindle. The other kills all power to the machine for that "oh crap my machines is on fire" moment we hope never happens.
     
  13. TomS

    TomS Active User H-M Supporter-Premium

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    Thanks for the info. I'm going to wire the existing e-stop into the limit switch circuit so I can reset Mach 3 and move on to setting my limit stops. In the mean time I'll order a 2 contact e-stop.

    Tom S
     
  14. TomS

    TomS Active User H-M Supporter-Premium

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    I wired the e-stop into the limit switch circuit. Started Mach 3 and everything was normal. I was able to move all three axis in both directions. I manually tripped one of the limit switches and as expected I got a limit tripped message in the status window. I clicked reset and immediately got the UC100 did not respond error message. Double checked my input pin settings and confirmed as follows:

    XX++, XX--, Y++, Y--, Z++ and Z-- are enabled, pin 12 in each of the pin number boxes, and active low checked for each. Also tried it with the active low boxes not checked.

    Restarted Mach 3 and clicked reset. Limit switch tripped error did not clear. Shut down and restarted Mach 3. Now I'm getting an e-stop tripped message in the status box and it won't clear when I press reset. I'm at a loss as to why it worked when I started up the first time but now it's not allowing me to reset. For info I opened the UC100 monitor window and #12 pin light is not lit.

    Tom S
     
  15. jbolt

    jbolt United States Active User H-M Supporter-Premium

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    Any time you get a fault with the UC100 you need to restart Mach3 to reset the plug-in.

    Try removing and re-installing the UC100 plug-in.

    What computer are you using?

    Jay
     
  16. TomS

    TomS Active User H-M Supporter-Premium

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    I do restart Mach 3 everytime I get the UC100 error message. I did reload the application but did not manually remove the initial installation. I'll try removing it and reload and see what happens.

    My computer is an HP laptop running Windows 7 64 bit. From what I've read Mach 3, D2NC (CAM software) and UC100 should run.

    Tom S
     
  17. bvd1940

    bvd1940 United States Active User Active Member

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    I am not sure Tom but I have saw a lot of posts that say it will not run on Win 7 64 bit. I think it has to be 32 bit to run Mach 3, I might be wrong but what do I know:anyone:
    Bill
     
  18. TomS

    TomS Active User H-M Supporter-Premium

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    Bill - Thanks for your input. I've read the same thing but have also read where Mach 3 and UC100 are 64 bit compatible. At this point I'm not sure what's causing the problems. I'm thinking I should reinstall Mach 3 and UC100.

    Tom S
     
  19. jbolt

    jbolt United States Active User H-M Supporter-Premium

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    I was not able to make them work on a desktop with win7-64. I went back to XP.

    Jay
     
  20. TomS

    TomS Active User H-M Supporter-Premium

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    I took the limit switches and e-stop out of the equation by assigning them to port #0. Still getting the UC100 error message. I'm going to reinstall the UC100 driver in the morning and see if that helps.

    I may end up going to XP or Windows 7 32 bit. Who knows where this will take me.

    Tom S
     
  21. bvd1940

    bvd1940 United States Active User Active Member

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    If twas me I think I would try win 7 32 bit, coarse it would be nice to see ifin the win 7 32 would run it but that's lots of work.
    I wish they would up grade Mach 3 for 64 bit after digging into 7 64 pro it has some nice features IMHO.
    Bill
     
  22. TomS

    TomS Active User H-M Supporter-Premium

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    I went to the Mach 3 website to find out what they had to say about specific software and hardware requirements. I found that if using the parallel port for control 32-bit version of Windows 2000, Windows XP, Windows Vista, or Windows 7 (64-bit versions will not work). However, if using an external motion device for machine control (options can be found on the Plugins page) a Desktop or Laptop with Windows 2000, Windows XP, Windows Vista, Windows 7, or Windows 8 can be used. I'm using a UC100 motion controller which is listed on the Artsoft plugins page.

    I've met Mach 3 requirements in that regards but the fact remains that I still can't get Mach 3 to reset without getting the UC100 error message. Without appearing to be stubborn I'd like to exhaust all other possibilities before changing operating systems. First item on the agenda is to reload the UC100 driver. I'm also looking in to a double shielded USB to UC100 cable with ferrite beads. Not sure if they make them but I'm looking. After that it's back to head scratching.

    Tom S
     
  23. bvd1940

    bvd1940 United States Active User Active Member

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    Well I will be following your progress to see how it comes out as I would like to change over later but not till I have the panel with finished wiring and proper power feeds installed (and running like it should).
    Good luck with your system and hope it falls into place for you.
    Bill
     
  24. tmarks11

    tmarks11 Active User Active Member

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    Why not just jump to Mach4? They have a plug-in for parallel ports (even better, there is a beta plug-in now for the Ethernet Smooth Stepper).

    This way you can use a modern OS, and have a modern GUI.
     
  25. jbolt

    jbolt United States Active User H-M Supporter-Premium

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    If you have or can borrow a pc with win xp I would give it a try. It will tell you if you have an os problem or a uc100/mach3 problem.

    Jay
     
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  26. TomS

    TomS Active User H-M Supporter-Premium

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    Thanks. Been trying different things trying to get Mach 3 and the UC100 to play together. Still not working but I'm not giving up.

    Tom S
     
  27. TomS

    TomS Active User H-M Supporter-Premium

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    I just purchased Mach 3 and haven't got my machine running yet. Putting out another $200 for software is not in the cards at this time. Everything I've read says that Windows 7 64 bit, Mach 3 and UC100 will work together and I'm determined to find out why it's not.

    Tom S
     
  28. TomS

    TomS Active User H-M Supporter-Premium

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    I think I may have a faulty UC100 or cable. I reloaded the driver from the CNCDrive.com website but still getting the UC100 did not respond error and occasionally a UC100 not found error. I'm going to contact the UC100 vendor and ask if they will send me another one.

    BTW - I'll ask around to see if anyone has a computer running XP. That will certainly answer several questions.

    Tom S
     
  29. TomS

    TomS Active User H-M Supporter-Premium

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    I connected the UC100 directly to my laptop instead of through the USB hub and I'm no longer getting errors. Also ran some simple pocketing g-code and didn't get any errors. Guess I have a faulty USB hub. Now I can focus on cleaning up the wiring and learning Mach 3 and it's capabilities.

    BTW - I put a 10mf capacitor on the SSR control signal feed and nothing happened. Still not completing the circuit.

    Tom S
     
  30. JimDawson

    JimDawson Global Moderator Staff Member Director

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    That is strange, I would love to look at the output of the wall wart with a scope and see what it looks like.
     

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