Upgrading 1984 Wells Index 820 with Allin1DC

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cncsnw
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Re: Upgrading 1984 Wells Index 820 with Allin1DC

Post by cncsnw »

It does not really matter whether the encoder counts up in CCW or CW rotation, as long as encoder direction is matched to motor rotation. Since you can easily reverse your motor rotation to match the encoder (by swapping the plus and minus power leads), you can live with the encoders wired either way.

If positive PID output and positive encoder counts do not correspond to positive axis movement on your particular machine, then you just need to set the "Direction Reversed" option on the Machine Configuration -> Motor Parameters table.

Yes, the axes will run away if you enable them while uncoupled from the encoders.

The reason you are not able to close the E-stop contactor with stall detection enabled is probably because your X and Z encoders are both showing differential errors:

Code: Select all

(1)   09-04-2021 13:31:27 406 Emergency stop detected
(1)   09-04-2021 13:31:56 412 X axis(1) encoder differential error
(1)   09-04-2021 13:31:56 412 Z axis(3) encoder differential error
(1)   09-04-2021 13:32:06 412 X axis(1) encoder differential error
(1)   09-04-2021 13:32:06 412 Z axis(3) encoder differential error
(1)   09-04-2021 13:32:08 406 Emergency stop detected
This means that there is not a correct differential signal on the A and/or B channels.

See:


and also:
http://www.cncsnw.com/EncoderTest.htm
Chevy427z
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Re: Upgrading 1984 Wells Index 820 with Allin1DC

Post by Chevy427z »

Thank you very much for your information.

I was so anxious to see how the thing ran with everything connected, but knew I had to wait until I was sure about what I was doing.

I've seen the differential error pop up on my screen and wondered what the hell is going on. I have seen that video and been over my encoders a hundred times for this very reason. I guess I will check them 101 times. Much of this entire discussion is about encoders back when I first got started. Something that puzzles me is that the instructions say that "to be sure that all errors are cleared, attempt to go into MDI". I've gone into MDI and everything appears as it should. Back to checking the encoders again.

Thanks again. Really appreciate your time.

Mark
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cncsnw
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Re: Upgrading 1984 Wells Index 820 with Allin1DC

Post by cncsnw »

If you have stall detection disabled, or you have suppressed encoder faults with Parameters 332 and 334, then MDI will open just fine, even if you have faulty encoders.

If the problem only happens some of the time, even when you have stall detection and encoder fault detection enabled, then you are looking for an intermittent issue, which will be harder to pinpoint.

However, it appears that you often get 412 differential errors on both X and Z simultaneously: perhaps any time you try to enable both axes at once (e.g. by opening the MDI prompt, or by pressing Cycle Start to find home).

What is different about your Y axis encoder?

It is not likely that you have two faulty encoder inputs to the Allin1DC, but you could test that out by switching inputs.

For example, if Y has been working without errors, you could swap both encoder and power connections between X and Y. If the problem remains with the logical X axis (now using the known-good Y axis motor, encoder, and cables) then you know there is a problem with the Allin1DC. If the problem moves to the logical Y axis (following the original X axis motor, encoder, and cables), then you know the problem is with the physical encoder or cable.
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Re: Upgrading 1984 Wells Index 820 with Allin1DC

Post by Chevy427z »

More excellent information. Thank you. I will take another look.

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Re: Upgrading 1984 Wells Index 820 with Allin1DC

Post by Chevy427z »

cncsnw wrote: Mon Sep 06, 2021 2:08 pm If you have stall detection disabled, or you have suppressed encoder faults with Parameters 332 and 334, then MDI will open just fine, even if you have faulty encoders.
Just as a point of reference. I had mentioned this a few times in previous posts and you were the first to pick up on it and explain it, so thank you for that.

I'm back to square one on these encoders. I bought a DB9 break out to check the encoders and the cables. Testing exactly as outlined in the video that Polar made, that you posted previously.

X- This is a brand new encoder from Automation Direct. Showed intermittent error messages. Could not get it read properly at the AllInOne cable end. Disconnected it at the machine end of the cable and retested. No difference between A and A/, or B and B/. Nothing changes when rotating the encoder. Each wire read high (4.5V or higher), none read low in any position.

Y - This one was tested ok by Polar. This was the only one not throwing an error, now tests exactly like X. No diff between A and A/, and B and B/.

Z - This one was repaired by Polar. Showed error, but tested fine, still does.

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Re: Upgrading 1984 Wells Index 820 with Allin1DC

Post by polaraligned »

You and encoders don't get along. :?

If the Y is not throwing an error from the Allinone, but yet it is not testing good doing a bench test, then it sounds like a problem with your testing method.

Overall it really does sound like an issue with wiring. I tested the encoders I sent to you on my machine and as seen in the video I posted there was no differential error and they were counting....what went wrong after that is beyond me.

Plug them all in and post a short video of the Encoder screen showing you turning each one. That screen will also show differential errors and what channel the errors are on.

If you want to mail me the encoders and cable assemblies, I can go over them and test each one on my machine and correct issues that I find. You just need to cover the $15 postage each way.
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Re: Upgrading 1984 Wells Index 820 with Allin1DC

Post by Chevy427z »

polaraligned wrote: Sun Sep 19, 2021 4:48 pm You and encoders don't get along. :?
You are absolutely correct on that!

I really appreciate your offer to check them out. I will send you a private message.

Mark
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Chevy427z
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Re: Upgrading 1984 Wells Index 820 with Allin1DC

Post by Chevy427z »

polaraligned wrote: Sun Sep 19, 2021 4:48 pm You and encoders don't get along. :?

Plug them all in and post a short video of the Encoder screen showing you turning each one. That screen will also show differential errors and what channel the errors are on.
How do I get to this screen? I'll try this before I remove them for shipping to you. I'll have to reattach the X encoder wiring as I cut it to test the encoder alone without it's wiring.

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Re: Upgrading 1984 Wells Index 820 with Allin1DC

Post by tblough »

F1 Setup / F3 Config / F4 PID / F3 Encoder
Cheers,

Tom
Confidence is the feeling you have before you fully understand the situation.
I have CDO. It's like OCD, but the letters are where they should be.
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Re: Upgrading 1984 Wells Index 820 with Allin1DC

Post by polaraligned »

Chevy427z wrote: Mon Sep 20, 2021 4:55 am
How do I get to this screen? I'll try this before I remove them for shipping to you. I'll have to reattach the X encoder wiring as I cut it to test the encoder alone without it's wiring.

Mark
Probably not worth reconnecting. If they are throwing errors, that screen will not cure them or do anything other than tell you what channel is seeing a differential error and that does not fix the problem.
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