Hardinge CHNC4 Retrofit

[lavrgs]

PROBLEM FOUND when I reinstalled the board I put the connectors in the wrong connector H11 vs H10...see I knew it was something simple 9_0. Let's see how it goes from here....I did get some bumpy action on the Z axis but I will have to spend more time checking.
Way back we changed the PID for the motors would that need to be changed again?

[lavrgs]

Getting the connector in the right slot did not instantly solve all the problems.

I did get the Z axis to move although it was not stable. I did find it moved in the wrong direction - I reversed it in the software - I read that may cause issues with the limit switches?
I was getting position errors so I had to reset in between moves. I will reverse the wires.
Lots of errors...
410 Z axis(1) position error 4
412 Spindle axis(6) encoder differential error 30
- there are all kinds of encoder errors; spindle X and Z.
I have reviewed the diag screen to set everything correctly - not forced etc
I have reviewed parameters to correct them from past debugging. The report above should represent the current status although I will add another later.

[cncsnw]

Since you are (probably) not using INP1 and INP2 for the actual Z- and Z+ limit switches, but instead (probably) have those inputs defeated with the DIP switches, there is no need to change the inputs that you are using when you toggle Direction Reversal.

If you are using the typical CHNC configuration, with the motor belted to the ballscrew, and with the encoder mounted to the end of the ballscrew (and not on the motor), then it is especially critical that the belt be tensioned correctly. Slop in the belt will lead to instability.

If you are getting "412 Spindle axis(6) encoder differential error", then you need to investigate and troubleshoot your spindle encoder, cable, and connections. Do all of your encoder signals still break out onto screw terminals mid-way between the encoders and the Allin1DC, or did you replace those runs with unbroken encoder cables?

[lavrgs]

Answers highlighted in red below. Perhaps my expectation are not set set correctly; the systems worked before the board/motor failure and the problems I am seeing were not exhibited before...once again I am convinced that something simple is the issue. I also realized the forced ready should be addressed.

If you are using the typical CHNC configuration, with the motor belted to the ballscrew, and with the encoder mounted to the end of the ballscrew (and not on the motor), then it is especially critical that the belt be tensioned correctly. Slop in the belt will lead to instability. I did change the belts so I will recheck

If you are getting "412 Spindle axis(6) encoder differential error", then you need to investigate and troubleshoot your spindle encoder, cable, and connections. Do all of your encoder signals still break out onto screw terminals mid-way between the encoders and the Allin1DC, or did you replace those runs with unbroken encoder cables? The cables are spliced. I am getting signal on the PID screen when I manually move the axes and spindle motor.

[lavrgs]

More thinking than doing recently but I have gone thru the wiring to ensure proper connections and make a couple corrections

In regards to the e-stop. On my mill when the e-stop is in the normal position the diag screen output 1 is active, when the e-stop is pushed output 1 is disabled. I expect the lathe should be the same but I had it manually overridden to activate. I believe the change to e-stop wiring has addressed that but I have not tested.

The one area I found that could be a cause for concern was that I had the current limit switches on the ALLIN1DC set to 12A and They should have been at 9A based on the servo motors I have. Could that have been the cause of servo motor failure???

[lavrgs]

i was fortunate to have Marc from CNCSNW come by to get me back to a running condition. This still means there is a lot of work to do but I am back to where I was before servo failure. Speaking of which, I believe I may understand the root cause of why the motor failed. The motor is apparently longer than original and because of that the axis could never get to the -X limit switch. essentially it got crushed 8-( Soft limits have been set up to avoid that but perhaps some alternate limit switch arrangement could make it fail safe. My enthusiasm for continuing the project had been stymied because I could not fully understand what caused the servo failure, now I'm confident enough to continue.

[cncsnw]

Correction: it was movement toward the X+ limit (the preferred homing direction) that was prevented when the servo motor hit the back of the bed.

The workaround for now is to home to the X- switch (cross-slide toward the back of the machine), then use software limits to prevent it going too far forward.

[lavrgs]

I have several tool offset questions ; primarily in regards to Z offset. I will measure relative to stock in the chuck. In the future I will set up a probe - I will make a stylus but for item # 2 believe I will need a flat surface on both sides.
1- recommendation for setting offset for dcmt21.51; should I touch off against the left edge of the tool holder and add 1/2 the width of the holder? How would probing work?
2- setting offset for tools that are facing +Z

3- I have a two hole holder for 5/8 shafts, I assume that the offsets will be set up for TX01 & TX02.

[lavrgs]

The fruits of the labor.
Now I need to attach the probe to my ALLIN1DC...

[lavrgs]

Still a lot to do to be fully working but progress is being made.
A bit of an update for the servo motor problem; The x axis servo motor had been replaced at some time; it was longer that the original. Bottom line it interfered with the bed. I had a clue early on as I was not able to trigger the -X limit switch, I just didn't see why...
This machine is not for production..(yet), it's a fantasy adventure, more expensive than a drug habit - the fact it's taken eight months to get back to it is completely my problem 9-).
During the downtime the collet closer was rebuilt, the seals in the stop cushion were replaced, the seals in the parts chute were replace AND it got shined up! The inner tray was bent - probably from hitting a chuck - that was straightened out.
After reinstalling the newly rebuilt servo motors and the Centroid ALLIN1DC, the machine was not happy and it was probably due to too much button pushing. Fortunately CNCSNW (Marc) was in the area one weekend and came over to get everything back on track. That left me at the point I was prior to the servo failure; meaning I still have a lot of work to do.
I just can't help playing with making parts so there is that distraction... However it does help to get me the setting the tool offsets dialled in. One of the first parts I made was a probe tip for my tool setter. I'm waiting for a cable so I can connect it.
I tested the collet closer and it works well...the collet closed signal doesn't come through - I believe it is related the collet closer pressure switch. I took it out today and there is a change in resistance when pressurized. From not quite zero ohms to not quite five ohms. Further investigation is needed. The switch should have the ability to adjust the pressure that activates it, I will have to mess with it some more.
My collet closer regulator has reached end of life - leaks like a muthah >>new one on order. I took it apart and it is rebuildable but that kit costs more than the exact same new regulator...
The next task that has been waiting for whatever, is cleaning the coolant tank. I have removed the plate that holds the pump and it gave me another point of access. The machine is located such that removing the tank is not possible 8-(. When I remove the chip tray there will be access from the top and through the pump opening. I will try and mix up the sludge and get it out some how...previous efforts did get some chips out along with whatever fluid was in the tank. I returned the fluids to the tank for further mixing...
My list of things to do is getting shorter;
I need to work on the cut off slide and
get the coolant system working.
There are still air leaks and I'm slowly getting them sealed. The new regulator should help.
I would like to figure out if there is a way to reduce the airflow the machine uses.
Fixing leaks has helped but I'm interested in hearing about mods that can reduce it from what the factory thought appropriate.
Lighting - The original Centroid retrofit did not control a light inside the cowling. I'm ok with an external switch. I just need to find where the original wiring goes. There is a panel at the top I could open but any insight would be appreciated.