Mori Seiki SL1H Oak Board Build

[Wolfenstien]

Morning all,

I had started a thread in the acorn forum where I was trying to figure out if I could get away with using an acorn board for this machine. Final consensus was not and maintain all of the functionality. Ultimately I've decided to go the oak direction.

I need to take the time to put together a build log, but at the moment its just not the priority.

I am making progress putting the machine together. Tried powering up for the first time last night. Ran into a couple problems that I not sure how to deal with.

1) I'm getting a 5161 fault code (Unconfigured mini plc1 found.) I assuming this is the Add1616 board that I have attached to PLC expansion port 1. What I don't know is what to do about it. I've haven't found anything related to (Configuring) the expansion board in either the oak install manual or the add1616 user manual. Not sure if I'm just glazing over it (Was 3 o'clock in the morning) Anyway if I could get some direction on where to find the step for setting the expansion board up that would be most appreciated.

2) I've been getting an 412 MPG1 encoder error. (I'm guessing that is related to my spindle encoder that is plugged into Encoder input 5. (Not sure I haven't attempted to do anything with that yet).

3) My estop circuit is giving me issues. (well maybe) When I go into the I/O screen if I have the estop pressed and then I cycle input 11 output 1 fires. However as soon as I unpress the estop button output 1 opens which essentially cuts power to my estop circuit. I'm not sure if its because of the other faults that are active or if something else is going on.

4) After looking at this last night I realized I haven't seen comprehensive troubleshooting menu. (I.e. is there a place where all the fault codes are listed with descriptions?

Appreciate the help. This is my first build so I'm a bit green.

(Not sure if you want me to post a config file I feel like I haven't gotten anything set up yet so the file would be a little useless at this point.

[cncsnw]

1) Set Machine Parameter 900 = 1
2) Set Machine Parameter 348 = 0
2b) If you ever install an MPG handwheel, change P348 back to 15
3) Something is not right with your PLC program. OUT1 should not be on (1, green) if INP11 is open (0, red)
4) Not a comprehensive one, no. Built-in CNC11/CNC12 messages are in Chapter 15 of the Operator's Manual. PLC-generated messages (such as 9023, 9030, 5161 etc.) are not documented in any central place.

[Wolfenstien]

Thank you sir,

I'll try that tonight.

I think my e-stop situation is me just being dumb with my wiring. I'll review it to the schematic.

[Wolfenstien]

That worked nicely.

Btw the way the estop issue was some schmuck decided he could wire up the estop with one set of wires and kill to birds with one stone. Problem is osk wasn't seeing input 11 so was not closing relay 1. As mentioned earlier. Wiring now matches scheme and what do you know it works.

Thanks again.

Will let you know what dumb move I make next.

[Wolfenstien]

Good evening all.

Made a little progress. Estop is working like it should now.

Limit switches are working like they should which is nice.

I hooked up my DMM Dyn4 servos and they ran fine in the DMM interface benchtest and parameter setup. I need to follow up with DMM as they manual they provided says to stick the enable logic in active low (I don't know how to do this) Didn't see it as a parameter I could change anywhere.

Anyway went into cnc12 and changed my axis to X and Z and well as configured the counts for the spindle encoder. As soon as I engaged them I started getting Error 412 differential and quadrature errors. I'm not sure what thats all about. Could have something to do with that active low not being set correctly, but I'm not sure. I was also getting a 455 error.

I was very disappointed to read the post further down the page about configuring axises. Sounds like someone who has an oak and the same drives I have and the last piece of advise they got was buy something else cause the DMM stuff doesn't work yet. Thats a pretty lame epiphany for me at the moment. I specifically asked DMM prior to purchasing these motors and drives about the compatibility with the oak board as Centroid had mentioned that there had been a problem they were addressing. I was assured that the problem was taken care of and the drives would work directly with the oak board. Can't say much at the moment as like I said i'm not so sure I don't have something screwed up.

Was nice to see encoder counts working in cnc12 could watch the spindle counts as I moved it and when the drives were not configured (I.E they were set to N in the axis area the motors were doing some sort of slow turn and I could see the encoders counting away.

Getting closer. Hoping the DMM compatibility issue isn't a wall. Kinda thought I was in the clear on that until now.

If anyone knows what DMM means about setting the enable logic to active low that would be helpful.

Also guidance on the encoder errors would be nice as well.

Getting closer.

[cncsnw]

A mismatch in active-high enable vs. active-low enable would not cause encoder differential or quadrature errors. It would just cause the drive to fail to enable (or cause it to enable all the time, even without permission from the control).

Differential errors generally have to do with signal levels on the encoder lines. Either high is not high enough, or low is not low enough, or the common reference is not connected. A differential error is reported if, for example, the A and /A lines are both high, or both low.

Quadrature errors generally have to do with insufficient edge separation or with noise interference. A quadrature error is reported if the A channel and the B channel appear to have changed state simultaneously.

Assuming you have two servo drives, connected to the axis #1 and axis #2 headers on the Oak board, then you can temporarily suppress encoder differential faults by setting Machine Parameter 332 to 3. You can temporarily suppress encoder quadrature faults by setting Machine Parameter 334 to 3. This would allow you to work through any other issues (e.g. enable signal levels) and perhaps get the drives running, so you can more effectively troubleshoot the encoder signals (e.g. with an oscilloscope).

Just setting P332 and P334 to 3 (and maybe P333 and P335 as well) permanently, and calling the problem fixed because there are no more fault messages, would be unwise. These parameters are for troubleshooting only.

[Wolfenstien]

Time for my evening installment.

So here is how event transpired this evening. I had received the latest revision of the dmm softward from dmm earlier today. (Not sure why the one on the website is a year old...) but this new (2018) version basically allowed me to check box the active low. This box was not part of the previous version.

I still experienced the same issues I was having before so I went ahead and changed parameter 332-335 to 3 and and restarted the system.

At that point I was able to start moving the motors from cnc12. At first I had an issue were I would type a command for one or both motors and the wrong motor would go to the position. What is weird is that it was internal to the software. Meaning I would command X..... and the control would move the Z axis motor and the z axis readout would move. (Take a look at the picture in MDI below you can see I commanded an x and z position and yet the wrong axis went to the wrong position. I fixed this by making motor 1 the z and motor 2 the x and everything seems happy now. I would guess if this was a big deal to you it might require moving an axis cable on the oak board.

I was confused to find that I couldn't do any rapid moves in MDI (or maybe everything was rapid and the rapids are set real low)

I also wasn't able to use a command like G1 X1Y1 F200. Not sure why not. (Maybe is in feed/rev mode?) I did try it with a g94 and no difference.

So something I found odd. When parameter 332-335 are at set to 3 I was able to control the motors. However if I reach over and touch the spindle (which has an encoder on it) I immediately get a spindle axis 6 quadrature error. ( I thought with the parameters set to 3 I shouldn't see this?)

What is even more strange to me is that I can unplug that encoder and it still get the same error. Meaning I unplug the encoder from the oak board and cycle e-stop and it will clear it but then it comes right back (????)

I'm not really sure where to go from here. I'm going to shoot some screenshots to DMM or my servo parameters and see what they think.

Something else that was weird. Once I had the motors running I went back into the parameters 332-335 and set them to 1.
When I did that I was able to continue controlling the motors, but when I touched the spindle again, boom I got errors for both the spindle encoder and the drive encoders. Its almost like the spindle encoder is tripping them. I think I'm going to leave the spindle encoder unplugged for now. (Will need it eventually, but not for now)

Something is subtly wrong and I'm not really sure what it is. If anyone has a recommended troubleshooting plan I'm all ears. Happy to run any type of diagnostics that are recommended.

Thanks again for following along, and also thank you for the assistance!

[Wolfenstien]

Time for my evening installment.

So here is how event transpired this evening. I had received the latest revision of the dmm softward from dmm earlier today. (Not sure why the one on the website is a year old...) but this new (2018) version basically allowed me to check box the active low. This box was not part of the previous version.

I still experienced the same issues I was having before so I went ahead and changed parameter 332-335 to 3 and and restarted the system.

At that point I was able to start moving the motors from cnc12. At first I had an issue were I would type a command for one or both motors and the wrong motor would go to the position. What is weird is that it was internal to the software. Meaning I would command X..... and the control would move the Z axis motor and the z axis readout would move. (Take a look at the picture in MDI below you can see I commanded an x and z position and yet the wrong axis went to the wrong position. I fixed this by making motor 1 the z and motor 2 the x and everything seems happy now. I would guess if this was a big deal to you it might require moving an axis cable on the oak board.

I was confused to find that I couldn't do any rapid moves in MDI (or maybe everything was rapid and the rapids are set real low)

I also wasn't able to use a command like G1 X1Y1 F200. Not sure why not. (Maybe is in feed/rev mode?) I did try it with a g94 and no difference.

So something I found odd. When parameter 332-335 are at set to 3 I was able to control the motors. However if I reach over and touch the spindle (which has an encoder on it) I immediately get a spindle axis 6 quadrature error. ( I thought with the parameters set to 3 I shouldn't see this?)

What is even more strange to me is that I can unplug that encoder and it still get the same error. Meaning I unplug the encoder from the oak board and cycle e-stop and it will clear it but then it comes right back (????)

I'm not really sure where to go from here. I'm going to shoot some screenshots to DMM or my servo parameters and see what they think.

Something else that was weird. Once I had the motors running I went back into the parameters 332-335 and set them to 1.
When I did that I was able to continue controlling the motors, but when I touched the spindle again, boom I got errors for both the spindle encoder and the drive encoders. Its almost like the spindle encoder is tripping them. I think I'm going to leave the spindle encoder unplugged for now. (Will need it eventually, but not for now)

Something is subtly wrong and I'm not really sure what it is. If anyone has a recommended troubleshooting plan I'm all ears. Happy to run any type of diagnostics that are recommended.

Thanks again for following along, and also thank you for the assistance!

Sorry pics aren't in any sort of order.

1) Z axis errors but x axis ok. (This was when I first tried running)
2) X and Z axis moving x to z location and z to x location.
3) Spindle axis error on start-up after restarting the machine to try and clear codes
4) Motor configuration screen in cnc 12
5) DMM softward configuration screen
6) Spindle and Z axis encoder errors.

[Wolfenstien]

Just musing about this on my commute.

Seems like some of my issue is my spindle encoder. All I did there was cut the existing end off and wire in a db9. I believe my connections are correct, but the one thing I didn't see was a shield. I need to peel the cable back a smidge and see if it is even shielded at all. I wonder if I'm getting noise from that cable that is causing havoc elsewhere.

For the time being I don't mind removing that cable and going without if that gets everything else playing nice.

(Still confused why I would get spindle encoder errors when its not hooked up at all.....)

[Wolfenstien]

Swapped encoder on the spindle with one from a different machine. Same issue so I dont think it's the spindle encoder itself.

I still dont understand how I can be getting error 412 spindle axis 6 differential error when the encoder isn't even hooked up. Note this occurs even if parameters 332,333,334,335 are all set to 3.

Sigh......