Novamill timeout M5

[shargreaves]

Hello, I have come back to my Novamill after about a year to set it up for a repeat machining exercise. The machine homes, jogs, runs a program etc but when it gets to a spindle stop command it times out. It was upgraded march 2010 with all the latest stuff and USB connectivity. Trying to solve this problem is costing me anormous amounts of time so I really need help! I noticed yesterday that the control box says it must not be PAT tested but it has been, twice! Could this be a problem or a red herring?

[Steve]

I am unsure as to what your problem is.

In the MINT control there is nothing that should cause the program to lock up after the M5 command.

Does this happen every time you stop the spindle in jog mode and program? Or is the problem intermittant?

There is an output from the spindle drive to indicate zero speed. This is used to activate the guard release relay which then unlocks the door. This would not however stop the MINT.

PAT Testing could do various things to the machine. The first issue would be the Insulation test. If this is done for too long a period it could damage the insulation and functionality of the EMC mains filter. The other issue would be if the USB cable was not disconnected before the test was done there may be some damage to the Control card on the USB card

There are a couple of things that could be relevant.

It could be a problem with electrical noise crashing the Mint. When the spindle stop command is issued there is a delay until the speed reaches zero then the Guard relay energises and the Guard solonoid releases. There is a suppressor fitted on the Guard solenoid.

If you download the latest version of VR Milling 5 from our website. Install this version.

Then install the easyupgrader software from the same download and check the machine firmware . Make any updates that are required.

[shargreaves]

Thanks for your help with this.

We have software version: 5.43.0.580 downloaded a couple of days ago.
The machine was upgraded around march 2010 to ver: H02130
Easy upgrader reports that the machine is up to date.

The problem is this:
I can start the spindle and when run at speed it locks the guard door.
If I stop the spindle it comes to a halt and the guard lock releases but the little win7 spinning circle thing just carries on as if it is waiting for something.
Further if I open the guard the message 'guard open' displays but when I shut it again the 'guard open, message remains.

Regards
Steve

[Steve]

Does this happen every time you stop the spindle?

If you open the guard and close it againg without having run the spindle does the guard message apear and disapear as normal?

Have you tried another computer with the machine? It could be something to do with Win 7 or the USB driver. Is this a 32 bit or 64bit system?

[shargreaves]

Yes, every time.
If I open and close the door without running the spindle the message appears and disappears.
It is 32 bit.
I have tried it on another machine, my laptop has the software on it and it does on that too.

[Denford Admin]

If I open and close the door without running the spindle the message appears and disappears.

Do you mean the guard open message appears and disappears ?

Did this machine work ok previously ? What has changed ?
Please can you open VR Milling, connect to the machine and go to the menu "Help > Support Me !"
Then post that info here or email to info denford co uk

[Steve]

It sounds like the processor is crashing as the spindle stops or the guard is being unlocked.

What speed are you asking the spindle to start at?

Have you tried starting it and stopping it from high speed? Have you tried from a slow speed?

[shargreaves]

At 150 rpm it starts and stops & the door guard message works properly
At 1000 rpm the guard lock actuates but when the spindle is stopped it crashes
here is the support me file:
When I tried to send it direct to Denford I got: "Asynchronous socket error 10060"
What does that mean!

[Denford Admin]

When it locks up try pressing ESCape.
Can you then do any other M commands ? ie, start the spindle again with M3 ?

Also, try running at 450 RPM then stopping, then try 550RPM and stopping.
If 450 works ok and 550 dosn't then it seems that the logic is hanging up waiting to see zero speed from the drive.
I'm sure these machines don't have a zero speed input so the input (input 7) which enables the feature may have blown...

Run VRMilling, connect to the machine and goto menu "Setup > Debug machine IO" then locate the onscreen LED for input 7 (hovering over them brings up a hint)
Let us know if input 7 is made (lit up) and changes state when running > 500RPM

[Steve]

The output is somthing I suspected, it is in the mint but not wired on this machine.

This could have been damaged during the EMC testing if the USB had not been disconnected.

[shargreaves]

When it locks up try pressing ESCape.
Can you then do any other M commands ? ie, start the spindle again with M3 ?

Also, try running at 450 RPM then stopping, then try 550RPM and stopping.
If 450 works ok and 550 dosn't then it seems that the logic is hanging up waiting to see zero speed from the drive.
I'm sure these machines don't have a zero speed input so the input (input 7) which enables the feature may have blown...

Run VRMilling, connect to the machine and goto menu "Setup > Debug machine IO" then locate the onscreen LED for input 7 (hovering over them brings up a hint)
Let us know if input 7 is made (lit up) and changes state when running > 500RPM

Pressing 'escape' doesn't work.
Up to 450 works, 550 and above doesn't.
Input 7 is lit up all the time (along with input 15) it doesn't change state at all.
See screenshot below.

[shargreaves]

Hello

Can someone reply please?
I'm feeling a bit lonely!!

Regards
Steve

[Martin]

It does now appear that input 7 has blown when the PAT test was performed.

[shargreaves]

Ok, so can it be fixed?

[Martin]

Yes, we normally ofer a service exchange on Baldor boards. If you are in the UK contact Denfords for the cost.

The alternative would be to alter the logic in the mint file to remove or invert input 7 from the spindle section. This would leave the machine as a one off & would need altering each time the software is updated in future.

[shargreaves]

Hi Martin, I can't believe you posted at nearly 3 in the morning, that is spectacular!!!!!
I will acontact Denford but in the meantime can you talk me through this logic alteration please?
I don't have any previous experience of this sort of thing so be gentle!

Thanks, Steve

[Martin]

It takes me a while to get to grips with the mnt file but this is the section that I presume would need to be altered.

' Stop the spindle
Sub SpindleStop( )
Dim ZSRAvail=0
If OUT0 And (Spindle > 500) Then :Rem if spindle running > 500RPM
If INSTATEX.7 Then ZSRAvail=1 :Rem if so is ZSR input working ?
OUT0 = 0
If ZSRAvail Then
Repeat : Rem if zsr available then wait for that
Until !INSTATEX.7 Or !INSTATEX.STOPSW
EndIf
If !ZSRAvail Then
Wait=Spindle :Rem otherwise just wait a time
EndIf
EndIf
OUT0 = 0 :Rem stop spindle now
Wait=200
SpindleRunning=0
End Sub

I will try to compile a file & post it later.

[shargreaves]

Thanks, Martin, I really appreciate your help.

[Martin]

Hope this works.

Make a copy of the original files first.

Then copy these files in to the VRMilling directory.

[shargreaves]

Thank you my friend.
Fingers crossed!
I will go into work tomorrow and try it out.
I'll report back
Steve