I think the encoder phasing is correct.. (not 100% sure) but this unit was working perfectly before..
Anyhow, I have been trying to get this servo on-line and working again for the past 2 or 3 weeks now. I have re-routed grounds to a "star" format..(as close as I could get it).. I have switched servo drives, hooked up and un-hooked shields.. NOTHING IS MAKING A DIFFERENCE.. grrr.. (I'm getting so fed up with this thing I am about to scrap it out)
Look,,, this is not brain surgery.. When I first got this package, (Camsoft, Galil 1832, ICM2900, etc),, it all worked perfectly. I hooked it up to a small (300 watt) table-top test servo and servo drive and I quickly found out what an "Un-tuned" servo was and it took me less than 20 minutes to figure out how to get it tuned or at least working within the parameters I need. (which are very loose by cnc standards). The single phase servo package worked perfect over and over for months while I played around and learned the camsoft software. Then I hooked up to a 3 phase servo. What's so different right? Its just more power. Sure enough, after I was done wiring it, I put it into a test and it worked perfect. (after a quick tune). I hooked it up to my load and again it worked perfect.
Then I decided to hook up the lifting part of my machine. Using a 1.5 hp motor and a 5hp VFD. I programed the drive to respond by way of the OPTO22 relays and the 24volt control strip. Made it all work. Then, as soon as I went to test the servo drive and the lifting device, nothing has been the same since.
First I found my 5volt supply start tripping out, then I find the encoder simulation port on the servo drive sending ghost signals to the galil card.
The problems just keep adding up. Solve one, another pops up.
I have a feeling that VFD screwed up the galil card or something.
I'm at my wits end... I knew this was going south when we started talking about grounds and ground loops.. Something just was not adding up but it almost made sense because my control box is powered by 2 different power supplies. I use 110V from the wall to power all controls and I use a 15hp rotary phase converter to get 3phase to the servo drive.
I thought perhaps there is a ground differential or something happening because of the fact that both the 110volts for the control side, and the 480 volts for the power side were coming from the same 240volt supply. I know it sounds weird but it looked good on paper and when I originally wired it all up, it worked like it should.
So I spend $175 on their software to find something wrong so I can send the card to them and spend more money having them fix it. (why does that not sit right with me?)
This card has already had 2 other malfunctions that were covered under warranty. (but I guess I should make sure its the card before I rant about that)
Thanks for the suggestions AL and everyone else who has helped me in these last few weeks.
Murphy
(Everything that can go wrong, has gone wrong)  |