Ajax 3rd party to Mitsubishi inverter - Need Wiring Help!

[cncsnw]

Well, if you don't bother to connect the inverter fault signal, then you have two PLC inputs available.

Your axis selector requires at least two inputs; your increment selector requires at least two. You could conceivably wire those things into the MPG header on the MPU11; but I think you said you also want to use an MPG.

You could leave three of your limit switches off the PLC (but perhaps still wire them as directional inhibits to your drives). The PLC only really needs to see the switches that you are going to home to. You can probably trust the software travel limits to keep you off the other end.

I don't think you need to tie up INP13, INP14 and INP15 with enable detection. If your objective is to detect when GPIO4D has set the axis enable outputs, your PLC program can just look at OUT17, OUT18 and OUT19 directly. The GPIO4D doesn't need to send them around to its own inputs just to see what state they are in.

So on review, you can probably free up enough inputs to make it work.

Feedrate and spindle override pots would require analog inputs, which you don't have at all.

[nvdave]

That's more encouraging - thanks cncsnw for taking another look!

On the mpg header, I wired into the pins for x,y,z axis select; 1x,10x,100x multiplier; wheel a,a-,b,b-;+5vdc,5vdc com. I assumed that these pins were for these connections. I saw in a post on Ajax where you said that the common for these switches should go to 5vdc com, so that's what I did - haven't tried it yet.

As far as the inputs 13,14,15 go, it seemed strange to have to lose 3 inputs just to loop a signal right back into the board, but I was following Scott's diagram for the AMC 30A8 drive, which has the exact same pinout as my 16A20AC drives and he confirmed to me on the phone, that it should be the same for my drives. You guys all know much more about this stuff than I do. I also downloaded the brain that he posted to make the diagram work, although I haven't installed it yet.

If my assumtions on the mpg header are right, I should have just enough inputs, I think. x-,x+,y-,y+,z-,z+,jog-,jog+,cycle start,feed hold,e-stop,enable-x,y,z,spindle fault. This is 15 of the 16 inputs - I hope I'm on the right track here.

Regarding the spindle fault: is this the circuit that goes through the A,B,C contacts (whichever is NC) on the inverter and do I feed it the 5vdc+ from the GPIO4D power header?

I am attaching Scott's diagram for the AMC drive as well as inserting a link to my build thread with some pics of my machine. I hope you will check it out and tell me what you think.

http://www.cnczone.com/forums/vertic...tml#post883802

I'm sorry to be such a pain, but it is very much appreciated!

Thanks One More Time,
Dave

[cncsnw]

Yes, the axis select and increment select inputs on the MPG header are for those purposes. Ordinarily they are used with selector switches built into an MPG pendant and apply only to the handwheel, but I don't see any reason you couldn't use them to control the function of jog buttons as well.

Perhaps there are limitations in the Mach I/O system that prevents it from reliably reading the states of OUT17-OUT20. I have only used CNC11 software, which can read any of the output states without restriction. That would be a question for Ajax or Mach.

You "feed" the spindle drive fault inputs with whatever voltage source you have chosen for that bank of inputs on the GPIO4D. For each bank of four inputs, you choose a voltage, source, and direction (sourcing or sinking); you wire one side of a DC supply to the input common terminal for that bank; you wire the other side of the same DC supply to the other side of the input switches (e.g. the C terminal on the inverter's fault relay); you wire the switches (e.g. the A or B terminal) to the input points; and you make sure you have the right SIP resistor installed for that bank: 470 ohm for 5V inputs, 1K for 12V inputs, 2.2K for 24V inputs).

You would wire the +5VDC from the GPIO4D logic supply to the common of the fault relay, if and only if you have wired the 0V side of that supply to the OUT13-OUT16 common and have installed a 470-ohm SIP for R4.

[nvdave]

Thanks, cncsnw! It's a relief to hear you say the mpg header wiring should work.

I believe the 17-20 inputs are all used for the x,y,z,a faults, so I'm not really messing with those.

After asking you about the spindle fault, I realized I have it going into a bank that utilizes +12v and that I will have to use that same voltage through the contacts on the inverter, I have the 102 SIPS in place for that bank already. I've been very careful to install the correct SIPS for each bank. I appreciate you giving me the heads-up on the SIPS and all the wiring help.

I just powered-up for the first time since initial testing last night. Output 1 wasn't closing, which kept my e-stop circuit open. I believe it's because I need to jumper out all the unused faults and inputs. I did see all the limits clear and the estop clear on the diagnostic screen in Mach. When I bypassed the Output 1 connection, my drive enable leds lit up, so it's looking promising, so far.
I printed out the CNC11 manual and am going to use the software as I have read Scott suggest to check all of my inputs, etc. I am going to connect the inverter as per your and Al The Man's suggestions and see how that works, if the other I/O testing goes well. I plan to connect the analog out on the GPIO4D to the speed reference (terminals 2 and 5) on the inverter. According to the inverter manual, it ships with a default setting of 0-5vdc, which can be changed to 0-10vdc. I'm not sure what the GPIO4D outputs, can't remember what I saw on that.

Did you, by any chance, check out the build thread?

Thanks for all your help; I'll let you know how it goes.
Dave