CAMSOFT HELP....Wiring...Please help ASAP

[SMcDevitt]

I am helping a friend wire up his CNC lathe to Camsoft. He picks me because of my Allen Bradley PLC and Ladder Logic experience and mechanical engineering education.

I have traced all of the wires in his machine and all servo wires are running straight into an ICM 2900. The limits will also be going to the ICM but my limits are 24v so I was told to throw in a 5v/24v relay.

Its seems all the wires I have from the machine are single wire except the 5v and ground and MOCMDX, MOCMDY, MOCMDZ and its grounds for the servo motors. The single wires for the ICM I have are AMPENX, AMPENY, AMPENZ, MAX+, MAX-, MBX+, MBX-, INX+, INX-, MAZ+, MAZ-, MBZ+, MBZ-, INZ+, INZ-, MAY+, MAY-, MBY+, MBY-, INY+, INY-, HOMEX, HOMEZ, OvertravelX+, OvertravelX-, OvertravelZ+, OvertravelZ-.

I have Coolant, DecelX, DecelZ, Chuck Clamp, Chuck Unclamp, Tail In, Tail Out, Turret Forward, and all Turret Position switches to go to an Opto board. These are all also single wires.

Are there any more wires that I missed that I should have hooked up into the ICM or Opto boards to get this machine running?

My machine runs on 24v so I was told to throw a 5v/24v relay in the loop for my limits and then connect the 5v side of the relay to the ICM and 24v side to the machine. As far as I know relays and the opto boards work off of two wires. Where do you get this second wire from? Is there a common in the machine somewhere? The only wire I can think that would be a common for all of the 24v devices is a wire that plugs into the 0v side of the 24v power supply on the machine. There is also another wire that is plugged into this 0v terminal which runs to a field ground block. Could I just connect all of the second terminals for the 24v relays to these two wires? and then for the 5v side of the 5v/24v relay just to a ground screw?

Any help will be great.

[Karl_T]

Oh boy, too many questions at once. I can see this is your first ever refit and you're in over your head. I first suggest you spend a weekend reading the Camsoft install manual. I'd also read the install manual for your motion card. Is this a Galil card? And what is the model number. Same question on your I/O card.

Lets just do limits first. Many Galil cards, not all, have opto isolation on the inputs so you can use 24 volt. Check this out first. The galilmc.com website has a GREAT install manual for your card.

I wire nearly everything sourcing. I'd put the DC common (0 volt) on pin INCOM on the galil ICM.Then run your power out to the switch and the return wire back to your limit input on the Galil ICM. I'll tell you now this is backward from the default and you'll have to add this to startup.fil COMMAND CN 1,1

As you wire each switch have your control running and make sure you can see it change state in diagnotics.

The first refit is quite a challenge for anyone. READ READ READ and go slow.

[SMcDevitt]

Yes this is my first retrofit. I have read the camsoft manual and to me it jumps all over the place so I was taking it one by one.

It is the gailil card DMC-18x2 and like I said we are running the ICM 2900. I know the ICM 1900 has 24v Inputs and outputs and the 2900 only has 24v outputs and 12v inputs. The guy who told me to use the 5v/24v relay for the limits was a guy who was givin to us by camsoft to call as a retrofitter and he said we dont have to get the 1900 and just to use a relay. I can isolate from 5v side of the relay like you said with the incom and limit input but the problem is the single wires I have from the machine for the 24v side.

As I mentioned in the post, all I have is single wires coming from the machine and no return wire for anything except the 5v and ground and MOCMD"n" and ground for each servo. Is the return wire for limits going to be this so called common I think is what is originally plugged into the 0v side of the 24v power supply on the machine?

The wiring diagrams for the machine have me taking the wires from the original connectors that plugged into the motherboard of the machine that go to the amps and limits.

To sum that up, supposing the wires in the 0v side of 24v power supply is the limits common...I wire the 0v from my 5v power supply to the incom and the 5v side to the relay, then I make my own return wire from relay to the limit input. I then take the 0v side of the 24v power supply of the machine and plug into 24v side of relay, then the 24v side of the power supply should run to the so called common that was in the 0v side of the power supply. Then the single wires from the machine would be the return wire for the limits to go to the 24v side of the relay. Is that correct?

I/O card is is a AdlinkTech pci 7296 for the Optos.

[Karl_T]

OK, if you don't have Opto's put them in. I'd use this board,Opto 22 Circut Board G4PB16H. Here's one on eBay:
Opto 22 Circut Board G4PB16H - eBay (item 380285589762 end time Dec-04-10 11:04:33 PST)

Then fill it with opto dc inputs that use 5V control. Again, I buy them on eBay all the time. You should use a small 5V power supply to power this board. You'll need it for the optos going to your 7296 card. You'll also use the same DC inputs on that card.

I can't answer the question on your specific machine. Understand the concept: Each input is just a light switch circuit:camsoft detects if the light is on, the light switch is whatever input you're working with. If you use the above components the little LED on each opto lights when on (circuit closed). You can get that working before attaching to the 2900 with no fear of breaking something. Then just do the 5 volt side to the 2900. Make sure the jumper to take 5V from the PC is removed.

again RTM,RTM,RTM. Get the galil install manual also. Its all in there. Did I forget to mention, Read The Manual.

Karl

[SMcDevitt]

I know how the Optos work and understand how you told me to isolate the limits on the ICM, they are simple relays or light switches like you said. But without that return wire its a dead circuit. So really the most important question out of all this was if I needed to find these individual return wires or what I was hoping, a single common wire in the machine. That you said you couldn't help me with. I was looking for an easy answer but now that I know there is a retun wire, I will just have to check for continuity in the hundreds and hundreds of wires.

We do have Opto boards and we have a 5v power supply for the logic and also an extra I can use to isolate on the ICM like you said rather then using the TTL. I was told by the retrofitter that camsoft recommended to me that the servos and limits have to run into the ICM. Everything else I listed going to my Opto boards will be 24V because thats what the machine is and that is why I need to put the 5v/24v relay in for the limits because the limits go to the ICM as I was told.

I downloaded the Galil Manual last night and Im gonna read through that as well.

Of the subject of limits, the servos, is the MAX MBX INX AMPEN just 1 wire or do they also posses a return wire?

And is there anything else going into the ICM that needs a voltage different then 5V?

And is there anything I am missing from my original list to get the machine to run? I listed all the wires I have.

[Karl_T]

...
Of the subject of limits, the servos, is the MAX MBX INX AMPEN just 1 wire or do they also posses a return wire?

And is there anything else going into the ICM that needs a voltage different then 5V?

And is there anything I am missing from my original list to get the machine to run? I listed all the wires I have.

Get all your I/O running and debugged before you touch the servos. There's a REALLY GOOD section on servo wiring in the manual.

For servos, wire and check encoders first

then power wiring to servos

then galil wiring to servos. I'm doing one today and have these connections on X:

Galil 1 MOCMDX X.32 signal
Galil 1 AnGrnd X.35 signal ground
Galil 1 HOMEW X.42 servo fault NOTE: I'm out of inputs, go to one on your Opto board
Galil 1 AMPENX X.40 servo inhibit


I'm sure there's something missing. There always is <VBG>

Karl

[HuFlungDung]

I don't think I've seen a machine that doesn't use the machine base as the ground return. The power supplies ground to the machine, but it can pay to run a ground wire from the ICModule to the main chassis where the various power supplies are grounded. Just in case there were to be a concatenation of bad connections through rust/paint/corrosion, this will ensure that the ground return is not intermittently 'open'. You can check the potential between the signal wires and ground with a VOM to ensure that the voltages are what you expect them to be, before you make the permanent hookup.

[Al_The_Man]

What I suggest is downloading the Galil App note 1427, there are also a few more that deal with ICM1900/2900 and Opto's, also the Opto-22 site will give you the logic requirement for the boards and the modules.
This shows how you can connect the 5v outputs for sink or source as needed by whatever Opto board you are using.
I always use the PC 5v, +ve & -ve to feed the logic side of the Opto board, if it is the non-isolated type.
I would suggest running a -ve back for common as opposed to using the machine ground, in spite of the fact the PC common is at ground potential.
Al.

[SMcDevitt]

I don't think I've seen a machine that doesn't use the machine base as the ground return. The power supplies ground to the machine, but it can pay to run a ground wire from the ICModule to the main chassis where the various power supplies are grounded. Just in case there were to be a concatenation of bad connections through rust/paint/corrosion, this will ensure that the ground return is not intermittently 'open'. You can check the potential between the signal wires and ground with a VOM to ensure that the voltages are what you expect them to be, before you make the permanent hookup.

What I'm looking for is a return wire from all of my limits. I thought it could have possibly been this wire coming to the 0v side of the machines 24v power supply.

Is the return wires just a ground?

[SMcDevitt]

What I suggest is downloading the Galil App note 1427, there are also a few more that deal with ICM1900/2900 and Opto's, also the Opto-22 site will give you the logic requirement for the boards and the modules.
This shows how you can connect the 5v outputs for sink or source as needed by whatever Opto board you are using.
I always use the PC 5v, +ve & -ve to feed the logic side of the Opto board, if it is the non-isolated type.
I would suggest running a -ve back for common as opposed to using the machine ground, in spite of the fact the PC common is at ground potential.
Al.

You say run the -ve back as a common. Now will this run to all my optos and icm as the return wire for all my limits?

[HuFlungDung]

What I'm looking for is a return wire from all of my limits. I thought it could have possibly been this wire coming to the 0v side of the machines 24v power supply.

Is the return wires just a ground?

No, a limit switch does not consume any power, it is basically 'one wire' going to and from the switch. It needs to route power from a power supply to the device that detects whether or not that circuit is interrupted. Then, after passing through this detection device, it would go back to the common ground.

[SMcDevitt]

No, a limit switch does not consume any power, it is basically 'one wire' going to and from the switch. It needs to route power from a power supply to the device that detects whether or not that circuit is interrupted. Then, after passing through this detection device, it would go back to the common ground.

OK, Is this correct?




Remember my limits are 24v so I have to throw in a relay.

Or it would be this if my limits were 5v