Format for "Send Command to Card"

[squarewave]

What is the proper format for sending a command to the motion card in the diagnostics screen box "Send Command to Motion Card"? I'm trying to get the last error code by using a TC command, but it always says "unrecognized command". I've tried several other valid Galil commands with the same result.

Do I need quotes, parenthesis, colon, etc?

Thanks for any insight anyone can provide!

[HillBilly]

COMMAND TC

[squarewave]

Thanks Hillbilly. That did the trick. I knew that was the format for use in the .fil files, but it never occurred to me that it would be required in the text box!

The TC command didn't give me any useful information, but the SC (stop code) certainly confirmed my suspicion. My motion is stopping from noise in my limit switch wiring. It is happening so fast that Camsoft is not responding to it, but the motion card is.

Now that I know the problem, all I have to do is figure out how to fix it!

[Al_The_Man]

Are you using opto isolated 24v inputs or 5v off the card?
Al.

[squarewave]

I'm using an isolated 12V to power them. If I have a 24V supply, I'll change to that to perhaps increase the Signal to Noise ratio, if you think that might help.

I've read people are having success with capacitors on the inputs at the ICM 1900 as well.

I also have some ferrite cores ordered that should be here shortly.

Al, you recommend tying all of the power supply 0V lines together at a common place on the machine chassis. Do you recommend doing that for the limit switch power supply as well, even though the Galil manual states "To take full advantage of opto-isolation, an isolated power supply should be used to provide the voltage at the input
common connection. When using an isolated power supply, do not connect the ground of the isolated power to the ground of the controller."?

[Al_The_Man]

I have always grounded my supplies and systems to a central ground plate, I just use opto isolation to go between voltage standards.
I also take my PC power supply common to the same plate, rather than allow it to just ground through the mother board.
In the case of Galil, I ground the 5v common at the ICM or other breakout board etc.
I have never had spurious trips due to grounding problems.
Al.

[Karl_T]

FWIW, I do it the same as Al. I also have all my limit switches NC (normally closed) and run the power to the switch and then to the galil input. You won't get noise this way, its always powered with you're good to run. (And if a wire ever breaks, you're shut down) One of my machines uses 12 volt. Note if you wire your switches this way you have to change the default polarity with COMMAND CN 1,1

Karl

[squarewave]

Thanks. My switches are also NC, but with an isolated power supply.

To verify that the problem is the limit switch wiring, I disconnected the switches at the ICM and told the motion card my switches were normally open (CN -1). The machine performed just fine with zero issues.

An electronics friend also mentioned the opto-isolators (on the motion card) have a limited life and the LEDs could be becoming weak. Has anyone had that issue?

I'll be checking grounds and trying the common ground approach. Thanks much for all the great input and suggestions.

[Karl_T]

The opto isolators are in the ICM.

I buy my parts used. I have an 1900 where the inputs didn't work. I'll sell it to you cheap <Grin>

Seriously, do you have any spares. My first move would be a brain swap <entire computer with galil and I/O card> Cuts the problem in two.

If its still in the machine, i'd jumper the suspect limit. if you still got trouble, then I'd swap ICM (do this last cause its a big job)

All this after you got the wiring right

Just a suggestion. other routes are possible. the whole idea is to start dividing the problem in two.

karl

[Karl_T]

Mind if i go Off Topic? About four years ago you had a lot of issues with a wire EDM. Did you ever get it running right? What was the solution? i just reread that old thread, it involved going too slow and stalling out.

If i ever get time, i have a wire EDM to put camsoft on.

Karl

[HillBilly]

I had some proximity switches hooked to a Galil that would speratically trigger the inputs. I put 2k resistors across the inputs at the Galil to require more current in the loop than 1mA.

Noise can be a BEAR on an EDM!

Darek

[squarewave]

Karl - Thanks for remembering. This is actually the same machine. I have taken a multi-year hiatus from my machining hobby. I had a need for the wire edm for a family project so I took some time to get it up and running. It brought back a lot of memories! I've actually solved several problems in the process so it has been a useful exercise. Ferrite cores are definitely your friend when you have noise issues. They cleared up my keyboard and mouse issues. Just put them on the PS2 cord right as it enters the computer. I've also put them on the limit switch wires, but haven't tried them out yet. I also got some capacitors to go across the switch inputs on the ICM if the ferrite is not enough. I'll report back when I've had a chance to really try it out.

By the way, I'm pretty sure the optos for the limit switches are on the motion card. The optos on the ICM are an option; but the ones on the motion card for the limit switches are standard.

Darek - Yes, noise is a bear on an EDM. I hadn't thought of your suggestion about the extra resistor. I'll add that to my arsenal listed above. Luckily, a lot of people are detailing their problems with Variable Frequency Drives, so I have learned quite a bit from reading their posts. If I get my noise issues sorted out, I might actually be able to concentrate on the software!