E-Stop error Dynapath Delta 10

[boysandjeep]

I'm new to the forum but I've been reading for awhile. I just purchased a Clausing knee mill with a Dynapath 10 controller. I have my phase converter hooked up, generated leg on the center (L2), so clean power to the controller. It seems to come up fine but I get an e stop error. There is an old post that addressed my problem but it’s not the same issue.
The old thread was helpful and allowed me to fix some improper wiring from the guy I bought it from. From the old thread started by buba447 & CNSKI;
“A 24vdc signal is sent out from pin J2-34 to TB18-1 on the MTB panel, then out via TB18-2 to the Emergency stop PB1. The string eventually returns to J1-9 on the CNC's DC I/O board with 24vdc” (reply from Macy41)
I rewired based on the above and I now have 24 V (25.3) going to J1-9 (Program Inhibit) via J6-6 but I still get an e stop error. Does anyone know if there is perhaps another input that needs to be high? Perhaps J3-1 Enable E-Stop (this was wired as the source of 24 volts for the e stop string when I got it.) Is this an input or output?
I also get 24v at J1-16, (Not E-Stop) as I think I’m supposed to based on the wiring diagrams on the Dynapath website. (Ref. 4201924) I don’t have any connections to J3 on the I/O board, should I have? I also checked all of the resistors on the I/O board and they are good.
Any help would be greatly appreciated.

[jagardner4]

A Clausing with a Delta 10 control used what DynaPath called an MCP (Machine-Control Package.) The correct wiring diagram for your machine is most probably the schematics under part number 4203642 on the DynaPath website.

The J2 connector on the DC I/O board (in the card rack) is the DC Outputs. Correspondingly, the J1 connector on the same board is the DC Inputs. J2 pin 34 is an output called "Z Move Req Lamp," a signal used on a 2-axis mill.

Referencing page 4 of 5 of the schematics 4203642:
-The E-Stop string starts at J2 pin 14, goes onto the MTB I/O card and is connected to J3 pin 1 on this card.
-There should be a wire going from J3 pin 1 to TB18 (pin 1?) on a card in the pendant. Although not shown, the signal passes through the K1 relay contacts and then shows up on TB18 pin 2 (lower right corner of sheet 5 on the schematic.)
-The string now continues through the E-Stop mushroom pushbutton on the front panel. I think the diagram maybe incorrect, because the overloads shown are definitely in the lower cabinet, but the string should end up on TB2 pin 2 back on the MTB I/O card (back on sheet 4.)
-The string now continues through all the overtravel switches (or the closed dip switches if overtravel switches aren't used), to end up on J1 pin 16, labelled 'Not E Stop', on the DC Input Connector.

Clear as mud, right? Suffice it to say, your E-Stop string should start at J2 pin 14 and return to the control on J1 pin 16. The +24VDC that returns to this pin also should pick up the coil of RL3, the pilot relay for the MCC contactor.

[boysandjeep]

Thanks for the response, it makes perfect sense but it tells me it was wired correctly and I wired it wrong. So my real problem seems to be I don't have 24 V out at J2 pin 14 (J3-1). Any ideas there?
What I don't understand is even with my improper wiring I do have 24 V at J1 pin 16 so I should have 24 volts on pin 13 of RL3 and that should clear the e stop error. Or does the e stop error show up because I don't have an output on J2-14?

[jagardner4]

If I've looked at the correct PLC listing, the 'Enable E Stop' output at J2-14 and the input at J1 - 16 should be high (+24VDC) for the control to come out of E-Stop.

Check to see that the control is not in TM5 (Readout) mode by going to the Setup mode (Mode 5). It should be in TM0 - Normal or TM1 - Rapid Override. Being in TM5 or having a servo error are the only two things that can keep the control in E-Stop.

If neither condition is present, check Word 8, Bit B (as in Boy) in the PIC I/O table. Get to the PIC I/O table by pressing the Fault/Status key, then the soft key labelled 'PIC Table' (or something like that). Page forward one page to get to the outputs, locate the line labelled 'Word 8', then scan across to under the column labelled 'B'. The bit should be a '1' if the output is enabled.

If this bit is a '1' (and not '0'), and the physical output is still not at +24VDC, then I would strongly suspect a bad I/O board.

If the bit is a '0', then you may have a more ominous problem. Unfortunately, I've seen where the PIC (the programmable interface), which is programmed onto an EPROM chip, has been corrupted. If this is the case, you may have to call DynaPath and spend some money to get a new chip.

Post back how you make out and I'll try to monitor for your answer.

[boysandjeep]

I fixed the wiring so the e stop is hooked to the J2-14 output, 0 volts. But I think that's a moot point. I checked the Word 8 Bit B and it is 0. I actually got the Dynapath manuals with the machine and someone had written 0 next to Word 8 bit B. So this must have been an existing problem.
I wanted to upgrade to a Delta 20 so that I can drip feed and I got a quote for $850 from Parts and Smarts to upgrade but I wanted to make sure the machine worked before before upgrading. That is still an option.

With it wired incorrectly the Servo Dynamics 1525 drivers kicked on. I tried to rotate the ball screw, I couldn't when the amps were on and could turn easily with them off. No LED lit either so I think the drivers are working.

Now I have to decide if I want to put more money in this controller or upgrade to something else. Then decide what else.

Any suggestions?

Thanks again for your help.

[jagardner4]

Based on the fact that the physical output reflects the information in the I/O table, I would guess the DC I/O board is good. That means you can't get rid of the E-Stop message because of the programming on the PIC EPROM. Based on this, I am thinking the EPROM with the machine code of the programmable interface has become corrupted.

Before spending $850 with Al, I would contact DynaPath and try to get a replacement EPROM. The EPROM I'm talking about is on the PIC Processor card, which is next to the DC I/O card in the card rack. The board has no connectors along the front edge. Find the correct card, pull it out of the rack and locate a socketed EPROM chip with the number 4201638F on the back. 'F' means it's a revision 6 program. If it's a different level, I think rev. 6 will still work.

Call DynaPath and ask them how much they want for a replacement. It shouldn't be that expensive. It use to be less than $100.

The upgrade that Parts and Smarts is offering is probably a processor card swap and won't affect the E-Stop issue. If the new EPROM fixes the E-Stop problem, then you can consider upgrading the control.

[boysandjeep]

Thanks for the info, I called Dynapath Fri. afternoon, but Glenn had already gone. I will try again Mon. I pulled the boards and looked at the PROMS, On the PIC card the PIC/MILL PROM is marked 4201642F. The 4201638G PROM is located on the processor board. Are you sure 4201638 is the right PROM and not the 4201642?
I also found a 4201642E & a F PROM in the door. It seems this machine has a history of E-stop issues. It came with the Installation manual and the operator manual. So I've been looking through them and every where there is a reference to the e stop it is circled. The manual seems to indicate that you can update the parameters on the 4201638 PROM but nothing about the 4201642. Not sure I'm ready to try doing that anyway.

I'll post more as I learn it.

[jagardner4]

Oops! Faulty memory on my part.

The 4201642 is the right part number. The other number is for the parameter prom.

Sorry for the confusion.

[boysandjeep]

I called Glenn at Dynapath on Mon. and he suggested that I should try the EPROMs that I already have. I installed the E Rev and same problem. With nothing to lose, I installed the F Rev that was marked "BAD". Much to my surprise when I released the E stop button the servo's kicked on and the E stop error cleared.
Now all I had to do was reference the axis, I got y and z to reference but when x hit the switch it just kept going until it hit the end and the servo errored out.
I checked out the switch and it's working. When closed Word 001 Bit C switchs to 1 and is 0 when open so I think every thing is working I just don't know why it does not recognize that it hit the stop.
I will call Glenn in the morning and see what he says.
I'm really happy that at least I can get the machine to move.

[jagardner4]

The marker channel on your X axis encoder seems to be out. Incremental encoders have three channels: the A and B quadrature channels and a marker channel (usually seen as a single strobe per rev of the encoder.)

The only time a marker is used on a DynaPath mill is when an axis is referenced. The axis will move correctly and under servo control if the A and B channels are working.

When you request an axis reference, the axis moves in the direction indicated until it sees the reference limit switch, then continues to the nearest marker. If the marker channel is missing, the axis will simply continue moving until it hits the limit.

[boysandjeep]

So now the question is how do I fix it? I took the housing off the back of the drive and the encoder inside is a SUMTAK OPTCODER LBL-015-1000 do I try and find a replacement? Or is it fixable? The help has been great.

[jagardner4]

The encoder is not usually fixable. DynaPath has a plug-in replacement. Be aware that you can probably source the encoder elsewhere, but it doesn't have the plug, so you'll have to deal with the wires.

You can check that the problem really is the encoder by moving the X axis motor cable over to the Y axis motor (with power off, of course). I know the Y axis cable won't reach X axis motor - just let it hang, the control won't fault unless you try to move the Y axis.

Now power up the control and drives as you normally would and ask the X axis to reference. The physical Y axis should start to move. When it does, push the X axis reference switch down by hand. The axis should stop moving within a motor rev, and the axis is now thought to be referenced by the control.