help me decide how to drive my servos...

[CJdave]

I just bought a used 7'x10' vytec router that has been out of service for a couple of years. The control is junk, but the servo amps and all related power supply parts seem to be in great shape. machine was running when It was taken out of service.
I am going to run this machine with Mach3. This will be my first time retrofitting a machine. I have a plasma table that uses mach and runs steppers so I am somewhat familiar with the software. My problem is how to interface to the old servo drives. I have seen several different ways to do this, but don't know what is the right direction.
Is it better to:
A: use a drive card like the kflop, or Galil card? and if so how do I decide which one to use? And what else would I need to use these cards to run the existing servo amps? BOB?
B: Or is it better to go with something like the Gecko servo card because it accepts step and dir signals straight from mach?
Budget is definitely in mind here but I want a good solution and won't cheap out just on cost, I want to make money with this machine so It needs to be reliable.
Any input or point me in the right direction to read and learn would be appreciated. If I should be asking somewhere else on the forum please let me know.
Thanks
Dave

[Al_The_Man]

What do the existing drives use? step/dir or analogue?
The Galil card does not require a P.P. BOB.
Al.

[CJdave]

existing servo drives are analog. they use standard 10v according to the manufacturer.

[CJdave]

Information I have on the servo drives are copley drives Model 4122 operates from +22 to +90VDC unregulated power
supplies, and outputs 10A continuous, 20A peak.
The active logic-level of the amplifier Enable input is jumper
selectable to GND or +5V to interface with different control cards. /
Pos and /Neg enable inputs remain ground active for fail-safe
operation
TECHNICAL SPECIFICATIONS Test conditions: 25°C ambient, Load = 200μH. in series with 1 W., +HV = maximum normal value
MODEL 4122 4212
OUTPUT POWER
Peak power ±20A @ ±80V ±12A @ ±120V
Peak time 1 sec unipolar from 0A, 2 secs. after polarity reversal
Continuous power ±10A @ ±80V ±6A @ ±120V
OUTPUT VOLTAGE ±Vout = ±HV*(0.97) - (Ro)*(Io)
Ro = 0.18W Ro = 0.4W
LOAD INDUCTANCE Selectable with components on header socket: 200 μH to 40mH
BANDWIDTH Current mode: 3kHz with 200μH load at maximum supply voltage, varies with load inductance and RH15, CH16 & CH17 values
PWM SWITCHING FREQUENCY 25kHz
REFERENCE INPUT Differential, 94K between inputs, ±20V maximum
GAINS
Input differential amplifier 1:1 (Volt / Volt)
PWM transconductance stage Ipeak / 6V ( I peak = peak rated output current; 6V measured at Current Ref J2-9 )
LOGIC INPUTS
Input voltage range 0 to +24V
Logic threshold voltage ( LO to HI transition ) 2.5V ( Schmitt trigger inputs with hysteresis )
/Enable ( Internal jumper JP1 reverses logic ) LO enables amplifier, HI disables
( Default function with JP-1 on pins 2-3. For +5V enable and GND inhibit, move JP1 to pins 1-2 )
Time delay on Enable 0.9 ms after Enable true to amplifier ON, <1ms to disable
/POS enable, /NEG enable Gnd enables positive or negative output currents. +5V or open inhibits (<1ms delay)
( Setting of JP-1 has no effect on ground-active level of /POS and /NEG enable inputs )
/Reset LO resets latching fault condition, ground for self-reset every 200 ms.
Input resistance 10K pull-up to +5V, R-C filters to internal logic
POTENTIOMETER
Balance Use to set output current or rpm to zero. RH1 = 10 MW for Balance function, RH1 = 100kW for Test function
LOGIC OUTPUT
+Fault ( /Normal ) HI = Overtemp OR output short OR power NOT-OK, OR NOT-Enabled; LO = Operating normally AND enabled
HI output voltage +5V ( 3.3kW pullup resistor to +5V ) +50V maximum
LO output voltage <0.5V typical, 1.25V @ 250mA max, Ro = 5W ( mosfet on resistance )
INDICATOR (LED)
Normal Green: ON = Amplifier Enabled AND Normal ( power OK, no output shorts, no overtemp )
Red = Fault ( NOT Normal, see +Fault output above )
ANALOG MONITOR OUTPUTS
Current Ref ( current demand signal to pwm stage ) ±6V @ demands ±Ipeak
Current Monitor ( motor or load current ) ±6V @ ±Ipeak (1kW, 33nF R-C filter)
DC POWER OUTPUTS ±15VDC each output in series with 10kW
PROTECTIVE FEATURES ( Note 1 )
Output short circuit (output to output, output to ground) Latches unit OFF
Overtemperature Latches unit OFF at 70°C on heatplate
Undervoltage shutdown @ <20V <20V
Overvoltage shutdown @ >92VDC >129VDC
POWER REQUIREMENTS
DC power (+HV) Transformer isolated from power mains +22 to +90VDC +22 to +125VDC
Watts minimum 2.5W 2.7W
Watts @ Icont 25W 41W
THERMAL REQUIREMENTS
Storage temperature range: -30 to +85°C; operating temperature range: 0 to 70°C baseplate temperature
Notes: 1. Heatsink optional ( add “H” to model number) 2. Fan = forced air over unit @ 400 linear feet/minute
MECHANICAL
Amplifier case size 4.3 x 3.0 x 1.0 in. (109 x 76.2 x 25.4 mm.)
Heatsink Adds 1.50 in. ( 38.1 mm ) to amplifier 1.0 in. dimension. Same length as amp.
Weight 0.43 lb (0.2 kg.) for amplifier alone; heatsink adds 0.78 lb. (0.35 kg)

[TOTALLYRC]

I use the DSPMC/ip to run my mill with +-10v analog amps (copley) and it works real well. V2 of the DSPMC/ip has up to 96 I/O which is great for adding all kinds of stuff.

Mike

[CJdave]

Ok, The dspmc is one I am looking at. I have the chance to pick up a Galil DMC-2030 new for dirt cheap. Will this work for my application? I know it is a 3 axis controler, can I control the spindle with it? the machine has a VFD? If not can I still use the 2030 and control the spindle some other way?
thanks
dave

[Al_The_Man]

Ideally you would want a fourth axis if using XYZ at present.
If you got it cheap enough, get a price from Galil to upgrade to 4 axis, usually a firmware change.
Al.

[battwell]

as far as i know if using the galil plugin. you cant use the parallel port too so you need a 4 axis minimum controller if you want 3 axis plus spindle.

[TOTALLYRC]

Originally Posted by CJdave Ok, The dspmc is one I am looking at. I have the chance to pick up a Galil DMC-2030 new for dirt cheap. Will this work for my application? I know it is a 3 axis controler, can I control the spindle with it? the machine has a VFD? If not can I still use the 2030 and control the spindle some other way? thanks dave

If your vfd for the spindle supports modbus you could drive it that way.

Mike

[CJdave]

Originally Posted by TOTALLYRC If your vfd for the spindle supports modbus you could drive it that way. Mike

Just read through the manual for the VFD (IDM P5 series). It looks like it does support Modbus.
I can honestly tell you I have no Idea how modbus works, Is it something that is built into the Galil card, or will I need something else to run the VFD that way? I can pick up the Galil card for $175 so I would like to use it if it is posible, but don't want to make my life difficult if it's not going to work.
Thanks
Dave

[japroach]

It states in the manual "communication interface card SI-K2/P must be mounted.", but it looks like that is just a RS485-RS232 converter.

So I don't see why it can't just be connected to a PC via RS232 and controlled (although quickly browsing the manual I didn't spot a simple speed up/down command, the number of configs available is crazy ).

http://www.omron247.com/doc/pdfcatal...7P5man0606.pdf

[TOTALLYRC]

Originally Posted by CJdave Just read through the manual for the VFD (IDM P5 series). It looks like it does support Modbus. I can honestly tell you I have no Idea how modbus works, Is it something that is built into the Galil card, or will I need something else to run the VFD that way? I can pick up the Galil card for $175 so I would like to use it if it is posible, but don't want to make my life difficult if it's not going to work. Thanks Dave

Modus can be either serial or Ethernet in Mach3.
If you are just going to run the VFD and possibly a pendant I would stick with the serial Modbus. It isn't that difficult to setup and works well. Just don't use it for the e-stop or any other time sensitive stuff.

Not to scare you away but the Galil connectors and cables can be pricey from what I have read.

I have used the p-port and the DSPMC. If I could get a Galil that cheap I would try it just for the experience.