PathPilot, Mesa 7I92H and Geckodrive G540

[rodw]

On another topic. With Mach3 I’m currently controlling my Spindle via Modbus. With the setup I can do semi rigid tapping using a compression/ tension tap holder.
My understanding is that PathPilot doesn’t support Modbus so I’ll need to use PWM for spindle speed control.

With that, presumably I’ll need to add an encoder to the spindle to synchronize the z-axis to the spindle speed?

Cheers
Peter


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There are a couple of ways to get modbus working with a vfd. I have been using vfdmod which seems to work well
https://github.com/aekhv/vfdmod/blob/master/main.cpp

I use a BD600 VFD from Conan motor (in .AU) and there is a complete config for it available on the linuxcnc forum which I used.

yes an encoder would be helpful. Using a Mesa 7i76 with your 7i92 and removing the individual drives from the G540 is probably the best way to achieve this.

I bought an optical encoder from Masso but it has 10 volt output so I'm not sure if the 7i76 would work with it. I am using ethercat so don't yet have an encoder input But I got good results cutting threads by thread milling withot the encoder.

[phomann]

Hi Rod,
Thanks very much for joining in.
The HP computer seems like it will do the job fine.
I’ve verified that Mint Mate works fine. Also the Logitech wireless keyboard and mouse work as does the WiFi dongle and the touch screen I have.
I chose PathPilot over LinuxCNC as I like the interface and also the Fusion360 post processor for it. If it doesn’t work out I’ll try LinuxCNC.
The reason I’m using the particular Mesa card is that I want it to fit into my controller that has an option for a SmoothStepper or UCCNC UC400


Cheers

Peter


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[vmax549]

HIYA Peter, There is a bit file for that card that matches the G540 pinout. That makes that part simple. IF you can use S/D for the spindle PP uses that normaly for spindle control but you can set it up as PWM. I have PWM here on my mill because it matches the DMM breakout board I used to work with the DMM servo drives I use. You will also have to ADD the spindle encoder IF you want rigid tapping. I always set the control up as a 1100 Series3 and add the encoder as that seems to be the easiest to work with. The later versions add in extra safety features that may not be the easiest to work around. Just depends on what kind of LinuxCNC Python wizard you are or will become (;-)



(;-) TP

[rodw]

Hi Rod,
Thanks very much for joining in.
The HP computer seems like it will do the job fine.
I’ve verified that Mint Mate works fine. Also the Logitech wireless keyboard and mouse work as does the WiFi dongle and the touch screen I have.
I chose PathPilot over LinuxCNC as I like the interface and also the Fusion360 post processor for it. If it doesn’t work out I’ll try LinuxCNC.
The reason I’m using the particular Mesa card is that I want it to fit into my controller that has an option for a SmoothStepper or UCCNC UC400

Fusion360 also has a post for linuxcnc. It might be called by its historic name EMC. But on the weekend I was seeing posts named linuxcnc so they may have caught up!
It is missing G64 P0.001 Q0.001 in the preamble which sets the path tolerance on corners. Not sure if its included in Tormach's.
This is the linuxcnc improved version of Mach's constant velocity mode. Without it, arcs will be fairly large on corners.

[shred]

Fusion360 also has a post for linuxcnc. It might be called by its historic name EMC. But on the weekend I was seeing posts named linuxcnc so they may have caught up!
It is missing G64 P0.001 Q0.001 in the preamble which sets the path tolerance on corners. Not sure if its included in Tormach's.
This is the linuxcnc improved version of Mach's constant velocity mode. Without it, arcs will be fairly large on corners.

FWIW, Some time back Tormach changed the G64 default to much-less-aggressive corner-rounding in PP, feeling that most customers preferred accurate shapes over tool velocity, (particularly when engraving text)

[phomann]

HIYA Peter, There is a bit file for that card that matches the G540 pinout. That makes that part simple. IF you can use S/D for the spindle PP uses that normaly for spindle control but you can set it up as PWM. I have PWM here on my mill because it matches the DMM breakout board I used to work with the DMM servo drives I use. You will also have to ADD the spindle encoder IF you want rigid tapping. I always set the control up as a 1100 Series3 and add the encoder as that seems to be the easiest to work with. The later versions add in extra safety features that may not be the easiest to work around. Just depends on what kind of LinuxCNC Python wizard you are or will become (;-)



(;-) TP

Hi Terry,
At this stage I really want to try and use PWM for the spindle control.
The VFD has output terminals for the motors encoder (128ppr) so I plan to use that. I’ll have to feed it into the 2nd port on the Mesa card.
The spindle motor is a 750w 6000rpm Adlee matchservo It can be controlled by Modbus, +/-10v or preprogrammed set speeds selected via input terminals. But no Step/Dir.

The PathPilot USB stick just got delivered so I’ll try to install it tonight.

Where do I get the G540 pin file from? Is it on the Mesa website?
Presumably, I can edit it?
Cheers
Peter.


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[phomann]

Fusion360 also has a post for linuxcnc. It might be called by its historic name EMC. But on the weekend I was seeing posts named linuxcnc so they may have caught up!
It is missing G64 P0.001 Q0.001 in the preamble which sets the path tolerance on corners. Not sure if its included in Tormach's.
This is the linuxcnc improved version of Mach's constant velocity mode. Without it, arcs will be fairly large on corners.

Hi Rod,
I guess I could add the G64 line to the PathPilot post processor. It’s not to difficult to play around with the post processor files if the changes are small.
Cheers
Peter.


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[kstrauss]

I always set the control up as a 1100 Series3 and add the encoder as that seems to be the easiest to work with. The later versions add in extra safety features that may not be the easiest to work around. Just depends on what kind of LinuxCNC Python wizard you are or will become (;-)
(;-) TP

What are the changes to add the encoder? Do you need a different bitfile for the 7i92? If so, where did you get it?

[rodw]

I doubt the 7i92 has an encoder. That would normally be on the daughter card like a 7i76 (1) or 7i77 (6)
The 7i76e is basically a 7i92 and 7i76 in one card.

[phomann]

OK, I've installed Pathpilot. Took all of about 10 minutes.

I plugged the 7I92 into the ethernet cable between it and the controller PC .
I then Turned on the PC. It asked me to select the machine, so I chose 1100M cos that's what TP chooses.
Selected save and exit.
Skipped entering a serial number and it started looking for the machine.
The 4 leds on the 7I92 started a binary counting pattern 0 to 0xF

I guess now the fun starts.
Presumably, I need to change a number of configurations, such as programming a config (bit file) into the Mesa card?

TP I may need some hand holding.

Cheers,

Peter

[pippin88]

The Mesa cards have a firmware (Bit file) that sets the functions of the FPGA. Number of Stepgens/pwn etc etc

Almost all config is done in LinuxCNC via the Hal and ini files. These do not get sent to the Mesa card.

Hal is essentially software wiring and logic

You can use a config generator in LinuxCNC to get started.

(I've never tried path pilot, I use LinuxCNC)

[vmax549]

Hi Peter, Did PP load all the way up to the main screen ??? IF so I can walk you in from there. This would be easier with email if you want. AS to the spindle we always use a S/D >> 0-10vdc card. But you can use a PWM >> 0-10v as well just have to take some code out of teh Hal file and add some code to the HAL file. BUT lets get PP where it loads up correctly first.

So you used the 1100M ? that has a lot of safety stuff added. THe one I use is from the OLDER versions list on the setup page 1100 S3 with the highest 3 diget s/n THat version is the last version that they used the 7i92 card in.

I am running from memory now as I sent out the last controller I had a card for. Except for my mill and I can use that if needed to walk you through.

Baby steps , (;-) TP

[PCW_MESA]

What are the changes to add the encoder? Do you need a different bitfile for the 7i92? If so, where did you get it?

The G540x2 bitfile includes 2 encoders (one on P2 and one on P1):
(Though you would normally have some signal conditioning like a line
receiver or buffer for the encoder signals rather than use bare FPGA pins)

Note that the stepgens on P1 and P2 DB25 pins 16 are for feeding
the G540s chargepump.

G540x2 Configuration pin-out:

IO Connections for P2
Pin#  I/O   Pri. func    Sec. func       Chan      Pin func        Pin Dir

 1      0   IOPort       None
14      1   IOPort       PWM              0        PWM             (Out)
 2      2   IOPort       StepGen          0        Step/Table1     (Out)
15      3   IOPort       None
 3      4   IOPort       StepGen          0        Dir/Table2      (Out)
16      5   IOPort       StepGen          4        Step/Table1     (Out)
 4      6   IOPort       StepGen          1        Step/Table1     (Out)
17      7   IOPort       None
 5      8   IOPort       StepGen          1        Dir/Table2      (Out)
 6      9   IOPort       StepGen          2        Step/Table1     (Out)
 7     10   IOPort       StepGen          2        Dir/Table2      (Out)
 8     11   IOPort       StepGen          3        Step/Table1     (Out)
 9     12   IOPort       StepGen          3        Dir/Table2      (Out)
10     13   IOPort       QCount           0        Quad-A          (In)
11     14   IOPort       QCount           0        Quad-B          (In)
12     15   IOPort       QCount           0        Quad-IDX        (In)
13     16   IOPort       None

IO Connections for P1
Pin#  I/O   Pri. func    Sec. func       Chan      Pin func        Pin Dir

 1     17   IOPort       None
14     18   IOPort       PWM              1        PWM             (Out)
 2     19   IOPort       StepGen          5        Step/Table1     (Out)
15     20   IOPort       None
 3     21   IOPort       StepGen          5        Dir/Table2      (Out)
16     22   IOPort       StepGen          9        Step/Table1     (Out)
 4     23   IOPort       StepGen          6        Step/Table1     (Out)
17     24   IOPort       None
 5     25   IOPort       StepGen          6        Dir/Table2      (Out)
 6     26   IOPort       StepGen          7        Step/Table1     (Out)
 7     27   IOPort       StepGen          7        Dir/Table2      (Out)
 8     28   IOPort       StepGen          8        Step/Table1     (Out)
 9     29   IOPort       StepGen          8        Dir/Table2      (Out)
10     30   IOPort       QCount           1        Quad-A          (In)
11     31   IOPort       QCount           1        Quad-B          (In)
12     32   IOPort       QCount           1        Quad-IDX        (In)
13     33   IOPort       None

[phomann]

The G540x2 bitfile includes 2 encoders (one on P2 and one on P1):
(Though you would normally have some signal conditioning like a line
receiver or buffer for the encoder signals rather than use bare FPGA pins)

Note that the stepgens on P1 and P2 DB25 pins 16 are for feeding
the G540s chargepump.

G540x2 Configuration pin-out:

IO Connections for P2
Pin#  I/O   Pri. func    Sec. func       Chan      Pin func        Pin Dir

 1      0   IOPort       None
14      1   IOPort       PWM              0        PWM             (Out)
 2      2   IOPort       StepGen          0        Step/Table1     (Out)
15      3   IOPort       None
 3      4   IOPort       StepGen          0        Dir/Table2      (Out)
16      5   IOPort       StepGen          4        Step/Table1     (Out)
 4      6   IOPort       StepGen          1        Step/Table1     (Out)
17      7   IOPort       None
 5      8   IOPort       StepGen          1        Dir/Table2      (Out)
 6      9   IOPort       StepGen          2        Step/Table1     (Out)
 7     10   IOPort       StepGen          2        Dir/Table2      (Out)
 8     11   IOPort       StepGen          3        Step/Table1     (Out)
 9     12   IOPort       StepGen          3        Dir/Table2      (Out)
10     13   IOPort       QCount           0        Quad-A          (In)
11     14   IOPort       QCount           0        Quad-B          (In)
12     15   IOPort       QCount           0        Quad-IDX        (In)
13     16   IOPort       None

IO Connections for P1
Pin#  I/O   Pri. func    Sec. func       Chan      Pin func        Pin Dir

 1     17   IOPort       None
14     18   IOPort       PWM              1        PWM             (Out)
 2     19   IOPort       StepGen          5        Step/Table1     (Out)
15     20   IOPort       None
 3     21   IOPort       StepGen          5        Dir/Table2      (Out)
16     22   IOPort       StepGen          9        Step/Table1     (Out)
 4     23   IOPort       StepGen          6        Step/Table1     (Out)
17     24   IOPort       None
 5     25   IOPort       StepGen          6        Dir/Table2      (Out)
 6     26   IOPort       StepGen          7        Step/Table1     (Out)
 7     27   IOPort       StepGen          7        Dir/Table2      (Out)
 8     28   IOPort       StepGen          8        Step/Table1     (Out)
 9     29   IOPort       StepGen          8        Dir/Table2      (Out)
10     30   IOPort       QCount           1        Quad-A          (In)
11     31   IOPort       QCount           1        Quad-B          (In)
12     32   IOPort       QCount           1        Quad-IDX        (In)
13     33   IOPort       None

Hi PCW,
Thanks for chiming in. I did look through the G540 bit files and noticed that it had the encoders defined on the inputs.
Cheers
Peter.


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[phomann]

Hi Peter, Did PP load all the way up to the main screen ??? IF so I can walk you in from there. This would be easier with email if you want. AS to the spindle we always use a S/D >> 0-10vdc card. But you can use a PWM >> 0-10v as well just have to take some code out of teh Hal file and add some code to the HAL file. BUT lets get PP where it loads up correctly first.

So you used the 1100M ? that has a lot of safety stuff added. THe one I use is from the OLDER versions list on the setup page 1100 S3 with the highest 3 diget s/n THat version is the last version that they used the 7i92 card in.

I am running from memory now as I sent out the last controller I had a card for. Except for my mill and I can use that if needed to walk you through.

Baby steps , (;-) TP

Hi TP,
It doesn’t get past trying to connect to the machine. I did find the 1100 S3 on the “other” machines page.
I’m not sure what PathPilot is looking for.
I’m not sure that PathPilot has found the Mesacard and that’s why it’s stuck on trying to connect to the machine.

That said the Mesacard’s four general purpose LEDS are running through a counting pattern. Does that mean it is connected to PathPilot, or is it the default behavior of the card while it is waiting to be connected to.
I’m thinking that maybe PathPilot can’t find the card due to a problem with the IP address or some other network issue. I have a straight through Ethernet cable connected between the computer and 7i92 card.






Cheers

Peter

[phomann]

The Mesa cards have a firmware (Bit file) that sets the functions of the FPGA. Number of Stepgens/pwn etc etc

Almost all config is done in LinuxCNC via the Hal and ini files. These do not get sent to the Mesa card.

Hal is essentially software wiring and logic

You can use a config generator in LinuxCNC to get started.

(I've never tried path pilot, I use LinuxCNC)

Thanks for the reply.
I’m wondering if I need to program the Mesacard with a bit file before trying to connect it to PathPilot? Or does PathPilot do that once the machine is configured.
Also I’m not sure if PathPilot knows the default IP address of the card and looks for that.
Cheers
Peter


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[David C. Allen]

Peter
I think you need to change Jumper W5

David

[phomann]

Hi David,
Thanks for that. Are you saying that the IP address needs to be changed from the default of 192.168.1.121 to being obtained via bootp?

Cheers

Peter


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[PCW_MESA]

Hi David,
Thanks for that. Are you saying that the IP address needs to be changed from the default of 192.168.1.121 to being obtained via bootp?

Cheers

Peter


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Pretty sure Tormach uses the 10.10.10.10 IP address so IP jumpers need to be
W5 DOWN, W6 UP

But beware, Path pilot will write it's bitfile to the 7I92, which is not what you want for a G540
This needs to be worked around (maybe a path pilot expert will chime in here)

[BIRDTOOL]

I think I remember reading an old post by a user rsdi? stating u need to change the network ip address to something like 10.10.10.1.