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Appendix A: Troubleshooting Communication Data Issues

Symptom or Error

PLC Communication

4. Is the “PLC Ok” LED on?

In Fault

If the “PLC Ok” LED is off, there is a problem with either the MPU11 or
GPIO4D board.

5. Does your MPU11 have the updated crystal installed?

MPU11 boards that shipped prior to ##### may need to have the
crystal replaced due to a manufacturing defect

in the crystal. If your

MPU11 is dated prior to ##### (see pic) return it for repair.

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Содержание GPIO4D

Страница 1: ...CENTROID GPIO4D Install Manual Velocity Mode For 3rd party drives Without Optic Direct Interface Last revised 20 June 2014 277...

Страница 2: ...Wiring auxiliary sub systems 16 1 Lube pump 16 2 Coolant pump 16 3 Spindle contactors 16 4 VFD Automation Direct GS2 Spindle wiring 17 System Test Appendix A Troubleshooting Communication Data Issues...

Страница 3: ...amiliarize yourself with the schematics manuals and installation instructions While doing the installation it is very important that you follow the instructions in order and that you follow them exact...

Страница 4: ...Centroid CNC11 Based CNC Kit you purchased contains Qty 1 GPIO4D 4 axis 3rd party Servo Drive interface with integrated PLC 1 ea 2 MPU11 Motion Controller 1 ea 3 Fiber Optic Cable 2 ea 4 12VDC 5VDC D...

Страница 5: ...A Z COM N C 5V B A Z ENCODERS 3 1 4 ETHER NET 4 1 2 5 6 3 5 2L 5L MPU11 Digital Power Supply 85 264VAC PC ETHER NET 110VAC 110VAC GPIO4D System Interconnect Diagram IMPORTANT The MPU11 and GPIO4D MUS...

Страница 6: ...ve surface and turn on your power strip to power up your components and PC While powering up you notice that there are 4 LED s next to the power connector see red rectangle below on the MPU11 that fli...

Страница 7: ...tware version It is important that you download the latest version of the Centroid CNC11 software before continuing Click on the link below to download the latest version of CNC11 software CNC11 Softw...

Страница 8: ...utomatically start the WinPcap at boot box when prompted 7 Click Next to continue After the WinPcap installation has finished click Next in the Installation Complete window above to continue 8 Network...

Страница 9: ...n basic under Mill GPIO4D to select it and click Install NOTE If your install does not contain gpio4d basic v2 src download it here gpio4d basic v2 zip Once downloaded copy the files in the zip file t...

Страница 10: ...pop up window asking you if you wish to allow CNC11 to communicate with the MPU11 Check both the Private and Public check boxes in the Allow cncm to communicate on these networks section and then cli...

Страница 11: ...generate a fault if any hardware does not respond as expected or if any channel of any encoder is not at it s expected signal level In addition the GPIO4D Basic PLC program contains default logic tha...

Страница 12: ...s F1 Setup F3 Config pw 137 F1 Contrl fig 6 2 After Saving Press escape to go back to the Main Screen press F10 Shutdown press F2 Power Off and then power off the MPU11 and GPIO4D Wait 30 seconds and...

Страница 13: ...leared correctly the following screen should be displayed If the above screen is not displayed there is an existing fault please check the status window to determine the cause of the fault and then cl...

Страница 14: ...ration turns off all drive and spindle enables and requires that the Estop input MUST be cycled in order to clear the fault To clear a stop fault press the alt i keys to bring up the real time I O scr...

Страница 15: ...B thumb drive and DVM Digital Volt Meter is required 1 Set Home and load benchtest cnc Press the alt s keys simultaneously to display the DRO press F2 Load use the arrow keys to select the file bencht...

Страница 16: ...age With benchtest cnc loaded press Cycle start alt s to begin The following screen will be displayed You may have to press Cycle start twice From there placing your probes as depicted and enter the v...

Страница 17: ...oltage Probe between Analog Out and Analog COM at the locations indicated each axis Each axis is tested from 0 to 10VDC and from 0 to 10VDC in 2 5VDC increments In total 8 measurements are made for ea...

Страница 18: ...is connected to the COM of a group of inputs it s opposite must be switched to each the input In the example below 12VCOM is fed to the COM for inputs 1 4 so 12VDC must be switched to each input For...

Страница 19: ...net disconnect instead of a power strip a Connect the 110VAC from the disconnect to the GPIO4D MPU11 power supplies b Connect the digital power cable from the MPU11 power supply to the MPU11 Connect t...

Страница 20: ...ntact type switches and utilize 12VDC your machine may utilize different voltage levels and different type devices devices such npn or pnp proximity sensors If your devices are proximity sensors they...

Страница 21: ...red they are wired incorrectly the switch is tripped or there is a problem with the switch if you only have 3 axes don t worry about inputs 7 8 Trip your Estop and limit switches individually and con...

Страница 22: ...der feedback there will also often be Tach and or commutation channels being returned from the motors The MPU11 requires only the encoder channels listed above and does not use the Tach or commutation...

Страница 23: ...assword 137 Press enter F4 PID This will display the PID screen below and allow you to monitor the encoder counts by watching the values in Abs Pos for each axis To confirm that each encoder is wired...

Страница 24: ...member how to get to the parameter screen review section 6 1 or see the Operators Manual 4 Enter the number of encoder counts rev in motor configuration Enter the encoder counts rev as calculated abov...

Страница 25: ...to drop the Estop contactor in the event that a fault occurs that the PLC is not be able to recognize such as a hardware communication error between the GPIO4D and the MPU11 The Estop switch and faul...

Страница 26: ...e clicking on the CNC11 Mill icon on your desktop After the MPU11 has initialized press F10 to continue to the main screen Press your Estop switch in and then release it Observe the estop contactor en...

Страница 27: ...le output pin down to 5VCOM If your 3rd party Servo Amplifiers require an active high enable you will need to wire it through an external 5VDC relay or use a PLC output Wiring the enable through a PLC...

Страница 28: ...e if the Fault input is connected to 24VDC the Fault COM must be connected to 24COM or an external drive fault will be detected and the axis will be disabled by the GPIO4D 3 Enabling your drive fault...

Страница 29: ...GPIO4D Analog Control Voltage If no faults are detected the GPIO4D provides 10 to 10VDC for analog control of up to 4 3rd party servo amplifiers When wiring the analog control voltage always use twis...

Страница 30: ...X DRO Y updates Y DRO etc If any of your encoders do not update as expected please review the encoder parameters above sec 12 2 and or encoder wiring and MPU11 connection If all your encoders update...

Страница 31: ...e while the tool remains stationary such as the X Y axes on a typical Bridgeport type knee mill the table motion is the opposite of the tool motion For axes that move the tool such as the quill on a k...

Страница 32: ...s more negative while moving in the negative direction To correct for an axis that is moving in the wrong direction Press F1 Setup F3 Config password 137 Press enter F2 Mach F2 Motor Use the arrow key...

Страница 33: ...ycle start Note If the motors do not move smoothly press Estop and move the axis manuallly from to 1 25mm 4 Measure the distance the axis actually moved and set your motor revs inch or motor mm s rev...

Страница 34: ...current revs inch 5 0000 4 997085 New motor revs inch Metric How to compute motor mm s rev Commanded distance Distance moved multiplier Multiplier Current revs inch corrected revs inch Ex Distance mov...

Страница 35: ...onfirm that all axes now move in the correct directions if any do not perform the procedures in section 15 5 again When all axes are moving in the correct directions jog all axes to the middle of thei...

Страница 36: ...s where it was and how much run time has been accumulated even between power cycles So that you actually get lube ever 10 minutes for 5 seconds of machine use Electronic Lube Pumps try to imitate the...

Страница 37: ...the coil of the contactor this prevents electrical noise when the coolant flood is cycled on and off A thermal overload is also shown this part protects the motor by opening the circuit if it stalls f...

Страница 38: ...16 Wiring Auxiliary Sub systems 3 Spindle Wiring Spindle Contactor Wiring...

Страница 39: ...16 Wiring Auxiliary Sub systems 4 Spindle Inverter Wiring AutomationDirect GS2...

Страница 40: ...it indicates that the MPU11 hardware did not initialize correctly is a and that it needs to be replaced or repaired 3 Is the network cable plugged in Is the network cable plugged in to both the MPU11...

Страница 41: ...enter Icon 2 Click on Open Network and Sharing Center 3 Click on the network adapter that is connected to the MPU11 4 Click on Properties 5 Click on Internet Protocol Version 4 to highlight it 6 Click...

Страница 42: ...reen You can now exit and install version 3 08 or later without issue 8 Are you sure all anti virus and firewalls have been uninstalled If the MPU11 can successfully pinged and other than the above co...

Страница 43: ...en network traffic from other network devices can cause a dramatic decrease in PC and network performance Remove all other network devices and connections to the PC uninstall any hardware drivers or n...

Страница 44: ...plugged into the fiber optic receiver labeled 1 on the MPU11 is connected to the receiver labeled 1 on the GPIO4D and that the fiber optic cable plugged into the fiber optic receiver labeled 3 on the...

Страница 45: ...lt If the PLC Ok LED is off there is a problem with either the MPU11 or GPIO4D board 5 Does your MPU11 have the updated crystal installed MPU11 boards that shipped prior to may need to have the crysta...

Страница 46: ...ress F1 Setup F3 Config password 137 Press enter F4 PID The Abs Pos fields display the raw encoder counts for each axis With Estop pushed in rotate the axis motor in question by hand while observing t...

Страница 47: ...ction Troubleshooting Hardware And Program Errors Reported By CNC11 to correct and clear the fault 4 Are the servo amplifiers powered up and enabled Confirm that the amplifiers are under power and tha...

Страница 48: ...d at least get the motor to move For further information please see the section on troubleshooting Motion is not smooth later in this Appendix To enter the PID screen from the main screen press F1 Set...

Страница 49: ...the GPIO4D Symptom or Error Motor jumps in one 1 Is the polarity of the analog output to the axis correct direction and CNC11 This symptom is often displayed when the polarity of the analog output im...

Страница 50: ...t 5VDC negate the p value to 5 and so on The PID loop on the control is not involved in this move so any instability in the move will be caused by the servo amplifier and or motor Issue multiple comma...

Страница 51: ...requirements Symptom or Error 3 Are your motor and encoder values set correctly in the control Motion is not smooth Confirm that the following settings match your mechanical and motor encoder specific...

Страница 52: ...in CNC11 by following Centroid Tech Bulletin 234 which is available here Symptom or Error Axis does not move 1 Are your encoder counts per motor rev set correctly the correct distance The encoder coun...

Страница 53: ...axis manuallly from to 1 25mm 4 Measure the distance the axis actually moved and set your motor revs inch or motor mm s rev if in metric as follows Press F1 Setup F3 Config password 137 Press enter F...

Страница 54: ...tance moved 6 0035 multiplier 999417 current revs inch 5 0000 4 997085 New motor revs inch Metric How to compute motor mm s rev Commanded distance Distance moved multiplier Multiplier Current revs inc...

Страница 55: ...d your inverter is reporting a fault or the overload on the spindle contactor is tripped Check that your inverter to determine the fault code being reported and write it down If your spindle is contro...

Страница 56: ...itch for proper operation Once input 9 is again green the Estop switch input must be cycled to clear the fault Symptom or Error Limit Tripped 4 Limit tripped messages Limit tripped messages for any ax...

Страница 57: ...r the limit in question is correct by toggling the limit switch and confirming that the correct PLC input toggles If a different PLC input changes states when the limit is tripped enter that PLC input...

Страница 58: ...er than 25 of the total number of encoder counts in 1 revolution of the encoder the message is displayed In general if the difference reported is less than a full revolution of the encoder this messag...

Страница 59: ...12 Counts differ on homing 13 Option not available 14 Parameter missing 15 Position error 16 FPWOM...

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