[Dan911]

Hello Everyone,

I think we may be there to finally take the label of Test off the plugin, thank you all who helped with testing and removing these bugs quickly. I ask hopefully one last time for those who can to test and post back your results with system specs, especially those who were having those random 0 frequency loads and skipped sets with spindle override.


Attachment 361364


Thanks,
Dan

[P.Passuello]

Hi Dan,

Good news and bad on Test7
The Sact comes up as matching the Sset everytime.

However when you start the spindle it may or may not be the speed shown on the Sact that the spindle starts at.

https://goo.gl/photos/uqZ1fBw27FRemVFT8

Sorry for the bad news.
I'm picking that my laptop is slow and is a worst case and fails more than others.

I am working today but will test ASAP anything you need done.


Cheers
Peter

[JackBerkhout]

Hi Dan,
thank you very much for your hard work on the plugin! Awesome!
Do you want me to test this version Test7 on UCCNC 37 and Windows10 (Intel I3)? I can collect some systems specs.
It is night here, my wife and son are sleeping, the machine room is just next to the bed room, and I would avoid to wake them up with a series of noisy tests...
Though, I would be able to do it tomorrow morning.

I did not have problems with test version 2 or 3 (I don't remember), the one that does not have the connection confirmation pop-up at the start, and that one just works fine.

Getting noticed by a pop-up window only in case of a communication failure could be very nice... But I believe you already build that functionality in.
Regards,
Jack.

[Dan911]

Hey Peter,

Yes that's disappointing, unfortunately I don't know what more I can do on plugin end. Briefly... the plugin uses the same variable sent to Sact for calculation of HZ, I been using all day and working flawless. You need to check on your end for possible noise related issues that can be the cause. I see you have your VFD right next to your controllers, I couldn't see if you were using a shielded cable from RS-485 and spindle.

I also see you have a speed control knob, have you tried disabling it? I think there's a jumper for this along with additional PD settings in VFD software, I read of many having trouble with this control. I'm certainly going to double check everything on plugin end.

Dan

[Dan911]

Hi Jack whenever you have time would be great. Our time difference is a killer, I'm about to go out to eat.

Thanks,
Dan

[P.Passuello]

Hey Peter,

Yes that's disappointing, unfortunately I don't know what more I can do on plugin end. Briefly... the plugin uses the same variable sent to Sact for calculation of HZ, I been using all day and working flawless. You need to check on your end for possible noise related issues that can be the cause. I see you have your VFD right next to your controllers, I couldn't see if you were using a shielded cable from RS-485 and spindle.

I also see you have a speed control knob, have you tried disabling it? I think there's a jumper for this along with additional PD settings in VFD software, I read of many having trouble with this control. I'm certainly going to double check everything on plugin end.

Dan

I really, really appreciate all the help you have given in trying to sort this out for me and others.
It makes sense that if I am the only one experiencing the speed issue then it is something at my end.
I have been in the fault finding game too long to blame or rule out any particular part as ok until I have tested and proved it.

I am very mindful through out all my testing of the noise issue given where the VFD is located, though realistically the cable will be run to it no matter where I put the thing.

The cable from the VFD to the RS485 is a balanced shielded cable with the shield connected to earthed.

To make sure the problem wasn't noise from the VFD I did the tests with the spindle unplugged and just monitored the VFD display to make sure the speed was changing.
It still fails for me though and using an audio probe I can hear the data being sent from the RS485 to the VFD so I'm sure the plugin is solid.
That is why I was thinking it may be an RS485 adapter issue. Maybe its output is dodgy.
I have already ordered a unit with the same chipset that Gerry and Jack are using to see if it produces different results and will post my findings.
It could also be an issue with my VFD but I don't see myself getting a spare one at this time.

The Jumper is in the VI position on my VFD and I had setup Analogue speed control just before moving onto RS485 to see how it went.

I will also go back to Mach3 and give it a damn good thrashing to see if I can fault it as well.

Once again thank you for all the hard work you have put into this.

Cheers
Peter

[Dan911]

I really, really appreciate all the help you have given in trying to sort this out for me and others.
It makes sense that if I am the only one experiencing the speed issue then it is something at my end.
I have been in the fault finding game too long to blame or rule out any particular part as ok until I have tested and proved it.

I am very mindful through out all my testing of the noise issue given where the VFD is located, though realistically the cable will be run to it no matter where I put the thing.

The cable from the VFD to the RS485 is a balanced shielded cable with the shield connected to earthed.

To make sure the problem wasn't noise from the VFD I did the tests with the spindle unplugged and just monitored the VFD display to make sure the speed was changing.
It still fails for me though and using an audio probe I can hear the data being sent from the RS485 to the VFD so I'm sure the plugin is solid.
That is why I was thinking it may be an RS485 adapter issue. Maybe its output is dodgy.
I have already ordered a unit with the same chipset that Gerry and Jack are using to see if it produces different results and will post my findings.
It could also be an issue with my VFD but I don't see myself getting a spare one at this time.

The Jumper is in the VI position on my VFD and I had setup Analogue speed control just before moving onto RS485 to see how it went.

I will also go back to Mach3 and give it a damn good thrashing to see if I can fault it as well.

Once again thank you for all the hard work you have put into this.

Cheers
Peter

I just watched your video again and seen on/off worked no problems and frequency is your problem. I can't help but feel that speed control pot may possibly be the problem, you have two choices with jumper with 3 pins, analog or pot and you are using neither, have you tried just removing jumper?

With the plugin sending 100hz to VFD for 6000rpm and it starts at 9000rpm makes me think there's some sort of interference.

Dan

[ger21]

you have two choices with jumper with 3 pins, analog or pot and you are using neither,

It's actually set to pins 2-3 for the onboard pot, and 1-2 for all other methods. (I think).

[P.Passuello]

I just watched your video again and seen on/off worked no problems and frequency is your problem. I can't help but feel that speed control pot may possibly be the problem, you have two choices with jumper with 3 pins, analog or pot and you are using neither, have you tried just removing jumper?

With the plugin sending 100hz to VFD for 6000rpm and it starts at 9000rpm makes me think there's some sort of interference.

Dan

The VI setting is analogue which is what it is currently set too. The other option is VR which is the POT but I can give removing the link it a go if you like.

I agree the frequency is the problem but the 9000 comes not from noise but because that is the speed it was left at on the previous test.
I just closed down and reopened UCCNC again which would have resent the speed info to the VFD and I'm sure it did.
I just think my VFD is not reading it properly. Some sort of communication error

I am thinking of trying different baud rates and parities to see if it helps in any way.
I really think the plugin is good and it is just something here that is causing the issue. Hopefully the RS485 adapter.

I would imagine noise would not be an issue until the spindle starts. I have everything else turned off in the workshop. Once the spindle starts all bets are off.

I will try everything I can think of and let you know how I get on.
I'm sure it isn't the plugin.


Cheers
Peter

[JackBerkhout]

Hi Peter,
can you post these setting of your VFD, please?
I'd like to check them for you.

Assuming a 400Hz/24000RPM spindle motor (otherwise it might be 300Hz/18000RPM).
PD001 - Probably already set to 2
PD002 -> Important, must be set to 2
PD003 - 400 (Hz)
PD004 - 400 (Hz)
PD005 - 400 (Hz)
PD008 - Maximum rated motor voltage
PD011 - below or equal 120 for a 400Hz spindle motor , 90 for a 300Hz spindle motor
PD044 - 2
PD070 - 0
PD072 - 400 (Hz)
PD141 - rated spindle motor voltage
PD142 - rated spindle motor current
PD143 - 2 (No of motor poles, likely 2)
PD144 - 3000
PD163 - 1 (should be OK)
PD164 - 1 (should be OK)
PD165 - 3 (Should be OK)

I skipped some Vf curve parameters (PD006, PD007, PD009, PD010) and some others as well, as it's not the issue, I guess.
My jumper (at the right side of the terminal blocks) is set to the left (VI), and I have nothing connected to the VI terminal.
If the parameters are set right, the jumper shouldn't matter, I guess, but this just to have a reference, because you are still having the speed issue.

Kind regards,
Jack.

[P.Passuello]

Hi Jack


Here are my settings.
Mine is a 2.2kw 220 volt 10 amp 400hz spindle

PD001 - 2
PD002 -> 2
PD003 - 400 (Hz)
PD004 - 400 (Hz)
PD005 - 400 (Hz)
PD008 - 220
PD011 - 100
PD044 - 2
PD070 - 0
PD072 - 400 (Hz)
PD141 - 220
PD142 - 10
PD143 - 4
PD144 - 3000
PD163 - 1
PD164 - 0 (I did all my testing at 9600 but have just reduced it to 4800 1/2 an hour ago and it has reduced the incidence of missing speed changes while steppng through spindle speeds but not this inital start speed.)
PD165 - 3

The link is in the left (VI)

For some obscure reason mine is not receiving the inital setup speed when it first initalizes everytime. (Enen with my lower baudrate set.
This bit makes no sense logically as it should fail intermittently not every time.
I can enter MDI command eg S10000 and it will set the speed in the spindle no problem.

Could I ask you to do a quick test for me.
Open UCCNC and start your spindle and set its speed to 10000 or similar that is different from the inital speed your spindle normally starts at. eg mine is 6000RPM
Stop the spindle and close UCCNC
Open UCCNC and press spindle start.
Read the VFD display and let me know if it is the start speed or the speed you left it sitting at when you closed it down.
Mine always starts at the previous speed not 6000 as it should.

Cheers
Peter

[ger21]

Mine always starts at the minimum speed, regardless of what it was at when I closed UCCNC.

[P.Passuello]

Mine always starts at the minimum speed, regardless of what it was at when I closed UCCNC.

Thanks Gerry that's what I thought is meant to happen.
I am under the impression that the Sact is got by reading the VFD and then displays it in UCCNC.
If this is the case then how can it be wrong everytime. ( of course I could be entirely wrong on this and talking through a hole in my head, Dan will know.)
I have now reduced my Baud rate to 4800 and it is now very hard to get the speed to fail when incrementing up and down. It may take several minutes of speed changes to get it to fail.
This would imply that the initial speed setting of Sact should almost be impossible to fail when I start UCCNC and yet fails everytime.

Clearly the problem is mine and i going to keep playing.
This is pretty irrevelant as a simple Sxxxxx MDI fixes it and all Gcode gives an S command before it starts so again not problem.
It is just perplexing and I hate not understanding.

I also have an RS485 adapter like yours comming so i will give that a test in a few days and see what happens.

Cheers
Peter

[ger21]

You did edit the screen so that the Sact field number matches what's in the plugin Config, right?

[JackBerkhout]

Hi Peter,
Note RPM min is 4000 for me and max is 24000 of course.
I used Plugin Test7.
START:
After starting UCCNC, readings on screen are: Sset: 4000.0, Sact: 0.0
Sact is always 0, because I do not use an analog signal back from the VFD to the UC300ETH-5LPT.
When I start the spindle the VFD reads 4000.
In the MDI, I enter S10000, the spindle speeds up and the VFD reads 10000 (my pot is set at 101%, so slightly higher, actually), Sset: 10000.0, Sact: 0.0
I stopped the spindel and closed UCCNC en then started UCCNC, al is now working as from the 'START:' above.

I think the initial speed is the low setting in the plugin, and will always be reset to that value after closing and opening UCCNC, wether that is desired or not.
If that is your issue, it is the same here, however, for me it isn't an issue, because I use the S command in my gcode, so it will always be set to a desired value once I start a job.
And I always have control from 25%-300% by a potentiometer (also on feed)

I hope this helps.

Hi Dan,
I used Test7 and do not find concerns in my case, in the short tests I did.
System: Shuttle DS67U3, Windows 10, fanless, 256GB SSD, 16GB memory, Intel Core i3-6100 (2 cores @ 3700 MHz), Intel HD Graphics 520.

Kind regards,
Jack.

[P.Passuello]

You did edit the screen so that the Sact field number matches what's in the plugin Config, right?

I sure did. As per Dans instructions.

Now for some good news
I have tested and found the same speed changing issue with the Mach3 Le royaume d'eole plugin at baud rate 9600.
Given the maturity of this plug in it points to either my Rs485 adapter or the VFD having communication difficulties so this eliminates Dan's plugin as the cause.

Further testing at 4800 baud went from running really well to running like a dog with even MDI command erratic and on / off became dubious.
I have decide to stop torturing myself until I get my hands on the new RS485 adapter and try that out and see if it makes a difference.
I am hoping my adapter is faulty. It is the most likely culprit to my mind.

I know from listening on my cable probe that burst of data are being sent to the VFD when an MDI command or a speed increment on /off is sent but the VFD is not receiving it either because of corruption, faulty receiver in the VFD or bad data from the adapter maybe timing issues.

The really annoying thing is I had 2 brand new serial to RS485 high spec adapters that I threw away about 4 weeks ago. They had been sitting on the shelf at work for over 10 years and were obsolete as far as what they were bought for.
They would have made troubleshooting so easy. It's always the way. You hang onto something for years and as soon as you throw it away you want it.

No matter how you slice it, it isn't the plugin.

Well it's after midnight here again and time to get some beauty sleep or I'll end up looking just the same tomorrow.

Thanks everyone for your help.

Cheers
Peter

[Dan911]

The Rpm frequency sent to VFD is the first function the plugin does on startup, not setting on start up tells me your serial port is open and extremely slow or faulty. With a quick google search of a "very slow USB" comes up with a lot of usb 2.0 and usb 3.0 conflicts. This also my point to driver your using since RS-485 is working but not properly, trying an older driver more compatible with XP may help. It's certainly worth a try while waiting for new one to arrive.

Dan

[Dan911]

Hi Dan,
I used Test7 and do not find concerns in my case, in the short tests I did.
System: Shuttle DS67U3, Windows 10, fanless, 256GB SSD, 16GB memory, Intel Core i3-6100 (2 cores @ 3700 MHz), Intel HD Graphics 520.

Kind regards,
Jack.

Thanks Jack I appreciate you taking the time to test and respond.

Thanks for all your help,
Dan

[JackBerkhout]

Hi Dan,

thank you very much for your time to develop this great plugin. It's really awesome!!!
BTW, on Windows 10, the driver for the USB to RS485 adapter got installed automatically and works like a charm.

Kind regards,
Jack.

[Dan911]

After starting UCCNC, readings on screen are: Sset: 4000.0, Sact: 0.0
Sact is always 0, because I do not use an analog signal back from the VFD to the UC300ETH-5LPT.
.

Jack it is unclear to me why you don't use Sact for your spindle speed, this is very useful when using spindle override so your able to see your actual RPM. The VFD or UC300ETH-5LPT doesn't fill this field the plugin does if you set it up. If you need step by step how to do this let me know, it's a simple edit in screen edit within UCCNC.

Dan