[wentbackward]

Tom et al,

My existing gecko G540 + steppers. 10 ustep driver with 1.8' steppers giving 2000 usteps per rev, leadscrew is 1mm per rev.
Trying to get a minimal config going, simply drive the X-axis, so I do the following:-

1. Fire up the KFlop
2. Set up and Download the channel 0 so it becomes enabled

	ch0->InputMode=NO_INPUT_MODE;
	ch0->OutputMode=STEP_DIR_MODE;
	ch0->Vel=40000;
	ch0->Accel=400000;
	ch0->Jerk=4e+006;
	ch0->P=0;
	ch0->I=0.01;
	ch0->D=0;
	ch0->FFAccel=0;
	ch0->FFVel=0;
	ch0->MaxI=200;
	ch0->MaxErr=1e+006;
	ch0->MaxOutput=200;
	ch0->DeadBandGain=1;
	ch0->DeadBandRange=0;
	ch0->InputChan0=0;
	ch0->InputChan1=0;
	ch0->OutputChan0=8;
	ch0->OutputChan1=0;
	ch0->MasterAxis=-1;
	ch0->LimitSwitchOptions=0x100;
	ch0->LimitSwitchNegBit=0;
	ch0->LimitSwitchPosBit=0;
	ch0->SoftLimitPos=1e+009;
	ch0->SoftLimitNeg=-1e+009;
	ch0->InputGain0=1;
	ch0->InputGain1=1;
	ch0->InputOffset0=0;
	ch0->InputOffset1=0;
	ch0->OutputGain=1;
	ch0->OutputOffset=0;
	ch0->SlaveGain=1;
	ch0->BacklashMode=BACKLASH_OFF;
	ch0->BacklashAmount=0;
	ch0->BacklashRate=0;
	ch0->invDistPerCycle=1;
	ch0->Lead=0;
	ch0->MaxFollowingError=1000000000;
	ch0->StepperAmplitude=20;

	ch0->iir[0].B0=1;
	ch0->iir[0].B1=0;
	ch0->iir[0].B2=0;
	ch0->iir[0].A1=0;
	ch0->iir[0].A2=0;

	ch0->iir[1].B0=1;
	ch0->iir[1].B1=0;
	ch0->iir[1].B2=0;
	ch0->iir[1].A1=0;
	ch0->iir[1].A2=0;

	ch0->iir[2].B0=0.000768788;
	ch0->iir[2].B1=0.00153758;
	ch0->iir[2].B2=0.000768788;
	ch0->iir[2].A1=1.92076;
	ch0->iir[2].A2=-0.923833;

3. Power on the gecko, 10kHz watchdog/charge pump is disabled
4. Confirm I have a green signal and holding torque - yes!
5. In the Step Response screen I have step at 3s and 1000 size, press Move and I'm getting nothing

Minimal connector is:

KFlop powered directly from USB on a desktop machine (not a laptop)

2 control pins
IO8, JP7 Pin 15 (axis 0 step) is connected to DB25 pin 2 X-axis step
IO9, JP7 Pin 16 (axis 0 dir) is connected to DB25 pin 3 X-axis dir

Pins 25 and 26 are connected to DB25 GND
DB25 Pins 18-25 are all connected together as GND
I'm not running any other ground to the connector

I wondered if some kind soul could confirm this minimal, single axis configuration should work, or am I missing something obvious?

Many thanks
- Paul

[wentbackward]

To answer my own question. The simplest configuration is:-

KFLOP JP7 Pin	Gecko G540 DB25 Pin
15 (IO8)	2 X-Axis Step
16 (IO9)	3 X-Axis Dir
17 (IO10)	4 Y-Axis Step
18 (IO11)	5 Y-Axis Dir
19 (IO12)	6 Z-Axis Step
20 (IO13)	7 Z-Axis Dir
21 (IO14)	9 A-Axis Step
22 (IO15)	9 A-Axis Dir
25 (GND)	24
26 (GND)	25

[wentbackward]

Just in case anyone is curious as to the configuration, here it is, slightly generified so that you can change the main params for all 4 axes. On my mill with all the same Nema 23 steppers and identical lead screws this makes sense, although its quite scary to watch Z rapidly plunge at full speed.

#include "KMotionDef.h"

// Defines axis 0, 1, 2 as simple step dir outputs
// enables them
// sets them as an xyz coordinate system for GCode

const int X=0, Y=1, Z=2, A=3;
const double VEL=88000;
const double ACCEL=160000;
const double JERK=4e+006;
const double PIDP=0, PIDI=0.01, PIDD=0;

int main() {
	FPGA(STEP_PULSE_LENGTH_ADD)=32+0x80;

	ch0->InputMode=NO_INPUT_MODE;
	ch0->OutputMode=STEP_DIR_MODE;
	ch0->Vel=VEL;
	ch0->Accel=ACCEL;
	ch0->Jerk=JERK;
	ch0->P=PIDP;
	ch0->I=PIDI;
	ch0->D=PIDD;
	ch0->OutputChan0=X+8;
	ch0->LimitSwitchOptions=0x100;
	ch0->LimitSwitchNegBit=0;
	ch0->LimitSwitchPosBit=0;
	ch0->SoftLimitPos=1e+009;
	ch0->SoftLimitNeg=-1e+009;
	ch0->BacklashMode=BACKLASH_OFF;
	ch0->BacklashAmount=0;
	ch0->BacklashRate=0;
 
 	ch1->InputMode=NO_INPUT_MODE;
	ch1->OutputMode=STEP_DIR_MODE;
	ch1->Vel=VEL;
	ch1->Accel=ACCEL;
	ch1->Jerk=JERK;
	ch1->P=PIDP;
	ch1->I=PIDI;
	ch1->D=PIDD;
	ch1->OutputChan0=Y+8;
	ch1->LimitSwitchOptions=0x100;
	ch1->LimitSwitchNegBit=0;
	ch1->LimitSwitchPosBit=0;
	ch1->SoftLimitPos=1e+009;
	ch1->SoftLimitNeg=-1e+009;
	ch1->BacklashMode=BACKLASH_OFF;
	ch1->BacklashAmount=0;
	ch1->BacklashRate=0;

	ch2->InputMode=NO_INPUT_MODE;
	ch2->OutputMode=STEP_DIR_MODE;
	ch2->Vel=VEL;
	ch2->Accel=ACCEL;
	ch2->Jerk=JERK;
	ch2->P=PIDP;
	ch2->I=PIDI;
	ch2->D=PIDD;
	ch2->OutputChan0=Z+8;
	ch2->LimitSwitchOptions=0x100;
	ch2->LimitSwitchNegBit=0;
	ch2->LimitSwitchPosBit=0;
	ch2->SoftLimitPos=1e+009;
	ch2->SoftLimitNeg=-1e+009;
	ch2->BacklashMode=BACKLASH_OFF;
	ch2->BacklashAmount=0;
	ch2->BacklashRate=0;

	ch3->InputMode=NO_INPUT_MODE;
	ch3->OutputMode=STEP_DIR_MODE;
	ch3->Vel=VEL;
	ch3->Accel=ACCEL;
	ch3->Jerk=JERK;
	ch3->P=PIDP;
	ch3->I=PIDI;
	ch3->D=PIDD;
	ch3->OutputChan0=A+8;
	ch3->LimitSwitchOptions=0x100;
	ch3->LimitSwitchNegBit=0;
	ch3->LimitSwitchPosBit=0;
	ch3->SoftLimitPos=1e+009;
	ch3->SoftLimitNeg=-1e+009;
	ch3->BacklashMode=BACKLASH_OFF;
	ch3->BacklashAmount=0;
	ch3->BacklashRate=0;


    EnableAxisDest(X,0);
    EnableAxisDest(Y,0);
	EnableAxisDest(Z,0);
	EnableAxisDest(A,0);

	DefineCoordSystem(X,Y,Z,A);

	printf("4 Axis init done!\n");

    return 0;
}

[TomKerekes]

Hi Paul,

Sounds like you got things moving. Thanks for the parallel port to KFLOP wire list.

When moving from the Step Response Screen the settings in the screens must be set properly for your system. You can normally Import the settings from a C Program using the "Import" button on the Config program. However if you use variables instead of constants that will not work.

Regards

[wentbackward]

Thanks Tom, Yes I'm basically up and running, it's all fine tuning from here on in. The performance of my machine is amazing compared to running off XP/Mach3/Parallel port. The motors stall much earlier than the spec sheets show, my scope shows my poorly rigged up cable has noise issues. I've just designed some basic circuit boards with the pinout above. Hopefully have those in a week or so. Once I have the basic boards tested I'll add headers for the various Gecko and KFlop pins allowing jumpers or any other use. I'll also post the Eagle CAD/CAM files as open source fairly soon, probably start another thread that is easy to find and reference all the details.

I did worry about the loading vars from the C code, but I actually find it as convenient to just run the code and then upload the vars directly from the KFlop. The code is also tied to the init button in KMotionCNC.

I'm not brave (stoopid) enough to trust my test cable to a long running G Code program so will wait for a few more days to get my boards, but a hugely successful few days.

Thanks for all your help. As many others have said, one of the main deciding factors was the support you give on here.

- Paul