Denford Software & Machines

I have a Starturn 8 and was wondering what software I need for it? I dont have the Denford tutor and need help trying to get the machine to work without it. Thanks.

Don't know if you've seen any of these posts before, but they may help!

DOS Software and Control Boards:
viewtopic.php?t=738
PC DOS boot disc make procedure:
viewtopic.php?t=1937
Bootdisk images:
https://www.bootdisk.com/bootdisk.htm
Dos Software free downloads:
https://www.denford.ltd.uk/index.php?opt ... &Itemid=51
Starturn problems:
viewtopic.php?t=1113
Dosbox:
viewtopic.php?t=844

Because you have an optimised smartstep control card, I guess you're looking to be using Fanucl (or similar)

I am not having any luck getting this lathe to work. I think I am going to convert my Starmill with a breakout board and stepper drivers. To save on money I will put the BOB and drivers in an enclosure to hook up to each machine at one time. What is the amps and voltage rating for the stepper motors? I also want to be able to thread. How will I be able to use the orginal encoder with a BOB? I think the name on the encolder was Bauwn Electrical?

The name on the encoder is Baumer Electric.

I got the lathe running but I have a problem with the RPM not reading the same as I set it for. The machine is reading about 200-400 RPM difference than what the machine is set for. It is also fluturating on the RPM reading. I am using the the latest version of VR Turning

I am using the the latest version of VR Turning

I didn't know we supported Starturn on VR Turning which machine have you chosen in that software ?

You probably will not get the encoder to read properly/accurately without the correct machine parameters and mint file for a StarTurn, which as far as I know has never been done before.

I used the Novaturn as the selected machine since that is a simular machine. There isn't an option for the Starturn. This lathe has been fitted with a Denstep card and the encoder has Baumer Electric on it, not the encoder with the slots in it.

I was able to go into the Novaturn machine config file and change the -Z travel to get almost 17 inches of Z travel, after I moved the stop for the home switch.

I also noticed in VR Turning that I cannot change the speed and feed when running a program. Is there something I need to change in the machine config file for the encoder?

I also noticed in VR Turning that I cannot change the speed and feed when running a program

it should be a case of setting the parameters to tell the software whether your machine has got an override pot fitted or not.
Go into Setup > Machine Paramters > password: denny > Machine_capability - speed / feed pot fitted ?

If the encoder is reading wrong, you could need to change the wrap value in novaturn.mnt, then download the mint file as these instructions:
Firstly - make sure any other Denford software is closed and disconnected from the machine
Then run the file: MintMan.EXE which is located in the VR Milling installation directory (C:\Program Files\Denford\ VRMilling)
Go to menu Setup -> Comm Port
Set the parameters to:
COM 1 (whichever machine is plugged into)
Baud: 19200
Parity: None
Data bits: 8
Stop bits: 2
Handshaking: none
Press OK
Press Upload Version button to check its working
then download the mint...

The MinitMan tells me the Comms are not OK after changing the settings.

Can you run VRTurning again, goto menu Help > Support Me, create a support file and post it up here ?

EXE Version
Ver: 1.22.2.425
EXE Date
7/13/2009 3:14:46 PM
Units
Inches
Fourth Axis
Disabled
Machine Info
Not Connected
Turbo
Unknown
System Info
Platform : Windows NT/2000/XP
Version : 5.1
Build : 2600
OS Info : Service Pack 3
Processor : 586 Mask : 1
Level : 6 OEMid :0
EXE INI: C:\Program Files\Denford\VRTurning\VRTurn.ini
[directories]
machine list file=C:\Program Files\Denford\VRTurning\machine list.ini
XNC Folder=C:\Program Files\Denford\VRTurning\Data\
Last Tooling=C:\Program Files\Denford\VRTurning\Tooling Files\
FNL Folder=C:\Program Files\Denford\VRTurning\CNC Files\
GNC Folder=C:\Program Files\Denford\VRTurning\Data\


[Default Settings]
Active Machine=NovaTurn
Metric=0
Help File=Turn.hlp
Help Reference=Help.ini
Billet X=19.05
Billet Z=63.5
Billet X Pos=0
Billet Z Pos=0
Expanded Cycles=1
Warn ON Play=0
Cutter Comp=0
PrimaryLanguage=1
SubLanguage=0
ScreenUpDate=200
Last Input=2
MintDebug=False
Support IP=62.49.128.243

[source]
File=1
Editor=2
Compiled=3
Fanuc21i=4
FanucOT=6

[Tooling]
Tool File name=C:\Program Files\Denford\VRTurning\Tooling Files\Default.tft
last tool=1
Show All Offsets=0

[RS232]
com port=0
Baud Rate=5
Data Bits=2
Parity=2
Hand Shaking=3
Stop Bits=0

[Jog Keys]
X+=37
X-=39
Y+=40
Y-=38
Z+=33
Z-=34
Trv=101

[readOut]
Font size=8
Font name=MS Sans Serif
Font Style=0

[MainForm]
Top=-4
Left=-4
Width=1032
Height=748

[EditorForm]
Top=24
Left=30
Width=300
Height=464

[screen]
Top=20
Left=39
Show Buttons=1
Left Side=0

[EditForm]
padding=SPACE
LineEnd=;
NumberString=N
numberstart=10
numberInc=10
NumberSize=3
formatting=0
Font size=8
Font name=MS Sans Serif
background colour=16777215
Token G Colour=32896
Token G BackColour=16777215
Token G Style=1
Token M Colour=0
Token M BackColour=16777215
Token M Style=0
Token T Colour=0
Token T BackColour=16777215
Token T Style=0
Token F Colour=0
Token F BackColour=16777215
Token F Style=0
Token S Colour=0
Token S BackColour=16777215
Token S Style=0
Token X Colour=0
Token X BackColour=65408
Token X Style=0
Token Y Colour=0
Token Y BackColour=16777215
Token Y Style=0
Token Z Colour=0
Token Z BackColour=16776960
Token Z Style=0
Token I Colour=0
Token I BackColour=65535
Token I Style=0
Token J Colour=0
Token J BackColour=8421631
Token J Style=0
Token ( Colour=0
Token ( BackColour=16777215
Token ( Style=0
Token [ Colour=0
Token [ BackColour=16777215
Token [ Style=0
Font Style=0
Token K Colour=0
Token K BackColour=16777215
Token K Style=0
FormatFile=C:\Program Files\Denford\VRTurning\VRTurn.ini

[Menu Tools]

[Button Map]
;FanucBut_O
0=$4F,$50
;FanucBut_N
1=$4E,$51
;FanucBut_G
2=$47,$52
;FanucBut_7
3=$37,$41
;FanucBut_8
4=$38,$42
;FanucBut_9
5=$39,$44
;FanucBut_X
6=$58,$43
;FanucBut_Z
7=90,89
;FanucBut_F
8=70,76
;FanucBut_4
9=$34,91
;FanucBut_5
10=$35,93
;FanucBut_6
11=$36,$20
;FanucBut_M
12=$4D,73
;FanucBut_S
13=$53,75
;FanucBut_T
14=$54,74
;FanucBut_1
15=$31,44
;FanucBut_2
16=50,35
;FanucBut_3
17=$33,61
;FanucBut_U
18=85,72
;FanucBut_W
19=87,86
;FanucBut_EOB
20=186,69
;FanucBut_-
21=189,43
;FanucBut_0
22=48,42
;FanucBut_.
23=190,47
;FanucBut_POS
24=24,24
;FanucBut_PROG
25=25,25
;FanucBut_OFFSET
26=26,26
;FanucBut_SHIFT
27=$10,$10
;FanucBut_Can
28=$08,$08
;FanucBut_INPUT
29=29,29
;FanucBut_GRAPH
32=232,232
;FanucBut_ALTER
33=233,233
;FanucBut_INSERT
34=234,234
;FanucBut_DELETE
35=235,$235
;FanucButPageUp
36=$21,$21
;FanucButPageDown
37=$22,$22
;FanucButCursorLeft
38=$25,$25
;FanucButCursorRight
39=$27,$27
;FanucButCursorUp
40=$26,$26
;FanucButCursorDown
41=$28,$28
;FanucButHelp
42=42,42
;FanucButReset
43=43,43

[Turn2DForm]
Top=18
Left=322
Width=647
Height=477

[Control Panel]
Docked=0
LeftSide=0
Display=2

[CaracelAndOffsets]
Top=41
Left=31
Width=338
Height=494

[ToolLib]
Top=182
Left=36

[WorkOffsetForm]
Top=359
Left=27

[VRT_form_turn]
Top=7
Left=218
Width=272
Height=261

[Compiled Input]
Top=52
Left=33

[Draw2D]
Top=254
Left=324
Width=375
Height=199

[Editor1]
Top=6
Left=6
Width=194
Height=338

[FileInputForm]
Top=76
Left=72

[Toolbar_File_Control]
Rev=2
Visible=1
DockedTo=DockBottom
DockRow=0
DockPos=458
FloatLeft=0
FloatTop=0
IconSize=0
ShowCaption=0
FloatRightX=0

[Toolbar_machine]
Rev=2
Visible=1
DockedTo=DockRight
DockRow=0
DockPos=387
FloatLeft=0
FloatTop=0
IconSize=0
ShowCaption=1
FloatRightX=0

[Toolbar_output]
Rev=2
Visible=1
DockedTo=DockRight
DockRow=0
DockPos=36
FloatLeft=0
FloatTop=0
IconSize=0
ShowCaption=1
FloatRightX=0

[toolbar_modal]
Rev=2
Visible=1
DockedTo=DockBottom
DockRow=0
DockPos=0
FloatLeft=0
FloatTop=0
IconSize=0
ShowCaption=1
FloatRightX=0

[dataInfo]
Rev=2
Visible=0
DockedTo=DockTop
DockRow=0
DockPos=0
FloatLeft=0
FloatTop=0
IconSize=0
ShowCaption=0
FloatRightX=0

[ControlPanel]
Top=36
Left=504

[VRT_form_turn_1]
Top=44
Left=44
Width=835
Height=402

[Draw3D]
Top=54
Left=141
Width=269
Height=250

[3DGraphics]
Auto Save Bmp=1
Billet Material=6
rapid colour=255
linear colour=65280
circular colour=4227327
thread colour=65535
plastic colour=16711680
background colour=8421440
move history amount=50
use plastic=1
show linears=1
show Rapids=1
show Arcs=1
show Threads=1
show cutter=1
use Offsets=0
show move history=1
bitmap width=320
bitmap height=240

[Graphics]
Auto Save Bmp=1
rapid colour=255
linear colour=65280
circular colour=33023
thread colour=65535
material colour=16711680
centre colour=0
background colour=8421376
hi lite colour=16777215
use tool colour=0
show linears=1
show Rapids=1
show Arcs=1
show Threads=1
show cutter=1
Shaded Material=1
Show Section=1
Use Offsets=0
Zoom In=1
Zoom Out=1

[Toolbar_ProgControl]
Rev=2
Visible=1
DockedTo=DockBottom
DockRow=0
DockPos=301
FloatLeft=600
FloatTop=318
IconSize=0
ShowCaption=1
FloatRightX=0


[ToolButtons Hidden]
0_11=Modal11
0_12=Modal12
0_13=Modal13
0_14=Modal14
0_15=Modal15
0_16=Modal16
0_17=Modal17
0_18=Modal18
0_19=Modal19
0_20=Modal20
0_21=Modal21
0_22=Modal22
0_23=Modal23
0_24=Modal24
0_25=Modal25

[Main ToolBars]
ImageSize1=1
CaptionV1=1
ImageSize2=1
CaptionV2=1
ImageSize3=1
CaptionV3=1
ImageSize4=0
CaptionV4=0
C:\Program Files\Denford\VRTurning\Config\NovaTurn.ini
[Material]
Default X=20
Default Z=100
Maximum X=140.0000
Maximum Z=176.0000
Position X=0.0000
Position Z=0.0000

[Home]
X=0.0000
Z=0.0000
Feed=1000.0000
Negative X=TRUE
Negative Z=TRUE
Negative 3=FALSE
Negative 4=FALSE

[Feed]
Default=100.0000
Maximum Rate X=1400.0000
Maximum Rate Z=1400.0000
Maximum Rate 3=500.0000
Minimum Rate=0.0010
Steps per mill X=160.0000
Steps per mill Z=160.0000
Steps per mill F=160.0000
Motor Direction X=1
Motor Direction Z=1
Max Contour Feed=10.0000
Max Contour Angle=25.0000
Jog Rapid Feed=1000
Shortest Move=0.0000
Shortest Time=0.0000
Maximum Rate 4=0.0000

[Spindle]
Maximum Speed=3000
Minimum Speed=10
Manual=FALSE
Encoder Count=4000
Encoder Fitted=TRUE

[Machine Capability]
Maximum Cut Depth=12.0000
Travel X+=0.0000
Travel Z+=0.0000
Travel X-=-140.0000
Travel Z-=-430.0000
Cutter Compensation=FALSE
High Speed Machining=FALSE
Table Size X=50.0000
Table Size Z=50.0000
Under Inspection=FALSE
Feed Pot=TRUE
Speed Pot=TRUE
Radius Programming=FALSE

[Tool Change]
Auto Changer=1
Maximum number=8
Turret number=8
X=0.0000
Z=0.0000
Change Pos X=0.0000
Change Pos Z=0.0000
Tool In Turret=1

[Communications]
Control Type=0
Baud rate=19200
Com Port=1
Mint File=NovaTurn.mnt
Polling Delay=50
M Code TimeOut=10000
T Code TimeOut=60000
Stop Bits=2
Hardware Handshaking=FALSE

[Post Process]
Library=C:\Program Files\Denford\Milling\LIBS\FANUCM.SLB

;first item=In or Out or Wait
;second item=Port Number
;third item=Is the IO + or -
;fourth item=Timeout time in seconds
;fifth item=Message to show
;sixth item=ErrorMessage
File Extension=Undefined
Denford Directives=FALSE
Add Comments=FALSE
Add Percents=FALSE
Force Points=FALSE

[MCode Description]
M3=Spindle Forward
M4=Spindle Reverse
M5=Spindle Stop
M10=Chuck Open
M11=Chuck Close
M38=Door Open
M39=Door Close
M62=Output 1 On
M63=Output 2 On
M64=Output 1 Off
M65=Output 2 Off
M66=Wait for Input 1 Activate
M67=Wait for Input 2 Activate
M76=Wait for Input 1 DeActivate
M77=Wait for Input 2 DeActivate

[MCode TimeOut]
M3=10000
M4=3000
M5=10000
M10=0
M11=0
M38=0
M39=0
M62=0
M63=0
M64=0
M65=0
M66=0
M67=0
M76=0
M77=0

[MCode Enabled]
M3=TRUE
M4=FALSE
M5=TRUE
M10=FALSE
M11=FALSE
M38=FALSE
M39=FALSE
M62=FALSE
M63=FALSE
M64=FALSE
M65=FALSE
M66=FALSE
M67=FALSE
M76=FALSE
M77=FALSE

[Input/Output Devices]
Tutor File=VRTurningTutor.keys
Com Port=0
Virtual World=NovaTurn.xvr
CIM RS232 Input=FALSE
CIM DDE Input=FALSE
Jog X plus key=VK38
Jog X minus key=VK40
Jog Z plus key=VK39
Jog Z minus key=VK37
Feed up key=VK116
Feed down key=VK117
Speed up key=VK118
Speed down key=VK119

[Miscellaneous]
Background Bitmap=default
Background Enabled=TRUE
Background Tiled=TRUE

C:\Program Files\Denford\VRTurning\NovaTurn.mnt
PON : REM Turn prompt on

CON : REM Change to configuration
NEW : REM Clear out previous conf
RELEASE : REM Clear all user variables

LOAD 2
AUTO : REM AutoRun the program
| : REM Send a CTRL-Z blank line (to quit edit mode)

PROG : REM Change to program
NEW : REM Clear out previous prog
RELEASE : REM Clear all user variables
REM : EDIT : REM Enter edit mode

REM ~~~~~~~~ Main Program Body Starts Here ~~~~~~~~~~

REM comms (2) = Current mode from PC
REM comms(21) 0=feed/min 1=feed/rev
REM comms(22) 0=RPM 1=CSS
REM comms(23) = FeedRate / Rev
REM comms(24) = Actual Spindle Speed
REM comms(25) = Setup Diameter for CSS (in motor steps)
REM comms(26) = Spindle Speed for CSS (in steps per min / 1000)

LOAD 1
COMMSON : REM (NovaTurn) Initiate the comms array
MINT328 = 1 : REM Initiate MINT/3.28
comms(1) = 0 : REM Use as Command register
comms(3) = 100 : REM Default Feedrate
comms(4) = 500 : REM default spindle speed
comms(5) = 100 : REM Default % feed override
comms(6) = 100 : REM default % Spindle overide
comms(10) = 0 : REM Manual Tool Post Fitted
comms(14) = 4000 : REM default max feed (Feed * (200/60))
comms(15) = 2500 : REM default max speed
comms(21) = 0 : REM Default to feed/min
comms(22) = 0 : REM Defualt to RPMs
comms(23) = 0 : REM Initialise feed per rev value
comms(31)= 14 : REM Mint file Version (Software)
comms(32)= 20 : REM Machine ID number
comms(33) = 0 : REM Machine problems
REM 1 is door open
REM 2 is low lube
REM 4 is low air pressure
REM eg 3 is door open and low lube
comms(34) = 0 : REM CIM Mode on (1) off (0)

DIM GreyCodes(8) = 7,3,2,0,1,5,4,6

SampleCounter = 1
SampleSize = 6
sumSpeed = 0
newSpeed = 0

LastAnal1 = -1
LastAnal2 = -1
feedOverride = 100
speedOverride = 100
OldSpeed = 100
FeedLast = 0
FeedPerRevLast = 0
SpeedLast = 0
FOverLast = 0
SOverLast = 0
Paused = 0
CSSDiameter = 0
CSSCentreLine = 0
FeedPerRev =0
lastspeed = 0 : REM remembers last actual speed so we can tell VR to look at comms 24
M62Mode = 0
M64Mode = 0
M63Mode = 0
M65Mode = 0
M10Mode = 0
JustPoweredOn=1
POKE 3, 50
POKE 3, 116
POKE 3, 176
POKE 0, 0
POKE 0, 32
POKE 1, 0
POKE 1, 255
POKE 0, 1
POKE 0, 0

WRAP = 4000 : REM Spindle Encoder Edge Count

SafetyFeed = 150 * 200 / 60 : REM convert 150mm/min into steps/second

CONFIG = 2, 2, 2
DISLIMIT
SCALE = 1, 1, 1
RAMP = 1, 1, 1
ACCEL = 10000, 10000, 10000

EV=1 : REM Enable Events

COMMS(19) = 0 : REM safety bit
X3.0 =1
X4.0 =1 :REM Turn off door sol when open

Time=0
HasChanged=0
PRINT "Novaturn Mint v1.2 (c) Denford Ltd"
LOOP
command = comms(1)
if comms(2) <> 2 THEN comms(21) = 0 :REM Feed/Min if not Auto
if comms(2) <> 2 THEN comms(22) = 0 :REM CSS Off if not Auto
if comms(21)=0 AND comms(3) <> FeedLast THEN GOSUB NewFeed
if comms(22)=0 AND comms(4) <> SpeedLast THEN GOSUB NewSpindle
if comms(5) <> FOverLast THEN GOSUB NewFeedOverride
if comms(6) <> SOverLast THEN GOSUB NewSpinOverride
command = comms(1)
IF command = 7 THEN GOSUB toolChange
command = comms(1)
IF command = 17 THEN GOSUB Poker
command = comms(1)
IF command = 18 THEN GOSUB mcode
command = comms(1)
IF Command = 20 THEN GOSUB NewBufferSize
IF comms(25) <> CSSDiameter THEN GOSUB CSSSetupCentreLine
GOSUB SafetyCheck
GOSUB CheckPot
GOSUB CheckSpindleSpeed
if comms(21) =1 THEN GOSUB CheckFeedPerRev
IF !comms(34)=0 DO :REM If in CIM mode
GOSUB CIMMcodeCheck
GOSUB ChuckCheck
ENDIF
ENDL

REM This SubRoutine is defined but never called !
#Non_Volatile
Pocket = 1 : REM Define Pocket non-volatile variable
RETURN

#STOP : REM Interupt Routine called by the STOP input activating
REM : GOSUB SpindleStop
RETURN

#NewFeed
IF comms(21) = 0 AND (comms(3) * feedOverride / 100.1 < comms(14)) DO
SPEED = comms(3) * feedOverride / 100;
FeedLast = comms(3)
ENDIF
IF comms(21) = 0 AND (comms(3) * feedOverride / 100 > comms(14)) DO
SPEED = comms(14);
FeedLast = comms(14)
ENDIF
IF comms(21) = 1 AND (FeedPerRev * feedOverride / 100.1 < comms(14)) DO
SPEED = FeedPerRev * feedOverride / 100;
ENDIF
IF comms(21) = 1 AND (FeedPerRev * feedOverride / 100 > comms(14)) DO
SPEED = comms(14);
ENDIF
RETURN

#NewSpindle
IF comms(4) * speedOverride / 100 < comms(15) DO
spindle = comms(4) * speedOverride / 100
ELSE
spindle = comms(15)
ENDIF
spinValue = 222 * (spindle / comms(15))
POKE 0,1
POKE 0, int (spinValue)
SpeedLast = comms(4)
RETURN

#NewFeedOverride
IF comms(8) = 0 THEN feedOverride = comms(5)
IF !Paused THEN GOSUB NewFeed :REM SPEED = comms(3) * feedOverride / 100;
IF comms(5) <> feedOverride DO
comms(5) = feedOverride
comms(99) = 5
ENDIF
FOverLast = comms(5)
RETURN

#NewSpinOverride
IF comms(9) = 0 THEN speedOverride = comms(6)
GOSUB NewSpindle
IF comms (6) <> speedOverride DO
comms(6) = speedOverride
comms(99) = 6
ENDIF
SoverLast = comms(6)
RETURN

#ChangeGreyTool
REM Check for a valid tool number
IF (comms(7) < 1) OR (comms(7) > THEN RETURN
GreyCode = GreyCodes(comms(7)) * 8
REM Check to see if we are already there
IF (IN & 00111000) = GreyCode THEN RETURN
NextTool = comms(7) + 1
IF NextTool > 8 THEN NextTool = 1
NextGreyCode = GreyCodes(NextTool) * 8
REM Switch the tool post motor Forward
OUT5 = 1
REM Look for the Requested Tool Position
REPEAT
UNTIL ((IN & 00111000) = GreyCode) OR STOPSW
REM Look for the Next Tool Position
REPEAT
UNTIL ((IN & 00111000) = NextGreyCode) OR STOPSW
REM Switch the tool post motor Reverse
OUT5 = 0
REM Look for the Requested Tool Position
REPEAT
UNTIL ((IN & 00111000) = GreyCode) OR STOPSW
WAIT = 250
RETURN

#toolChange
IF comms(10) = 1 DO
GOSUB ChangeGreyTool
WAIT = 250
ENDIF
comms(1) = 0
pocket=comms(7)
RETURN

#Poker
POKE comms(17), comms(16)
comms(1) = 0
RETURN

#mcode
IF comms(18)=3 then GOSUB SpindleStart
IF comms(18)=4 then GOSUB SpindleStart
IF comms(18)=13 then GOSUB SpindleStart
IF comms(18)=5 then GOSUB SpindleStop
IF comms(18)=30 then GOSUB SpindleStop
IF comms(18)=0 then GOSUB SpindleStop
IF comms(18)=10 DO
M10Mode = 1
GOSUB ChuckOpen
ENDIF
IF comms(18)=11 DO
M10Mode = 0
GOSUB ChuckClose
ENDIF
IF comms(18)=38 THEN GOSUB DoorOpen
IF comms(18)=39 THEN GOSUB DoorClose
IF comms(18)=62 AND comms(34)=0 then GOSUB Mcode62 :REM outputs on/off only if not in CIM mode
IF comms(18)=64 AND comms(34)=0 then GOSUB Mcode64
IF comms(18)=63 AND comms(34)=0 then GOSUB Mcode63
IF comms(18)=65 AND comms(34)=0 then GOSUB Mcode65
IF comms(18)=62 AND !comms(34)=0 do
M62MODE = 1 :REM outputs on/off if IN CIM mode
comms(62)=1 :REM for debugging
ENDIF
IF comms(18)=64 AND !comms(34)=0 do
M64MODE = 1
comms(64)=1 :REM for debugging
ENDIF
IF comms(18)=63 AND !comms(34)=0 do
M63MODE = 1
comms(63)=1 :REM for debugging
ENDIF
IF comms(18)=65 AND !comms(34)=0 do
M65MODE = 1
comms(65)=1 :REM for debugging
ENDIF
WAIT = 250
IF comms(18)=66 then GOSUB Mcode66 :REM wait inputs
IF comms(18)=76 then GOSUB Mcode76
IF comms(18)=67 then GOSUB Mcode67
IF comms(18)=77 then GOSUB Mcode77
comms(1) = 0
RETURN

#SafetyCheck
IF JustPoweredOn DO
JustPoweredOn = 0
comms(7) = Pocket : REM read comms 7 1st to remember last tool on machine
ENDIF
IF STOPSW DO
stop[0,1] : REM AT added 5/4/2004 to stop axes carrying on homing if ESTOP released
GOSUB SpindleStop : REM Stop the Spindle
ENDIF
IF IN0 DO : REM If the door is open...
IF (OUT & 1 = 1) THEN GOSUB SpindleStop : REM Stop the Spindle
IF (comms(2) = 2) AND !IDLE DO : REM If in Auto mode...
REM : STOP[0,1,2] : REM stop the Axes
Paused = 1
OldSpeed = SPEED : REM rememeber the original feedrate
SPEED = 0; : REM Set the Feedrate to 0
ENDIF
IF (comms(2) < 2) AND (SPEED > SafetyFeed) DO : REM If not in Auto then
comms(3) = SafetyFeed : REM limit the feed to a safe feedrate
GOSUB NewFeed
REM SPEED = SafetyFeed; *** removed to stop juddery jogging
ENDIF
ENDIF
IF !IN0 and Paused DO
SPEED = OldSpeed;
Paused = 0
ENDIF
REM machine safe = door closed AND not low lube AND air pressure ok
MachSafe = (IN0=0) : REM AND (IN1=0) : REM AND (IN2=0)
IF Comms(34)=0 DO :REM if NOT in CIM MODE then
IF comms(19) <> MachSafe DO
comms(33) =0
IF (IN0=1) THEN comms(33) = comms(33) OR 1 : REM Tell PC what problem is
IF (IN1=1) THEN comms(33) = comms(33) OR 2 : REM Low Lube
IF (IN2=1) THEN comms(33) = comms(33) OR 4 : REM Low Air
comms(99) = 19 : REM Tell host the door has just moved
ENDIF
Comms(19) = MachSafe : REM Set the Safety flag
ENDIF
IF Comms(34)=1 DO :REM if in CIM MODE then
IF comms(19) <> MachSafe DO
comms(33) =0
IF (IN0=1) THEN comms(33) = comms(33) OR 1 : REM Tell PC what problem is
IF (IN1=1) THEN comms(33) = comms(33) OR 2 : REM Low Lube
IF (IN2=1) THEN comms(33) = comms(33) OR 4 : REM Low Air
comms(99) = 19 : REM Tell host the door has just moved
ENDIF
Comms(19) = 1 : REM If CIM mode set it to Door OK all the time
ENDIF

RETURN

#SpindleStart
GOSUB SafetyCheck
IF Comms(19) THEN OUT0 = 1 : REM Only if safe
RETURN

#SpindleStop
OUT0 = 0
Gosub WaitZeroSpeed
RETURN

#CSSSetupCentreLine
CSSDiameter = comms(25)
CSSCentreLine = ABS(POS[0]) + (CSSDiameter / 2)
RETURN

#CheckPot
Anal1 = (A1 / 1024) * 75 : REM Spindle Override Pot
ScanPots = 0
IF Time > 2000 DO : REM look at pots every so often
ScanPots = 1
Time = 0
ENDIF
IF (ABS (Anal1 - lastAnal1) > 2) OR Scanpots DO : REM 2% hysterisis
NewA1 = INT (Anal1 / 5) * 5 + 50
IF newA1 > 120 THEN newA1 = 120
speedOverride = newA1
GOSUB NewSpinOverride
LastAnal1 = Anal1
ENDIF
Anal2 = (A2 / 1024) * 155 : REM Feed Override Pot
IF (ABS (Anal2 - lastAnal2) > 2) OR Scanpots DO
NewA2 = INT (Anal2 / 5) * 5
IF newA2 > 150 THEN newA2 = 150
feedOverride = newA2
GOSUB NewFeedOverride
LastAnal2 = Anal2
ENDIF
RETURN

#NewBufferSize
MBFULL = comms(20)
MBHALF = int (comms(20) / 2 + 0.5)
comms(1) = 0
RETURN

#CheckFeedPerRev
REM ~~~ feed/min = feed/rev * actual spindle speed
FeedPerRev = comms(23) * lastspeed: REM comms(24)
If FeedPerRev > comms(14) THEN FeedPerRev = comms(14) : REM clamp too big a feedrate
GOSUB NewFeed
FeedLast = 0
RETURN

#CheckSpindleSpeed
REM Average and update the current spindle speed data

SampleCounter = SampleCounter + 1
sumSpeed = sumSpeed + -PULSEVEL / WRAP * 60
if SampleCounter > SampleSize DO
newSpeed = sumSpeed / SampleSize
sumSpeed = 0
SampleCounter = 1
ENDIF

comms(24) = newSpeed
IF ABS (newSpeed - lastSpeed) > 20 DO
comms(99) = 24
lastSpeed = newSpeed
ENDIF

REM Check for CSS
IF comms(22) = 0 THEN RETURN
REM ~~~ RPM Spindle Speed = CSS / Pi*D
LastSpeed = -PULSEVEL / WRAP * 60
CurrentDiameter = 2 * ABS(CSSCentreLine - ABS(POS[0]))
comms(4) = comms(26) / (3.142 * CurrentDiameter / 1000)
GOSUB NewSpindle
RETURN

#WaitZeroSpeed
REPEAT
Gosub CheckSpindleSpeed
UNTIL (LastSpeed<30) OR STOPSW
Wait=400
RETURN

#ChuckCheck
:REM Checks for Chuck commands from CIM Device Driver
IF X1.0 THEN GOSUB ChuckOpen
IF !X1.0 AND !M10Mode THEN GOSUB ChuckClose
RETURN

#ChuckOpen
GOSUB SpindleStop :REM just in case !
OUT3 =1
IF !comms(34)=0 THEN X1.0 =1 :REM Chuck status output OUT2
RETURN

#ChuckClose
REM Gosub SpindleStop
OUT3 =0
IF !comms(34)=0 THEN X1.0 =0 :REM Chuck status output
RETURN

#DoorOpen
Gosub SpindleStop
X3.0 =0
X4.0 =1
REPEAT
UNTIL X4.0 OR STOPSW
WAIT = 250
X3.0 =1
X4.0 =1 :REM Turn off door sol when open

RETURN

#DoorClose
X3.0 =1
X4.0 =0
REPEAT
UNTIL !IN0 OR STOPSW
WAIT = 250
X3.0 =1
X4.0 =1 :REM Turn off door sol when open
RETURN

#CIMMcodeCheck
:REM If in CIM mode, checks for M62 M64 and allows them if door is OK
IF M62Mode AND !IN0 DO
X0.0=1 :REM Turn auxiliary output OUT1 on if door closed
M62Mode=0
comms(62)=0
ENDIF

IF M64Mode AND X4.0 DO
X0.0=0 :REM Turn auxiliary output OUT1 off if door open
M64Mode=0
comms(64)=0
ENDIF

IF M63Mode AND !IN0 DO
X1.0=1 :REM Turn auxiliary output OUT2 on if door closed
M63Mode=0
comms(63)=0
ENDIF

IF M65Mode AND X4.0 DO
X1.0=0 :REM Turn auxiliary output OUT2 off if door open
M65Mode=0
comms(65)=0
ENDIF
RETURN

#Mcode62
REM: Turn auxiliary output OUT1 on
X0.0=1
RETURN

#Mcode64
REM: Turn auxiliary output OUT1 off
X0.0=0
RETURN

#Mcode63
REM: Turn auxiliary output OUT2 on
X1.0=1
RETURN

#Mcode65
REM: Turn auxiliary output OUT2 on
X1.0=0
RETURN

#Mcode66
REM: Wait for AUX input 1
REPEAT
GOSUB SafetyCheck
UNTIL X0.0 OR STOPSW
RETURN

#Mcode76
REM: Wait for not AUX input 1
REPEAT
GOSUB SafetyCheck
UNTIL !X0.0 OR STOPSW
RETURN

#Mcode67
REM: Wait for AUX input 2
REPEAT
GOSUB SafetyCheck
UNTIL X1.0 OR STOPSW
RETURN

#Mcode77
REM: Wait for NOT AUX input 2
REPEAT
GOSUB SafetyCheck
UNTIL !X1.0 OR STOPSW
RETURN

| : REM Send a CTRL-Z blank line (to quit edit mode)

C:\Program Files\Denford\VRTurning\Tooling Files\Default.tft
[1]
X=0
Z=0
Radius=0
[2]
X=-36.51
Z=35.98
Radius=0
[3]
X=-0.87
Z=-20.29
Radius=0
[4]
X=-31.83
Z=35.98
Radius=0
[5]
X=0.81
Z=-4.91
Radius=0
[6]
X=-31.83
Z=14.66
Radius=0
[7]
X=-0.64
Z=-3.81
Radius=0
[8]
X=-31.83
Z=36.45
Radius=0
[Global]
Current Tool=1
[Tool1]
Tool Name=Roughing Tool
[Tool2]
Tool Name=Boring Bar
[Tool3]
Tool Name=Finishing Tool
[Tool5]
Tool Name=External Thread
[Tool7]
Tool Name=Parting Off Tool
[Tool4]
Tool Name=Drill 2
[Tool6]
Tool Name=Center Drill
[Tool8]
Tool Name=Drill
C:\Program Files\Denford\VRTurning\VRTurn.TTD
[Roughing Tool]
Type=0
Class=0
Tool Orientation=8
Tip Orientation=3
Colour=255
Nose Radius=0.4
Maximum Tool Life=50
Current Tool Life=-1
Tip Angle=60
Tip Clearance=-10
Tip Size=12
Length=60
Width Diameter=12

[Grooving Tool]
Type=2
Class=0
Tool Orientation=8
Tip Orientation=3
Colour=16711808
Nose Radius=45
Maximum Tool Life=50
Current Tool Life=0
Tip Angle=6
Tip Clearance=-45
Tip Size=2.2
Length=60
Width Diameter=12

[Internal Thread]
Type=1
Class=1
Tool Orientation=7
Tip Orientation=6
Colour=16384
Nose Radius=0
Maximum Tool Life=0
Current Tool Life=0
Tip Angle=60
Tip Clearance=0
Tip Size=9
Length=60
Width Diameter=12

[Boring Bar]
Type=0
Class=1
Tool Orientation=7
Tip Orientation=2
Colour=16744576
Nose Radius=0.4
Maximum Tool Life=0
Current Tool Life=0
Tip Angle=60
Tip Clearance=0
Tip Size=6.35
Length=40
Width Diameter=8

[Center Drill]
Type=4
Class=1
Tool Orientation=7
Tip Orientation=7
Colour=65535
Nose Radius=0
Maximum Tool Life=0
Current Tool Life=0
Tip Angle=54
Tip Clearance=-45
Tip Size=3
Length=20
Width Diameter=5

[External Thread]
Type=1
Class=0
Tool Orientation=8
Tip Orientation=3
Colour=16711680
Nose Radius=0
Maximum Tool Life=50
Current Tool Life=0
Tip Angle=60
Tip Clearance=-45
Tip Size=7
Length=60
Width Diameter=12

[Finishing Tool]
Type=0
Class=0
Tool Orientation=8
Tip Orientation=3
Colour=4227327
Nose Radius=0.4
Maximum Tool Life=50
Current Tool Life=0
Tip Angle=60
Tip Clearance=-15
Tip Size=12
Length=60
Width Diameter=12

[Drill]
Type=3
Class=1
Tool Orientation=7
Tip Orientation=7
Colour=32768
Nose Radius=0
Maximum Tool Life=50
Current Tool Life=0
Tip Angle=90
Tip Clearance=0
Tip Size=15
Length=40
Width Diameter=5

[Parting Off Tool]
Type=2
Class=0
Tool Orientation=8
Tip Orientation=3
Colour=8421376
Nose Radius=0
Maximum Tool Life=50
Current Tool Life=0
Tip Angle=60
Tip Clearance=-45
Tip Size=2.2
Length=60
Width Diameter=12

[Pusher]
Type=5
Class=1
Tool Orientation=7
Tip Orientation=7
Colour=4259584
Nose Radius=0
Maximum Tool Life=50
Current Tool Life=0
Tip Angle=60
Tip Clearance=0
Tip Size=15
Length=60
Width Diameter=12
TipIndex=18
Attach_X=34
Attach_Y=22
0_X=23
0_Y=35
1_X=23
1_Y=30
2_X=23
2_Y=30
3_X=32
3_Y=30
4_X=32
4_Y=30
5_X=32
5_Y=27
6_X=32
6_Y=27
7_X=32
7_Y=27
8_X=32
8_Y=27
9_X=29
9_Y=27
10_X=29
10_Y=27
11_X=29
11_Y=22
12_X=40
12_Y=22
13_X=40
13_Y=27
14_X=37
14_Y=27
15_X=37
15_Y=30
16_X=45
16_Y=30
17_X=45
17_Y=35
18_X=34
18_Y=35

[Drill 2]
Type=3
Class=1
Tool Orientation=7
Tip Orientation=7
Colour=16777215
Nose Radius=0
Maximum Tool Life=50
Current Tool Life=0
Tip Angle=60
Tip Clearance=0
Tip Size=15
Length=40
Width Diameter=10
C:\Program Files\Denford\VRTurning\VRTurn.TOL
[Offset 1]
X=-97.75444
Z=-132.17906
Current=1
[Offset 2]
X=0
Z=0
Current=0
[Offset 3]
X=0
Z=0
Current=0
[Offset 4]
X=0
Z=0
Current=0
[Offset 5]
X=0
Z=0
Current=0
[Settings]
Use Machine Only=0
********** END OF SUPPORT DATA ****************

That all looks ok.
Can you try mintman again and double check:
1. VR Turning (and any other Denford software) is closed down
2. Baud rate is 19200, com port is 1 and stop bits 2

I'm not sure yet that you need to change the encoder wrap value in the novaturn.mnt file and download it with MintMan - we really need to find out what the speed really is (with a handheld tachometer), what the encoder is telling us it is, what has been programmed and what the speed override is set to...

It did the same thing when I ran MintMan again, and Denford software was shut down. On the software the speed was set to 50%, but the spindle was running faster than that, if the spinlde was set to 1200 it was running like 850 or so. I did run the spindle to max, which i think is 3000 RPM for a Starturn. The software did show that it was almost 3000 RPM but for like a second, but was reading like 2800.

I will see if I can get a handheld tach and check the spinlde speed.

I was losing steps/postion last time i posted something. I used a travel indicator and the lathe was off like 20% everytime it was in step mode. If i moved 0.010" its moved 0.008" or 0.100" it moved 0.080" but always went back to zero. It like that on Y axis and half on X axis since its radius. Whats making it do that? I never got around on checking the RPM on the spindle either.

I am also considering using Mach 3 with the lathe and use the Baldor card with a breakout board. The lathe has a Jay Electronics speed controller on it. Would i need an analogue board to control the spindle with the breakout board?

The reason the movement is incorrect will be the steps/mm setting. If you go to the machine setup page and look at the feed section it tells you how many steps are required to move 1mm.

I think there are 200Steps / Rev of the motor (it may be 400 half steps)

If you can check the ballscrew pitch (probably 5mm) and then the belt ratio on the motor and Ballscrew you will be able to find out how far the machine moves for 1 rev of the motor. you will then be able to calculate the number of steps / mm

The alternative is to change the number its set to now by 20% if you are sure this is the scaling factor you aare out by.

The settings have the steps per mill set to 160, which is 80% of 200. I would also assume that the spindle encoder count needs to be changed, its at 4000. I have no idea to what it needs to be changed to.

160 or 200 steps per mm are usual for those machines.
4000 spindle encoder pulses also is right...if its reading 2800 RPM for 3000RPM programmed, i'd say you just need to adjust a pot somewhere...hopefully Martin or Bradders can tell you the best place to adjust it.

I tested the lathe and it was better after changing the steps per mm. Used a travel indicator and worked, besides being off 0.0005"

Ran the spindle on manual at 3000 RPM and showed that the spindle was going 4000 RPM! Where is the pot at, on the speed controller?

And btw, ran the spindle at 250 and it showed 275 or 280.