On 12 February 2013 13:06, Pete Matos <petefro...@gmail.com> wrote:

> Basically my machine has a huge rotary switch with a big
> lever that was originally used to switcg power to the machine on and off.

I think that should stay, and kill absolutely everything. (I have such
a switch on my machine).
When I refer to a "contactor"  mean something like:
http://uk.rs-online.com/web/p/contactors/7434908/
Which can be used to kill all drive power reliably.
Actually, there are special relays for the job. They are a lot more
expensive but are probably what you should use in an industrial
setting.
http://ab.rockwellautomation.com/relays-and-timers/safety-relays
I am not a qualified electrican and I don't know what the differences are.

>  I know when the original control was switched on nothing
> was energized until you got the computer to a certain initialization point
> then you would hit another button to energize the drives after which you
> would align the machine which is basically homing everything

This is how my machine works. When I power it up only the PC and
24/12/5V PSUs are live. The axis drive PSU and the spindle VFD are
completely unpowered until the Mesa card comes out of watchdog mode
and I press the machine-on button on the screen. That turns on an
output on a Mesa card, and as long as the E-stops (wired in series
with each other and the Mesa IO board) are also closed the main
contactor is pulled-in and the drives power up.

If an e-stop is hit, the drives shut down and the GUI goes into e-stop
if the PC crashes, then the Mesa watchdog dies, and the drives power down.
if I press the on-screen e-stop then the drives power down (and I
can't turn back on for 10 seconds, due to a timer I put in HAL)

-- 
atp
If you can't fix it, you don't own it.
http://www.ifixit.com/Manifesto

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