I have some good news and some bad news here. I will start with the bad news first. I received the power supply in the mail and installed it into the machine and tried to run it. I immediately started having some issues. With a call to Rob Varney at Mag we troubleshot the machine and got it working again and everything was really starting to look real good. I got it all aligned and setup and was ready to start running my test program and then I turned it off to go meet my wife for lunch and when I came back I powered up the Rotary phase converter and fired up the machine. The second I hit the energize servos button I heard a really loud pop and saw a flash of light from the back of the machine and smelled smoke. I hurriedly slammed the estop button and ran to the back to disengage the machine from the power and was extremely pissed to find that the Y axis SPARE servo drive fried on me. I do not know what the hell went wrong with it and I was EXTREMELY PISSED OFF!! I killed the power to the entire shop and went inside and had a LONG HARD THINK about what the hell I am going to do here. :drowning
wedge)(nuts)(nuts)
After a long sleepless night pondering what the hell I am gonna do about this damn infernal machine and a lot of long talks with my pal art I have decided that the original control in the machine is ENTIRELY too old, EXTREMELY EXPENSIVE to fix, and I simply do not know enough about it to be able to troubleshoot it adequately. The last couple times I had to repair things really puts it into perspective for me here . When this ***** breaks down I am gonna have a real hard time affording to fix it.
SO.............. I have a couple options. I can try to sell the damn thing for whatever I can get out of it and kiss goodbye to my dreams of machining parts for money and fun on a REAL machining center. I can sell it and try to buy another machine probably a used CNC knee mil or something like that which could ALSO have issues and will ALSO have an older electronics system on it. OR I can try to do a homebrewed retrofit on it myself and Keep the damn thing.
After a lot of thought and long conversations with my wife and art and other friends I have decided to do a retrofit of the machine. I will GUT THIS ***** and try to sell off all of the good working parts left inside it INCUDING the axis motors and remaining working drives and also the entire control system components and replace them with modern PC based components.
At this point I am ACTIVELY looking for two things. One is someone who has this same machine who would want to buy parts from it. The other is INFORMATION..... I want to hear ANY and ALL ideas about the best way to go about a homebrewed retrofit of this control to a PC based system. I would like to do this as SIMPLY as possible and result in a system that I can fix if it breaks and the parts are less expensive to replace as well as readily found online. I have been looking at using EMC2, Mach3, I really don't give a damn what as long as it is capable of supporting this machine entirely including tool probes and a fourth or fifth axis if I want. Basically I want to take this very nice and heavy duty good condition machine and exorcise the demons in the original control and replace it with something I can manage and repair should it break on me. I am ready and willing to listen to any ideas or suggestions as I am OFFICIALLY now putting this machine into the category of LONG TERM PROJECT DREAM. It is not gonna run no matter how much money I throw at it and this few little repairs I have done make me realize with painful clarity that the machine control is just not worth fixing since I do not know how long they will continue to support it and the parts are getting very expensive and some are apparently not replaceable anymore. It just makes sense to me that if I intend to keep this machine for any period of time that I am gonna have to bite the bullet and gut this pig.
So in that light I am now going to find a job full time and put this dream on the back burner at least for awhile. I have some other ideas about the shop and I am going to sell my Digi 256 20HP rotary phase converter because the new machine will be strictly single phase and I have some other ideas and things I want to try.
SO basically that is it in a nutshell. I am OVER the emerson control and not skilled enough with electronics to even try to fully troubleshoot the system and figure out why it keeps blowing drives and power supplies. I have however retrofitted another machine and I am pretty confident in my abilities to do that and while it will certainly NOT be easy I have to tell myself that it is the only way that I will ever be able to truly trust this machine and feel good about trying to run it. I have a couple select folks who have pledges their assistance and help with the setup so as of right now I am going to start pulling boards and motors out of the machine and put them on ebay or whatever for sale. If anyone here has this kind of machine with this kind of control and you want spares or whatever feel free to contact me. Thanks and peace
Pete