Build Thread- CNC Update Log - SuperMax YCM-40 (Anilam to Mach3)

[radioactive]

Bad weather delayed the pickup of the milling machine until this weekend, however I'm exicted to start the conversion.

It's an 88 Supermax YCM-40 with anilam controls on it now. Has servo drives model SEM 30M4-59, 2400 rpm, 142 volts, 30 pulse amps? Mist system, auto lube system, tool changer, etc.

Plan is to retrofit it with what ever is necessary to run Mach 3.

Already built a new PC and have Mach 3 loaded on it (trial version). Will be making a new display box to house the 17" flat screen, keyboard, mouse USB port, and all the buttons needed.

Already purchased a Hitachi X200-022NFU 220 volt input (single phase), 220 volt output (3 phase), rated for 3 hp which is what the spindle motor is. VFD is currently running a large grinder in the garage to verify operation. Very slick...

This past weekend I ran 220V out to a subpanel in the garage to power the milling machine, and a few other pieces of equipment. So that is out of the way.

Need opinions on what route to go as far as drives, breakout boards, etc. For the longest time I thought the machine had steppers on it, so my plans changed alittle when I found out it used servo drives.

I've done a ton of reading on this site and others to try and grasp what will need to be done... I'm thinking a smooth stepper board from the PC (USB vs. no printer port), then possibly Gecko drives? I think then can accept step/dir signals?

Also, the tach will be disconnected from the servo's and I'll probably have to mount encoders on each one. Where to buy?

The mill has glass scales on it as well (not really sure if that would be useful or not), maybe for manual machining DRO purposes?

Thanks for any help and I'll be sure to post pics!

[radioactive]

Well, the machine is now in the garage. Had to remove the spindle motor to fit under the door opening.

The machine has a smaller panel on the back where the old 3-phase power entered. It contains the ON/OFF switch, three fuses, some sort of over voltage or under voltage relays???, etc. Can I gut this entire box? My new setup will be 220V single phase to a Hitachi VFD. Power coming in is controlled with a sub panel breaker, and the VFD has an on/off button.

Should get some pics tomorrow once I get the garage warmed up...

[radioactive]

After reading thru the manual on the Hitachi VFD it appears as though the VFD replaces all of the motor protection devices located on the back of my milling machine. It's amazing how much you can do with this VFD! Remote on/off, spindle direction, spindle speed, alarm contacts to show fault state, reset fault state remotely, E-stop input, etc.

Gecko 320's and Renco encoders are in the mail, smooth stepper should be as well. Kurt D688 is on order, and looking for a new power supply right now. Slowly making progress...

[radioactive]

Finally some pics...

Coming home on the trailer, inside the back box with the 3 phase and motor protection devices. A shot of the transformer, cap, rectifier, drives, line filters, and one pic of the front of the machine.

[radioactive]

Made more progress last night. I gutted both boxes on the machine. The only things left entering the box are the Servo drive cables, glass scale cables, mist system power wiring, lube system power wiring, spindle motor wiring, etc.

I went ahead and connected my Hitachi VFD up to the spindle motor just to verify it operates correctly. Sure enough it works like it is supposed to...

I also did some testing last night with the existing power supply for the drives. It seems as though it is alittle to high to use for the Gecko drives. It outputs 108 VDC (after the rectifier and across the Capacitor).

Also removed the covers off the weighs (sp?) and cleaned everything up. I still need to soak the covers and wash them as they are down right nasty...

pics of removed stuff and one of the transformer...

[Ed VanEss]

Thats a real good lookin mill you have there. Keep us updated on the progress.

Ed V

[radioactive]

Made some more progress this weekend, I started mounting components on the backplane of the large cabinet. Should get my last breakout board tomorrow in the mail. The smooth stepper has been installed and is configured and working with the PC. Next up is to install the VFD in the cabinet and interface it with Mach 3.

I had some fittings made up to mount the encoders to the servo shafts and next have to make some blocks to secure the outside portion of the encoder to the motor housing.

Anyone know how much of a heatsink is required to be mounted to the Gecko drives? Will a 1/4" thick plate of aluminum be enough or will it require a heatsink with fins on it to better dissipate the heat?

[Ed VanEss]

I Made an alum plate with fins to mount geckos and the BOB , with 3 -. 12v fans behind. Remember , heat kills electronics.

Ed V

[radioactive]

More progress... All components have been installed on the backplane (except the transformer which will get mounted on the lower right corner of the plate). I mounted the Gecko's on 4" by 6" heatsinks with 1" fins and have three 12 VDC fans directly under the heatsinks.

The backplane has been installed in the cabinet and two 6" holes have been cut in the cabinet for two new 120 VAC fans (inlet at the bottom, outlet at the top).

Next is to wire up the limit switches, land the glass scale encoder wiring, install the new rotary encoder wiring, and then reconnect the 3 phase spindle motor and 240 VAC wiring to the VFD.

[gavztheouch]

Nice setup radioactive, Im currently doing something similer with a cnc wood router, with servos rated at 140v max and a actual output voltage of 115V

Let me know how your motors run at the lower voltage im still debating if I should go with a lower voltage or wait and use a higher voltage driver. Granite devices have a 160v card coming out soon, which would be perfect.

Also how did you get on with mounting your encoders on the motors, I take it they where elsewhere on the machine?

Did you find out what pulse amps meant? I also have a pulse amps rating on my motors but no information as to what the continuous or max current is?

Gav

[radioactive]

I will let you know in the next few days. I'm almost ready to start making chips...

The motors had holes in the center of the motor shaft. I threaded the hole and installed a stud in the hole. Mounted the encoders in the end of the motor, with the hub of the encoder positioned over the shaft.

Not sure on the pulse amps? The previous setup used 120V to power the transformer that fed the servo driver cards and only used 20A fuses on the line coming in. That must have been adequate before...

I should get some more pics up in the next few days.

[Teyber12]

great log, can't wait to see some more updates