From my workplace in 2016, I got a drowned, neglected machine.
The machine hasn't been gone for two years, its primary fault is the spindle frequency converter - if it were just ...
I don't know much about his history, by type Peisa PT-505, by machine board 199? made in. After continuous installation after the installation, I realized that the complete refurbishment should not be lost. First of all, I wanted a step / dir system, but it's just an open loop system, like that we do not put it on an industrial machine. I chose the closed-loop system. Unfortunately, the General Electric Mark Century 2000 One Plus / Fagor 8010M 'Control' motherboard ruined - the cause of the error is revealed in the steps of the renovation. Practically my hobby it has become one of its best machines. It is accurate and it works within its borders. For home use ideal, small power requirement.
Step 1: Status Check, 'Just Go' Fixes
- After the first cleaning, the control was improved. 2 NiCd batteries
which is memory defective was wrong. After the replacement I installed the GE Mark Century 2000 one plus Fagor 8010M controller.
- I switched my frequency converter to another active used Danfoss VLT.
- First refurbishment of unreliable lubrication, replacement of oil dispensers. xyz cleaning of sliding lines
- Electrocupplung-belted belt converter was upgraded first:)
- I managed to get a Fagor 8010M controller, unfortunately power and motherboard were faulty, EEPROM and keyboard worked. I moved the old GE Mark Century 2000 one plus control - Fagor 8010M with a minimal difference. And I installed led lighting.
Step 2: Fagor 8010 M Failure, Complete Electronics Remodeling Decides
One day, when the power was turned on, the controller signaled a long beep. Started several times to turn on. Parameter repository damaged, M function board damaged, ball spindle correction table damaged, program library damaged, datum table damaged. But he wrote everything in small letters.
Luckily, I can now get a Fagor 800 MGI controller. This is a 3-axis controller, and I have been able to buy it from England in an excellent state. But it is only partially compatible with the 8010M controller.
Before the fault, the Z-axis lubrication received a new 4 mm flexible tube. And a new lubricating unit.Oil was also a problem with dispensers, so they had to be replaced.
Step 3: Breakdown.
Instead of continual 'just go' fixes, I decided to go for complete electrical reconstruction.
Practically it is worth doing the painting. So it was in the line.
In addition to encoder cables, I replaced 90% of all electrical cables and connectors. Originally a tool changer was a cnc machine, the mechanics were dismantled, so its electronics remained in it but it was turned off. I also got rid of these unnecessary things.
I had to get a Dymo LetraTag printer, so I labeled the remaining parts and the remaining encoder cables. Later on, all relays controlling the main unit of the machine were labeled.
The dampness of the electric cabinet and the swim in the oil are caused by the principle of the cooling fan. Practically draws dust and oil mist into the cabinet. Over the years, this is a sticky oil shale: (You can even drive electricity, but overheating is guaranteed. The easiest solution to this problem is the air-conditioned, enclosed electric cabinet. I decided.
The purchased used cabinet climate must be mounted on the machine before painting, the holes and the cutouts are cut out.
After this step, I painted the inside of the electric cabinet with water-based paint in the final phase of the disassembly.
There was no picture about painting because of the high-dust grinding, and the paint had to be worn quickly. I chose a 3-component industrial epoxy paint.
Step 4: Machine Assembly
First, I select materials from AliExpress:
-2 pcs 24 V power supply
-C rail-mounted electrical conductors markers supplied cables (not AliExpress, Hungarian company, IlDiverso)
In the next step I cut my polyfoam foam with my blue laser machine,
cabinet for air conditioning insulation. Or the terminal block markers I've developed a simple method:
-Nitro Thinner Wash, disappears old inscription
-Matt painting with black pain
-Burning laser-labeled inscriptiont
-Black paint release with nitro diluent
I placed the main units on the main board of the electrical cabinet. Then I put it in the electric cabinet. He got new cable ducts, the old ones were thrown into plastic waste.
I made the control / electrical cabinet connection. Practically, things went very fast.
The source of the primary error that had to be rebuilt was the short-circuit winding of the isolating transformer. The old control got 260 volts, it couldn't handle it. That is, he became a victim of surge. Here I note the current new separator transformer is directly inverted. Because there is a certain voltage drop in the secondary coil. So it's not a 1: 1 but a little bit bigger than the transformer. 240 V from 230 V input voltage. No problem, I turned the primer into a secunder. The primary fault is therefore over. In the cable jungle that characterized the machine was insoluble, I had no pleasure in correcting the oily, dirty cabinet.
It was a very expensive learning money, and the 8010 M took $ 100 -I was doing this well, now looking back too, because I became an extra monitor. Fagor 800 MGI shipped $ 210-It was cheap. Things that seem tiny are costing $ 8-900, and many little things go.
I made the cabinet inscriptions with Dymo LetraTag printer. Very useful tool!
I have an electric cabinet with lighting, practically the climate is turned off by a switch when the cabinet door is open and the lighting is switched on. Air does not blow cold air during assembly. I learned from my work machine. There, the spindle motor cooler goes to the open spool door. It is not good to install it if the wind gets the hair down :).
Step 5: Milling Capabilities, Work Performance, Modifications
The machine is mainly designed for making small parts. As one man said, 'better from file'. It has some shape defect, 0.01-0.02 mm. Unfortunately, he's worn out. But it was worth renovating. With the digital oscilloscope, the analog servo amplifier was tuned. The fine tuning has already been done with tuning during measurement milling.
That's why there is a 3-axis milling machine just because I haven't even given a spindle to the spindle. If I can say this to a small machining center.
The machine is equipped with analog dc servo amplifiers and dc servo motors. It works with Baldor TMF 160-60-3. 360 W can handle each servo amplifier channel. I managed to get another card so I have a spare. There are also a few pieces of transistors. The feedback of the servo amplifier is the tachogenerator. I managed to remedy the significant kefepor contamination of the X-axis engine. Virtually this axis works more.
The spindle is capable of 100 to 1700 rpm in range 1. 2 and range from 1701 to 10,000 rpm et. A mechanical transmission is useful. The spindle motor is 1.4 kW os. Its main body is ISO 25. There is also a new basic body available. The old Schaublin basic bodies can be fitted with an ER16 cartridge, and there are also some basic weldon systems manufactured by my workplace. The new Chinese body can be fitted with an ER20 cartridge, with a maximum tool diameter of 13 mm.
The capabilities of the Fagor 800 MGI control have been shown in a photo, detail from the manual. I really like the graphical programming interface, the drip feed function. It is rather a cnc tool mill control, but it is excellent for one piece of work.
Machine clearance: X 308.2 mm, Y 190.4 mm, Z 236.2 mm. With some shaping you can win a few mm.
I couldn't use the machine because of an accident, the tool change takes place with two hands, and I remembered the foot switch. This is what I leave after my healing, very useful! I put a ban if the spindle rotates or the tool cannot be replaced in a cycle.
Two improvements have been made since the renovation. It has a smaller water space, but the pump has received a frequency inverter. Thus, the tool cooling became variable pressure. 4 chillers are available for cooling. I'm currently using 1 stump. I had to replace the monitor, my original monitor was ruined. Lcd over. Unfortunately, I was unable to set the formality on this monitor.
Further development will be that the frost-cooled spindle circle gets a radiator.
The spindle receives a moving cover, so the water will not flow from the open machine to the material. With a simple arduino solution, you can follow the movement of Z when drilling. That is, it does not reach the material.
Thank you for reading. I hope he has done a good deal of hobbist repair. I wish everyone a successful renovation. Don't forget about such machines, knowing the features of the controller have no limit to development! You can always experiment with new ideas.
Thanks to AliExpress for components, IlDiverso KFT wires and TST Machine KFT - Fagor plci documentation. Without them and without perseverance, there would have been no renovation.
Last time for the donation of the machine by Sebi-Metal KFT .