Retrofit Prolight 5000 (Benchman 5000) to run Mach

Hey guys and gals,

I'm looking to retrofit my newly aquired Prolight 5000 (Benchman 5000) to run Mach 3.

I received 3 whale3 drivers and a parallel breakout board with it.

I'd like to get some ideas if using these Whales would be the best route to take or buy newer drivers.

Spindle control is one of my concerns and not completely sure how to control it and get the speed control to Mach.

Thanks!

http://i.imgur.com/QZlDzhdl.jpg
http://i.imgur.com/K0tBLwal.jpg
http://i.imgur.com/v83pw8el.jpg
http://i.imgur.com/b8fOjrSl.jpg

Are you sure a Prolight and a Benchman are the same? I thought the Benchman had a full enclosure and tool changer.

Since you have everything there to get movement, I would try with what you have. I see the power supplies. How about a few more close ups of the electronics?

What issues are you having in regards to spindle control? Do you have it wired up and set up correctly in Mach? Relay control?

Quote:

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Originally Posted by Fastest1

Are you sure a Prolight and a Benchman are the same? I thought the Benchman had a full enclosure and tool changer.

Since you have everything there to get movement, I would try with what you have. I see the power supplies. How about a few more close ups of the electronics?

What issues are you having in regards to spindle control? Do you have it wired up and set up correctly in Mach? Relay control?

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Thanks for the reply Fastest

From what Ive found, the Benchman was made by Prolight. Same machine minus the ATC. My machine shipped with the enclosure yet was removed at some point.

Its currently run by an Acramatic 2100. It's pretty quirky and I'd rather update it before I loose a hardware component as well as making it a bit more streamlined.

I got 3 Whale3s and a breakout board with it but was leaning towards using currently supported hardware such as the Gecko 320x and a C11 but wanted other opinions.

C11 ? 6 axis, Multifunction CNC Breakout Board with Relay and Spindle Control | Automation Technology Inc

I wasn't sure if the breakout board would be able to control the onboard spindle controller.


http://i.imgur.com/qtu7uhFl.jpg

Spindle Controller:

http://i.imgur.com/fUajh0Ol.jpg
http://i.imgur.com/KkGSqHkl.jpg

Main Board:

http://i.imgur.com/uyH7Hb3l.jpg
http://i.imgur.com/ibWZoxul.jpg


Servos:
http://i.imgur.com/COu4MBSl.jpg
http://i.imgur.com/WuAleGcl.jpg
http://i.imgur.com/3UQfVEll.jpg

Whale and current Drivers
http://i.imgur.com/OO35a99l.jpg
http://i.imgur.com/1izyEDDl.jpg

I am sure the interface with the spindle control (Minarik) would be easy.

Ok guys,

I decided to go with the Gecko 320x's and a C11 BOB. I now have those on hand.

I plan to use the spindle motor, speed controller, servos, encoders, and PSU that are on the unit ATM


I plan to share as much info as I go along as this is a bit of a pain, well at least to me as I've never done much of this style work. Hopefully it will help others as they convert their older machines.

I've found that Intelitek, the company that purchased Light Machines, shares ZERO info about these older, non supported machines. They have but will NOT release any wiring info on them. Oh well...


Here's what I have in my machine:

Speed controller: Minarik Z1BOSS15AC-1Q-0596

Spindle Motor: Eastern Air DB34D-62a

Servos: Litton C23-L50W10M09

Encoders: Computer Optical Products CP 550-1000-LD 1396

PSU: Transformer:Toroid 5549 - Input: 110v AC Output: 55v AC
Choke: 7062

I've got a hold of most of the manufactures of the components to get their manuals for each unit.

I'm building a wiring diagram at the moment and will post it once I have it all together

Ok guys, I got most of the stuff that is not staying pulled out and wired up the PSU to test the output.

I created the wiring diagram for the servo PSU. Still working the the rest.

I also wired up the Gecko G320x to the C11 and a servo and encoder to the Gecko. Mach is installed on the PC. I don't seem to be getting any signals to the board C11. I'm pretty sure they are making contact as Mach resets when the power is pulled from the C11.

When I boot up the C11 almost all LEDS light up and when Mach loads the input LEDS all go off. I can also hear the relays click once Mach loads.

I've got a 5v and 12v PSU on the way to power the Minarik and C11 outputs.

http://i.imgur.com/w9s3G0El.jpg
http://i.imgur.com/CtnNZxfl.jpg
http://i.imgur.com/suB97iql.gif
http://i.imgur.com/xhXsXAHl.jpg
http://i.imgur.com/SbFeuP3l.jpg

Charge pump?

Quote:

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Originally Posted by Fastest1

Charge pump?

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I actually disabled it. I forgot to add the pic of when Mach loads.

The pic with just the USB power LED is when only USB power is added and non other.

The pic attached is when 5v is added and after Mach loads

http://I.imgur.com/pzK2Xebl.jpg

Ok guys and gals,

I got the machine running. Well, all Axis. I canned the OEM encoders and went with AMT-102v's and that solved all my pulsing. I'd still like to test the factory encoders at a later date.

I now need to wire in my speed controller for the spindle motor.

I've got 2 relays on the C11 I can use but from the Speed Controller diagram, it appears I need 3 and I'd like to use one to trigger a larger relay used to provide AC power to the speed controller.

Should I use the floating voltage signal or potentiometer?

Are the VPOTs only needed with the potentiometer? They are already wired to my spindle more when I got it but wasn't sure if it's better to go with the potentiometer or 0-10v.


Info on the speed controller:
http://www.minarikdrives.com/descrip...t/250-0224.pdf

I'm open to opinions.

Thanks!

http://i.imgur.com/3EC7t04l.png

A video of the machine running.

https://www.youtube.com/watch?v=d294tR5IYPA

Congrats. It looks like it is running smoothly too. It will be a nice machine.

Must be nice to see it run.

What frame size is the spindle motor? Do you know much about it?

Feels great. I still need to fine tune it, rewire control box, and get the spindle running with Mach but I'm pretty happy so far.


Here's the spec sheet on the motor.

Click to enlarge

http://i.imgur.com/h7m3TLjl.png

I have the ProLight 3000 lathe that I've been thinking about converting..

Lets see the right side of the miniark. I want to see where the pot hooks up.

Quote:

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Originally Posted by Fastest1

Lets see the right side of the miniark. I want to see where the pot hooks up.

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Not sure where you'd like a pic of. Can you explain a little more?

Quote:

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Originally Posted by diyengineer

I have the ProLight 3000 lathe that I've been thinking about converting..

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I'd do a conversion again. My biggest issue was the encoders. Once I decided to get new ones all problems were solved.

Quote:

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Originally Posted by arizonavideo

Must be nice to see it run.

What frame size is the spindle motor? Do you know much about it?

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I just noticed it was you Arizonavideo. If i get a G0704 I'll surely get your mount kit. They look great!





More great news!

I got the speed controller figured out and wired up.

https://www.youtube.com/watch?v=2bXVDF6walo

When I posted for the extra pic, I was looking at the minarik catalog trying to find that model. I finally realized you had unplugged a stackable component. Confusing my ability to determine which model you had.

Quote:

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Originally Posted by Fastest1

When I posted for the extra pic, I was looking at the minarik catalog trying to find that model. I finally realized you had unplugged a stackable component. Confusing my ability to determine which model you had.

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I see. Thanks for trying.

I did a little cleaning up of the wiring lastnight. Sadly, this machine will be put up for sale once I get it all cleaned up and running again. I purchased a 2nd hand UMC-10 and the wife says no to 2 machines. I was really looking forward to building the PDB and using TTS holders.

http://i.imgur.com/ak8cW0Fl.jpg

Oh how I pity you now! A UMC 10? 1 of Dave's machines?

Public Surplus: Auction #1328701

Kinda last minute but if anyone wants one..

Quote:

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Originally Posted by Fastest1

Oh how I pity you now! A UMC 10? 1 of Dave's machines?

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Yes a Fadec UMC-10. One of Dave's machines. It's gonna be rough but I'm sure I'll survive with it.

I don't think I ever shared my 1st cut with the machine before I started the rewire.

The surface finish on the edges left a little to be desired, largely due in part with using an 1/8in downcutting bit (my mistake). You can see the large chips from when I failed to double check my DOC and it did a full DOC which caused the tool to pull out a bit driving it further into the part. I saw what was happening and figured it was a $3 EM and let it run. It did great until it it the 1st arc and snapped.

The engraving was cut with an 1/8in 60 degree vBit from Drillman1 on eBay. I use his bits a lot on my router.

I used it to stamp the AF logo into some leather. I was pretty impressed with the results.

http://i.imgur.com/Ky9KflGl.jpg
http://i.imgur.com/DBsAg23l.jpg
http://i.imgur.com/Ttsbae4l.jpg
http://i.imgur.com/hUvMltcl.jpg
http://i.imgur.com/zSzRovml.png
http://i.imgur.com/3Xt5bM8l.jpg

Quote:

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Originally Posted by Impyman18

I see. Thanks for trying.

I did a little cleaning up of the wiring lastnight. Sadly, this machine will be put up for sale once I get it all cleaned up and running again. I purchased a 2nd hand UMC-10 and the wife says no to 2 machines. I was really looking forward to building the PDB and using TTS holders.

http://i.imgur.com/ak8cW0Fl.jpg

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Impy,

Would you share the cost of the retrofit for everything?

Quote:

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Originally Posted by why9faster

Impy,

Would you share the cost of the retrofit for everything?

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Sure,

Machine: $3000

C11 BOB *$129.00

3 x G320X *$344.85

Encoders - $123.81

Mach3 - $149.00

PC - NIB CL Find - $175

Monitor - $15

New Wiring - $30

PSUs, 12v, 5v, 24v - $100


I was able to sell the 2100 controller for $1500 which covered the conversion and more. I've still got the screen and pendant listed on Fleabay and I'm sure I'll get another K for those total in time.

Still have the Whales, drivers, and OEM encoders as well.

The biggest cost IMO was my time. I have probably 100+ hrs into it. I have product that I make that was taking the backburner while doing the conversion. Though I'd do it all over again the same way. I had a blast and learned a ton.

An FYI for others thinking about this conversion. The existing copley (AMC) drives are good analog drives (+\-10v in 10a cont 20a peak). Mesa makes a interface/daughter combo (5i25+7i77) for $239. 6 axis analog (+/- 10v and diff/ttl encoder interface + 48 I/o) and expendable. This would have saved at least $234 (gecko's and Bob)

This would require (gasp!) Linuxcnc but given you true closed loop control.

Sam

Impyma18, I recently got a Prolight 5000. I am thinking about upgrading the machine, if I can't get the controller to work, and I was wondering if you have a wiring diagram for the mods you have done.

Quote:

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Originally Posted by Impyman18

More great news!

I got the speed controller figured out and wired up.

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Hello! I'm going down a similar path with a Benchman VMC4000. I'm planning to use an Ethernet SmoothStepper and C25 terminal board. Could you please share a diagram of exactly how you wired the spindle controller? (And save some of us from duplicating your effort?)

In the mean time, here's what I have learned so far. The Minarik User Guide for the BOSS BLDC controller is in a new location. Here are figures 9 and 10 from that document, the connection diagrams:

Fig 9 (basics) https://photos.app.goo.gl/BGCmABHg5e9zmFc36
Fig 10 (alternate power hookup for encoder) https://photos.app.goo.gl/WbSjmoVQUi8Wk9bcA

Benchman's wiring job seems very strange. Some pins on the spindle connector are wired toward the encoder, some are wired toward the power card, and some are wired in BOTH. It appears that pins 8..12 are for connection to the Hall Effect sensors, including power for them. Pins 1 through 4 are contact closures for Enable/Disable, Run/Brake, and Direction. Pins 5 and 6 are for a 10k pot for speed control. (It'll be easy to set that up for testing, but I'm not sure how I should set that up on my C25. Is this just a voltage divider, something I can drive with an analog output pin?)