[melee]

Hi
I have recently bought one of these, which of course is missing the PC, manuals and all software.

It is approx 2000 vintage and has almost had no use.

Given that it works perfectly in manual mode and is a fairly new machine with 8 position tool turret and Mitsubishi inverter, I can see no compelling argument to throw away half the machine and replace the steppers, motors etc.

Does anyone have experience of getting one running as is??

Does anyone have manuals for the 160?

Does anyone have a wiring diagram for the 160?

Previous posts suggest the paperwork is out there, but I can see nothing about conversion using original equipment, except that it appears possible.

All help gratefully received

Melee

[melee]

Have now received copies of the User and Programming manuals in .pdf format from Simon at the Mach 3 forum.

If anyone else wants a copy I can forward same.

Melee

[sterl9]

I have just got one of these running using mach 3 and the original hardware, i still need to get the spindle encoder sorted, but can't see a problem with it (famous last words).

I will also try turbocnc, but again i can't see a problem.


Where abouts in the UK are you?

[melee]

Hi

Sounds like we might have some info to share over the next few months.

Ultimately I want to get mine running via EMC2 (Linux) as I work and program solely with Linux.

I will be using a DIYCNC opto board, which arrived on Friday.

Initially I can see that all the main pins required for axis movement and rotation are on one board connector on the stepper board.

When I have satisfied myself that I can control all this in isolation, I have in mind a solution involving patching in, thus enabling most of the facia controls to work as jog controls if nothing else.
This may require complete isolation by means of a 'manual / computer' switch and the actual patch points will require diodes to prevent reverse current feed, but in theory at present it seems feasible.

Your current stage, working out how to get speed control sorted seems a common sticking point. Lot of mention of having to widen the single slot in the disc to enable Mach3 to use it.
By the time I get there, hopefully you will have cracked it!

I got your message, easiest way to contact is via email junk398ATtiscaliDOTcoDOTuk.

I am in, not so sunny at the moment, Dorset

regards

Melee

[melee]

Hi

I have had partial sucess, but not in a way that will please Mach 3 fans

Had a complete blank under Mach 3

I cut the 12 pin plug on the stepper board, which includes the X Y and Z step and dir connections, in half so that the other feeds remained between stepper and processor board.
I then replaced the top half of the plug with another linked into relevant connections on my opto board (DIYCNC optoport).

All I got was a slight clunk when changing direction but no stepping. Swap the plug back over and the lathe moves fine in manual mode so nothing wrong with steppers etc.

I increased the step pulse time to max, swapped drives from active low to active high, re-checked wiring until blue in the face - nothing, just a slight clunk when changing direction from + to -

Then I did what I should have done in the first place, I went to Linux and started EMC2

The configuration is pretty detailed, but even with default settings I had something trying to happen on both axis.

I took off the stepper motors, counted teeth, measured how far the carriage moved in one revolution of the screw etc to get the motor tuning figures I needed.

Motors are 400 step, step drivers are GS-D200S which data sheet says can drive are step or half step, so max micro steps are 2
X axis motor has 16 tooth sprocket - screw has 20 tooth sprocket

Z axis motor has 12 tooth sprocket - screw has 20 tooth sprocket

Both screws appear to have a 2mm pitch, so 200 steps per mm

The max speed of travel from data sheet is 1200mm/min which = 20mm/sec
Acceleration is mm/sec squared so calculated at 400 mm/sec

Having entered these figures into the configuration screen of EMC2, I went to the AXIS_turn screen, brought the lathe on line and had control of both axis straight away!

I only started with Mach3 because I thought it might be easier until I found my way around things!
As I program in Linux and use it for everything else, I should have stuck with it.

I tried entering the same settings in Mach 3 (albeit Mach3 wants them in a slightly different format) and still nothing whatsoever happened!

By assigning the tool changer turret to the Y axis, I was able to jog it under EMC2.
I will have to figure out how to link it to 'M6Tn' G codes and get the stepper to move in 50 step increment (8 tools / 400 steps per rev).
That is of course assuming there is no reduction gear in the tool changer, more stripping down possibly required.

How have other people got their turrets working properly?

cheers

Melee

[battwell]

i wired one of these last night on mach 3 (a 125 model)

the output from the original pcb to the stepper board is floating around 10v so to get it to work i connected directly to the inputs of the output transistor array 2803a. worked perfectly and can still be controlled manually with pc inputs off! this way the driver board is receiving the same input voltage as it had originally.
the only wire i disconnected was the 10v signal at the gemini motor driver to feed it its 10v from the d to a converter run from mach 3.

if you connect direct to the stepper input board the motors will only move with the direction input removed, obviously no good!

[thomasrook]

Have now received copies of the User and Programming manuals in .pdf format from Simon at the Mach 3 forum.

If anyone else wants a copy I can forward same.

Melee

If you will be so kind can I have this copy I am new and I dont know what to do

[melee]

Didn't you already ask that yesterday?

I have put the manuals on my webspace for download by whoever wants them.
Only condition is don't download them and try to sell them on Ebay!
Keep information and code free.

User manual Here

Programming Manual Here

They are of limited usefulness but do have a wiring schematic for more recent 160's.

The programming exercises look useful until you begin to realise that Boxford obviously use a lot of proprietary G code etc. because the numbers for basic routines like G71 canned rough turning are different and have different parameters.

Melee

[thomasrook]

Thank You !!!!

[thomasrook]

Can I have this manual for tcl 160?

[turkazer]

hi from kitchener

[battwell]

i converted my as factory 125 to mach in an evening but the resolution was c**p. its now been converted to mitsubishi servos so fast threading is now childs play with 6000mm/min speed available on both axis with no lost steps.

anyone else done this to a boxford?

[danielbriggs]

Hi,
I've just picked up a Boxford 160, and it didn't come with a serial cable.
On the back of the unit the only port is a 37 pin connector. Does anyone have the pin out of this? Or could advise on how best to connect to a computer?

I have all the Boxford software working, just no means of plugging it in!

Cheers,
Dan

[x3UK]

Dan,
Is the 37 way connected to the Microprocessor Board SK1 ?

136-00-03 just has a std sub min D serial connector, RS232
is this an old old one that connected to a BBC micro?, but you say you have the software? running on what?

[danielbriggs]

All sorted... Well; ish...
It turns out it was a BBC Z80 board inside. So all that will be pulled, and rebuilt appropriately on Mach3.
Before the lathe arrived I spent hours getting the software working and setup. I managed to get v4, v5 & v6 of the Boxford software working! But it seems that it was a waste of time, as I'll never get to use it now...
Ah well... I guess Mach 3 is much superior, and was what I was aiming for long term.

Cheers for your help.
I'll be sure to make a post when the conversion is done.

Ta,
Dan

[SuperNorenore]

hello,
what to do when the machine doesn't auto home?
problem with the z axis
thanks

[abc27]

Ok, I have a few questions here about this CNC lathe.

I have one of these here that i'm trying to get working. The situation is as follows

I have no manuals, no software and cannot modify the hardware in any way as it does not belong to me.

The manual controls don't appear to be working (I'm not quite sure why, perhaps the controller board has been changed).

How exactly would I get this working? Would EMC2 or Mach3 work with it presuming that it may be stock?

Is there are any alternative to Boxford's proprietary software?

[melee]

The manual controls don't appear to be working (I'm not quite sure why, perhaps the controller board has been changed).

Is there are any alternative to Boxford's proprietary software?

Hi
This thread was about converting a TCL160 to Mach or EMC utilising the existing hardware, as described in the post below.

If your manual controls do not work you could have a major problem.
However there is a main power switch on the rear, a smaller green botton on the side which activates the contactor and powers the boards and motors and an Estop on the front which is easily knocked inwards.
Make sure you have 1 and 2 on and 3 out before you decide it is dead ( plus checking wiring and fuses etc)

Boxford do not support these any more, they never supported individuals only educational establishments at great cost.
That is why everyone who gets them without software converts them to Mach or EMC

regards

[abc27]

Hi
This thread was about converting a TCL160 to Mach or EMC utilising the existing hardware, as described in the post below.

If your manual controls do not work you could have a major problem.
However there is a main power switch on the rear

Yes, that's definitely switched on.

a smaller green botton on the side which activates the contactor and powers the boards and motors and an Estop on the front which is easily knocked inwards.

The Estop is definitely disengaged but i've never seen that green button on the side however? The left simply has the hatch that you can open for extra long stock and the right doesn't appear to have anything at all. On the back however there is a black push switch of some sort underneath the mains power switch. It's unsprung and it doesn't really feel like a switch. I have no idea what it is truthfully.

Make sure you have 1 and 2 on and 3 out before you decide it is dead ( plus checking wiring and fuses etc)

The thing is that when I push spindle forward for example the button flashes red once and then the motor makes a low humming sound as if its trying to move. When I move the chuck by hand with the button pressed down the button flashes and makes this strange clicking sound. That'd lead me to believe that there is power going to the motors.

Boxford do not support these any more, they never supported individuals only educational establishments at great cost.
That is why everyone who gets them without software converts them to Mach or EMC

regards

The thing is that we are a school. It's just that these machines were purchased way back in 2000 and have never ever been used since. I tried Mach3 today. Absolutely nothing.

I also tried Boxford V6 which I downloaded from their site but it refuses to run because it's 16 bit and the computer in question has issues running old DOS software...

But, in a strange turn of events in another workshop in our school there is a computer hooked up to a different CNC lathe (Emco Turn 55)... But for some strange reason it has the Boxford V10 software as well. So tomorrow I may try and transfer that on to the other computer and i'll give it a shot.

Thanks for the help so far.

[barney205]

Boxford probs
I am having a problem with a Boxford CNC.When I press the down jog key in the x axis the toolpost moves down(ok) but when I press the up jog key to go back up it continues to move down.Is this due to a problem with the stepper motor?
Barney205