Colchester Triumph 2000

[ecs]

And so it begins.... The lathe conversation that will bring my old lathe into the 21st century.

The upgrades:
Masso
1.5kw lead shine servo motors and drives
Ball screws for both axis
Lubrication system
VFD for spindle motor
Spindle encoder for threading
Automatic tool post (have decided which on yet) - Anyone have any suggestions?

The lathe has been partially stripped to take measurements for the plates and ball screws which need to be made.
Ball screws have been draw and sent oversea to be made. I opted for the BSH type nut for the cross slide as it was the smallest nut i could find and will need the least amount of material removed from the lathe carriage and a double nut for the x slide. Both are ground ball screws with the X a C5 and the Y a C3.
Plates have been draw and ordered through my laser cutter.

Have most of the parts on order and hope they come before Christmas as i have a couple weeks off and would like to have the mechanics side of the machine done before i go back to work.

Been a machinist already i have a plan on how to machine and attached all the necessary parts but the electronics is the parts which i'm unfamiliar with. I already have my masso, motors and drives, lubrication pump and my VFD.

So the first plan to tackle while i wait for the other parts to arrive is to wire all the electronics up on the bench.

 

[clover]

Sounds like you are well on your way to an interesting conversion @ecs. It will be interesting and informative to see an old workhorse come to life under Masso.

You will find plenty of help on this forum especially from @masso-support. A good starting point this end would be to tell us the makes and models of your motors, drives and VFD.

Good luck and we look forward to your story as it unfolds.

 

[ecs]

Thanks @clover. The lathes in good condition but just needs someone to man it all day....

So the specs of the parts been used:

servo motors - 1.5kw lead shine part # EL5-M1500-1-51 (http://www.leadshineusa.com/UploadFile/Down/EL5-Md.pdf)
servo drives - 1.5kw lead shine part # EL5-D1500 (http://www.leadshineusa.com/UploadFile/Down/LSC_High_Voltage_Servos.pdf)

VFD - Delta Inverter VFD drive VFD075E43A-M 3Phase 380V 7.5KW 10HP 0.1~600Hz (https://www.deltaacdrives.com/wp-content/uploads/2012/06/VFD-E-Catalog.pdf) *i have the little screen to adjust the rpm as well.

Lube Pump - Miran MR2202-410XA (a picture of the wiring diagram on the front of the machine.)
The lube pump needs to be used with a relay masso said. I purchased a relay the other day from JayCar. Its a 12V 4 channel like the ones i've seen mentioned around the forum.

Thanks,
Josh

 

[clover]

Thanks for the info @ecs, the driver link just provides a product manual with little connection information and from what I can observe some of this is misleading. I cannot find a manual on this unit. Do you perhaps have a link or even a hardcopy manual that came with the units?

Josh, having the drives and the motors from the same manufacturer and family certainly will make things much easier.

 

[ecs]

Thanks for taking a look @clover!

The documentation that came with the unit didn't have any wiring information. I did find this manual online. I think page 16 fig 3.3 is what is needed?

Yes i paid extra to have English manuals and units which would be easier for me to install!!!

Thanks,
Josh

 

[clover]

Thanks Josh.

I did find this manual online. I think page 16 fig 3.3 is what is needed?

If you put up a link to this documentation I can't find it. The documentation in the 3 links previously supplied have less than 16 pages.

Patrick

 

[masso-support]

Hi Josh

This sounds like a really interesting project you are embarking on.

I did a google search of the Triumph 2000 and it is a beautiful looking machine.

Could you provide some details on the relay you got for the pump as the only relay I could find on the Jaycar site that seems to fit your description is a 4 channel Radio controlled relay board.

 

[ecs]

@clover Sorry Patrick i forgot to paste the link!!!

https://www.google.com/url?sa=t&source=web&rct=j&url=http://www.americanmotiontech.com/upload/Manuals/el5-dm_v1.0.pdf&ved=2ahUKEwiL-9iIypzfAhUDbn0KHfz0DXAQFjAMegQICBAB&usg=AOvVaw2reRbn9mfNVk5DjeqBESU7

It shows the pin out for cn1. Which I think is meant to go to the masso?

@masso-support I actually did my apprenticeship on one. After that I was hooked! It's a very nice and well built machine.

Relay - https://www.jaycar.com.au/arduino-compatible-4-channel-12v-relay-module/p/XC4440

Thanks,

Josh

 

[ecs]

I've been studying the basic overview wiring needed for my drive.

It shows a noise filter. Is this an EMI filter? There seem to be alot of different names for filters. Do they all do the same thing?
Do i need one for every drive or can i put one in where the power source first comes into the machine?

How do i work out what size i need? My servo motors show 7.5A continuous or 25A peak. The machine has a compliance plate for the existing setup (spindle motor/coolant pump/spindle brake) which shows 10/16A but i checked the spindle motor and it has a 25A on the motor plate.



@clover was that the correct manual to work out the correct wiring to the masso?



Thanks again,
Josh

 

[clover]

Thanks @ecs. The manual is exactly what is required. I'm sorry I haven't been able to get to the wiring diagram today, I will try and do it tonight or early tomorrow morning. Australian time - are you in Oz? If so where? I'm in Brisbane for what it's worth.

Re noise filters etc, yep there seem to be hundreds of them! I wrote a little bit on this subject for another member that may help a tiny bit. Basically as I understand it there are simple noise filters designed to prevent harmonics, transients and noise from entering a system. These are little more than capacitors, resistors and voltage clipping devices. Then there are the reactor type devices that are tuned to eliminate the aforesaid harmonics, transients and noise generated by a component in your system (e.g. a VFD which can generate a lot of harmonics and noise). But Josh I have to admit this is getting beyond my experience and I shall have to leave it to @masso-support for their comment.

 

[clover]

@ecs I have just had a quick look at EL5 manual. You are correct in that the Direction + & - and the Pulse + & - out of your Masso go to the respective pins on CN1.

What other communication do you want between Masso and the EL5 driver. e.g. alarms etc.?

 

[ecs]

Thanks for getting back to me @clover.
Yes i'm from Australia, actually from the Central Coast NSW.

No rush, like i said just trying to do some research on what is needed and what is best practice. There are sooo many little elements and they all need to be accounted for.
Wasn't sure if it was needed for a lathe? It will have a VFD on the spindle. So I think it wont hurt to have something.

Regarding the communication, Alarms yes! Other than that is there anything else useful?

Another question sorry, but is there anything wrong with using some of the original electronics from the lathe? I mean all the motor contactors are there, circuit breakers and a cool transformer with a bunch of different volts which would be quiet helpful. All of them designed for that machine.

Its even been setup up on a DIN rail system and board. See the attached pic.

Thanks,
Josh

 

[ecs]

Hey Guys,
Its been a while since my last post but i have made some progress.


Things I have now achieved are:

1. I now have all the plates machined and installed where necessary (I used all the machine surfaces on the lathe to try and keep everything square as possible for less binding issues. I also tried to machine steps/grooves to help with assembly and support.
   
2. Long travel ball screw installed with the motor now attached and adjusted with a belt.
   
3. Cross travel bracket (back one) installed but still needs minor adjustments for the nut.
   
4. Cross travel ball screw is ready to install just awaiting for my bracket for the nut to screw into. (should have made this before stripping the lathe)
   
5. All pulleys have been machined to fit and been broached with keyways. Just need to drill and tap the pulleys with 1 x M6 grub screw.
   

Thats about it so far. Been back at work busy again so little bits and pieces getting done here and there. I'll attach the photos.



I did have one problem/question. The motors i chose aren't slot friendly. When i say slot friendly most CNC conversions i've seen usually slot the motor hole and bolt holes and tighten the belt from this. But the motor i have has a huge motor/centre hole which is bigger than the PCD of the bolts. I planned to just add an idler pulley to adjust the belts. Has anyone tried this or can see a problem using this method? (see picture attached)


Josh

 

[ecs]

Some more photos. The last image is the one where i have drawn a plan of how i would like to run the idler pulley.

Any feedback would be great.

Josh

 

[ecs]

Forgot the one showing the nut placement

 

[machinedude]

a idler pulley should work fine for taking the slack out of your drive belt. that's what's on my lathe for belt tension. mine pivots on a slot then just tightens up to hold the setting.

 

[ecs]

Thanks for the feedback @machinedude

Do you have a photo of yours i can look at?

Cheers Josh

 

[machinedude]

if I get a chance in the morning I can take a picture and post here. I can look around online while I am working tonight and see if I can find something sooner.

 

[machinedude]

got lucky and they had a good picture in the manual.

 

[machinedude]

just a thought but if you look around on the grizzly site and look through some of the lathe manuals and see something that looks like a good fit for your project you can download all the manuals and get a part number and get parts through them. might be cheaper than making one yourself? just a idea to toss out there.

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