Denford Triac VMC with ATC Conversion / Fix

[Chaz]

OK, up early, cant sleep. Some of many questions:-

Current plan is to use the CS Labs IP-A controller. Gary from Zapp (and JazzCNC) seem happy that this should work based on the info shared. Let's assume it does but I may have a drive or motor faulty (I cant test them at present), what do I do then? These motors / controllers look to be too pricy to replace like for like. If I get something that uses Step / Direction, I need a different controller? Also, if I am looking at 4th axis for later, how do I plan to take that into account? I dont want to buy and IP-A and S model, the costs are too high and I dont know if you can use both together.

In terms of other considerations:-

Convert to single phase. The coolant motor can be wired for this, problem solved. It looks like someone has fit a newer 24V PSU as per the pic below. Will use this for 24V logic.



I need 110V, not for a lot though, if needed, can fit a transformer for that. There is also a 15Volt feed that comes from the 110V line to supply power for the Axis Drive Logic, I assume I need this for the retrofit?

The remaining 110V items are a mix of relays and solenoids, mainly for the pneumatics for the ATC. I am missing all the solenoids and the pneumatic ram for the left/right of the ATC. i2i (thanks very much for your time yesterday), may be able to provide the details / measurements for a replacement.

There is a board where the X Y and X axis connect, do these breakout anywhere that allows for wiring to the new controller?



There is then the terminal strip however this doesnt seem to cover all connections, mainly power (wire 31 / 32 etc)?



In terms of connections needed to make this work, missing anything below?

E Stop
X Y Z Axis input / feedback
X Y Z Limit Switches
Spindle input / feedback (forward and reverse)?
Spindle Enable?
Coolant stop / start
ATC controls, carousel up/down (relays), Drawbar solenoid, Door open / closed (is this used?)
Do I need air pressure / lube float / guard contact (not sure if thats the main door or something else)?
Feedrate / Spindle override?
X Y Z Overlimit (wired via estop)
Carousel switches (in, out, up, down, sensor)

Phew, anything else?

In terms of things to get:-

Controller
PSU for 110V potentially, this is currently having 400V as its input, so need to replace this with 220V input
Missing actuator for Carousel left / right
Missing Solenoids (all)
PC - have a number of older machines, will make something from the bits
Monitor, want to use the existing arm / base if possible, ideally touchscreen
Mach 4 (possible?) or Mach 3
Possible buttons for common things (Stop / Start etc)

Anything Ive missed?

Is there any easy way to test the X Y Z drives / motors considering I have no real way to power anything on the 110V rail and 15V Axis PSU?

Thanks in advance.