Yes, the All-in-one has nine relay outputs.1.Can you confirm that I would be able to run my existing auto-lube
system and flood coolant pump with this setup? is anything extra
required to accomplish this?
Standard PLC support uses one for Lube and one for Flood Coolant.
The Lube relay can be used to power the 110V or 220V lube unit directly. If there is not already a snubber (e.g. Quencharc or other RC or Varistor suppressor) on the lube unit terminals, then you should add one.
The Flood relay cannot drive the pump motor directly. It is intended for switching the coil of a suitable motor starter (contactor and overload combination). You can probably re-use the starter from the old control system. Again, make sure there is an arc suppressor across the starter coil.
You would need to add to DC1 drive unit, and either supply or purchase a suitable DC servo motor. Software support for a fourth axis is included standard. The DC1 drive add-on is $525.2.How can I later add a 4th axis? What would I need to purchase to do this?
Yes.3.Will the rigid tapping kit from elrod machine work with this without
too much trouble down the road?
The spindle encoder would plug into the fourth, fifth or sixth encoder input on the All-in-one unit.
You would need to purchase the Rigid Tapping software option for $550.
You would only reuse the servo power supply (rectifier assembly).4.Will I only reuse the servo power supplies with this kit or the
drivers themselves too?
You would not reuse the old servo drives.
The All-in-one is its own three-axis DC servo drive.
There are no special requirements. The controller will provide run-forward, run-reverse, and fault-reset outputs via three of its nine relays. It will also provide a 0-10V analog speed reference signal, proportional to commanded spindle speed. It expects a spindle fault signal wired from the VFD's fault relay back to a PLC input.5.When I go to install the VFD are there any special requirements to
interface with your controller so I can control the spindle speed,
direction/reversing, breaking, etc?
If you will be using back gear, it is a good idea to install a range-detect switch: e.g. a limit switch behind the back gear lever, wired to another PLC input. The PLC will use such a switch to automatically reverse spindle direction and compensate motor speed when in low gear.