Bridgeport Boss5 to Centroid Acorn retrofit

[pulsenpal]

the T1 transformer should work nicely for step down power input as incoming main into Leadshine drive--leave as ac voltage is my recommendation

you need a 2:1 stepdown ratio with 120 vac input giving 60 vac output approximately

I have used that transformer on many retrofits--20+ years ago so some specifics may be fuzzy

do not use any active component from Boss--this includes bridge rectifiers, electrolytic capacitors,
the caps in particular have experienced millions of cycles and are likely near failure--another reason to take advantage of alternating current input option offered by Leadshine

fusing--save all din rail and fuse block connectors integral to the Boss cabinet a huge oversight in Leadshine literature is no mention of fusing--both internal drive and external input power input referrences are lacking--this will need to be sorted out
I ahve a stripped down Boss 5 as my daily miller--I will snap a few pics and post of the simplified stripout conversion

[Tapburrbit]

I'll look into a step down transformer. I haven't thrown away any of the old stuff yet and also ordered some new fuse holders, terminals , rails and plastic din rail mounts for the acorn.

[Tapburrbit]

Ok ... I'm back to too many options again.

I first had to take a step backwards and look into that T2 3 phase transformer again . I believe it is a Delta / Delta . The plate say's Delta Primary and doesn't specify Delta or Wye for the secondary. I think that mean that No neutral is possible from the secondary. It's out, I'm not going to try and mess with it. .

.
Here's a great link about Transformers..http://www.electronics-tutorials.ws/tra ... ormer.html

T1 is staying put for the 120Vac . Being that It's a 3 phase machine I think it would be better to add the drivers power supply to the incoming power rather then T1. I took closer look at some of my other machines and they all distribute the incoming 3ph to 2 transformers.

1L1 and 1L2 to the control components
1L2 and 1L3 to the drive components
Here's the schematic from a Torqcut 22:

Torqcut 22

An explorer X26 :

Explorer x26

Ezsurf Grinder :

Ezsurf grinder

So the question is I need to decide on a T2 ?

option 1: Just add a transformer and power the DMA860E with AC power from 220Vac (1L2 and 1L3) thru a Avel Y236904 800VA 55V+55V Toroidal Transformer
https://www.ebay.com/itm/Avel-Y236904-8 ... SwDN1UTmDu

option 2: Which I think is easier and safer for a novice CNC builder like myself. Supply the Drives with DC power from a assembled Toroidal power supply like the KL-????
https://www.automationtechnologiesinc.c ... -65vdc20a/

Option 2 seems quicker and will cover up some holes in the back of the cabinet. It can also come with 5vdc, 12vdc and or maybe 24vdc ready to go.

Option 1 intimidates me a bit. I'm still having trouble grasping the concept of a second neutral to ground connection coming from another transformer. I guess the two neutrals float independently ? it seems like they are labeled in the machines (2) or (12) from one and (102) from the other and they only come together at ground directly from the transformers ?

option 1 costs around $120 and option 2 is $189 is you figure in the the time of assembly 2 is probably cheaper.

[pulsenpal]

suggestions

avoid delta wound transformers--the center tap neutral complicates your application

toroids are great as long as you know wiring and how to handle unused leads

stick with laminated core ac to ac transformers if possible toroids in preassembled form
with clearly tagged leads as in your linked pics are excellent

avoid 220 vac input power--needlessly complicates neutral/grounding
and is less safe if shocked than 110 vac

explanation of pics

Robotool -BP clone retrofit using Gecko dc servo drives--you will recognize transformer as
removed from BP Boss and powering dc supply for input into Geckos

Bridgeport Boss 5 with Superior 2000 D6 step drives original steppers
20 year old conversion which has never had a failure
vfd to spindle motor 220 vac single phase input

toroid with unlabeled taps--

[Tapburrbit]

Thank you Pulsenpal for all your help and posting your pictures . I have to remember to check the box at the bottom of post to be notified when there is a reply. I keep forgetting.

I'm going to move forward with this project by supplying the DMA860E with AC voltage. I called Antek Inc this morning and now feel more comfortable with it .

I just bought 'AN-8458 - 800VA 58V Transformer' on AnTek Products Corp. It can be supplied with 115V or 220V .

Hopefully I can start putting it all back together again this weekend . I've already tested out the acorn on my PC and it's up and running. I just wish it would work with a smaller touch screen. I have 2 spare 15" screens that almost fit perfectly in the original control panel housing. I can't get them to display the control panel menu properly.

[pulsenpal]

transformer and voltage you note should work great for Boss retrofit

fuse all applications properly and you should have a highly reliable drive system

pulsenpal

[Tapburrbit]

I was able to start putting components into the machine this weekend . I installed the new transformer , power supplies and acorn board. Also managed to trace out the original E-stop and wire it in. Powered it up and it actually recognized me hitting it. Next Time I get a chance to work on it I'll connect the home switches and the X-axis drive for a test. Then it's on to spindle control. To start with I'm planing on using the original contactors. Even though it seems easier to install and wire a VFD.

When looking for a VFD should I buy one exact to the motor specification or up it a little to the next available capacity ? I have three of these bridgeports here and all the motors have a slightly different amp rating on their plates. All are 2HP and draw 5.6 to 6.5 amps. When shopping around I saw Vfd's rated at 1.5kw for 2 HP motors and then there were 2.2kw ones for 3HP.

Side cabinet 01/28/18

Back cabinet 01/28/18

Why do my pictures keep coming up sideways ?

[frijoli]

Personally I usually up-size my VFD's, but that from experiences of years past. I don't think it's necessary these days with name brand inverters, but old habits and all that.
If I were buying a Chinese drive I would DEFINITELY up-size.

Clay

[Tapburrbit]

I'm considering the Mitsubishi FRD720-70-NA . it's priced mid level . 3phase in and 3phase out 7 amp .

[martyscncgarage]

I'm considering the Mitsubishi FRD720-70-NA . it's priced mid level . 3phase in and 3phase out 7 amp .

I'm partial to the Teco Units. The L510 is an economical Sensorless Vector unit, but it will not accept a braking resistor. The E510 is new, likely the L510 with the ability to add a braking resistor.

http://dealerselectric.com/230V-three-phase-input.asp

Factorymation sells Teco units as well
http://www.factorymation.com/ac_drives_qs

Both companies have great support and will talk to you about your application.