AXYZ Millennium Router Acorn Controller Retrofit Build

[Quebecois_Sti]

Hello everyone, about 3 years ago I bought a small router table (AXYZ Millennium)
from an industrial auction. You can follow a thread I started for
more infos and details on another forum, CNC Zone, here:
https://www.cnczone.com/forums/commerci ... forum.html

FYI, I created the same thread on CNC Zone:
https://www.cnczone.com/forums/centroid ... ost2442430

TLDR: go to questions below: ***



General specs of the machine:
- 220V, 1 phase, 15A
- About 41" x 41" x 6" work area, safer size is more likely 39" x 39"
- Slotted aluminium table
- Italian ELTE model TMPE3 12/2 air cooled spindle: 2.2 kW (about 3hp)
AC 3phase spindle motor, 18 000 rpm max., ER25 collet
- Air input needed for dust boot cylinder retraction/release
- All axis are based on rack & pinion (screw type on Z), linear bearing
- Controller is called AMC, newer model from AXYZ recent machines is called A2MC

Since then, I worked a bit with the machine, it's working good but it's a
small pain to send program, adjust Z height and follow/config the machine while
live or not because mostly of the older AMC controller and communication way of
doing it, RS-485 serial connection.

Recently, I just got a hold on another machine that seems to be the same one I have
but according to the auction it isn't working. I didn't have the machine yet in hand,
I am supposed to receive it soon. However, since I already have this machine here,
I am supposing the stepper motors and electronics should be the same, more-or-less.

I never retrofit any machine before and was unsure which controller to select. Some
people were promoting the hardware ESS SmoothStepper,UC300ETH and Acorn. On the software
side Mach3/4, LinuxCNC, UCCNC and the Acorn CNC12 software. I've done some research and decided
to go with Centroid because of this forum and support availability plus the way the company
didn't started in DIY but much more in the industrial market and goes towards DIY afterwards.
A nice plus is the way they are based in USA and not in some far away places, even if I am not
an American (I am canadian), I prefer and try buying product from North America.

So, since it's not working and have no communication converter box with it according to auction
I finally decided to order an Acorn system and do the conversion soon. The idea is to see
how it is and use it as a small laser engraver system (will add low power laser diode system, right
now it might be the hardware from OptLasers) since I already have another machine for non-ferrous material.

If I succeed and like the system I might order another Acorn to convert my actual machine to it
or use another controller if not satisfied. Furthermore, I recently got a knee mill machine too
and the Centroid CNC retrofit kit are interesting me alot as well but out of my budget at this
moment, maybe cheaper system with Acorn and servo/drivers system from DMM Technology Corp. could
be alot cheaper but not sure if strong enough (right now they offer a max 1.8kW servo)

***
Some questions I have at the moment:
- The stepper drivers of the machine seems different from what standards one offered on the
market, if possible I wish being able to use the one with the machine instead of buying new
ones. It seems the drivers are based/made by AXYZ and can't find so much documents/datasheet
of them (AXI 2200). Someone online looks like he found a way to make it work but there's not so
much details of it: https://www.cnczone.com/forums/stepper- ... llers.html

If I cannot find drivers, do you recommmend specific drivers that are better than some
other ones ? To me, it looks like there's alot of chinese crap stuff in those electronic components
and some people rebrand fake-bad stuff to higher price to look better as well... Good thing I got ahold
on the wiring manual which specified alot. You can see it here:
https://drive.google.com/drive/folders/ ... sp=sharing

- Can I used any automatic tool height Z sensor ? Yes I know Centroid offer a sensor but it's really expensive,
especially for me since I have to pay in $USD and $CAD/$USD is not the best right now. I saw quite few
cheaper alternatives online ranging from 75 to 200$USD. If you have any recommendations let me know.

- Having a touchscreen with the Acorn, is it worth it ? I am trying to find an All-in-One touchscreen PC
or just the touchscreen and add a PC I was able to buy cheap used.

Best Regards from Eastern Canada,

[cnckeith]

***
Some questions I have at the moment:
- The stepper drivers of the machine seems different from what standards one offered on the
market, if possible I wish being able to use the one with the machine instead of buying new
ones. It seems the drivers are based/made by AXYZ and can't find so much documents/datasheet
of them (AXI 2200). Someone online looks like he found a way to make it work but there's not so
much details of it: https://www.cnczone.com/forums/stepper- ... llers.html

new motors and drives are cheap and work so much better than the old stuff and you will not have a research project on your hands:-) as there are many makes and models that have been presorted see the Acorn schematics zip file for all the different motors/drives that are officially supported.
https://www.centroidcnc.com/centroid_di ... matics.zip


If I cannot find drivers, do you recommmend specific drivers that are better than some
other ones ? To me, it looks like there's alot of chinese crap stuff in those electronic components
and some people rebrand fake-bad stuff to higher price to look better as well... Good thing I got ahold
on the wiring manual which specified alot. You can see it here:
https://drive.google.com/drive/folders/ ... sp=sharing

https://www.centroidcnc.com/centroid_di ... matics.zip


- Can I used any automatic tool height Z sensor ? Yes I know Centroid offer a sensor but it's really expensive,
especially for me since I have to pay in $USD and $CAD/$USD is not the best right now. I saw quite few
cheaper alternatives online ranging from 75 to 200$USD. If you have any recommendations let me know.
yes.. see this doc.
https://www.centroidcnc.com/centroid_di ... _setup.pdf
found here with all acorn docs.
viewtopic.php?f=60&t=3397

- Having a touchscreen with the Acorn, is it worth it ? I am trying to find an All-in-One touchscreen PC
or just the touchscreen and add a PC I was able to buy cheap used.
I like to do the touch screen and a separate PC. the touch screen is nice but not necessary you can use the mouse.
here are the screens i use.
https://www.centroidcnc.com/centroid_di ... _gear.html

Best Regards from Eastern Canada,

[martyscncgarage]

Since you have the documentation for the drives, yes, you could connect them to Acorn.
Keith does have a point. Drives are pretty inexpensive BUT it does appear you have what you need to try and reuse the stepper drives.

I would try:
Run Pin 1 Blue (Step) to Acorn header ST1 (X axis)
Run Pin 2 Black (Dir) to Acorn header DR1 (X axis)

Do the same for Y and Z axis (ST2, DR2 and ST3, DR3)

You will need to tie the Acorn power supply com to the 5VDC Power supply Com in the existing cabinet OR replace it with the 5VDC on the Acorn Power supply (Better)

I might reuse the toroidal power supply just for the stepper drives and add a standard bridge rectifier and filter capacitor. But unless you are good with electronics the rest should go. Keep the spindle drive for now, but you have to figure out how its inputs work.


Marty

[Quebecois_Sti]

The only weird thing I am seeing regarding the AXI drivers
and standard driver are the number of pins which doesn't fit.

Standard drivers often seen:
Enable -
Enable +
Direction -
Direction +
Pull -
Pull +

the AXI 2200 driver:
1 pin named Step
1 pin named Direction
1 pin +5VDC

So it's only 2 pins instead of 6... Is it something we see somewhere else ?

[martyscncgarage]

The only weird thing I am seeing regarding the AXI drivers
and standard driver are the number of pins which doesn't fit.

Standard drivers often seen:
Enable -
Enable +
Direction -
Direction +
Pull -
Pull +

the AXI 2200 driver:
1 pin named Step
1 pin named Direction
1 pin +5VDC

So it's only 2 pins instead of 6... Is it something we see somewhere else ?

You obviously don't need the enables.
That leaves four
The Pul+ and Dir+ are internally tied together and require +5VDC
That leaves the Pul- to go to ST1 and Dir- To DR1

Don't overthink it....just try it.

[Quebecois_Sti]

Good news on my side, finally got the machine!



More pictures here: https://drive.google.com/drive/folders/ ... sp=sharing

The machine seems to be in a better condition than what I was expecting!
(Especially because the auction pictures weren't that good and infos on
it not so well detailed.) I was happy that my contact was able to wrap
and secure the pallet correctly and sent it by freight to get it in good shape here.
The machine was used in a school and it seems it sits there unused (needing repair)
for a long time. There was even a small manual and some class course papers.

I was surprised to see that they already done some kind of controller conversion to it:

- The AXYZ Inverter Control board were removed which control the spindle in some ways according to my understanding
- it looks like I would have to find a Spindle Drive if I am not using a diode laser because the first idea was that.
However, with the condition of the machine it tempted me to convert my older one to laser and keep this one for
router job... will see how it goes.
- The Stepper Drivers are the Pacific Scientific 6410
- There's a Warp9 USB Smooth Stepper ver 1.2. However, the USB connection on the Warp9 board
seems crocked, I will check it out if the board is still good but I continue
the retrofit with Acorn https://warp9td.com/index.php/products
- There's a PMDX-122 Breakout board, https://www.pmdx.com/PMDX-122
- There's a PMDX-105 Quad isolator board, https://www.pmdx.com/PMDX-105
- Some wiring are let loose and not connected, I will need to check why and what they are used
for.

Furthermore, I was able to find an used cheap Lenovo All-in-One PC that fits the
minimum hardware and software requirements of Acorn (ie. benchmarking around 1700 and Windows 10).
Too bad the display isn't touchscreen but for the price I got it, it was pretty decent.

It seems the 6410 drivers are those ones:
https://www.electromate.com/pub/media/a ... atalog.pdf

Found a small install documentation of those drivers from AXYZ itself, so maybe the 6410 were upgrade, option or replacement parts ?
https://www.axyz.com/us/wp-content/uplo ... manual.pdf

Next steps on my side:
- Start by removing the spindle and test it on my other AXYZ to see if it runs since they seems
to be exactly the same model, I should be able to unplug/plug in directly for checking it out.
- Make a table for it since I have none at the moment, maybe I will use saw horse until then...
In the end I already have some angle iron that I will need to cut 45º and weld together
- Installing Acorn CNC12 software on the PC and test it ensuring it works all o.k.
- Cleaning and passing air all around
- Greasing the linear bearing on all axis
- Checking to see if the stepper motors are the same as the one on the machine I already have
- Once Acorn working condition is confirm, I will start doing the wiring retrofit

I will keep you updated.

[Quebecois_Sti]

Some updates guys:

Few pics here: https://drive.google.com/drive/folders/ ... sp=sharing

I prepared the configuration of Windows 10 according to video and installed the CNC12 Router software on the PC.
It went flawlessly. When I powerup the Acorn and check connectivity on the PC everything was
all good, got a small problem because I forgot to turn (all) OFF the Windows Defender/firewall but besides that it was good.
I just follow the video guides provided by Centroid on the forum which guides you steps by steps easily:
https://www.youtube.com/channel/UCMkvlx ... wJw/videos

- I 3D printed a support for it. Found on Thingiverse: https://www.thingiverse.com/thing:4778889
- The working condition of Acorn was confirm using bench test method shown, everything went good.
- I made a steel table for the machine.
- Since I don't have any spindle drive at the moment, I concentrated my efforts on the other wiring to see the gantry moving.
- E-Stop is working
- I configure the Acorn to the best I could, had to modify the dip switch to fit.
- I kept the Connection board from AXYZ to power the stepper drivers and use the power from 220VAC
- I adjust the X and Y to 0in negative and 39in positive, the Z not sure about height to 4in positive, 0in negative

It seems the stepper drivers are dead or I am missing something:
- I connected the STEP+, DIR+ and ENABLE+ of the drivers to the Acorn
- I measured about 40VDC on their input (they need between 24VDC and 75VDC
- I measured some voltage on the motor phases but I am not sure what I should look at

In the Acorn Wizard:
- I adjusted the steps/rev to 6400 and fits the dipswitch on the drivers for it
- The thing I am unsure is the Overall Turn Ratio, I used the 0.88422 rev/in found in the AXYZ manual.
However it stated normally it's around 5 or so, I tested this and the other
- Not sure about the accel/decel and the drive enable delay as well
- I made some trials changing the overall turn ratio

Nothing is moving when I use the jog on any axis.

Questions:
- Do you have any good reference website or video explanation for stepper driver to help me understand how they work and how they are wired ?
- How I can test stepper drivers to see if they are in working condition or dead ?
- What is the COMMON connection for them ? It doesn't seems to be widespread this connection on drivers...

[martyscncgarage]

Did you replace the original stepper drivers or reuse the original ones?
Did you connect to the Acorn headers for Step Dir signals or did you use the DB25?
When you power up the machine and reset CNC12 BUT before doing any thing else, are the axis motor rotors locked? Meaning you can't turn them by hand?
Did you connect the ENAble lines? (If so, temporarily disconnect the enable lines and see if you can turn the motors)

Please post a picture of your control cabinet including your Acorn board.

And ALWAYS post a FRESH Report when asking for assistance. F7 Utilities, F7 Create Report.

Marty

[Quebecois_Sti]

Did you replace the original stepper drivers or reuse the original ones?
Did you connect to the Acorn headers for Step Dir signals or did you use the DB25?
When you power up the machine and reset CNC12 BUT before doing any thing else, are the axis motor rotors locked? Meaning you can't turn them by hand?
Did you connect the ENAble lines? (If so, temporarily disconnect the enable lines and see if you can turn the motors)

Please post a picture of your control cabinet including your Acorn board.

And ALWAYS post a FRESH Report when asking for assistance. F7 Utilities, F7 Create Report.

Marty

Pictures are in the GDrive link I posted...

I used the Pacific Scientific 6410 drivers that were already there, I made new wiring connection to ensure they were good.
I connected the Step/Dir/Enable from green screw block terminal of Acorn to the DB9 connector of the stepper drivers (pins #1 to 3)
I have no idea if those drivers works because the auction were stating the machine was not in working condition but
at the same time there wasn't any spindle drive and the motion controller seems broken at the USB plug so...





I will test if the motor/axis are locked this morning and send a fresh report.

[martyscncgarage]

If they are locked after you start and reset CNC12 but nothing else, then disconnect the Enable wire and test movement.
If that works reconnect it and go into the ADVANCED settings tab in CNC12 Wizard and either CHECK or UNCHECK the box in front of ENABLE. This will invert the ENABLE state. Then retest

If you are connected to the ACORN headers, Under DB25 Mapping in the Wizard, at the top of the screen make sure it says SCREW TERMINAL not DB25