re-named to 'Bridgeport EZ Trak Conversion.

[Topaze47]

I got my new acorn controller from Amazon a couple of days ago and I have started the 'bench test' phase; I had successfully powered up and loaded the software when I noticed that the In5 LED looked 'odd' compared to the others. In the others the red section was 'on' and the green section was 'off'. On the In5 LED, both the red section and the green section were lit, but were both dim... This is with nothing connected to the Acorn except for power, the ethernet cable and the relay card. Also, on the relay card, the opto-coupler for output 1 is twisted badly out of line. Somebody must have been asleep in the QC department. Here is a link to pictures; https://photos.app.goo.gl/Sr1ApfqEAUrrohJn8

[cnckeith]

i moved this post to the Acorn forum.

[cnckeith]

looks like the opto got bumped but everything is working.

[Topaze47]

Actually, perhaps this topic should be re-named to 'Bridgeport EZ Trak Conversion.'

Description: 1992 Bridgeport EZ Trak SX, 2 axis, power drawbar and Bjier auto lube. The machine is located in my garage in a residential area, so I don't have 3 phase power available.

Build plans:
1 Convert to CNC with Acorn using hybrid stepper motors
2 Add mist coolant
3 Add 3rd axis on quill
4 Add 4th axis on rotary table

I'm starting to think about how I need to tackle the old Bridgeport controls; what I can save and reuse and what I can safely eliminate... Obviously, the old computer, display and the associated hardware can go, along with the DC servo drivers and power supplies.

Since I am planning to use a variable speed drive all of the spindle motor control stuff can go as well.

I have 220 VAC in the garage, so I plan on using the original disconnect switch and fuse block, just with one less fuse. I plan on keeping the 220-110 VAC step-down transformer and powering everything else from that.

Picture of control cabinet here: https://photos.app.goo.gl/Sr1ApfqEAUrrohJn8

Anyone have any comments or suggestions?

[tblough]

If you decide to do a spindle encoder, here's one idea for the 2J head: https://centroidcncforum.com/viewtopic. ... 245#p13245

[Topaze47]

Tom, that's on the list, since I will have to open the head anyway. The plastic bushings in the variable speed pulleys are badly worn and making noise, so I am planning to convert the head to a fixed 1:1 ratio and rely on the VFD for speed control. When I start that job, I will certainly do the spindle encoder at the same time.

[tblough]

I went with a Micro-v (Poly-V) belt for my single speed conversion (J-section 10-ribs) and was really happy with the results. Significantly quieter than the 3VX 2-belt setup I previously had and WAY quieter than the original variable belt configuration.

[Topaze47]

I've started to gut the EZ Trak's control cabinet and I found this surprise hiding behind the floppy disk drive; I'm guessing that it is some kind of filter or surge protector. It is obviously a modification since it is bolted over what appears to be a 'High Voltage' warning sign. Also, the date is 4 years newer than the machine... I did a quick internet search and didn't find anything.

Does anyone know anything about this? (See https://photos.app.goo.gl/Sr1ApfqEAUrrohJn8 for a photo.)

[Topaze47]

Ah ha, found it, I guess I should refresh my typing skills... It is a surge protector, now the question is do I still need it? It's been 16 years since it was installed and electronics are much better now. On the plus side, it can't hurt; on the minus side, it's just one more thing that can fail.

[Topaze47]

Total destruction! Once I started, I just couldn't help myself... Actually, after looking at the schematics, I realized that almost none of the components in the original EZ Trak would be relevant once the Acorn and the closed-loop steppers are installed. Besides, the inside of that cabinet was filthy with oil, grime and even metal shavings. As a bonus, I've decided to build the new controls in sections on individual back plates. That way I can build and test them on the bench, then install them in the cabinet and interconnect them. The less time spent crouched down and stooped over the better! New photo in: https://photos.app.goo.gl/Sr1ApfqEAUrrohJn8