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emco pc mill 50 manualTo start viewing messages,I picked up the mill in February of '17 from an auction at a local university. The guy that ran the shop said he hadn't seen it run in the 10 years he had been there. It came with a bunch of tool holders, manuals, and even a CD and floppy disk that supposedly had the Emco software on it. No dongle or PC board to control it. They had it on a pallet so we used a pallet jack to roll the approximately 350 pound mill onto a tilt trailer. Unloading at my end was easy. I don't know how I got along without a skid loader for so long. That thing is really handy. Similar Threads: Build Thread- Emco PC Mill 50 Retrofit. Emco VMC100 retrofit EMCO CNC5 Retrofit. Then they were dunked in water to neutralize the acid, followed by a soak in WD40 to get rid of the water, then rubbed down with oil. The same process was done on the 6 tool holders (ER25 collet holders). I flushed the ballscrew nuts with spindle oil until they ran clean and then repacked them with new lithium grease. All axis use double nuts so I had to re-adjust since they were taken apart. I found a service manual pdf for the F1 CNC and followed the instructions they gave for getting the ballscrews aligned when re-assembling. This made quite the mess just pushing an oiler into the back of the adapter so I made a threaded barrel for one of the oilers that would accept the M6 thread of the welding tip. This is less messy but the oiler still leaks pretty good when under pressure. I can see oil oozing out of the ways when I do this so it is definitely working.First step was to determine what axis motors to use. The original stepper motors were 5 phase and pretty low torque. From the documents I have, the original max feed rate was around 30 inches per minute on each axis. This was with a 2.5mm pitch ballscrew and a 2:1 belt drive reduction. To keep the original ballscrews and pulley ratio, that meant I would need the stepper to have sufficient power for rapids at a little over 1400 RPM.http://www.dean-cpa.com/files/adminpic/delonghi-pac-400-manual.xml

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The recommendation I have seen from others that have done this conversion is around 2 NM (280 oz in) of holding torque. I decided to go with 276 oz inch NEMA 23 steppers from Automation Technologies (KL23H276-28-4B). To power the G540, I bought a toroid transformer (Antec 5234) that outputs 34 VAC which when rectified and filtered should be close to 48 VDC. I used an 18000 uF 100 VDC electrolytic cap for the power supply filter. Installing the motors was mostly straight forward. The original motors were close to a NEMA 23 mounting but the holes for the mounting screws didn't quite fit so I rotated the motor slightly and drilled and tapped new mounting holes. Instead of drilling the motor shafts for a roll pin as was originally done, I used Loctite 609 retaining compound to glue the pulleys to the shafts. I did some calculations based on the surface area that would be wetted by the retaining compound and I think there should be plenty of margin to be able to support the full torque of the motors. I wanted to run the entire machine from 110 VAC to make it easier to sell when the time comes. I went with a Hitachi WJ200-007SF which fully supports outputting the voltages necessary for the motor from 100 VAC. I went with the Hitachi in part because I already had another WJ200 for my lathe and used that one to test the motor and it worked well. The Hitachi supports a variety of input and output (10V analog, modbus) so I was confident I could hook it into whatever control I went with. However, while I was working on this I picked up another CNC mill that I want to retrofit that would be better suited to the configurability that LinuxCNC provides so I decided to get a different controller for the Emco. The Centroid Acorn had been getting good reviews since its release so I thought I would give it a try.http://enviomundial.com/userfiles/delonghi-pac-ct110-manual.xml It has specific requirements for the PC which my Linux box didn't meet, so I turned to eBay and found a used Lenovo M92Z All In One with an i3-3320, built in wired and wireless networking, and a 23 inch touchscreen for a good price. It didn't come with a hard drive so I picked up an 180GB Intel mSATA SSD. I loaded Windows 10 on it and followed the instructions on configuring it for CNC duty as per the Centroid site. Installing the CNC12 software went without a hitch. I reused the original grey wiring ducts, IEC power port, key switch, and DIN rail mounted fuses. To make sure I had enough space for everything I mounted the transformer, rectifier, and filter for the motor power supply on the horizontal part of the mounting plate. The G540 was mounted on a couple of right angle brackets I made out of the original card cage. It was positioned to be over one of the cooling fans. Speaking of cooling fans, the original fans were 220VAC but I didn't want to retain the original transformer or switch to 220VAC input power. Instead, I picked up a couple of 24 VDC ball bearing fans and used the 18V output of the Antec transformer along with the original rectifier and filter cap to supply the 24VDC for the fans. The Emergency stop switch worked intermittently so I replaced the 2 internal contact switches (ZB2-BE102). The door switch tested fine but I doubt I'll be actually using it. All switches are wired as NC (normally closed) with one side tied to digital common. I originally wired the limit switches and emergency stop through the G540 but was getting some spurious triggers. By switching the inputs directly to the Acorn those triggers went away. The G540 now doesn't have the E-stop wired to it, but since it isn't a servo drive and has the charge pump enabled, I don't think this is much of a safety concern. The other E-stop circuit is wired to the GS1 and GS2 inputs on the Hitachi VFD.https://www.informaquiz.it/petrgenis1604790/status/flotaganis22052022-1918 The VFD is using 2 digital outputs from the Acorn for forward and reverse and the 10VDC analog output from the Acorn is used for speed control. There are still a few inputs and outputs left on the Acorn to support additional functionality (coolant, air, probe, encoder for rigid tapping, etc.). I was able to easily hit the 70 IPM I was shooting for on all axis. I kept turning up the max jog speed waiting for the motors to stall but stopped when I hit 200 IPM with no stalls. More travel could be had but that would require modifying the Y axis covers (front cover would need to be cut or extended, rear cover would need some changes around the limit switch trigger point). Spindle control works well both forward and reverse up to max speed. I have done some basic cuts using manual code entry. My next steps will be to continue tuning (G540 motor tuning, accel settings) and to start learning Fusion 360 so I can actually start making some parts. I've got the main transformer, all axis motors, and the control boards.I added some cable clamps to provide some strain relief of various cables. These were 3D printed and then stuck down with double sided tape. I also added a panel mount RJ45 pass through port so I don't have to run the ethernet cable directly from the PC to the Acorn. The terminal is shielded as is the new short cable running from it to the Acorn. I used a step drill starting in the hole left by the original DB9 connector. I used Fusion 360 for the CAD and CAM. The fixture plate has holes every half inch. The clamps specify 0.301 from the center of the hole to the edge of the clamp and the pins are 0.125 from center of the hole to the edge. MiteeBite says shims can be used but this being my first attempt I didn't want to deal with another variable. Milling and spot drilling went well. The drilling not so much. Should have used Deep Drilling (Peck Drilling) cycle. Here is why.https://newhotelcolombia.com/images/97-ford-expedition-repair-manual-free.pdf Then during the retract cycle it yanked the part out of the fixture clamps and the spindle started spinning again heading back to 2500 RPM. The part was very imbalanced and the rotation quickly caused the drill bit to snap and the part to get thrown. It made a nice dent in the Z axis ballscrew cover. For reference, here is a picture of the part: It is a fixture for another part. I made some minor changes to the part from the first attempt. Obviously I changed the drill cycle for the two holes. In addition I added a chamfer and messed around with the strategies for the milling. Here is another piece of stock ready to go. Note I added an additional clamp as well. Here is the machining: I am having terrible luck with mine. I have done the control retrofit using a Gecko G540 and Huanyang VFD. But twice now, the x-axis ball screw has blown up. I didn't blow it up the first time mind you, I got the machine that way. I tried to repack the balls into the nut but found the recirculating tube was damaged. I was able to buy a new nut off ebay. I had to machine back up and running just recently and I accidentally overstroked the x-axis because my limit switch wasn't set right. I was slowly jogging the table and the pulley end very slightly tapped the nut and blew out the balls again. I think I'm going to look into changing out the ball screw for something a little more robust. The trick is going to be finding something that will fit under the table, or I might have to modify the table. They do look identical to the ones you have posted in your thread. I'm pretty sure I did slow jog (10 ipm) at least one axis into a hard limit without issue when I was configuring the limits and I have stalled the Z axis at low speed when machining (spindle stalled when drilling) so I'm pretty sure I've put the full motor torque on the screws. I'm running 2 NM (276 oz in) steppers at 48 volts with the original 2:1 reduction pulleys. Any chance you are running significantly higher torque motors. I haven't seen others complaining about these ballscrews blowing up like that. I have 381 oz. steppers. I have my doubts that it was due to that though. I have re-packed the ball nuts a couple times and came the conclusions that the 'catch' that is supposed to keep the balls from getting past the recirculating tube broke off. I don't see a way to fix it either. This 'catch' appears to be a little piece of the recirculating tube that they intentionally leave sticking up in the nut. So I can re-pack the nut, wind it back onto the screw but as soon as I reverse direction, all the balls spill out the other side. I have been hunting for a replacement but I have yet to find anything I can make fit without getting into significantly modifying the table. I just picked one of these up myself and am doing some research before buying the stuff. I keep thinking of questions to ask but then see you've already provided most of the information. When I get closer to putting things together I'll be sure to have more questions about how the electrical stuff worked out, as I don't quite understand how all the voltage changes are exactly taking place. Anywho, Thanks again! Please feel free to post any questions and I'll answer as best as I can (I'm certainly no expert). I actually used the Hitachi WJ200-007MF which is the model that supports 110VAC single phase input. The WJ200-007SF only supports 220VAC single phase input. I can't edit the original post so this will have to do. The site is 100 free to join and use, so join today! I am in to process of fixing the machine. I have rebuilt the controller pc and got it working. I have now moved onto the machine itself. I tested it with the belt pulled from the motor and then used a push stick to try and stress the motor and it did not make and whine or screech so i am going on the assumption the motor is fine. So far i have the head apart and the bearings pulled. So i have ordered 2 new bearings just in case (32007X) But was wondering what grease to use in it. This machine maxes its RPM out at 3,000 Or if there is a way to inspect the bearings or just clean them. Any advice on what to use to clean out the ballscrew and nuts and then what to lube them with. Also for the ways i was thinking of using Vactra No.2 Way Oil by mobile one. So i am hoping to restore the machine and have a great miniature prototyping mill that does not run on ATF or Bar lube. Or just any advice this is my first time doing much work on a machine like this. I did try to contact EMCO but they told me they had no software for it and no documentation but offered me a retrofit kit for several thousand dollars. When i asked about consumable specs they just never answered me back.Did you get the software running. If you have problems with it I can help. As for ballscrews there should be oiling nipples for them, regular way oil will do just fine. Emco main office has provided manuals for my 55 concept turn by emailing them. MarkoYes the lube is pricey, but you only need to buy the 50 gram tube. The Bearings DO NOT get Packed, they only get a small Pea size amount which gives a light film. More lube can cause the bearings to overheat. This is what I was told from Emco Maire tech in Austria when I was redoing the spindle in my 340 Turning Center. There used to be some really great, knowledgeable and very helpful people at Emco.and then there was the rest of them.The load on the 55 series is so small and considering it only turns 3000rpm. Oh yeah, try contacting Emco headquarters at Austria MarkoDid you get the software running. If you have problems with it I can help. As for ballscrews there should be oiling nipples for them, regular way oil will do just fine. Emco main office has provided manuals for my 55 concept turn by emailing them. Marko Dont have a temp reading but i would not keep my hand there for more than 5 seconds. After removing about 60 of the grease it runs much better. I just finished removing both X and Y ball screws. I flushed way oil via the port and ran the ball nut up and down the screw and wiped the screw in between passes. Is it safe to use any cleaners on these ballscrews.Or is it just best to keep running way oil. Also the oil ports on this machine do not fit any of my oiling tools.Thinking of removing the ports and adding a central feed system. As far as software goes i got the original software working with the machine.The frame was full of shavings and I mean full. M1 fanuc? I cant remember if can you run the newer Concept cam on the pc version of the acc. I would advice to take a ghost image from the drive and of the acc memory card if it has one. Central oiler is a good mod for any cnc if it don't have one. MarkoThe frame was full of shavings and I mean full. M1 fanuc? I cant remember if can you run the newer Concept cam on the pc version of the acc. I would advice to take a ghost image from the drive and of the acc memory card if it has one. Central oiler is a good mod for any cnc if it don't have one. Marko I made a full backup and converted all the floppy's to a single CD image. Also upgraded the PC with a USB card so i can make my g code in fusion 360 (with post processing) and transfer it. I also just finished my first step in making a new controller for the system. So far i have control of all stepper motors via the original stepper drivers the VFD and home switches. The only thing left is the encoders. Want to use a more modern software that can run with auto probes. But i am building it in a way that going back to stock control is a just a swap of 2 cables.It works great as is, if wanting more features I would consider a completely different machine. Interesting as a project but is it worth it?it still is just a small Emco. Does it have the 8 tool magazine or just manual tool change?The controller works great when it works. But I had to do some motherboard repair and replacement of caps and modify and adapt it a new psu to function. Also had to get it a new hdd and cd and floppy drive. I'm worried about the life of the pc controller so once I got it running I probed out every signal and hand built some boards and some chips to adapt the logic. I looked into buying some newer win 98 ISA PCs but from my reading these controller cards only like a few mobos. Somepeople report buying 4 different mobos and only 1 they can get working. Each mobo is around 100 to 200. And you dont know the age or quality. So I decided it would be safer route to reverse engineer the boards build my own. Also I hate the.msd file has a checksum in it so it cant be modified or you get an error. I know I am going to ask more than 100 than this machine can give and will outgrown it once I have learned what I wanted to learn. Then comes buying a used haas vf1, tm, or mini mill.Those are real picky, so no wonder you want a different controller. The newer ones has small linux pc as logic and the main pc just runs the simulated fanuc, sinumeric, or whatever you want to train with. I use mainly camconsept on my lathe, fast and easy to make small parts in the shop when prototyping and testing new stuff.Practical Machinist is the easiest way to learn new techniques, get answers quickly and discuss common challenges with your peers. Register for the world?s largest manufacturing technology forum for free today to stay in the know. Learn more about us. All rights reserved. Register today. To learn more, please refer to the cookie policy. We'll bring you the most relevant peer-to-peer conversations happening in the trade and tips and tricks to help you get the job done. You may unsubscribe at any time. Win 3D-View provides realistic part program simulation, going beyond the graphics normally represented on machine controls. The PC Turn 120 is a powerful training machine that performs all the same functions of production lathes. Cost is kept down by reducing power and speed. Unfortunately, gaining that kind of versatility in training is not always possible. Often times schools can't afford technologically advanced full-sized CNC equipment and manufacturers can't afford to let new employees spend precious production time learning these concepts on expensive, shop-floor machines. EMCO Maier, a manufacturer of full-sized production machining centers headquartered in Columbus, Ohio, also makes training machine tools.Any given training machine is on-line with a PC that can host up to four different control software programs—GE Fanuc, Siemens, Heidenhain, and EMCOtronic. These programs operate and function identically to the original control systems. Changing from a Siemens to a Fanuc system is as easy as switching the control panel and double clicking on the preferred control software icon to choose the new operating system. Murray says EMCO has plans to offer six control systems by next year. On one of our machines, training software ensures that crashes result in a shutdown of the spindle, so there is no damage done to the machine.Saturn filled its training department with EMCO training equipment. Now manual machine operators and new employees can get acclimated to the CNC production environment before ever going out onto the shop floor. Cost is kept down by reducing power and speed. The 100 series, however, can also cut light steels. There are no plastic machine bases or band iron ways. All machines are built along the lines of their full-size production counterparts.Both 50 models have fully-enclosed machining areas, machining area door limit switches, lockable main-power key switches, and emergency stop-push buttons. The machines also meet stringent CE electrical and mechanical safety requirements. It has standard cast construction, hardened guideways, pre-loaded ball screws for X, Y, and Z axes, and 10 tool drum turret with directional logic. It also has chip blow out, high-resolution stepping motor, automatic lubrication for guideways, helical interpolation, enclosed work area, and CE safety standard compliance.The WinTrainCNC is a menu-driven Windows software package that serves as a reference source and lesson plan for the classroom. The software presents a variety of basic concepts with an easy-to-use format that prompts the trainee. Graphic simulation aids learning for topics such as: cutting tools and materials, chip formation, lathe and mill construction, and CNC tooling requirements. Users receive immediate feedback to responses and incorrect entries are referenced to the software section that explains the concepts. The system also has video clips and over 900 pages of documentation. The software provides realistic part-program simulation prior to actual machining to increase comprehension and safety. It was developed to provide trainees with an easier, faster, and more efficient introduction to the total CNC process. The system has user guidance, graphic interface, and on-line help. Then the training machine can make the part.Instructors can send or receive information from any student station. Similarly, students can transmit their work to the instructor station. Students benefit from a split screen where they can work along with the instructor as the part program is developed step-by-step. The Instructor package includes everything necessary to complete several workpieces, including a teacher's guide, student worksheets, and overhead transparencies. The Instructor package, which comes in a briefcase, also holds finished part examples of each workpiece drawing, aluminum stock, and a 3.5-in. disk with all workpiece programs. For worksheets, the classroom guide provides a detailed, step-by-step, self-paced study that takes students through the machine operation and the control systems. Teachers don't want to have to do a lot of preparation work. We usually fill them up with 8 to 10 people per class. Aug 13, 2020 Start Slideshow Quality control is an expanding aspect of manufacturing, representing distinct operating divisions for many OEMS and their tier suppliers, and thus it represents a particular channel for expertise and innovation. The developments that happen in testing, inspection, and quality control of one manufacturing supply chain very quickly find relevance in other sectors. Rapidfit, an additive-manufacturing business, has deployed a horizontal-arm coordinate measuring machine (CMM) to check the accuracy of custom gauging and holding fixtures produced for use in automotive manufacturing. Using this device, Rapidfit has reduced costs and lead-times by making use of additive manufacturing to produce workpiece locators that are added to standard fixture components. For automotive manufacturers and suppliers, this innovation means vehicle production can be streamlined further, because fixtures can be made with greater functionality and better repeatability. Frequently, this is achieved by incorporating complex clamping elements with freeform contours that are produced by conventional machining. It is expensive, time consuming, and creates a lot of waste material. Integrating intelligent, quick-release mechanisms that do not damage the component being retained is another possibility. Even moving elements like hinges can be printed, as well as features such as clips, pins, and holes. High-wear plastics are used to manufacture the components, sometimes with steel inserts or bushings. Customers include automotive OEMs like Audi, Bentley, Lamborghini, and Volvo as well as important supply chain partners, like Mecaplast and Valeo. Shorter lead-time from receipt of order to delivery of the fixture, especially when complex geometries are involved, is a result of not having to program a milling machine to remove typically 90 percent of material from an aluminum billet, or spending time and expense having a casting made and then machining it. Users are given more time and flexibility to fine-tune their product designs and still meet deadlines. An added advantage is that the locators and contours are typically half the weight of their conventionally machined equivalents, so the fixture is lighter and less tiring for operators to use. A high degree of modularity is provided using standard holding elements, such as the Aluquick range supplied by Horst Witte, to support the custom 3D-printed locators. The system allows easy modification simply by replacing them, so fixtures can be reconfigured inexpensively to accommodate design changes. The patented products supplied by Rapidfit are of two types: gauge fixtures are for inspecting automotive components after manufacturing, to verify dimensional accuracy; while holding fixtures support components as they are built into a vehicle and measured using CMMs or other metrology equipment. Both types provide comprehensive management of dimensional accuracy, which is vital to the overall quality of the vehicles being assembled. Accuracy is critical — In turn, this means that quality control of the fixtures is critical. At Rapidfit, in Leuven, Belgium, there was a need for greater accuracy when checking fixture calibration, and to achieve this an LK Metrology HC90 40.16.16 horizontal arm CMM was selected and installed, together with the manufacturer's CAMIO8 multi-sensor programming and analysis software. The coordinate-measuring machine allows almost unrestricted access to its 4x1.6x1.6-meter measuring envelope and features ceramic guideways and air bearings for stability at high velocity and acceleration. A Renishaw PH10-MQ, motorized indexing head with in-quill head mount and autojoint probe mount, together with a TP200 touch trigger probe and various extension bars, formed part of the installation too. The HC90 is housed in a climate-controlled metrology room and currently it is operated over a single shift. The accuracy and repeatability of the LK CMM is very high for its large size. CEO Filip Dehing added, “With a worldwide sales and support network, our company is in an ideal position to grow by becoming a preferred partner for large automotive companies on a global scale, and by fully exploiting new opportunities. Underpinning all of this is our commitment to high quality. The fixture is constructed virtually in CATIA by one of RapidFit's design engineers, and the 3D locator elements are output as STL files so that they can be produced by powder laser-sintering additive manufacturing. After 3D printing, the locators are assembled with standard holding elements and a measuring program is created in CAMIO8 (offline, or even off-site), which makes maximum use of the CMM for inspection. As each fixture is different, ease of programming based on the original CAD file is a critical advantage. The program is transferred to the LK HC90 and the inspection cycle is run to verify that all fixture dimensions are in tolerance. If changes are needed, engineers modify the fixture and run the cycle again. Measuring program changes can be made quickly in teach-mode, if necessary. Turn-around for a fixture of average complexity is three to four weeks, although a very complex fixture may take up to six weeks. Then, the customer is invited to the RapidFit measurement room for acceptance and sign-off. More recently, to check contours faster, the manufacturer has added laser-scanning capability to the CMM by incorporating a Nikon Metrology LC15Dx laser scanner. It is interchangeable with the touch probes and both are supported by LK's CAMIO8 software. The technology offers twice the resolution of camera-based optical systems, so it is suitable for quality control of RapidFit's automotive fixtures. It is therefore replacing relatively slow touch-probing routines in parts of the cycle that involve collecting freeform data. All rights reserved. Find out more Live steam locomotives Locomotives powered by any method except steam Main shows and Club Events Manual machine tools Materials Miscellaneous models Model Engineer. Model engineering club news Model Engineers' Workshop. New products from advertisers in My HobbyStore Magazines. Northumbrian Pre Moderated topics Related Hobbies Scale Model Railway Wagons Scientific Instruments Shand Mason Fire Engine Southern Q1 Stationary engines Steam boats Subscription issues and Digital magazines Suggested Online Resources The Tea Room Traction engines Trams Vehicle Restoration Website Announcements Website FAQ's Website Questions, Comments, and Suggestions Work In Progress and completed items Workshop Techniques Workshop Tools and Tooling Then I came across a pair of ex college Emco PC 50 Mill and Lathe that had been used to provide spares and been left to rust in a storage unit. The electrics were good, but the electronics were suspect. I didn't have the Emco software or the PC interface card The fully working demo version was a good start, I could do testing without too much of a learning curve. I had a couple of old XP pc's and decided to use parallel port control. This is an obsolete technology dead end, but it works and I was confident to support it myself. There is also a voltage control card for the LED lights. Use our magazine locator links to find your nearest stockist! You can also get in touch about this website, advertising or other general issues. Does anyone have the original software and manuals I can get from you? Does anyone have the original software and manuals I can get from you?