Rip and replace of the Dynapath control system with Kflop

Here's a shot of the test bench setup for the Kflop. I have it arranged with some terminals for encoders, servo outputs, spindle and coolant. It served it's purpose dutifully. Once I tested it all out, it was time to start tearing into the Dynapath Delta 10 system.

Here's the old beast. It was actually much easier to trace out the wiring that I had initially thought since all the controls came through d-sub connectors separated by function (i.e. servo control, encoders, interlocks...).

This is the operator console. It has some functions that I'd like to migrate over to the Kflop system. Specifically, the motion start/stop buttons, pot for feed rate override and spindle speed override. I'm not sure how to pull it off yet but once I dig into the Kflop I'll post as I develop.

Here's the panel over I mounted the Kflop and set up some terminals. On the left is the encoders and servo output (+/- 10v) then the 5v and 24v power supplies. On the right, is all of the discrete inputs, outputs and interlocks.  Above the horizontal panduit is the 3-phase power and the baldor DC servo controller. It's amazing how much smaller the Kflop is than the Dynapath! I could rent out a room in this panel:)

My next challenge was the power supply panel. It was equipped with multiple contractors for motor rotation, external power as well as the 24vdc power supply. Since the machine is equipped with a VFD and I don't have any plans for external 3-phase devices, I was able to pull it all out and start over.

And, in a flash, the panel is done (it took a bit longer in real life).

For all the current devices I just needed a couple small relays, fuses and terminals. Ahhhh, clean....

I accommodate for a 24vdc work light, 24vdc z-axis limits, 120vac air solenoid, 120vac lube system and a 240vac coolant pump.

 Once all the wiring was complete I started some moves and interlock tests which I put in another post.