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EMCO F1 Mill
Servo Conversion Project
All parts included and most of the work is done
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Project Overview
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I sold this setup in 2005 to a local guy who took it home and put it in the corner of his heated garage. He never touched it
again. In April of 2008 he called me to say he was moving and needed to sell it fast. So I went over and removed it from the
corner it had sat in since he unloaded it. I toyed with the idea of completing the project but I've got too many irons in the fire.
Below is the description I wrote when I listed it on eBay back in 2005.
The EMCO F1 CNC mill is a fine machine and this one was in good working condition. But the stepper motors with
open loop control did not allow the desired precision. So a complete conversion to DC brush servo motors
was undertaken. The F1 computer (control) cabinet was completely stripped and most parts were sold.
The F1 spindle drive was moved to the mill cabinet with the current meter, on/off
switch and speed control mounted in the upper left corner. The spindle and drive have been tested and are completely
functional in the new configuration. The E-Stop switch was moved to the upper right of the mill cabinet with the
master on/off key switch on the upper right end. On the lower right end is the AC power input (with fuse), AC power
output for the new control cabinet (with fuse), DC power output to control cabinet and the Servo Motor drive input cable
connector from the control cabinet. On the left end of the mill cabinet is the control signal (limit switch, E-Stop, encoder, etc)
interface connector to the control cabinet. Also on the left end is an Aux AC power outlet for coolant pump or whatever.
The new control cabinet contains the 3 Gecko 340 DC servo drives (mounted on a 7.5" x 13" x 1.25" heat sink),
a Sound Logic PC2 break-out board and a Sound logic Relay Board. The Sound logic boards have been bench top
tested with the laptop PC and the Mach 2 control software and all functions work great once we got
the bit states sorted out. The Gecko drives are straight out of the shipping box and have never been powered. The
control cabinet interface ports are in place but the internal cabinet wiring is not complete.
The PC to interface board wiring is complete, but the control signals from the mill cabinet need to be wired as does
the DC power to the drives and the motor drive back to the mill cabinet. All these wires and cables are included
and ready for hock-up.
The DC power supply is mounted in the mill cabinet. It is completely functional and produces a clean 65 volts DC at
10 amps. The transformer is rated at 40 amps and the bridge rectifier is rated at 25 amps. It has
120,000 uf of capacitor on the output, which is enough to produce a clean 65 volts DC at 10 amps load (more than enough current for the
3 servo motors). A muffin fan plays cooling air over the large heat sink that the bridge rectifier is mounted on.
Mill cabinet AC wiring is complete. The AC power for the Fan, DC power supply, Aux outlets, etc is run through
a large power relay which is controlled by the master on/off key switch and interlocked with the manual E-Stop switch.
During a manual E-Stop, AC power is removed from everything except the control cabinet (so the control can stop
the drive motors using stored energy in the power supply capacitors).
The servo motors are mounted on the F1 adapter plates, new timing pulleys and belts have been purchased and are
included. I don't remember the drive ratio that was selected but lots of
research and calculations went into selecting the best torque vs speed relationship. New motor drive & encoder
pigtail cables and connectors are included but installation is only started on one motor.
Limit and Home switches for all 3 axes are included but only the X axis switches are installed. The X axis switch
stop blocks are made but not mounted on the table yet. The table has some light rust and is partially disassembled,
ready for cleaning and tapping holes for mounting the limit switch stop blocks.
All small parts and screws are stored in the tool box.
Lots of wiring is still needed in the mill cabinet. Both the control signal connector and motor drive connectors are
installed and wired to terminal strips on an aluminum rail across the lower part of the cabinet, but none of the wiring
between the terminal strips and the limit/home switches, encoders or motors is done yet.
The laptop PC and Mach 2 CNC control software have been used to checkout the PC interface board and relays in
the control cabinet and that all works great. Except, The laptop PC has an intermittent connection between the main
body and display. So you need to play with the display angle until it starts working then as long as you don't change
the display angle, it continues to work fine with no further problems.
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Items you get: |
Condition: |
Pics: |
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 F1 table, cabinet, spindle & spindle drive |
Very Good |
Pictures |
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30 Taper Tool Holders
 1" Shell Mill Holder and
ER-25 Collet Chuck with 10mm collet
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Very Good |
Pictures |
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3 servo motors with encoders and F1 mount plates |
Excellent |
Pictures |
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4 spare servo motors with encoders |
Excellent |
Pictures |
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65 volt, 10+ amp DC supply |
New |
Pictures |
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Steel Control Cabinet (20" x 20" x 9") |
New |
Pictures |
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3 Gecko 340 servo drives
See Gecko Website and Gecko 340 manual (large PDF file) |
New
(never powered) |
Pictures |
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Sound Logic PC2 break-out board
See Website and
PC-2 users guide (large PDF file)
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New |
Pictures |
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Sound Logic Parallel Port Relay Board - See
Website
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New |
Pictures |
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Inter-cabinet cables
3 wire 12 awg DC power cable
10 wire 16 awg motor drive cable
2 wire 16 awg cable and connectors for motor pigtails
several DB25 cables
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New |
Pictures |
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Tool Box full of parts & supplies
timing pulleys, timing belts, connecters, switches, tape, fan,
fan screen, lights, bridge rectifiers, hook-up wire, heat shrink tubing,
wire ties, screws, nuts, bolts, etc. etc. |
All New |
Pictures |
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Dell Inspiron 7000 laptop PC (Pentuim II)
Includes Port Replicator II docking station,
MS Windows XP, power supply, gender changer and
DB25 parallel port interface cable to the control cabinet.
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Functional |
Pictures |
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Mach2 Mill CNC control software installed on PC
I assume that this is the demo version (which has some minor
restrictions), but it may well be the fully functional registered version.
See ArtSoft Website and
Mach2 SW manual (large PDF file)
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Works great |
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Loading
I will hoist it in the air and set it in the back
of your pickup
I'm located about 50 miles north of Seattle on I-5
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No charge |
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Note:
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You can not add this item to your cart and complete an online purchase via the normal checkout process.
Please contact me if you are interested.
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Delivery:
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Local pickup would be best. But if you need it shipped, you have few options:
1. You could have someone come get it, crate/pack it and ship it for you.
2. You could pay me $250 to:
bolt it to a custom pallet that I would make
pack all the other items in and around it
enclose it with light plywood
cover it with plastic tarp
arrange trucking to your local trucking transfer station
delivery it to my local trucking outfit (Oak Harbor Freight Lines)
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 Your total cost would then be: Purchase price + $250 + Actual Trucking cost + Sales Tax (if WA location).
I currently do not know the shipping weight - I have to figure out how to weight it.
I will post the estimated shipping weight and pallet dimensions in the near future.
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