Colchester 4000L retrofit

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09 Jul 2026 16:34 #347637 by JThom
Colchester 4000L retrofit was created by JThom
Hello,
I'm investigating a lathe retrofit on a Colchester 4000L Fanuc 0T-A.

I've done a couple of retrofit/hybrid, and 'from scratch' LinuxCNC machines before, but none involving Fanuc, which I know is often difficult-to-impossible depending on the particulars. I've looked at numerous paths forward balancing time/difficulty vs up-front cost. 

Been reading old manuals, searching the forums, and I must admit, taking a significant amount of input from ai, and I have a plan. But, while it was nice to seemingly make rapid progress compared to my previous projects, I would be glad of input from other actual humans. If CNC has taught me anything, it's don't trust a machine! I've tried to include enough relevant detail without turning the post into War and Peace.

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I'll be using MESA boards - most likely a 7i96 connected to a 7i77. I already have them from a previous project where they worked very well.

For axes, I want to keep the Fanuc motors (red caps: A06B-0513-B032#7000 amd A06B-0512), and (for now) their drive/VCU (it's a dual axis unit A16B-1200-0520). 
If I've understood correctly, LinuxCNC can read the positional feedback from the encoders via serial port on the 7i77, then using DC injection to find the magnetic offset, generate commutation data and command the motor via 7i77's 10V into the pre-existing VCU. 

I'll Keep the fanuc spindle motor, an 11kW A06B-0745-B201, which seemingly has an encoder with ABZ output that LinuxCNC can use via encoder input on the 7i77. 

I'm replacing the spindle-driver/VCU (A06B-6060-H008) with a heavy duty VFD. Something like a Yaskawa GA70C2056BBA. The failing fanuc spindle driver is actually the straw that broke the camel's back and instigated this project.

Toolcahanger is a duplomatic BSV-160. There seems to be ample history for successfully using similar units.
Coolant pump is either on or off, I think it'll be OK.

Control will initially be primarily PC based, probably some touch-screen, but will probably add a pendant for easier manual positioning and the dopamine hit of pushing real buttons.

Really just wondering if anything is obviously foolish. 
 

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