Hurco KM3 Conversion HELP!

It looks like the drives only use the tacho feedback and the position feedback only went to the control. That should make it a pretty straight forward conversion.
You need to confirm that the motors have encoders and not resolvers. If they are encoders a 5i25/7i77 would be perfect. If they are resolver you will need a different set of cards (5i24+7i49+ another card or 2 for digitlal io).

I have been in the middle of the same ( Hurco KM3 ) conversion for some time.

I am overbuilding / over complicating this build because I have machine paranoia. I do not believe that any machine motion should be controllable via an HID ( keyboard or mouse ) so all jog commands will be hard wired with appropriate switches into GPIO.

I am using a HP DC7700 mATX with a with a 5125/7i77 and a 7i74 on the 5i25's 2nd port. I have several of the 7i77 plugs wired up and am dealing with issues of too many differing control voltages. The 7i74 allows me to use multiple SSerial cards for more I/O for the panel and other options.

I removed the Hurco OEM Intel Multibus card cage and OEM control power supply. The ServoMate uses 120VAC 1ph that it gets from the OEM stepdown/isolation transformer. I have a Teco FM-50 VFD to drive the spindle motor and I will add a run capacitor or 1/4hp VFD for the coolant pump so the machine can run on 240VAC 1ph.

I do not intend to control spindle speed with the VFD. I will use it to ramp up to speed 2.5 seconds to 60Hz and likewise 2.5 seconds to stop. I will use the Vari-drive to control speed for now to provide best Hp/torque from the motor running at its data plate rpm.

I have (lost at present) the VFD breaking resistor which will allow for harder spindle breaking in the future. Since I read that G84 has finally been supported (v2.8 or later) I will be able to tap using the U200 tension/compression tapping heads I have for the Hurco.

I am waiting for a tapered gib for my manual mill that was ordered a few weeks ago to get that machine running again so I can complete the chassis parts and get things all mounted up. Being impatient I used my 3D printer to make a partial gib since I could not print a 15" part. Was a partial mistake. I used AL spacers at each end to center the gib - but as I used the machine it pulled the gib into the taper and wedged it in there but good. The AL end spacers just deformed the plastic more, increasing the wedge effect.

I have made up several spread sheets which document where a signal wire is sourced on the Hurco (using OEM wiring diagrams) and which terminal connector it is connected to on the Mesa boards.

I have 24VDC/6A and a 5VDC/4A power supplies - how ever after reading many of Gene's rants I am wondering how clean these power supplies will be. I don't have a scope at present, and no budget.

While I have done an install on a laptop HDD with v2.8pre I have not begun any config. I have a remote pendant that I may use exclusively for jog functions until the machine is running well enough to cut out a proper control panel.

I have yet to tackle a good hardware E-Stop Chain. Also the OEM Icecube relay panel the Hurco used is running 120VAC control voltages to drive air valve solenoids and Siemens contractors for spindle and coolant. I will have to work with some of these, but have not gotten to that point.

Part of the OEM Hurco E-Stop signal went along with the keyboard signals which totally voids its re-use.

Amazing!! Sounds like a proper project there!
I'd be very interested in the pin connections from the Hurco to the Mesa Boards, if you'd be willing to forward them on.

On a slightly connected issue - I don't suppose you have any spare 5i25/7i77's you'd be willing to sell on?

Sorry no spares at this time. mesausa.com can get you what you need in short order.

I am almost tempted to hunt for another dead MAX-II KM3 and basically make a breakout board for the cables that went directly to the tops of the PCB's in the card cage. It would dramatically speed up a conversion reusing much of the existing wiring.

I pulled off the console and console support arm. The MAX-II control console is so radically different from other controls I can't see any way to re use the console. The E-stop switch, Power / Motion Hold / Start buttons can be used with all new wiring, and I suppose you could mount a new console on the arm.

While I have never used a FADAL, I do admire the utilitarian simplicity of the CNC88HS left side control panel. I hope to do a hybrid design that includes the wired pendant I have replacing the panel mounted MPG and related switches.

I will be glad to post the basic 7i77 wiring connections as soon as they are tested and confirmed. Nothing worse than having bad info out there that search engines will keep serving up even after corrections are posted.