2nd stage of Crusader II retrofit

And here is the 801 again. I know yours is older but similar. I would clip the connections on the left as shown and documented by others.
Also I think polarity is important on switching the relay. I assume the diodes I see on my board are for flyback protection.

BTW, it looks like pin2 on your left J1 connector has the crimped connector not fully seated? They will pull out super easy if not latched.

OT-CNC

Is it okay to just hook up 24vdc to the 801-P2/P1 without any other hardware? I have removed the extra wiring on the J1.
I am still awaiting a 7i77 card.

Thanks
Jim

I have not turned on the drives without the control connected. In theory, 0v would keep the motors from spinning but not having the encoders counting and linux doing the pid maybe you get drift or runaway? I would try it just to see if the drives power up. Just position the x y and z manually somewhere in the middle of travel so you have enough time to turn them off if you have a runaway. Or remove the belts.

OT-CNC

Looking at your pictures of the PCB-801 you have wires at P5 2 at the top and at P4 are 2 at the bottom. My 801 has no P5 and all the wires coming from the P4 go to the manual/auto switch for the spindle. Is that what the 2 wires on your P4 do?

Thanks
Jim

On the P5 connector, I'm powering the oiler. It was a convenient place to tap into for me. On P4, the 2 wires traces back to the auto/man switch.

Well I got the replacement 7i77 card and have it installed in the box. I made sure that W5 was set to the right since I am using a 5vdc power supply at TB1 and that's what my 5i25 is setup for. I am also powering TB2 with 24vdc and W1 is set to the left.
But now I am just steeling my nerves to power it up. Maybe tomorrow after I've had time to think about anything I might have missed.

Jim

Is it okay to just hook up 24vdc to the 801-P2/P1 without any other hardware? I have removed the extra wiring on the J1.
I am still awaiting a 7i77 card.

Did the drives enable with 24v to the 801 board? I would try that 1st.

OT-CNC

Well its 10:00am here and I connected the 24vdc power to the enable circuit on the 801 and the power came up but the drives didn't lock up as they would normally.
I reconnected the P4 connector with all wires and that brought up the 15vdc power on the amp cards and all three axis locked up.

Jim

Well its later and now after bring up the machine thru linuxcnc and having tested all my limit switches, e-stop, and run/stop pause/resume buttons in the Show HAL Configuration panel. I don't have read-out from any of the axis I am thinking something is not providing power to the scales but not sure what.
So I am scratching the old punk'n and wondering, any ideas?

Jim