I'm where the machine is now and starting the actual retrofit. I've been going back and forth between schematics and spindle wizard engineering diagrams and the actual machine and have developed a much better understanding of what exactly I've got here. As I understand it now the machine casting and spindle drive are Ex-Cell-O's standard 602 contribution. From there the knee, huge tubular ways, ballscrews, and "Position Wizard" super upgrade table which give it the huge and acurate travels that attracted me to the machine are Spindle Wizard upgrades. Spindle Wizard also put on the quil motion, power draw bar, coolant, and their own control for things like gear changes, spindle speed, tool changing, and coolant. One of the buttons on the 11 button front panel is an auto/manual button. With that button set to manual the other buttons can be used to control all those functions. With it set to auto the spindle wizard control takes commands from a cnc control (originally a bandit) to control those functions.
The way this Spindle Wizard control is set up a custom "M card" in the Bandit control would send m codes to Spindle Wizard control. The Spindle Wizard control has its own power supply supplying 5 volts for the ttl logic and 24 volts for the signals to operate relays, a 'logic board" that translates the binary input of the m code into a single pin output to the "power board," a "power board" that amplifies and distributes those signals to the designated relay or solenoid, and a "jog board" that supplies the signal voltage to shift between high and low gears and the spindle jog timing to engage the gears after they have shifted.
The Spindle Wizard power supply, logic board, and power board housed in a cabinet on the right side of the machine. I have the chasis with holds the power supply and is the card rack unscrewed here but you don't actually have to unscrew it to pull the cards out. Each wire from the harnesses plugs individually into securely mounted card edge plugs at the bottom of the card file.
The logic card pulled out of the card file
Fortunately I have the logic diagram for the logic card. Looking at this, it looks like I can easily interface with the control the same way the bandit did through the same wires the bandit did. It's using 4 wires ( card edge pins L, M , K, 19 ) as binary input of the decimals 0 through 9 and 3 wires ( card edge pins P=10, R=40, S=20 ) for the decimals 10, 20, and 40. That's only 7 wires I need to hook up to the Galil control outputs to be able to send the m codes to the Spindle Wizard control. Then card edge pin Y is the input for emergency stop. That's 7 I/O pins. Since I have a 6 axis model Galil I have 16 uncommitted I/O pins.
The power card
The relay box. The jog car is in the box behind all the relays.