Here I go.  I've run this for years.....'till the control died.

Control cabinets

So far I have loaded Mach3 R 1.84.000 into an old box and have been messing around with it. (That was the lockdown when I downloaded)
Purchased a 17" LCD and a touchscreen kit.
Will be getting a Dell pentium 4 1.4g to set up for real.
Bought an extra printer port for the Dell.

Entries into the Mach3 so far.  (thinking that I can use the .xml files in the new setup)
Spindle setup:  Min speed 0, Max speed 6000 (5hp 7800?rpm spindle motor, that's what the advertised max spindle speed is and the best guess I could get on the pulley ratio.  hard to measure accurately without a teardown)
Disable spindle relays:  checked
Disable Flood/Mist relays:  unchecked
Use Spindle Motor Output:  checked
PWM:  checked

Not sure what to else to do on the Spindle setup dialog.

Motor Tuning:  The ball screws are 5 turns/inch
                      The encoders are 635 pulses per rev 1:1 to the screws
                      3175 steps per inch
                      Velocity 399.24
                      Acceleration 78.346457

I figure I'll get this running pretty quick, soon as I find the answers to a few hundred questions.

NEXT:...... Figure out what the questions are.

You'll be fine. There is a lot of people here willing to help.

Brett

I have a mill that is just about like yours I wish the head of mine was like that but the base is the same. I put AC brushless servos on the mill, man is that thing FAST! It is 1.34 Hp per axis and I took the belts off the X and Y axis. I get about 500IPM and it will move a .00002 inc (only based on the Encoder,Didn't check to see if it was true). I also got a 10" 4th axis for it Nice mill, I think you are going to be happy with it!

That's good to hear. Something tells me he likes to go fast.

I have a mill that is just about like yours I wish the head of mine was like that but the base is the same. I put AC brushless servos on the mill, man is that thing FAST! It is 1.34 Hp per axis and I took the belts off the X and Y axis. I get about 500IPM and it will move a .00002 inc (only based on the Encoder,Didn't check to see if it was true). I also got a 10" 4th axis for it Nice mill, I think you are going to be happy with it!

These servos are ferrite brushed.  Handbook says rapids are 400 ipm.  Torque is 4.5 Nm, I think that's 637 in/lb.  Hope that comes out to be around 600 Hp. 

I printed out the manual and have read it a few times.  Been reading forum posts ad infinitum.  Now have I/O (Information Overload).

My integrator pal, the famous/infamous Mike Pearman of NC Repair, is coming over today to laugh at me.  If I scmooze him right he might even help.

Nice machine. Kinda built like a Bridgeport Mk2 Interact.

You'll be ok with the brushed motors, if your drives are still ok you may be able to reuse those too.

Wayne...

Nice machine. Kinda built like a Bridgeport Mk2 Interact.

You'll be ok with the brushed motors, if your drives are still ok you may be able to reuse those too.

Wayne...

The drives were working OK when the control went south.  At least I hope that's what my problem was/is.  None of the axis would settle to light up an "in position" on the display.  If I tweaked the pots on the drivers I could get it to work to run one or two parts.

How unsettling.

I changed out the drives and motors because i wanted the mill to run everytime I wanted it. Not to say that I can't have made the brush motos work but I just wanted to have a good machine that I could cut and not muck with. TI cost me about 1300 and axis for the drive motor and cables per axis and if you have been making parts you know that is not that much money for something that you need to have running all the time. On the other hand if you are at home and making things for fun OR you just like to work on things... Get some parts and see how cheap you can get it to run I have done that in the past and had a great time working and learning 

What every you do please keep the 400 IPM