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#1 - 29/06/2026
Well, seems I have a contribution.... Let's see.... I like to create, break, renew, replace and just generally piss about. I went to create something on my Denford CNC Mill I bought second hand a few years ago, but the Baldor (Allen Bradley) controller shat itself.
After trying many fixes, including trying to refresh the original firmware all I got was a progress bar to 1% then a bad address error. It recognised the USB controller but unfortunately knew it was firmware less.
Well, seems I have a contribution.... Let's see.... I like to create, break, renew, replace and just generally piss about. I went to create something on my Denford CNC Mill I bought second hand a few years ago, but the Baldor (Allen Bradley) controller shat itself.
After trying many fixes, including trying to refresh the original firmware all I got was a progress bar to 1% then a bad address error. It recognised the USB controller but unfortunately knew it was firmware less.
#2 - 29/06/2026
First view is when I decided to remove the up and over guard and convert it to hinges doors instead. This is the offending door.
IMG20260530120102.jpg
First view is when I decided to remove the up and over guard and convert it to hinges doors instead. This is the offending door.
IMG20260530120102.jpg#4 - 29/06/2026
I am quite far along so will update when I remember. This was the offending controller.
IMG20260607102203.jpg
I am quite far along so will update when I remember. This was the offending controller.
IMG20260607102203.jpg#5 - 30/06/2026
One thing I had an issue with was wiring diagrams. Luckily the nice folks over at Denford Data have all the files. I have no idea what version mine is, and the stepper drivers don't match any of the drawings but here is the link to the PDFs. https://www.denfordata.com/bb/viewtopic.php?t=3721
One thing I had an issue with was wiring diagrams. Luckily the nice folks over at Denford Data have all the files. I have no idea what version mine is, and the stepper drivers don't match any of the drawings but here is the link to the PDFs. https://www.denfordata.com/bb/viewtopic.php?t=3721
#6 - 30/06/2026
I started by naming all the connections to make sure the wiring was correct and back pulling the cables and using some awesome printable heat shrink for my Brother labeller.
IMG20260609191025.jpg
I started by naming all the connections to make sure the wiring was correct and back pulling the cables and using some awesome printable heat shrink for my Brother labeller.
IMG20260609191025.jpg#7 - 30/06/2026
Here are all the parts of the machine. A Sprint 1200 DC Thyristor Drive to power the spindle (2HP 180V DC motor).
IMG20260601132146.jpg
Here are all the parts of the machine. A Sprint 1200 DC Thyristor Drive to power the spindle (2HP 180V DC motor).
IMG20260601132146.jpg
#9 - 30/06/2026
This large beast is the main Estop and machine control board and Power Supply. The mains comes in the bottom and out to a large transformer. I eventually worked out the wiring as well. It supplies 60V DC to the main stepper drivers, and 24V to the main controller. The 60V is controller via an EStop relay which is the white unit right of centre. One energised by pulling it to ground it enables the 60V supply and the main functions of the machine.
IMG20260607102211.jpg
This large beast is the main Estop and machine control board and Power Supply. The mains comes in the bottom and out to a large transformer. I eventually worked out the wiring as well. It supplies 60V DC to the main stepper drivers, and 24V to the main controller. The 60V is controller via an EStop relay which is the white unit right of centre. One energised by pulling it to ground it enables the 60V supply and the main functions of the machine.
IMG20260607102211.jpg#10 - 30/06/2026
The spindle disconnect relay which also serves as a status indicator that the spindle power is energised.
IMG20260605194139.jpg
The spindle disconnect relay which also serves as a status indicator that the spindle power is energised.
IMG20260605194139.jpg#11 - 10/07/2026
Jumped to a slightly different thing while I'm doing other things 😄 . Since I have a load of inputs and outputs I'm not going to use, I might as well upgrade the panel! All it has on was estop, feed and speed knobs. So I'm adding cycle start and stop buttons.
Jumped to a slightly different thing while I'm doing other things 😄 . Since I have a load of inputs and outputs I'm not going to use, I might as well upgrade the panel! All it has on was estop, feed and speed knobs. So I'm adding cycle start and stop buttons.
#12 - 10/07/2026
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IMG20260710201834.jpgIMG20260710202202.jpgIMG20260710202629.jpgIMG20260710203400.jpgIMG20260710203409.jpg#13 - 10/07/2026
Yes, the cycle stop will be red. When I find the button I most definitely bought. Yes, I'm going to put a better decal on it to cover the scars 😄
Yes, the cycle stop will be red. When I find the button I most definitely bought. Yes, I'm going to put a better decal on it to cover the scars 😄
#15 - 11/07/2026
Decided to put back the top covers over the motor. This is what hides under the hood of the machine.
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Decided to put back the top covers over the motor. This is what hides under the hood of the machine.
IMG20260711133338.jpgIMG20260711133345.jpgIMG20260711133355.jpg#16 - 11/07/2026
On top of the motor is the Z brake. Its a failsafe to stop the head dropping in a power cut or estop situation.
On top of the motor is the Z brake. Its a failsafe to stop the head dropping in a power cut or estop situation.
#17 - 11/07/2026
However, I reckon do it once.... So decided to lube up the z rails via the bearing blocks. I managed to find a couple of ball bearings on the top for some reason. So I decided to remove the block, this is a calculated risk since the balls can pop out and make it irretrievably knackered.
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However, I reckon do it once.... So decided to lube up the z rails via the bearing blocks. I managed to find a couple of ball bearings on the top for some reason. So I decided to remove the block, this is a calculated risk since the balls can pop out and make it irretrievably knackered.
IMG20260711144441.jpgIMG20260711145231.jpgIMG20260711145613.jpgIMG20260711145620.jpg#18 - 11/07/2026
Luckily there was plenty of grease and I managed to refit the errant ball bearings. Phew! However, I do have the block order number for future reference. HIWIN HGW20CCH 140646-60 for the Z Axis on. Denford VMC1300 Milling Machine. Approx £30-45 by the looks of it. It takes 4....
Luckily there was plenty of grease and I managed to refit the errant ball bearings. Phew! However, I do have the block order number for future reference. HIWIN HGW20CCH 140646-60 for the Z Axis on. Denford VMC1300 Milling Machine. Approx £30-45 by the looks of it. It takes 4....
#20 - 16/07/2026
I spent a lot of time finding out what it takes to enable the main relay board and see if I can repurpose it. Since it has nearly all the voltages I need then it makes sense! The first thing was to start pulling wiring out of the old control and labelling it all up.
I spent a lot of time finding out what it takes to enable the main relay board and see if I can repurpose it. Since it has nearly all the voltages I need then it makes sense! The first thing was to start pulling wiring out of the old control and labelling it all up.
#24 - 16/07/2026
Removed the old controller as I was going. Piece of very expensive rubbish now 🤣.
Removed the old controller as I was going. Piece of very expensive rubbish now 🤣.
#26 - 16/07/2026
The board it was mounted on. So I reused this as well. Removed the end piece, flipped it over and drilled and tapped 8 mounting holes at work on the mills.
The board it was mounted on. So I reused this as well. Removed the end piece, flipped it over and drilled and tapped 8 mounting holes at work on the mills.
#28 - 16/07/2026
This suits the new AXBB-E controller and the secondary breakout board. I now have LOADS of I/Os to play with 😀
This suits the new AXBB-E controller and the secondary breakout board. I now have LOADS of I/Os to play with 😀
#30 - 18/07/2026
The one thing the Denford doesn't have that I needed is a 5V PSU, so let's add a nice little Meanwell 5V DIN rail one 😄
The one thing the Denford doesn't have that I needed is a 5V PSU, so let's add a nice little Meanwell 5V DIN rail one 😄
#32 - 18/07/2026
The new board installed and the power wired up. This is the "faked" enable stage. Proof that the Denford Router board that controls the main power and E-Stops works.
The new board installed and the power wired up. This is the "faked" enable stage. Proof that the Denford Router board that controls the main power and E-Stops works.
#34 - 18/07/2026
One complaint I have seen is not enough connections for 24v and 0v for the I/O connections on the main motion control board so moved the mains filter to a vertical configuration, added a new length of DIN Rail and then added a new Terminal Block so I now have lots of hook up points for both!
One complaint I have seen is not enough connections for 24v and 0v for the I/O connections on the main motion control board so moved the mains filter to a vertical configuration, added a new length of DIN Rail and then added a new Terminal Block so I now have lots of hook up points for both!
#35 - 18/07/2026
This threw up an issue I knew was coming. The 230V AC supply I had to add for the additional PSU I crimped into the existing connections for the filter, but it was unstable and hard to route properly. So I added a second set of terminals for this in the gap at the end.
IMG20260620110820.jpg
This threw up an issue I knew was coming. The 230V AC supply I had to add for the additional PSU I crimped into the existing connections for the filter, but it was unstable and hard to route properly. So I added a second set of terminals for this in the gap at the end.
IMG20260620110820.jpg#36 - 19/07/2026
The 5v is used purely for the signals by the looks of it, so no real load. The kit they supply with the AXBB-E comes with a 500mA PSU so 3A should be more than enough heh!
The 5v is used purely for the signals by the looks of it, so no real load. The kit they supply with the AXBB-E comes with a 500mA PSU so 3A should be more than enough heh!
#38 - 19/07/2026
First thing to connect is the Charge Pump. This is the enable signal from the controller to the Denford Board and goes to the Isolated Output. When UCCNC first starts, it has the option for an enable signal to be sent to a safety relay system (in this case the Original Denford Router Board) to enable the 60V system for the stepper drivers and turn on all the accessory relays. This is what I have been manually turning on. It needs configuration in the UCCNC software to work.
First thing to connect is the Charge Pump. This is the enable signal from the controller to the Denford Board and goes to the Isolated Output. When UCCNC first starts, it has the option for an enable signal to be sent to a safety relay system (in this case the Original Denford Router Board) to enable the 60V system for the stepper drivers and turn on all the accessory relays. This is what I have been manually turning on. It needs configuration in the UCCNC software to work.
#39 - 19/07/2026
After this I wired in the 3 limit switches to individual inputs. You can actually daisy chain them as NO or NC contacts, as the machine is only looking for a signal to say it's either broken or enabled the switch. If it's only homing one axis at a time, then any break in the system works. I did them all separately, and also wired them as Normally Closed. This way a cable or switch fault won't cause the machine to drive past it's limits.
After this I wired in the 3 limit switches to individual inputs. You can actually daisy chain them as NO or NC contacts, as the machine is only looking for a signal to say it's either broken or enabled the switch. If it's only homing one axis at a time, then any break in the system works. I did them all separately, and also wired them as Normally Closed. This way a cable or switch fault won't cause the machine to drive past it's limits.
#41 - 19/07/2026
The 3 status lights on the inputs is where it's at. These are setup as pulled to ground. The AXBB-E can do either or depending how they are wired.
The 3 status lights on the inputs is where it's at. These are setup as pulled to ground. The AXBB-E can do either or depending how they are wired.
#43 - 20/07/2026
The wiring for the stepper drivers. You can use any of the non isolated inputs, you just tell UCCNC what pins do what. The motion control board supports steppers and servo drives. We have steppers in the Denford.
Daisy chain the 5V supply to the steppers, and wire up the Step and Dir pins to the ports and tell UCCNC what you have.
I will tidy the wiring later 😄
IMG20260719104034.jpg
IMG20260719104046.jpg
The wiring for the stepper drivers. You can use any of the non isolated inputs, you just tell UCCNC what pins do what. The motion control board supports steppers and servo drives. We have steppers in the Denford.
Daisy chain the 5V supply to the steppers, and wire up the Step and Dir pins to the ports and tell UCCNC what you have.
I will tidy the wiring later 😄
IMG20260719104034.jpgIMG20260719104046.jpg#44 - 31/07/2026
Haven't had much of a chance to get much farther.... Ethernet port I bought as a pass through is too small (the original Denford one was a USB connection).
IMG20260731174411.jpg
Haven't had much of a chance to get much farther.... Ethernet port I bought as a pass through is too small (the original Denford one was a USB connection).
IMG20260731174411.jpg
#46 - 31/07/2026
I might eventually make a one that fills in the massive void around the thread. However, I would need a mill to do this. Meh.
I might eventually make a one that fills in the massive void around the thread. However, I would need a mill to do this. Meh.
#47 - 31/07/2026
I did chuck some crimps and wire on my 2 new buttons! Behold an awesome tool, the HT-225D. I've had this one for many years, also does Molex and the 2.54mm crimps.
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I did chuck some crimps and wire on my 2 new buttons! Behold an awesome tool, the HT-225D. I've had this one for many years, also does Molex and the 2.54mm crimps.
IMG20260730165931.jpgIMG20260730165939.jpg#48 - 01/08/2026
Wired the switches.... Went to do some multimetering to check some cables and discovered my 9V battery was dead. Turns out auto power off on a fluke isn't actually powered completely off.... More once I get a new battery!
IMG20260801143819.jpg
Wired the switches.... Went to do some multimetering to check some cables and discovered my 9V battery was dead. Turns out auto power off on a fluke isn't actually powered completely off.... More once I get a new battery!
IMG20260801143819.jpg#49 - 10/08/2026
Been some movement on this! Got the wiring for the buttons all sorted, tidied up the cabling into the main control cabinet as well. Ran the wiring for both the switches and lights and got all that working. I will be going through all the settings and how I done all of that at some point.
Been some movement on this! Got the wiring for the buttons all sorted, tidied up the cabling into the main control cabinet as well. Ran the wiring for both the switches and lights and got all that working. I will be going through all the settings and how I done all of that at some point.
#50 - 10/08/2026
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IMG20260810145706.jpgIMG20260810160432.jpgIMG20260810160437.jpgIMG20260810160501.jpg#51 - 10/08/2026
So, the lights are on O1 and O2 on what's known as port 3. This is the daughter board for the AXBEE controller.
So, the lights are on O1 and O2 on what's known as port 3. This is the daughter board for the AXBEE controller.
#52 - 10/08/2026
The switches are on I10 and I11. I haven't yet decided what they need to control on this controller, as the options are feedhold and cycle start/stop. I am used to industrial machines such as Mazatrol/Fanuc and Siemens controls. This won't actually be the same as the buttons are dual use (the green button is generally used as both feed hold off, and cycle start)
The switches are on I10 and I11. I haven't yet decided what they need to control on this controller, as the options are feedhold and cycle start/stop. I am used to industrial machines such as Mazatrol/Fanuc and Siemens controls. This won't actually be the same as the buttons are dual use (the green button is generally used as both feed hold off, and cycle start)
#53 - 10/08/2026
One thing I have also done is to wire in the Feed and Spindle overrides for the controller as well. On the UCCNC software these are configurable as hell, with the top and bottom settings doing a huge range or a small range as you see fit. I would love a variable pot with a 'notch' so I can feel it clicking at 100%, maybe I need to 3D print and invent one....
One thing I have also done is to wire in the Feed and Spindle overrides for the controller as well. On the UCCNC software these are configurable as hell, with the top and bottom settings doing a huge range or a small range as you see fit. I would love a variable pot with a 'notch' so I can feel it clicking at 100%, maybe I need to 3D print and invent one....
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