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Save X3msnake/a61aff262578f847e3e8226740d4a190 to your computer and use it in GitHub Desktop.
Forum posts with same machine
Working machine, not connecting to PC
Linux CNC conversion
- https://youtube.com/shorts/gTI93IFkSJ4?si=jU5h775N6eTpOhDA
- https://www.denfordata.com/bb/viewtopic.php?t=6013
Dynamotion Kflop conversion
https://youtu.be/Exf-O6kZ_Vw?si=qLeitAQVJAlsmCYF
Spindle power up with isolated leads
xy markings
Toolchanger cylinder issues (top up oil)
https://www.denfordata.com/bb/viewtopic.php?t=5531
About reverse enginnering the board and backing up the EEPROM?
Chat GPT Consultation
https://chatgpt.com/share/69c6a0ee-6e8c-8330-aaa6-0da55cc3eab6
Here’s a concise summary of what was covered:
1) Reverse engineering the Denford controller
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Your board runs Denford MINT firmware stored in an EPROM (socketed chip).
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You can dump the firmware easily using an EPROM programmer.
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However:
- No public documentation or GitHub projects exist for the protocol
- Reverse engineering is complex and time-consuming
- The system uses compiled MINT programs, not simple motion commands
2) Communication with the board
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Communication is via RS232 serial
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Protocol is proprietary and undocumented
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To understand it, you’d need to:
- Capture serial traffic from a working system
- Reverse engineer message structure
3) Missing software and dongle
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The dongle is for PC software licensing only
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It is not required by the controller hardware
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Without the original software:
- You cannot easily run the machine in its original configuration
4) Testing the machine without original software
You can still evaluate hardware condition by testing subsystems:
Possible tests:
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Power-up behaviour (LEDs, relays, faults)
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Axis drives:
- Check for faults or holding torque
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Limit switches and sensors
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Serial output (to confirm controller is alive)
Spindle:
- Can be tested independently, but requires caution
5) Safety correction (important)
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The spindle drive may be non-isolated from mains
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This creates:
- Shock hazard
- Risk of damaging equipment
👉 Safe approach:
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Do not inject signals directly
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Use:
- Isolation
- Battery-powered floating circuits
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Or limit testing to observation
6) Practical paths forward
Option A — Reverse engineer
- Dump EPROM
- Sniff RS232
- High effort, uncertain outcome
Option B — Retrofit (most common)
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Replace controller with:
- LinuxCNC or similar
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Keep motors, drives, mechanics
Option C — Hybrid
- Reuse some electronics, replace control logic
Bottom line
- You can dump the firmware, but that alone won’t give easy control
- There is no existing open solution for these boards
- Most users end up bypassing the original controller
- For now, focus on safe hardware testing before deciding next steps
If needed, the next useful step is identifying your:
- Motor drivers
- Spindle controller
- Power system
That determines whether retrofit is straightforward or not.
NAMUR SENSORS
About the datum (induction) sensors used on the triac mill
How does a NAMUR sensor operate?
The operation of a NAMUR proximity sensor is intriguing. It detects a metal object or "target" in its vicinity through changes in impedance.
These sensors are powered by a nominal 8.2 VDC supply, sourced from a switch amplifier. Functioning as 2-wire devices, they differentiate between the presence and absence of an object by switching between two distinct current levels, in accordance with the EN 60947-5-6 standard.
Here's how it works:
When the sensor detects a metal object or target, its impedance increases, and the electric current flowing through it drops to less than 1.2 mA. However, when the target object moves away and the sensor no longer senses it, the impedance drops, and the current increases to more than 2.1 mA.
Claude inquire on connecting to the machine for testing with current equipment
https://claude.ai/share/8b2ac229-0b38-4d84-842b-8b3ab1c5bc66
Let me look up the specifics before giving you a list.Good, I have enough solid information now. Here's a complete breakdown:
Hardware needed
For machine communication (one serial port):
- A PC with a real physical RS232 serial port, or a USB-to-Serial adapter. However — the FANUCMD drivers address COM ports by their hardware I/O address (
$3F8,$2F8, etc.). USB-to-serial adapters assign non-standard addresses that FANUCMD cannot map to, which is a common cause of "Error 128 / communications failed". A genuine PCI or PCIe serial card is more reliable than USB adapters for this software. - The baud rate for your EPROM version is 2400, not 9600 — confirmed by forum users with the same
v1.05fEPROM. - Serial cable machine side: The machine's RS232 is a 9-pin female on the control card going out to a 25-pin female on the cabinet. The wiring from the PC 9-pin to the machine 25-pin is: 2↔2, 3↔3, 8↔4, 7↔5, 5↔7, with pins 1, 4 and 6 linked together on the 9-pin end, and pins 6, 8 and 20 linked together on the 25-pin end.
For the Tutor console (second serial port):
- A second physical RS232 serial port on the same PC.
- A straight RS232 cable from the PC to the Tutor's DB25 connector.
Software
On Windows 11, FANUCMD is a 16-bit DOS executable — it will not run natively even in a CMD window. You need DOS emulation:
- DOSBox-X (preferred over plain DOSBox for this use case — it has better serial port passthrough and supports real COM port redirection to physical hardware). Free, runs on Win11.
- Download FANUCMD_TRIAC.zip from the Denford website (
denford.co.uk/dos-vintage-machines). Do not use the plain FANUCMD.zip — that version is the offline programming variant only and will not control the machine.
Configuration — FANUCMD.GO file
This is the critical file. Based on forum-confirmed working configs for a Triac PC with Tutor:
IBM.RS2 2 ← loads 2 RS232 ports
$3F8 4 ← machine COM port address and IRQ (COM1)
MACHINE
$2F8 3 ← tutor COM port address and IRQ (COM2)
COM2
DENFORD1.KBD 1 ← new-style desktop tutor with overlay
18.2 $2F8 3 ← tutor baud clock and address
VGA.CRT 0
FANUCMD.APP
Use DENFORD1.KBD for the newer desktop tutor with a removable overlay, and DENFORD.KBD for the older tutor with a solid/printed overlay. You need to know which physical tutor you have to pick the right driver.
DOSBox-X serial passthrough config
In dosbox-x.conf, add:
[serial]
serial1=directserial realport:COM1 ← machine
serial2=directserial realport:COM2 ← tutorAdjust COM1/COM2 to match what Windows assigned to your actual serial ports.
Recommended setup order
Forum consensus is clear on this: get the machine communicating first, forget the tutor until the machine is working. The Tutor adds a second variable that makes fault-finding much harder. Once FANUCMD connects and you can jog axes, then add the Tutor on COM2.
One important caveat
Your EPROM v1.05f is one of the earliest versions — some functions like the tool changer and automatic door may not work correctly with the latest FANUCMD_TRIAC software, as the firmware and software evolved together. If you hit odd behaviour with specific functions, that's likely the cause rather than a wiring or hardware fault.
Main breaker plugs:
Harting Han D
https://mauser.pt/096-4483/harting-09990000052-ferramenta-para-desmontar-terminais-tipo-hand-d
If you are machining your own removal tool, the internal diameter (ID) is the most critical measurement. It needs to be large enough to slide over the contact's locking "fingers" (the spring clips) but tight enough to compress them so the contact can slide out.
For a standard Han D (10A) contact, here are the precise dimensions you need for the tip:
Technical Specifications for Machining
To successfully release the contact, your sleeve should meet these tolerances:
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Internal Diameter (ID):
$2.1\text{ mm}$ to$2.2\text{ mm}$ .-
Why: The Han D contact has a maximum diameter of roughly
$1.6\text{ mm}$ , but the locking springs expand beyond that. A$2.1\text{ mm}$ ID is the industry standard for the "shroud" that collapses those springs.
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Why: The Han D contact has a maximum diameter of roughly
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External Diameter (OD):
$2.9\text{ mm}$ to$3.0\text{ mm}$ .-
Why: The hole in the Han D insulator (the plastic insert) is typically
$3.2\text{ mm}$ . If your OD exceeds$3.0\text{ mm}$ , the tool will bind in the plastic.
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Why: The hole in the Han D insulator (the plastic insert) is typically
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Wall Thickness: Approximately
$0.4\text{ mm}$ .- Note: This requires a high-strength material like hardened tool steel or stainless steel 303/304. If the wall is too soft, it will flare out or collapse after a few uses.
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Sleeve Depth (Bore Depth): Minimum
$12\text{ mm}$ .- This ensures the tool can fully seat over the contact head and reach the locking mechanism.
Suggested Design Dimensions
If you are turning this on a lathe, aim for these targets:
| Feature | Dimension | Tolerance |
|---|---|---|
| Tip OD | ||
| Tip ID | ||
| Tip Length | ||
| Handle OD | User preference |
A Few Machining Tips:
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Chamfer the ID: Give the inside leading edge a very slight
$30^{\circ}$ or$45^{\circ}$ chamfer. This helps the tool "find" and glide over the contact's locking springs without snagging. - Polished Finish: Ensure the ID is as smooth as possible. If there are heavy tool marks inside the bore, the contact springs might catch on the ridges, making extraction difficult.
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Heat Treat: If using tool steel (like O1 or D2), heat treating the tip is highly recommended. The
$0.4\text{ mm}$ wall is quite thin and prone to deformation under pressure.
Do you have a specific grade of steel on hand for this, or are you planning to use whatever is in the scrap bin?
ABOUT CONNECTING TO COM PORTS
ERROR 128 and testing the Eurocard (MIRAC - Not a TRIAC)
https://www.denfordata.com/bb/viewtopic.php?p=22552&hilit=TEST+EUROCARD#p22552
SUCCESS!! I M A HAPPY MAN!!
The problem was down to the way I was trying to run the software. What I had to do in the end was this:-
- Create an MS-DOS Start up disc using a Windows XP PC. It's an option in the format menu.
- Delete all the files from the disc with the exception of IO.SYS, MSDOS.SYS and COMMAND.COM. This is the minimum set of files needed to run DOS.
- Unzip the file DRIVERS and copy the drivers to the disc. Don't just copy the folder
- Unzip the file DRIVERS2 and copy the drivers to the disc. Don't just copy the folder. This overwrites some of the drivers from DRIVERS.
- Unzip the FLSTEP files. Copy the files FLSTEP.APP, FLSTEP.EXE, FLSTEP.GRT AND FLSTEP.SHP to the disc.
- Copy the files from the folders GENERIC and MIRAC to the disc. Don't just copy the folders.
- Replace the text in the files FLSTEP.GO and FLSTEP.OPT with that posted by Martin.
- Open a new .txt file on the disc and type into it "FLSTEP". Save the text file and rename it AUTOEXC.BAT.
This creates a single bootable disc.
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By using this disc I was able to get the software running and talk to the machine via its keypad. I've managed to jog both axes, turn on the suds pump and start the spindle. The air operated tail stock will have to await an air supply. I've yet to work out how to rotate the 8 tool turret. Some reading of the manual is needed.
Thanks for everyone's help.
Max.
TRIAC PC 1991 _DOS ERROR COMMUNICATION
https://www.denfordata.com/bb/viewtopic.php?t=3492
Finally it worked. I am very satisfied and happy
I suspect that the problem they was the cards. I removed and put the all cards, afterwards all via yeast it worked
Your contribution they was despite very auxiliary. I have read a lot in my forum for problem and I acquired a lot of interesting things that me helped I reach in the result.
The programme that works fine for triac pc with dos was
Fanucmd.go
NARROWSIMBOX 0
SHOWTOOL 0
USE3D 0
FANUC_SDEVICE machine
UTILS_MENU_1 Dos Access
UTILS_GO_1 dos
TOOLORIENT 0
HIGHSPINDLE 4000
Fanucmd.opt
IBM.RS2 2
$3F8 4 COM1
$3F8 4 MACHINE
DENFORD1.KBD 1
18.2 $2F8 3
VGA.CRT 0
FANUCMD.APP
Many thanks
Thanks particularly Martin and denford Admin and Graham Bradley for his interest and the advices.
Pantemis Gregori
Teacher high school
Lesvos
Greece
Run machine with a QWERTY keyboard
https://www.denfordata.com/bb/viewtopic.php?t=59
eg TriacPC has a file called FANUCMD.GO
it looks similar to (but not necessaruily exactly like) this
IBM.RS2 1
$2F8 3 MACHINE
DENFORD1.KBD 1
18.2 $3F8 4
VGA.CRT 0
FANUCMD.APP
The two lines that read...
DENFORD1.KBD 1
18.2 $3F8 4
specify the keyboard driver file to use (DENFORD1.KBD) and the parameters this file reuires (18.2 $3F8 4)
So changing these two lines to read.....
QDENFORD.KBD 1
18.2 0
Will make the software use the QWERTY keyboard instead of the Desk Top Tutor (DTT).
Things to note...
The MODE keys on the DTT are replaced with ALT- combinations
JOG = ALT-J
EDIT = ALT-E
AUTO = ALT-A
HOME = ALT-H
In JOG mode, use the cursor keys to move the axes, and PgUp / PgDn for the Z axis on a miller
Function keys will alter feed and speed overrides (can't remember which ones though - just give them a try!)
To home the machine press the corresoponding axis letter - eg press the X key to home the X axis (on the tutor you used to press the jog keys)
Finally, see my earlier post if you want to connect your machine to COM 1 on your PC
DOS SOFTWARE DOWNLOAD
https://denford.co.uk/dos-vintage-machines
Gemini consultation on option for LinuxCNC conversion
https://gemini.google.com/share/65fb64f56fc9
what is needed to convert a denford triac pc circa 1992 to linux CNC reusing the most possible parts?
| Component | Recommendation | Why? |
|---|---|---|
| Motion Controller | Mesa 7i76E | Best support for LinuxCNC; handles 0-10V spindle and 24V sensors natively. |
| PC | Refurbished Dell Optiplex | Cheap, reliable, and usually has good "latency" scores for LinuxCNC. |
| Spindle Isolation | Already in Mesa | Prevents electrical noise from the spindle drive from crashing your PC. |
| Wiring | Shielded 4-core cable | To replace any brittle 30-year-old signal wires. |
From troubleshoot section of Triac Series Manual
All versions
The DOS CNC Milling software is started by executing the “FANUC.GO” file.
Check the COM port being used on your machine controller computer matches the COM port number specified in the “FANUCMD.GO” file.
If you are unsure, assume the COM port being used is COM1.
The GO file can be opened using Notepad on a Windows system.
Find the line ending with the word “MACHINE”.
If the RS232 cable is plugged into COM1, the line should read $3F8 4MACHINE.
If the RS232 cable is plugged into COM2, the lineshould read $2F8 3 MACHINE.
Change the line to read thecorrect port number being used, then save the file.
Remove the “HIMEM.SYS” line from the "CONFIG.SYS" file.
Often times environmental factors will
interfere with proper communication.continued
From denford forum
TRIAC PC 1991 _DOS ERROR COMMUNICATION
https://www.denfordata.com/bb/viewtopic.php?t=3492
in the AUTOEXEC.BAT i have input the command MODE COM1:9600,o,7,1 & MODE COM2:9600,o,7,1
Troubleshooting connections
https://www.denfordata.com/bb/viewtopic.php?t=544
Direct connection without adapters
https://denfordforum.com/viewtopic.php?t=211
About EEPROM versions on mint 3.28 eurostep cards and also has hex files
student retrofitting projects with mach3
https://pt.scribd.com/presentation/455523859/M-28-Mid-Sem-Presentation-pptx
Reference images on the web
Dongle?
Triac-Pc with PC
Eurostep Controller Board and io
Working machine - code 8 (Servo Powerup and Idle)
Eurocard Codes
Serial Cable Diagram - PC DB9 --> Machine DB25
Fuse locations
Spindle Controller Board - Unisolated high voltage - with cat600v isolated leads RUN and COM can be bridged to test the motor run
ELECTRICAL BOX - LABEL MEANINGS
Spindle servo motor with pin names
If you are retrofitting this to a modern CNC controller (like Centroid, LinuxCNC, or Mach4):