Working documentation

This page is generated from the project's working notes. It records a real retrofit in progress, corrections included. Anything marked 🔴 or ⚠️ is unresolved or carries a caveat - read those before acting.

Physical layout - pendant, pushbuttons, cabinet, terminals, machine¶

2 September 2026. From wiring diagram sheets 36 (COLL. PULSANTIERA), 37 (PULSANTIERE B.M.), 38 (LAY-OUT Q.E.), 39 (MORSETTIERE Q.E.) and 40 (LAY-OUT B.M.).

These five close the 40-sheet Q.E. section.

The pendant - sheet 36¶

DISPOSIZIONE PULSANTIERA. Two rows of controls:

Top row

Symbol	Device	Type	Wires
lightning	(lamp/indicator)
tool	(lamp/indicator)
`RESET //`	`SB15`	Yellow pushbutton `ZB4-BA5`	75/18, 14A/58, 103/89, 14A/14A
`?X`	`HLX`	Red lamp	194 / 3
`?Y`	`HLY`	Red lamp	196 / 3
`?Z`	`HLZ`	Red lamp	198 / 3
`-`	`SB2`	White pushbutton	14 / `E130` - JOG minus
`~`	`SB3`	White pushbutton	14 / `E131` - FAST
`+`	`SB4`	White pushbutton	14 / `E132` - JOG plus
round	`SE1`	Mushroom E-stop	124 / 129

Bottom row

Symbol	Device	Type	Wires
`START`	`SA2`	Illuminated 2-position selector, white	600/3, `Y1`/`Y2` 123/124, 2/600
circle	`SB1`	Illuminated white pushbutton	17A/3, `Y1`/`Y2` 127/128, 2/122
hand	`SA1`	2-position key selector	2/193, 17/17A
triangle	`SBEC`	White pushbutton	14 / `E129` - END CYCLE
dashed rect	`SB6`	Red pushbutton	801 / `E107` - on the HOLD chain
slider	`FR1`	Feed override switch	`+24V` giallo, BIT0-3 verde/marrone/grigio/bianco
dial	`R6`	Spindle speed potentiometer	to the inverter `FC`/`FR`/`FS`

🔴 `R6` is a manual spindle speed potentiometer¶

The device list calls it SPINDLE TECNOS, KIT SPINDLE LUNGO + CAVI (025TEC0027). Sheet 5 draws it as a 2.5 kohm potentiometer with a 330 kohm series resistor across the inverter's FC (common), FR (SPEED REF 0-10V) and FS (+12 V, 20 mA) terminals - and the CNC's analog output from CONN.S pins 15 (marrone) and 8 (bianco) lands on the same node, on wires 23 and 24, referenced to MASSA C.N.

⚠️ This has to be resolved before the spindle control is designed. Whether the pot is the primary speed reference, a trim on the CNC's output, or a maximum-speed limit changes whether LinuxCNC's S word controls spindle speed at all. One zoomed screenshot of the -R6 block on sheet 5 settles it.

Machine pushbutton stations - sheet 37¶

Station	Position	Devices
SX (left)	Machine, left end	`SB8` black (800/14), `TAPPO` blank plug, `SB603` green illuminated + 24 Vdc LED (`E101`/14, lamp 7/`A208`)
DX (right)	Machine, right end	`SB613` green illuminated + LED (`E102`/14, lamp 7/`A237`), `TAPPO`, `SB7` black (801/800)
-	Machine	`SE2` mushroom E-stop (28/29)
-	Machine	`SB201` green illuminated + LED (`E118`/14, lamp 7/`A240`) - manual tool release

So the zone start buttons are green illuminated buttons at each end of the machine, lit by OF.8 (zone A) and OF.37 (zone D). SB7 and SB8 are the black buttons in the HOLD chain with SB6 on the pendant.

🔴 There is no rope switch on this drawing¶

The complete set of emergency devices in the whole 40-sheet section:

Device	Type	Where
`SE1`	Mushroom `ZB4-BS844`	Pendant, wires 124/129
`SE2`	Mushroom `ZB5-AS844`	Machine, wires 28/29 on `X3`
`SB6`, `SB7`, `SB8`	N.C. buttons in series	Pendant and the SX/DX stations, forming the HOLD chain to `EIN7`
`PONTE`	A link, `-X3 29` to `-X3 30`	Sheet 11

🔴 Revised 2 Sep: `-SQF1` is very likely the rope switch¶

Grant's point that it may be labelled as a door or another safety circuit sent this back to sheet 11, where there is a device passed over on the first read:

-SQF1, drawn dashed inside the =BM+X3 group, contacts 21-22, with wire 30 bridging it, in series with the auxiliaries chain.

In Italian a rope-pull switch is an interruttore a fune. SQ is the position-switch prefix and F reads as fune - rope. SQF1 = "rope switch 1".

The location fits: =BM+X3 is the SCATOLA ELETTRICA SOTTOPIANO, the box under the table running the length of the machine, which is exactly where a rope switch terminates.

Where to look: terminals X3:28, X3:29, X3:30 and X3:50 in the under-table box. SE2 sits on 28/29; SQF1 and -SP1 on 30/50. Whatever the switch is labelled on the machine, its wires land there.

⚠️ Still worth confirming physically, and the general caution stands: assume the drawing may not capture every later modification. But the machine is better documented than the first reading suggested.

Cabinet layout - sheet 38¶

LAY-OUT Q.E. is a physical map of the cabinet. Reading left to right:

Zone	Contents
Far left	`-UF1`, `-UF2`, `-UF3` stacked; below them `-CH1` hour counter, `-G3` 24 Vdc PSU, `-XS1` the PC mains socket
	`-UF4`, `-UF5`, `-UF6` stacked
	`-IF1` to `-IF6` in a single row
	`-KAMF`, `-KAA`, `-KA`, `-KA2`; above them `-KA560`, `-KA562`, `-KAX`, `-KAY`, `-KAZ`, `-KAF`, `-KA4`
Centre	Terminal blocks `X1A`-`X1D`; fuses `F1-2-3`, `F7-8`, `F9`, `F10`, `F11-12`, `F13`, `F14`, `F15`; converters `OPT1`, `OPT2`, `OPT11`-`OPT16`
	Breakers `QF101`, `QF601`, `QFX`, `QFY`, `QFZ`, `QF560`, `QFINV`, `QFRI`
	Contactors `KMI`, `KM101`, `KM560`, `KMX`, `KMY`, `KMZ`, `KM601L/T/Y`; `QM1` the main isolator (note: `MONTARE QMI SU SUPPORTO`)
Right	`-U1` inverter; drives `-UX`, `-UY`, `-UZ`; `-U560` Panasonic; terminal `X1C`
Far right	`-KM200`, terminals `X1G`/`X1E`, transformers `-T3`, `-T2`, `-C1` capacitor, `-G2` bridge

Note on the sheet: USCITA CAVO ALIMENTAZIONE M68K (-CNC) L=60cm DA CANALA - the controller's supply cable leaves the trunking 60 cm long.

✅ This validates the retrofit boundary¶

The IF1-IF6 and UF1-UF6 modules are separate DIN-rail units in the cabinet, not inside the Monoscheda box. The four 26-way ribbons run from the Monoscheda's front panel to those modules.

That is exactly the boundary set in CLAUDE.md §5.4: Mesa connects at the ribbon, the modules and every field wire stay untouched. Confirmed from the drawing rather than inferred.

Cabinet terminal blocks - sheet 39¶

Strip	Purpose	Terminals
`X1A`	Control commons and distribution	`8B`, `14A` x2, `14` x4, `12` x2, `8A`, `8`, `7` x3, `15`, `16`, `2`, `3` x2, `630`/`631`, `30`, with jumper bars linking each group
`X1C`	`RES. FR. ASSE Z`	2 terminals, `BK2`
`X1D`	`RES. FR. INVERTER`	4 terminals: `ZDU 4` x2, `ZDU 2.5` x2 - to `-R2`
`X1E`	`1 PANTOGRAFO`	2 terminals `ZDU 4` - spindle motor
`X1P`	`POMPA VUOTO`	`U2`, `V2`, `W2`, `X2`, `Y2`, `Z2`, `600`, `601`, PE - star-delta pump motor

X1A is where the control rails (7, 8, 8A, 8B, 12, 14, 14A, 15, 16, 2, 3) are distributed. That strip is the single most useful place in the cabinet to measure any control rail.

⚠️ X1C is labelled RES. FR. ASSE Z (Z-axis braking or brake resistor) but no such resistor appears in the device list, which lists only -R2 (inverter, 30 ohm) and -RX (X axis, 75 ohm). Possibly provisioned and unused; check physically.

Machine layout - sheet 40¶

LAY-OUT B.M., a side elevation showing:

PROTEZIONE CE - the CE guard frame, drawn as a perimeter of posts and rails around the machine
PROTEZIONE NO CE / UL-CSA - the alternative guarding for non-CE markets
SCATOLA ELETTRICA SOTTOPIANO - electrical box under the table
SCATOLE ELETTRICHE ASSE Z - electrical boxes on the Z carriage
SCATOLA ELETTRICA - a further electrical box
ELETTROVALVOLE VUOTO - vacuum solenoid valves
ELETTROVALVOLE BATTUTE - datum/stop solenoid valves
QUADRO ELETTRICO - the cabinet, freestanding beside the machine

🔴 The machine junction boxes are the `=BM+Xn` terminal groups¶

The boxes on this layout are the =BM+X3, =BM+X4, =BM+X5 and =BM+X43 groups that every field device on sheets 16-28 carries.

So a device's terminal group names the physical box it lives in. Combined with the wire number from io-map.md, anything on this machine can be located without tracing a single wire.

The rope switch, if it runs along the machine, would be attached to the PROTEZIONE CE frame drawn here - which is consistent with it being a CE-compliance addition made after this drawing.

io-map.md - the wiring plan
device-list.md - part numbers for everything above
safety-and-enable-chain.md - the emergency and enable circuits
spindle-vfd.md - the R6 network on sheet 5