Moray, Tripping of the RCD may not be a fault in the equipment but a fault in the RCD. I had an issue with my TIG welder where when I turned it on it tripped the RCD when it hadn't before and the TIG welder tested perfect so I called in an electrician I knew and he tested the RCD and found it fault...

If they are field wires, then you'll need to connect them to the field output from the KBIC.

Which if the wires weren't connected before, makes me suspect they're not really field wires.

Are there any model numbers on the motor?

IIRC early triacs did have spindle orientation, along with drive dogs for the toolholder, however they were dropped from later models to simplify the design, as they weren't really needed due to the motor not being able to produce enough torque to overcome the self locking taper. Some did also have ...

Thermal cut-out wires?

I think you've not wired the motor correctly. What happens if you only connect the two thickest wires to the KBIC? The main reason I fitted a new motor, was the original one was stuttering at higher speeds, and causing the main RCD in the workshop to trip. Rather than spend money trying a new drive ...

I've just had a quick scan through the photos on my phone, and here's a photo of the original SEM motor that was fitted to mine - https://www.flickr.com/photos/mc_mtb/36516798863/in/album-72157674158270440/ If yours is the same, A's are power, and T's and K's are Tacho and Thermal cutout (I can't re...

I'm sure somebody more familiar with all the variations will comment, but I'm pretty sure Denford only ever used induction motors (very early machines), or Permanent Magnet DC motors (typically SEM).
The latter, two wires are for power, and two for the tacho output, along with the GND wire.

If you want to try the absolut minimal approach, download the DOS software from the denford site, copy it to a floppy, and see if the machine powers up and loads the software. Barebones conversion would be Mach or LinuxCNC via parallel port with a 24V capable breakout board (or two - one probably wo...

Your conclusion is correct regarding the spindle board, however you need to be aware that those terminals will be near mains voltage. You'll need to ensure that whatever 0-10V supply you're connecting them, is fully isolated. The home sensors are NAMUR output. They switch between a high resistance, ...

If you're on that side of the big pond, then the Gecko stuff doesn't carry as big a premium over the other options, but ultimately they are still using at least 10 year old technology. The latest Leadshine drives are probably the best drives available just now. Personally I'd go for individual drive...

The G540 is overpriced for what it is, as you can buy separate components for less money, especially since a G540 will cost you at least £330 ($299 + about $40 shipping. So say $340, at the current exact exchange rate is £259. Then IIRC the import tax is 2.5%, then VAT on top of that, comes to just ...

In my experience of an old connect cnc lathe with DC spindle, those are the symptoms of a failing drive. It had the same problem, and a new drive cured it. The SCRs start to fail short circuit, so the mains essentially starts seeing a fast switching dead short. The main breaker being tripped is like...

Down there, it could be a spindle overheating sensor, which would explain why it's wired into the E-stop.

Where about exactly?

I'm aware early ATC Triac's had a spindle alignment sensor for the tool changer, or it could be an RPM sensor.

The Balluff sensors should be for homing, and the microswitches should be for limits (and connected as part of the E-stop circuit).

Regardless of dongle, the computer should still boot and show you the usual BIOS screen. As Martin has suggested, try removing and reinserting the cards (the beep code is for the graphics, and that is the main card that would cause nothing to show). The other suggestion if that doesn't change anythi...

I doubt there's many of these around Chicago, let alone people on here who could help. It certainly sounds like the computer isn't powering/booting up. My first suggestion would be to see if there is any power coming out of the computer power supply. Easiest point is one of the 4 pin molex connector...

That's just a piggy back lead to provide power for the CPU cooling fan.

Where about are you?
You never know, there may be somebody nearby who might be willing to have a quick look.

Are you sure it's a Baruffaldi turret? The TOE60 doesn't pop-in/out, it simply rotates, with the sliding/locking mechanism all contained internally. It's also purely electrical with no air supply needed. I'm aware other turrets were used, however I've only ever seen the TOE60/80. If it is a differen...

Does the damage affect what you want to do with the mill?

Personally, unless the damage was causing issues with clamping things down, I wouldn't worry about it.