how do I get the x axis of the mill back on its limits?
Richard

on my boss 6 you have to hold down limit reset while you jog off the limit switch.

Matt

If my memory serves me correctly, there is a jog off limits key. Do you have the operations manual?
But if it is stuck at the end of travel, it may take physical force to free up. The Z axis especially known for this.

George

Hi George
the x axis is to the extreme left.
the physical force? do I need to remove anything or just give a Push or disconect the limit switch? or hand turn belts?
thanks for you input.

There is a trick with the X axis on these machines if it is a series one. There is a nut that holds the X axis ballscrew on the right side of the table. Loosen this nut a couple of turns (it is keyed so the ballscrew will not turn). This will free up the X axis if it is jammed. Get it off the limits and tighten the nut back up.

George

Hi George
My fault for not indicating that I do have a Series II , will the fix be the same. ??
thanks
Lefty

On a series 2 the X axis belt cover is only two screws. I remove that cover and move the belt.

George

George
I did ther physical movement of the drive belt in the x axis.
then I did the start up, it moved the quill down and up, and then I did the home process and that worked.
BUT then after that, when I would try to jog, I would get the ERROR light.
the display indicated " Enabel drive axis"
I would key enter: then display read "Jog x axis limit"
if attempting to jog in Y i jgot the same message.
same for X.
This machine worked the last time I put it under power, and it passed all the self test. and all worked, I did not have air line pressure so I the spindle would not run. We were only testing out operations.
Then a worker ran the table the the extreme left. And that is when all this probelm started.
What can I do now?
thanks
Richard

Time to take a step back and do some checking.
You may have a bad switch. Each axis has a home switch and a axis limit switches. If an axis is on a home switch, when asked to home, it will back off and see the switch change state, reverse direction, see the switch, look for the marker pulse on the motor encoder, and move an additional 300 thousandths.
It is possible that if the marker pulse and switch coincide, the home may vary about .100 inches depending if the switch is seen a fraction of a second later and the machine moves to the next marker pulse. It may then go into limits (overtravel switch). That is why we try to set the switch 180 degress of motor rotation away from where the marker pulse will be seen.

So if all your home switch move freely and change state crisply, I would check the emergency stop 24 VDC string. Look at the 24VDC and see that it goes through the emergency stop switch and then goes through all the overtravel switches. Check where the voltage stops and you will know which switch is bad or which axis is overtraveling. Start there and see what you find.

George

Hi George
I thank you for all your help in the matter. It is truly an effort on your part and I do appricate all the help.
I did not understand about setting the timing 180 deg. from the motor pulse.
But after reading in the maintence manual ( mine is on a CD that I ordered on-line) and the illstrations are for a Series I R2E3; and do not look exactly like the series ii back panel.
But what I did learn was about that Emergency Stop button, and you also indicated the same.
I now think that this could be the prob. As I recall the last time it ran and did all the self test fine, then we used that Stop button and that could very welll be when the proplem started. As this machine was in stroage for over 3 years.
Could it be that that stop button is not releasing?
I checked the relay in the back of the machine, located mid height to the far left.
The manual said that if pin #4 (the heavy red leed) is at ground , then the Axis drives would be shut down. IT IS AT GROUND
this sounds like the problem because I get the error in All axis.
Is there a method to by-pass the Emergency stop switch; just as a temp to troubleshoot????
Could this be accomplished at the relay or would I need the remove the front panel and the Stop swithch.
Also: on the magnetic starter switch: the red reset on the right side; should this be in when operational: because the reset stays out, and when pushed in it will not hold.


thanks again
Richard

The emergecy stop (E-stop) has two ways to be actuated. You can tap it and the drives drop out. You can press it harder and it stays in. Is yours pressed in? Does it need to be pulled out gently?
The spindle motor overload is in a normal state. If tripped, you press it in and hear/feel a click and it comes back out to its original position.

Lets start here and see where it gets you.

George

Hi George
I removed the front panel to check the E-Stop. It seems OK
then I looked into the right side elec. panel, this is where the logic boards are and in the bottom are 3 contactors for the drives. these do kick in then I key the Axis Drives Enable button.
But I did notice a fuse was MISSING in that right panel. It was the one next to the left circut board. There are 2 fuses and the one to the far left was missing.
So I installed what I had, I do not have or trust the manual on CD that I have , so I do not know the proper size fuse.
Then I power up and get the same error light.
Please remember that I do not have the air to the lubrication for the spindle connected. Will that give an error message??
Will that stop the self test program from running?
OK back to what happens with the fuse installed.
Same error message: Enable Axis Drives
so I key that button and all the contactors ,3 kick in.
then the display reads JOG x ; axis limit
I removed the belt cover so to see the belt and the X it is moving very slow.
I key the JOG handwheel. and all works , left ; right fast and slow
BUT I can not get the X to completly stop.
Then i key the Y JOG. it moves.
the Z will not move.
Then if I attempt to JOG with Incremental or the + or - keys then the contactors will kick out.
At that point I have to use the reset button to start up again.
Does this sound like low power?

thanks
Richard

You are not in an ESTOP condition if the drives enable.
BUT! If an axis drifts, there is no position loop. No 5VDC to the encoders or a bad FMDC, open cable, etc. Especially if 2 of the axis are doing this.
The Z may be bottomed out but toward the top of travel or the offset is actually adjusted correctly.
Air is not a factor.
Axis limit means that it is on an axis limit switch (past the home switch).
If you use the belt to move the x axis toward the center of travel, then press on each switch related to the X axis and see if you feel it click.
Same with Y and Z.

George

Hi
George
Please describe what the FMDC is and location.
and if this does not check out I think its might be time that I pay a local tech. to look at this.
With all that we have discussed , do you have any idea of an estimate of time to do the troubleshooting?
thanks again
Richard

In back cabinet, botton right, there is a white door. On the back of it is the FMDC board. Across the top are 8 LEDs of different colors. If the board boots correctly, the two green LEDs will be blinking at rates different from each other. The K3 connector can be used for diagnostics using a laptop. It is called the FIST monitor. This is in the maintenance manual.

George

Hi George
I think that I really screwed up trying to set that 5vDC to the encoders.
I was at the same location on the lower right cabinet ; only at the front part.
I was checking voltage on the board in the front lower right.
at the top are 2 knobs ; K1B and K1A .
I probed the conector blocks, and found the vdc at about 4.5
and that is were I made the adjustment; thinking this is were the 5vdc should be, so I dialed in to read 5.1vdc on each.
then I also did the same on the lower board where the K3 and K2 conectors are.
there was a very small white POT adjustment bock next to K3 and I adjusted it also to 5.1 vdc
THIS REALLY STARTED ANOTHER PROBLEM:
Problem now is that I lost all the display and lights on the front panel.
Machine still had power. But nothing up front
Did I really screw this up?
I truned back all those POTS to previous values.
shure wish you lived in the Houston area.
thanks again.
Richard

Those pots/knobs are to set backlash on X and Y axis.
As I stated there are 2 logic power supplies. I believe you found one. There were 2 different ones used but I cannot picture the individual components. But, the %VDC is very critical. It needs to be set with a digital meter as close to 5 VDC as possible.
But this should NOT affect the front panel. Maybe you blew a fuse. There is another logic power supply in the wire way near the front control. See what voltages you have there BUT DON"T ADJUST ANYTHING UNLESS YOU CLEAR IT WITH ME!

George