Need Help!- TC-22 with DX32 Uncontrollable Spindle Speeds!

[MetalicGlow]

My TC-22 was sitting for a 3 month period in the summer without running. I now have some work lined up and fired up the machine. Everything appears to be working okay except there is no control over the spindle or feed overrides, and both are stuck at the maximum. These are are controlled by a pair of turn knobs located underneath the E-stop button.

The monitor shows:

S,ACT 200%

F,OVR (ON) 150%

Turning the speed and feed override knobs give no response. However, hitting the "3" key does work to toggle the F,OVR (ON) and (OFF).

(The "RUN" and "HOLD" buttons work fine as well)

When using the "6" key to enter a spindle RPM, the stated spindle RPM on the monitor shows as follows:

When I enter between 50-912 RPM, the machine runs at, and the monitor shows the entered RPM times two (as it should because speed override is stuck at 200%).

When I enter between 913-1825 RPM the machine runs at, and the monitor is STUCK at 1825! In other words, there is no spindle speed adjustments when entering between 913 and 1825 RPM.

When entering any speed over 1825 RPM, the spindle speed does what is expected once again (entered speed x 2).

Here is the state of the LEDs on circuit boards:

BMDC: Blinking Green/ Steady RED on LED at the very corner of board

AUF: Blinking Red LED (D12)/ Steady Red LED (D11)

TLAUF: Blinking Red LED (D5)/ Steady Red LED (D4)

X, Y, Z Axis: All 3 are Steady Green

I pulled the BMDC board and cleaned the contacts and reinstalled - which did not help anything.

I am hoping to get this sorted out quickly. Any help would be greatly appreciated!

EDIT: I should have mentioned that when I first fired up the machine and tried to do a manual tool change, it stopped in the middle of it, and returned an error: "invalid shot pin state" or something similar. I immediately rebooted the machine and the error never came back and the machine performs tool changes just fine.

[EFI-Unlimited]

Check fuses CB-9 and CB-10. They are .2 amp, and one of them is likely the cause of your feed override symptoms.

EDIT: Since your start and stop buttons work, it has to be CB-9

EDIT:EDIT: CB-9 doesn't appear to be a fuse. It is a circuit breaker of some kind. I suspect it may installed on the AXSBOB.

The shot pin stuck alarm is just from the machine sitting. Your best bet with that is to manually cycle the shot pin solenoid several times to help unstick the actuator.

Brian

[machintek]

I have had cases of a large voltage drop/high internal resistance of these two devices. They are mounted on the sheet metal supporting either the AUF or TLAUF. They remind me of circuit breakers I have seen on aircraft. They are the push in/pop out type. Cycling them does NOT seem to help.
There is another post about these devices.

George

[MetalicGlow]

Originally Posted by EFI-Unlimited Check fuses CB-9 and CB-10. They are .2 amp, and one of them is likely the cause of your feed override symptoms. EDIT: Since your start and stop buttons work, it has to be CB-9 EDIT:EDIT: CB-9 doesn't appear to be a fuse. It is a circuit breaker of some kind. I suspect it may installed on the AXSBOB. Brian

I did find fuses: FU 11 and FU 12 on the side of the metal bracket that mounts the AUF board. Both fuses test positive for continuity.

I was unable to locate the CB-9 and CB-10, but I did find the "C9" and "C10" on the BMDC board. I have not tested continuity yet and just now I noticed your edits.

I am unfamiliar with what/where the AXSBOB is. So far I've looked at every possible thing that is obviously (to me) a breaker or fuse that is in plain sight after opening the electronics cabinet. I must be missing something, but I will do some more checking.

Thank you so much for the response!

[MetalicGlow]

Originally Posted by machintek I have had cases of a large voltage drop/high internal resistance of these two devices. They are mounted on the sheet metal supporting either the AUF or TLAUF. They remind me of circuit breakers I have seen on aircraft. They are the push in/pop out type. Cycling them does NOT seem to help. There is another post about these devices. George

I can't find anything on the sheet metal supporting either the TLAUF or AUF boards resembling a circuit breaker. I did not see any circuit breakers labeled "CB-X" anywhere. Could they be labeled by some other method? The labels appear to be factory decals. The existing gray circuit breakers mounted in a row at the top of the cabinet are labeled "FU-8, FU-9, FU-10, etc" in which I tested "FU-9" positive for continuity. Could this be it?

I am stumped.

[EFI-Unlimited]

On my machine, CB-9 and CB-10 are located in a row of relays that are immediately above the row of drive cards on the bottom of the panel box. They are to the right of the AUXBOB and below the AUF and LaTAUF.

They are a regular resettable circuit breaker.

Brian

[MetalicGlow]

Originally Posted by EFI-Unlimited On my machine, CB-9 and CB-10 are located in a row of relays that are immediately above the row of drive cards on the bottom of the panel box. They are to the right of the AUXBOB and below the AUF and LaTAUF. They are a regular resettable circuit breaker. Brian

It turns out that your CB-9 and CB-10 circuit breakers are the equivalent to my FU18 and FU19 fold-out fuse boxes containing 250V 1/4A non-slow blow fuses - both located in the same place as yours. The FU18 was blown.

Well, 32 cents later and I'm back in business! ! I appreciate your help so much, THANKS!