Need Help!- Boss 6 Mispositioning

[edsgarage]

I have a Boss 6 series I machine.
I would like to know if anyone knows the correct dip switch positions on the ZCK board.
I have part of a manual and it describes the alignment procedure for this board.
In the procedure it says to set the dip switch to sw 1 to on sw 2 to off.
The machine was left in this condition.
The machine runs but if you set the frequency and voltages to spec it will misposition when driving in X and Y simutaneously.
You have to run the drive voltage all the way down and lower the frequency to get it to position correctly
If you run the axes individually in rapid it will position OK.
It seems from the schematic that both switches should be in the off position for running.
However when I do that the machine will not run at all.
If anyone has any ideas I would be grateful.
Also if anyone has a full manual please let me know.

Thanks,

Ed

[machintek]

When I get to my office, I can check and see if I have any data on that. If you search my responses concerning stepping motors you can get more detail including a tuning cheat sheet. In a nutshell these motors lose their permanent magnetic fields with age and heat. Thus they have less torque and stall easier. By lowering the rapid rate, to flatten out a bit the acceleration curve (more time to achieve speed) and thus minimize stalling. Also to check would be the AC voltage going to each drive section and DC voltage while running a loop of a 45 degree move with the X and Y axis. You may have a voltage drop under load. Also to check would be static DC current and what final drive transistors that are in your machine. The BOSS 6 steps in .0005 inches thus requiring twice the pulses of a previous BOSS machine.

George

[edsgarage]

Hi George,
Thanks for the info.
I did check the motor current (static) and set all axis to spec on the ACC board.
The voltage on the DC side drops about 2V when in rapid.
On a failure it never finishes the count in the Y axis.
I am only able to run the machine in what appears to be the alignment mode.
That is with The DIP switch set to 1 ON 2 OFF.(ZCK board schem sht 1)
If I try to run it with the DIP switch positioned to 1 and 2 OFF as it appears in the schematic the axis will not run nor will the display count to the programmed position.
If after it mispositions, you force it to go to zero again, it will count down to zero but The y axis zero is off
There is an alignment procedure I need to try on the ZCK board.
There are null, accel/decel, frequency(16khz) and a voltage to frequency converter adj.
Would a misaligned ZCK board cause it not to run with the DIP switch set to the position in the schematic?
I have not seen the motor stall but would a deteriorated magnetic flux cause the axis to not finish the count?
I have had experience with bad motor flux (X Axis motor which I replaced) and it would finish the count but I would hear a whine from the motor when it failed.
The drive transistors are 2N6547.
I tried switching the SMD boards to see if the problem followed the original Y axis SMD board but the miscount stayed in Y

Thanks Again,

Ed