Interact 412 error

[smirob]

Hello all,
I've recently purchased a Bridgeport Interact 412. I'm getting an error when I start it up that says:
Axis PSU Fault

I'm not sure what its reffering to, nor can I pinpoint the problem. I assumed it may be a power supply issue, so I switched my Pole 1 and Pole 3 on my 3 Phase power.

If someone has seen this error, or has an idea as to what it may be, I would appreciate it. I can't home any of the axes with this error on screen, nor can I just clear it.

Thanks,
Rob

[machintek]

This machine came with a Heidehain control or a Fanuc. Also the insides of the machine varied. You need to be more specific.
A axis Power Supply Alarm is a bit odd as if it has the Bosch axis drives, there was no power supply for them. It received power from a transformer. Maybe you have some blown fuses or the power to the machine is wrong.

George

[smirob]

Thanks for the reply machintek. I've just spent 5 hours tonight on it and progress was made. Here's what I've found out.

I never checked the 3 phase going into the master breaker, and one leg had become unattached, and the others were loose. After addressing that, I was able to get the machine up and going.
As far as the servo drives go, the original Bosch's went out, so the prior owner replaces all 3 with Advanced Motion Drives. Also, the Fanuc drive went out, so he replaced with a Mitsubishi VFD A-200. He did say, that that VFD wouldn't work with my tool changer without the optional input board. He also said that he thought that the X axis board went out, so he swapped the cable to the A axis board and swapped them at the control as well. BTW, its a Heidenhain control. He said that the X axis wouldn't home, but he was still able to cut parts. That said, I do have 2 issues I'd like to ask about.

1) When I try to move the x axis, whether by manual jog, or in running a program, the x axis jogs back and forth, almost like its hunting for position. The Y and Z move just fine. I'm wondering if a loose ground or other wire are possibly loose?

2) Where can I find this accessory board for my VFD, so I can use the ATC? If it's too much of a chore, then where can I find the Fanuc OM control to run the spindle, as the tool changer is important to me.

3) I haven't been able to reach by telephone the fella' I bought this from, but I'm not sure how he entered spindle control from the heidenhain console. I can physically go to the VFD and turn it on, and it will run, but I don't know how to adjust the rpm's either at the VFD or at the control. It's puzzling, because 2 BT40 tapping heads came as part of the tooling I got from him. It makes me believe that I'm overlooking some way to control the Spindle fwd/rev or rpm's.

I apologize for my ignorance on these subjects, its just this is very new for me to delve into. Any helpful advice, would be greatly appreciated.

Thanks in Advance,
Rob

[gus]

Wow, what a nightmare.



x axis sounds like it needs the tach feedback adjusted in a big way. The PO sounds ummm, technically, umm, challenged. Drives aren't that flakey, why did the boschs die, then an AMC?

Download manual for the drive if yo don't have one, and tweek the drive, sounds like it is sending out way to high a signal for a given speed then trying to back up, which it thinks it is doing too fast etc, etc loop.

Spindle speed is set in the tool call, on and off should be m3/m5

[smirob]

Well as far as I know, when I picked up the machine, I asked why he replaced all 3 bosch drives, he said "one went out and it was $500 for a single from England, so I got 3 advanced motion drives for $340". I have given it an m3 and m5 for spindle calls, both in MDI and with a program that was already in the control. When it gets to that line, it doesn't do anything when it sees the command.

Thanks again,
Rob

PS-Yes, the prior owner was a real "winner". The machine does not look like it was well kept, however, the ways are good, and there is potential. And for $1300 I'm hoping I've found a diamond in the rough. I'm not opposed to spending some money to get it back to working condition. I just have to draw a line as to when it gets to be too much money, do I retrofit the control with Mach, Ajax or something else.

[machintek]

Typically, as stated, a servo motor with a velocity loop (tach) will yo-yo when this loop goes open. It will oscillate back and forth.
The spindle speed is defined with the tool? I am trying to remember. Then a M function is called up to turn it on. But are you using conversational or G&M code with the special G&M code keypad? I have not run one since 1987. But since this is a non-standard set up (Frankenstein), all bets are off as to what signals are connected.
The tapping heads may be from when the OEM guts were inside the machine.

George

[gus]

ok, which heidenhain?

the m3 starts the spindle, the tool call will set the speed, if there is no speed set, it is running, but at 0 rpm.

22 TOOL CALL 0 Z S 2000

23 L X+2,000 Y-1,3100 R0 F2000 M03

24 Z+0,1000 R0 F2000 M

this sequence is right out of a program, should set a spindle speed, and start it rotating. If you can't move the axis change them to IX0 IY0 etc

If the machine is emo'd the spindle won't run......

[gus]

BTW, this is probably not a control problem, so you are MUCH better off trying to make it run right as it is, then see if the control has shortcomings that need a retrofit. I don't think any aftermarket control can do anything this one can't, but like many older controls, memory is somewhat limited

[smirob]

Thank you for the input thus far.

So, I had someone who is much more familiar with these things than I come look at it. He determined that the X axis encoder bulb was going bad. He removed the unit and is going to attempt soldering a replacement. He said it is very tedious work, and I should look on the internet for a backup in case all does not go well. So I took a picture of the encoder cap and it says its an ERO 115 200, Id. 217 900 10.

Here's a picture of the light unit mounted inside the cap.

http://s178.photobucket.com/albums/w...t=IMG_1542.jpg

Here's a picture of the encoder endcap.

http://s178.photobucket.com/albums/w...t=IMG_1548.jpg

So, if anyone knows of where I can buy the light setup or, if necessary the entire encoder, I would appreciate the help.

My buddy also suggested I try to get the orginal Fanuc OM from the prior owner, so I was able to finally contact him and he said he pulled it because the top board burn up. He said the other board in there was worth $150, so that's what he wants for the junk Fanuc. I'm hesitant to drive back to his place (4 hours one way), but I'm willing to spend some money to get this machine back to what I should be. I'm just wondering how much a good used Fanuc or new Fanuc costs.

Thanks again for all the help,
Rob, MI

[smirob]

OOPS! I forgot to mention. This is an Heidenhain 151 control.

[Al_The_Man]

The board you want for the VFD to orient the spindle is a FR-EPA Option, you can get it from MEAU in Chicago, but it may be hard to get and/or expensive as this is now a legacy drive.
The VFD has to be in External Run to accept external commands, if you are commanding it from the keypad, then it is in local mode.
I have installed a few of these using the analogue signal and M codes to control.
I have the manuals for this drive, including the Training Manual in PDF.
The MEAU site is also a source of them, I believe.
Al.

[smirob]

Any idea of the cost for the add-on board? Obviously, because its the weekend, I'm SOL right now.

I too have the Manuals and Training Manual for this drive. Much of it reads like Greek to me, but I'm hoping it will help anyone I can corner for assistance with the machine.

I'm assuming when you made mention of Analog setup that this is included in that realm. Also, I got to thinking abou the breaking or stopping of the spindle for a tool change and holding it into place. How would that happen?

Regards,
Rob