R2E4 Boss9 Problems

[JohnJames]

I recently acquired a Series 1 cnc with a R2E4 Boss 9 control. It had all the boards taken out of it in the computer cabinet because the machine was due to be scraped. I got all the boards back and put it all back together again. The wires were cut going to the power supply, the drive boards, and the pneumatic valves. I traced the wires and spliced everything back together. Also the buss bars on the big capacitors on the drive power supply were missing (they were going to scrap the copper). I got them back and replaced them and hooked up all the wires to it. I have checked everything over and over again to see if I made a mistake. I think everything is right.

The problem. When we first powered up the machine we only switched the T2 transformer from 480 to 230 volt. Did not switch the T1 transformer because we could not see any tag on it. When we turned it on the red LEDs on the drive boards lit up, I do not remember the status of any other LED's, and we had almost no voltage out of the power supply. When we realized what we did we switched the T1 transformer over to 230v. Turned it back on and still read low voltage out of the power supply. Started playing around and found that if I removed the -12v wire from the power supply that goes to the computer board the voltages off the power supply came into spec. It acted like it was shorting to ground before I removed the wire. After attaching and removing the wire the short seamed to go away and the voltages were ok with everything hooked up. At this point all the big LED's on the FMDC board were on, all the lights on the control panal were on and the CRT did not work. The green LED on the EAF board was on. I checked the voltages on the T2 transformer and the one that was suppose to be 90v was at 200v, also the 24v lead on the EAF board measured 35v. The manual that came with the machine also had 200v and 35v hand writhen in it, so I assume that the previous owner had the same problem. I think that the computer should still run with the high voltages on the EAF board, because the power supply runs the computer. The book says that the lights on the control panel will come on when the computer is doing a diagnostic on the EIZ/O board. I removed the EIZ/O Board while the machine was on and it had no effect. I think the EIZ/O board may be bad but it would not explain the high voltages. The batteries were removed along with the boards, is there any software that I need to uploade or peramiters I need to run this thing.

Any Ideas.
Thanks

[machintek]

Get a cup of coffee and go through the whole machine again.
The FMDC LED will light up each time the machine is turned on. Their status tells you what state the board is in. It goes through a bunch of self tests. A description of the function of each board is in the manual. Bridgeport was very good at that.
The EZIO retains the part program if the batteries are good, and bit maps the CRT. The CRT run off 12 VDC.
How is the back plane of the FMDC, EZIO and BSP? I remember a bunch of wires back there. If the AUF passes its self test, that one LED will be lit. If it is communicating to the system, it will be blinking.
Disconnecting anything electrical while ON is a no-no. The exception is a USB device.

George

[JohnJames]

Got computer to work. One of the boards was not seated in the socket all the way. It is telling me now that there is a "dive axis fault: May take 30 seconds to clear", but it never clears. I am using a roto-phase. I think that the roto-phase could this be causing the problem. I am going to try and hook 220v single phase to the controler's transformers and only run the head off of the roto-phase. Any ideas about what is causing the fault

[machintek]

Axis drive fault may take 30 sec to clear is usually a FMDC fault.
Check the LED status.

George

[JohnJames]

Hooked single phase 220v to transforms that feed computer. No change, still same error message. It says "Drive fault" not "drive axis fault" like stated before, sorry got it wrong below. We did check the FMDC LED's, if memery serves me correctly they were ok per the manual. The back plane of the FMDC, EZIO and BSP does have a bunch of wires but I think they are ok. When we first started going through the machine one of the connectors on the back plane had pulled off (the wire was kind of short and must off pulled off when someone fliped open the back plane). The connector was marked K1. The back plane was not marked as to where it was to go, but from going through the manual and looking at the machine we think we got it right (pluged in on the lower left side of the back plane). The book does not go into much detail about the connector or where it goes. I think that it goes from the back plane and directly into the board that houses the memery batteries.