Strange problem ! BP II interact 4

[bherr]

Well I've got a strange problem that I haven't been able to figure out-Help Please. BP series II Interact 4 witha Contraves ADB/F 200 series 200 spindle controller, Bosch drives and Heidenhain TNC 155b. the other day while troubleshooting another problem I accidentally shorted out the 440V on the CPI board of the Contraves. this blew the Triresistor and one of the SCR's. I replaced them and now have spindle rotation, but another problem has happen. When powering up the machine I can reference all the axis and in manual mode I can do rapid movement and the handwheel also moves the 3 axis. When I go into the auto or step program mode the Spindle rotates and the X axis moves about a 1/4 inch and then stops. I get no error message on the TNC 155b and the flashing courser is not blinking. I've checked all the relays, tacho feedbacks to the TNC and the axis drives outputs and they all seem to be working. I've gone thru the schematics on the TNC, Contraves and the Heidenhain and can't determine what is causing this problem. when I'm in the step program mode I use to be able to switch to handwheel and move the 3 axis, but I can't seem to get into the handwheel mode, at least not all the time, were I use to be able to switch all the time. I've got the BP manual, Contraves and Heidenhain, but the schematics leave alot to be desired.
Can anyone point me in the right direction????

Thanks in advance.
ben

[erd39030]

Just a post to follow this thread.
(I do have a BP Interact 412 with a TNC 151)

[machintek]

is there any way to determine if the drive has tripped? Or perhaps is not turning as fast as it should? If the actual spindle speed differs from the command by 20 percent or more, it should go into a feed hold. There may be other damage from the power surge that will not make itself known through normal channels.

George

[bherr]

Originally Posted by machintek is there any way to determine if the drive has tripped? Or perhaps is not turning as fast as it should? If the actual spindle speed differs from the command by 20 percent or more, it should go into a feed hold. There may be other damage from the power surge that will not make itself known through normal channels. George

George,
I did notice that the spindle didn't seem to be turning as fast as it should. I've checked all the SCR's in the Contraves controller. My 440 v is normal, although I did notice that one leg was about 30 volts higher on the one leg. do you have any suggestions as to were to look for the problem. I just downloaded the Heidenhain service instructions so now I can troubleshoot that. I also am going to put LED's on all the DC relays and 110v lights on the ac relays to track if the relays are kicking in the way they should. there's a total of 20 DC and 7 AC relays. If the spindle isn't turning at called for RPM's. then I would assume the problem lies in the Contraves and that would make sense. I've checked all the fuses so I know they are good.

thanks,
ben

[machintek]

If you provide me with your email address, I can scan and send you my contraves maintenance course notes (once I dig them up).

George

[bherr]

Originally Posted by machintek If you provide me with your email address, I can scan and send you my contraves maintenance course notes (once I dig them up). George

George,

Can't thank you enough! bherr@atlanticbb.net My machine has been down over two weeks.

Again, Thank You,
Ben Herr

[bherr]

George,
OK here's some additional information that may be useful. the D107 light , which is the Current Limit light is on and shouldn't be. I tried reversing the spindle with a M04 and it did reverse, so that is good, however I measured the voltage on Pin #63 on the CPI board which is feed by the FRU bd. terminal #4 which is the +/- 10 volts for the armature. At full 3750 RPM programmed in the cycle I only get 7.3 vdc and with the RPM's adjusted down to 930 ( minimun permitted by the adjustable RPM adj. I get 1.9 vdc. I also noticed that D107 (Current Limit lite) goes out when the RPM's are adjusted below 1500 and the "F"(feed rate indicator) on the monitor is highlited over 1500 and not highlited under 1500 RPM's.

Ben

[machintek]

Check your email.
The last time I worked on a contraves spindle drive was 20 years ago!

George

[Big Daddy]

I use to run those controls man its been 22 years ago! And I know my way around that machine inside & out! I just can't remember crap about the little jewel anymore. Sorry I wish I could help you guys!

[bherr]

Originally Posted by machintek Check your email. The last time I worked on a contraves spindle drive was 20 years ago! George

George,
Thanks for the troubleshooting stuff. I finally manged to find the problem, which really was two items. when I shorted out the 440 it actually burned one of the connector pins which ran from the SCR's, so that was one of the problems. I decided to start tracing wires and circuit board connections, as some of the voltages were way out of line, but only when I exceeded 1500 RPM's. so using my OHM meter and the schematics I started checking all the connections,especially around the area were I shorted the voltage. Found a board line that was open and fixed that and now the machine is running the way it's supposed to. Still have the spindle shutting down during cycle runs, but feels this is a incoming voltage problem. I upgraded my electrical service to 200 amp and this has helped some, but still getting the same issue. I'm going to do some milling late at night to see if the problem lessens, due to lower power demand at midnight. If this proves successful I may then consider getting pricing on the electric company installing 3 phase power to the shop and if that is too expensive, which I think it will be I'm also looking into a PhaseTec voltage stabilizer. Well, so goes the battle. Again thanks for the help.

ben

[mostafa.bagheri]

have problem

i have a huron machine with tnc 155 controler this machine doesnot use for 3 years and now i want to start it again baut i cant enable the spindle drive & i need electrical wiring for repair it
anybody have this cataloge for help to me

[machintek]

To Ben.
Check the brushes on the spindle motor.

George