The Craftmans Shop > New from Old
The Sequel - Oh Blimey I bought a CNC Lathe (Beaver TC 20)
vtsteam:
Finally!
Amazing how much reverse engineering you have to do, even with manuals for these things. You wonder, is it a faulty component, or is the manual accurate, or are both the problem? Then if you do something and get the green light it's like Christmas! Except, on to the next.... anyway: :clap: :thumbup: :beer:
awemawson:
After more 'going round the houses' with a meter and wire sniffer (*) I've eventually deduced that those two small relays are nothing to do with monitoring the 24 volt power supply :bang:
The one on the left is monitoring the overload trip circuits for various motors, and the one on the right is NC-READY ! - relays suitably labelled. But the controller is still reporting a 24 volt psu problem and I have no idea how it is monitoring it :scratch: The relays shown on the diagram as CR10 and CR20 are nowhere to be found and I did eventually find the correct bit of the diagram showing the Overload and NC Ready relays.
Oh well maybe they will turn up somewhere else but I thought that I'd been everywhere by now in the mammoth structure of a lathe !
(* Tempo 200EP Inductive wire tracer intended for telecomms use)
awemawson:
:clap: :clap: Well guess what I've found :clap: :clap:
The only places left were the hydraulic cabinets for the tailstock and chuck - and on their control cards we have - CR10 and CR20 - hoo blooming ray :ddb:
The odd thing is that they both have tell tail green LEDs which are glowing away merrily when the power in on, but at least now I have a further avenue of investigation to follow :thumbup:
. . have to stop now as entertaining for lunch and need to be presentable :scratch:
awemawson:
Back from entertaining relatives at the Pub, and straight back to the workshop to chase that fault. Lucky I was the driver, so my head is quite clear on only Soda and Lime !
Chasing now I know where the relays are, it turns out that CR10's contact is working, but CR20 - either the relay or the wiring is duff. I have temporarily wired round it, and guess what - things started happening.
She's ALIVE
I could jog the Z axis up and down as I wished. Initially the X axis moved a fraction then something tripped - repeatable problem - I thought that perhaps it was on the limit switches, and wanted to remove the cover from the servo motor / ball screw drive to wind it by hand, but it was in an inaccessible place too close to the tail stock. But - hey - I can JOG Z where I want it. So the saddle was trundled down the ways giving access to the belt cover.
Cover off revealed the expected drive belt and pulleys and what I had forgotten - the X axis brake unit. As the X axis is tilted up at a step angle, without a brake, and with low friction ball screws, it will descend under it's own weight. I checked the current though the brake coil (0.6 amps) with my clamp on ammeter - no way can I turn the pulleys, and I dare not remove the brake or the X axis will plunge.
Well it looked a bit grotty with surface rust - perhaps the plates are rusted together. A few gentle taps with a plastic mallet, and guess what - X now moves as it should. As you jog it's slightly disconcerting hearing the loud 'click' as the brake comes off, and on again when motion ceases. (Brake is spring loaded ON with no power)
SO - I was able to move X & Z to their home / reference positions to make the controller happy, and was just starting initialising the Tool Turret when there was an almighty :zap: BANG :zap: and the workshop filled with acrid smoke - it still stinks as I type this .
I leapt to the main switch to kill the power - smoke was pouring out from below the KTK Mentor main spindle drive. Closer inspection (holding my breath) showed that in fact it was coming from the Field Coil Controller which is mounted below the Spindle Drive, and the culprit was one of those 0.1 uF 500 volt AC RFI suppressor capacitors, identical to the ones I replaced on the Mentor drive. Luckily I still have some left over.
Oh boy it made a loud bang and a huge volume of smoke - fortunately due to the hot weather I had my roller shutter door open and fans blowing. Knowing how hard it was to clean the mess off the Mentor board, I quickly set to with some IPA to try and clean the mess off the grey trunking - no way was it shifting, and I can see globules of molten solder have embedded themselves in various places.
However I am a happy bunny - this is a major milestone passed. OK I need to bottom the CR20 relay problem, I still need to replace that I/O card, and no doubt there will be a few more 'issues' along the way. I've not yet got the Main Spindle turning under power, nor the drive for Powered Tooling.
. . . but satisfying . . . :ddb:
awemawson:
Well no point in putting it off - remove board - replace capacitors - return board to it's rightful place and switch on keeping fingers crossed.
It all went ok - capacitors replaced and now I can jog X & Z, I can send the X & Z axis to their reference points, and I can jog the spindle. What I can't do at the moment is initialise the Tool Turret - it's asking me to do it but the format of the command is eluding me at the moment.
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