Background

Your machine axes require power and control signals to work. If either of those are disrupted you can lose any or all axis motion. If all of your motors are not working, go to All Axes Won't Move When Commanded.

Tools

Digital multimeter
Small flat-bladed screwdriver
Metric hex wench set
Phillips screwdriver

1 Reseat the connectors on the machine control board and motors
2 Inspect the motor’s drivers
3 Inspect the DC power supply
4 Inspect the motor
5 Inspect the motor coupling
6 Ensure oil is getting to the motion system
7 Push fresh oil through the system
8 Inspect the gibs position (dovetail ways machines only)
9 Clean the ball screw
10 Manually move the axis (1100MX and 770MX only)
11 Tension or replace the axis belt (1300PL only)

Reseat the connectors on the machine control board and motors

Reason: Control signals aren't reaching the electronic driver modules/servo motors.

Power off the machine.
Examine the data cables at the machine control board and the servos removing then re-connecting them to ensure they are seated.
1. Machine control board: Degson style
  1. 424 (J13) (X-axis)
  2. 425 (J14) (Y-axis)
  3. 426 (J15) (Z-axis)
2. Servos: Molex style
Examine the power cables at the DC-Bus and the servos removing then re-connecting them to ensure they are seated.
1. DC-Bus: Spade connector
  1. 210/211 (X-axis)
  2. 220/221 (Y-axis)
  3. 230/231 (Z-axis)
2. Servos: Molex style
Continue to the next troubleshooting topic.

Power off the machine.
Examine the data cable at the machine control board and the axes drivers.
1. Machine control board: 26 pin IDC (ribbon cable); J6
2. Stepper driver controllers: 10 pin IDC (ribbon cable)
  1. 423.1 (X-axis)
  2. 423.2 (Y-axis)
  3. 423.3 (Z-axis)
Examine the power and control cables at the DC-BUS and the stepper driver controllers removing, inspecting, and re-connecting them to ensure they are seated.
1. DC-BUS: Spade connectors
  1. 210/211 (X-axis)
  2. 220/221 (Y-axis)
  3. 230/231 (Z-axis)
2. Stepper driver controllers: Degson style
  1. 211-214 (X-axis)
  2. 221-224 (Y-axis)
  3. 231-234 (Z-axis)
If there is any discoloration, replace the cable and driver.
Continue to the next troubleshooting topic.

PCNC 1100/770 only: Check connection of J2-5 and J2-6 jumper.

Power off the machine.
Examine the data cable at the machine control board and the axes drivers.
1. Machine control board: 16 pin IDC (ribbon cable); J6
2. Stepper driver controllers: 10 pin IDC (ribbon cable)
Examine the power and control cables at the DC-Bus and the stepper driver controllers removing, inspecting, and re-connecting them to ensure they are seated.
1. DC-Bus: Spade connectors
  1. 302/303 (X-axis)
  2. 304/305 (Z-axis)
2. Stepper driver controllers: Degson style
  1. 302, 303, 308, 309, and 310 (X-axis)
  2. 304, 305, 311, 312, and 313 (Z-axis)
If there is any discoloration, replace the cable and driver.
Continue to the next troubleshooting topic.

Power off the machine.
Examine the data cable at the machine control board and the axes drivers.
1. Machine control board: 26 pin IDC (ribbon cable); J6
2. Stepper driver controllers: 10 pin IDC (ribbon cable)
Examine the power and control cables at the DC-Bus and the stepper driver controllers removing, inspecting, and re-connecting them to ensure they are seated.
1. DC-Bus: Spade connectors
  1. 203/204 (X-axis)
  2. 207/208 (Y-axis)
  3. 209/210 (Z-axis)
2. Stepper driver controllers: Degson style
  1. 203, 204, 213, 214, and 215 (X-axis)
  2. 207, 208, 216, 217, and 218 (Y-axis)
  3. 209, 210, 219, 220, and 221 (Z-axis)
Continue to the next troubleshooting topic.

Inspect the motor’s drivers

Assess the state of the motor or stepper driver controller

Reason: There's a defective or malfunctioning axis driver/cable.

Examine the motor status LED and compare it to the manufacturer's blink code document.
Continue to the next troubleshooting topic.

Power on the machine and take it out of reset.
Examine the LEDs of the stepper driver controllers.
1. If the stepper driver controller has an illuminated green light: It is ready and operating normally.
2. If the stepper driver controller has an illuminated red LED: The machine should be power cycled to try and reset the stepper driver controller or the stepper driver controller needs to be replaced.
3. If the is no light on the stepper driver controller: Continue to the next troubleshooting topic.

Power on the machine and take it out of reset.
Examine the LEDs of the motor drivers on the MX3660 driver.
1. If the stepper driver controller has an illuminated green light: It is ready and operating normally and you should continue to the next topic.
2. If the stepper driver controller has an illuminated red LED: The machine should be power cycled to try and reset the stepper driver controller or the stepper driver controller needs to be replaced.
3. If the are no lights on the stepper driver controller: Continue to Inspect you power source.

Full stepper driver controller swap (full driver swap) NOTE: 4th AXIS DRIVERS CANNOT BE SWAPPED WITH SERIES 3 OR 'M' SERIES MACHINE DRIVERS.

Power off the machine.
Identify the stepper driver controller corresponding to the malfunctioning axis and its two sets of wires; a green power connector and 10 pin IDC (ribbon cable). Remove and examine them:
1. If there the connector appears burnt: Replace both the cable connector and driver.
2. If the cable and pins appear normal: Continue to the next step.
On the malfunctioning axis stepper driver controller, replace the ribbon cable connector power connector with those from a functioning axis driver.
There will be no change to how to jog the swapped axis.
Power on the machine.
Jog the malfunctioning axis and swapped axis in both directions.
1. If the malfunctioning motor now functions properly: It is likely that the malfunctioning axis driver is defective.
2. If the malfunctioning motor continues to move erratically: Continue to the next troubleshooting topic; but, it is likely that the malfunctioning axis motor is defective.

Half stepper driver controller swap (half driver swap)

Power off the machine.
Verify that the wires and cables are in their original position.
Swap the ribbon cables between the malfunctioning stepper driver controller and a known good stepper driver controller.
The controls on the machine change, depending on the ribbon cables you swapped.
Jog the malfunctioning axis in both directions.
1. If the malfunctioning motor now functions properly: It is likely the ribbon cable or control board are malfunctioning.
2. If the malfunctioning motor continues to move erratically: Continue to the next troubleshooting topic; but, it is likely that the malfunctioning axis motor is defective.

PCNC 440 driver swap

Power off the machine.
Verify that the wires and cables are in their original position.
Swap the green plugs between two different axes.
The controls on the machine change, depending on the ribbon cables you swapped.
Power on the machine.
Jog the malfunctioning axis and swapped axis in both directions.
1. If the malfunctioning motor now functions properly: It is likely that the malfunctioning axis driver is defective. A replacement MX3660 Driver will be needed
2. If the malfunctioning motor continues to move erratically: Continue to the next troubleshooting topic; but, it is likely that the malfunctioning axis motor is defective.

Inspect the DC power supply

Reason: There's a blown fuse on the DC-BUS board.

Power on the machine and take it out of reset.
Examine the green LED on the DC-BUS board.
1. If the green LED is not illuminated: Go to https://tormach.atlassian.net/wiki/spaces/IMK/pages/2849374265/All+Axes+Won+t+Move+When+Commanded
2. If the green LED is illuminated: Continue to the next step.
Power off the machine.
Remove the cover from the DC-BUS board.
Using the table below, locate the corresponding axis fuse and measure its resistance across the fuse with a digital multimeter set to resistance.
1. Replace the fuse if the digital multimeter reads OL, shows a resistance in the MΩ, and/or doesn’t produce continuity tone.
2. If the fuse measures 0-5 Ω, reinstall it.

Function	Fuse Number	Amperes	Speed

Function	Fuse Number	Amperes	Speed
X-Axis	F1	8 A	Fast
Y-Axis	F2	8 A	Fast
Z-Axis	F3	8 A	Fast
A-Axis	F4	8 A	Fast
Main DC-BUS fuse	F6	10 A	Slow
ATC	F8	5 A	Fast

A blown fuse can be the result of a deceive driver or wiring. Inspect the axis' wiring carefully and repair any damage observed. If you replace a fuse and it immediately blows, it's likely a defective axis drive or its wiring.

Inspect the DC power supply for power by examining if the green power light is illuminated.
1. If it does: The stepper driver controllers or motors will be illuminated.
2. If it doesn’t: Go to https://tormach.atlassian.net/wiki/spaces/IMK/pages/2849374265/All+Axes+Won+t+Move+When+Commanded .

Inspect the motor

Reason: There's a defective motor or motor connection.

Power off the machine.
Unplug the servo's cables and examine the motor and cables for signs of coolant or contamination.
1. If there is coolant or contamination: Replace the servo and cable.
2. If there is nothing: Reconnect the cable and continue to the next step.
Power on the machine.
Examine the motor status LED and compare it to the manufacturer's blink code document.

Power off the machine.
Remove the motor leads from the axis stepper driver controller, and examine the motor for signs of coolant or contamination.
1. If there is coolant or contamination: Replace the stepper driver controller and cable.
2. If there is nothing: Continue to the next step.
Based off of the chart, measure the resistance of windings at the green connector on the axis driver.
1. If the resistance is out of spec: Then the motor is defective.
2. If the resistance is within spec: Then inspect the cable and connectors between the axis motor and axis driver.

Axis	Probe		Resistance
Axis	From (black probe)	To (red probe)	Resistance
X	212 212 213	213 214 214	0.5-2.0 Ω
X	Each wire	Ground (bare metal or wire labeled PE)	>1 M Ω or OL
Y	222 222 223	223 224 224	0.5-2.0 Ω
Y	Each wire	Ground (bare metal or wire labeled PE)	>1 M Ω or OL
Z	232 232 233	233 234 234	0.5-2.0 Ω
Z	Each wire	Ground (bare metal or wire labeled PE)	>1 M Ω or OL

Resistance across leads on all phases for X, Y and Z should be about the same. Deviation may indicate a problem. This does not apply to the A-axis.

Power off the machine.
Remove the motor leads from the axis stepper driver controller, and examine the motor for signs of coolant or contamination.
1. If there is coolant or contamination: Replace the stepper driver controller and cable.
2. If there is nothing: Continue to the next step.
Based off of the chart, measure the resistance of windings at the green connector on the axis driver.
1. If the resistance is out of spec: Then the motor is defective.
2. If the resistance is within spec: Then inspect the cable and connectors between the axis motor and axis driver.

Axis	Probe		Resistance
Axis	From (black probe)	To (red probe)	Resistance
X	226 226 227	227 228 228	0.5-2.0 Ω
X	Each wire	Ground (bare metal or wire labeled PE)	>1 M Ω or OL
Y	236 236 237	237 238 238	0.5-2.0 Ω
Y	Each wire	Ground (bare metal or wire labeled PE)	>1 M Ω or OL
Z	223 223 224	224 225 225	0.5-2.0 Ω
Z	Each wire	Ground (bare metal or wire labeled PE)	>1 M Ω or OL