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One Axis Won't Move (or Only Moves in One Direction), and Other Axes Move

One Axis Won't Move (or Only Moves in One Direction), and Other Axes Move

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

Table of Contents

Reseat the connectors on the machine control board and motors

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

  1. Power off the machine.

  2. 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

  3. 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

  4. Continue to the next troubleshooting topic.

  1. Power off the machine.

  2. 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)

  3. 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)

  4. If there is any discoloration, replace the cable and driver.

  5. Continue to the next troubleshooting topic.

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

  1. Power off the machine.

  2. 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)

  3. 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)

  4. If there is any discoloration, replace the cable and driver.

  5. Continue to the next troubleshooting topic.

  1. Power off the machine.

  2. 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)

  3. 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)

  4. 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.

  1. Examine the motor status LED and compare it to the manufacturer's blink code document.

  2. Continue to the next troubleshooting topic.

  1. Power on the machine and take it out of reset.

  2. 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.

  1. Power on the machine and take it out of reset.

  2. 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.

  1. Power off the machine.

  2. 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.

  3. 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.

  4. Power on the machine.

  5. 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)

  1. Power off the machine.

  2. Verify that the wires and cables are in their original position.

  3. 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.

  4. 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

  1. Power off the machine.

  2. Verify that the wires and cables are in their original position.

  3. Swap the green plugs between two different axes.

    The controls on the machine change, depending on the ribbon cables you swapped.

  4. Power on the machine.

  5. 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.

  1. Power on the machine and take it out of reset.

  2. 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.

  3. Power off the machine.

  4. Remove the cover from the DC-BUS board.

  5. 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.

  1. 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.

  1. Power off the machine.

  2. 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.

  3. Power on the machine.

  4. Examine the motor status LED and compare it to the manufacturer's blink code document.

  1. Power off the machine.

  2. 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.

  3. 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

From (black probe)

To (red probe)

X

212

212

213

213

214

214

0.5-2.0 Ω

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

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

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.

  1. Power off the machine.

  2. 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.

  3. 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

From (black probe)

To (red probe)

X

226

226

227

227

228

228

0.5-2.0 Ω

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

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

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.

  1. Power off the machine.

  2. 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.

  3. 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

From (black probe)

To (red probe)

X

308

308

309

309

310

310

0.5-2.0 Ω

Each wire

Ground (bare metal or wire labeled PE)

>1 M Ω or OL

Y

312

312

313

313

314

314

0.5-2.0 Ω

Each wire

Ground (bare metal or wire labeled PE)

>1 M Ω or OL

Z

316

316

317

317

318

318

0.5-2.0 Ω

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.

Inspect the motor coupling

Reason: There's a loose axis motor coupling.

  1. Jog the axis and listen to determine if you can hear the motor run.

  2. Remove the cover plate over the coupling and make witness marks across the coupling and ball screw.

  3. Jog the axis to determine if the motor's turning but the screw isn't.

    1. If the coupling is slipping, locate the hex screws and tighten them down.

Ensure oil is getting to the motion system

Reason: Oil isn't getting to the ways and ball screw.

  1. Examine the oil level in the oiler.

  2. Investigate the oiling system for lack of oil and/or plugged lines (for more information, see Tormach service bulletin SB0031).

Push fresh oil through the system

Reason: There's oil residue from long-term storage.

  1. Repeatedly pump oil and slowly jog the axis.

  2. If the machine has been sitting for a significant amount of time, the oil layer may have a suction effect. In this case, go to Manually move the axis (1100MX and 770MX only).

Inspect the gibs position (dovetail ways machines only)

Reason: The gibs are too tight.

  1. Follow the appropriate gib adjustment procedure below for your machine:

    1. Follow Gib adjustment procedure in Mill operators manual.

    2. Follow Gib adjustment procedure in Lathe operators manual.

Clean the ball screw

Reason: There's debris on the ball screw.

  1. Clean the ball screw.
    Debris on the ball screws can rapidly accelerate wear and reduce the lifespan of your machine. Evaluate if additional measures are required to protect your machine's ball screws and ways (like supplemental dust collection).

Manually move the axis (1100MX and 770MX only)

Reason: The axis motor faulted on start-up at end of travel.

Never manually release the Z-axis on a machine. If you do, the head will fall.

  1. Power off the machine.

  2. Locate the motor couple of the axis that is producing the error and turn it by hand away from the end of travel.

  3. Power on the machine and take it out of reset.

  4. Try to reference the axis that was faulting.

https://www.youtube.com/watch?v=n-nqzGE7Lu4

Tension or replace the axis belt (1300PL only)

Reason: The belt is too loose or it’s broken.

  1. Remove the Y-axis covers from the machine.

  2. Inspect the belt. If it’s broken, replace it.

  3. Adjust the belt tension until the longest straight portion of the belt will deflect in the middle only 1/8 in.