BGL
Hot Rolled
- Joined
- Sep 14, 2010
- Location
- Maryland, USA
A long story shortened, 2008 Agie Classic S. Hard drive failed. Replaced and software reloaded [as far as I know]. Everything seems to be working with these exceptions, yet to make sparks with it. Problem with the wire tension/feed is new, was working before hard drive failure. The tank fill / drain / fill to level, was an issue before the repair. I have little experience operating this machine. I have a lot of experience with cleaning, repairing and just trying to figure out the problems. No actual cutting but have a whole two weeks on an equal vintage Mitsubishi.
I have attempted to document the issues and troubleshooting in a concise format.
Yes, I have been in contact with GF Machining Solutions. I may have overstayed my welcome or they are just overwhelmed. I have been waiting for well over a week for a reply. I will attempt to make contact again tomorrow. For now, I am hoping the PM collective intellect and experience can guide me to what I hope are easy answers.
1) Spool tension – Too sensitive, too much.
Wire was in place so as part of the fresh start I ran wire feed for a minute or so. Water flow, chopper and bin suction working normal. I was preparing to go thru the wire change and calibration procedure per Manual C3.2 pg. 30. Wire cut nicely, went to jog down in Z the wire snatched back on the spool, distinct sound of jockey roller bouncing and thump of spool stopping from fast rotation. Result was a rat’s nest of wire at spool, fixed that and attempted to hand feed. Every time wire tension sensor got to a certain point, the spool pulled back very fast. Scary the first time, fingers near wire. By the fifth time, I knew it was not something I was doing wrong. This was working, impossible now. It is super sensitive and jerks the wire back, even snapped when hand threading by the brake roller. Tight grip, slow rotation.
I did a test. Anchored to spool with tape. With one hand holding the spool and other hand moving the jockey roller. It goes from gentle tugging to fast speed. Holding on I estimate about ten foot pounds of torque. This happens at about half the range of motion. With spool free, moving arm, roller goes from slow rotation to several hundred rpm as if it hit a switch. Intuition tells me the parameters are off, searching around my best guess are these below, as found.
Under CONFIGURATION menu
WIRE tab
SPEED MOTOR SPOOL AT CHANGE COMMAND 150
Acc SPOOL MOTOR AT CHANGE COMMAND 100
DISTANCE bw. BRAKE MOTOR AND WIRE SPOOL 2000
JOCKEY ROLLER FORCE UPPER MECHANIC LIMIT STOP 0.2
JOCKEY ROLLER FORCE UPPER MECHANIC LIMIT STOP 10
2) Tank fill / Fill to operation / Tank Drain
Command: Fill Tank
STOP symbol flashes once. No alarm, no water flow.
Note:
1) Flow check command works, water flows from upper and lower guide, some water flow from rapid fill area but.
2) Moving door up the drain closes. Door down, drain opens. That makes sense to me and I presume verifies function.
I disconnected control air to valve (YV10). I used an air gun to apply pressure into valve piston, works fine with impressive water flow. With line still disconnected, I commanded tank fill. No airflow.
Traced hose back to solenoid #10, top one in the stack. I swapped with the solenoid body below it, and repeated, no airflow. I activated solenoid by pressing on the little green button, got airflow. Reconnected the line, I get an impressive amount of water flow.
I have only a quick scan of the schematics. I suspect no power to it. Tried to check voltage but need better probes. What is the voltage, where does the power come from?
Command: Empty to opening level
… W S DA 88: Request for emptying the work tank to the opening level not possible because already effective already effective
I held the float in the up position. No effect, same alarm.
Command: Empty
… W S DA 89: Request for emptying already effective
I held the float in the up position. No effect, same alarm.
I have attempted to document the issues and troubleshooting in a concise format.
Yes, I have been in contact with GF Machining Solutions. I may have overstayed my welcome or they are just overwhelmed. I have been waiting for well over a week for a reply. I will attempt to make contact again tomorrow. For now, I am hoping the PM collective intellect and experience can guide me to what I hope are easy answers.
1) Spool tension – Too sensitive, too much.
Wire was in place so as part of the fresh start I ran wire feed for a minute or so. Water flow, chopper and bin suction working normal. I was preparing to go thru the wire change and calibration procedure per Manual C3.2 pg. 30. Wire cut nicely, went to jog down in Z the wire snatched back on the spool, distinct sound of jockey roller bouncing and thump of spool stopping from fast rotation. Result was a rat’s nest of wire at spool, fixed that and attempted to hand feed. Every time wire tension sensor got to a certain point, the spool pulled back very fast. Scary the first time, fingers near wire. By the fifth time, I knew it was not something I was doing wrong. This was working, impossible now. It is super sensitive and jerks the wire back, even snapped when hand threading by the brake roller. Tight grip, slow rotation.
I did a test. Anchored to spool with tape. With one hand holding the spool and other hand moving the jockey roller. It goes from gentle tugging to fast speed. Holding on I estimate about ten foot pounds of torque. This happens at about half the range of motion. With spool free, moving arm, roller goes from slow rotation to several hundred rpm as if it hit a switch. Intuition tells me the parameters are off, searching around my best guess are these below, as found.
Under CONFIGURATION menu
WIRE tab
SPEED MOTOR SPOOL AT CHANGE COMMAND 150
Acc SPOOL MOTOR AT CHANGE COMMAND 100
DISTANCE bw. BRAKE MOTOR AND WIRE SPOOL 2000
JOCKEY ROLLER FORCE UPPER MECHANIC LIMIT STOP 0.2
JOCKEY ROLLER FORCE UPPER MECHANIC LIMIT STOP 10
2) Tank fill / Fill to operation / Tank Drain
Command: Fill Tank
STOP symbol flashes once. No alarm, no water flow.
Note:
1) Flow check command works, water flows from upper and lower guide, some water flow from rapid fill area but.
2) Moving door up the drain closes. Door down, drain opens. That makes sense to me and I presume verifies function.
I disconnected control air to valve (YV10). I used an air gun to apply pressure into valve piston, works fine with impressive water flow. With line still disconnected, I commanded tank fill. No airflow.
Traced hose back to solenoid #10, top one in the stack. I swapped with the solenoid body below it, and repeated, no airflow. I activated solenoid by pressing on the little green button, got airflow. Reconnected the line, I get an impressive amount of water flow.
I have only a quick scan of the schematics. I suspect no power to it. Tried to check voltage but need better probes. What is the voltage, where does the power come from?
Command: Empty to opening level
… W S DA 88: Request for emptying the work tank to the opening level not possible because already effective already effective
I held the float in the up position. No effect, same alarm.
Command: Empty
… W S DA 89: Request for emptying already effective
I held the float in the up position. No effect, same alarm.