CASTLE TSM-21 Diagnostic Manual Download

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CASTLE INC

Diagnostic
Manual

TSM-21

Summary of Contents for TSM-21

Page 1: ...CASTLE INC Diagnostic Manual TSM 21 ...

Page 2: ...8 CLAMP SOLENOID CHECK 21 11 5 4 19 CLAMP CYLINDER CHECK 21 12 5 5 21 PILOT VALVE CLAMP EXHAUST CHECK 21 13 5 6 22 PILOT VALVE CHECK AND REPLACEMENT 21 14 5 7 24 ROUTER MOTOR OPERATION 21 20 5 8 26 ADJUSTING THE WEB ROUTER STOP PLATE 21 21 5 9 27 ROUTER STOP SWITCH NC 21 22 5 10 29 UNCLOGGING THE ROUTER SOLENOID 21 30 5 11 30 ROUTER CHECK SOLENOID 21 31 5 12 31 ROUTER FEED RATE ADJUSTMENT 21 32 5 ...

Page 3: ...CHECK AND REPLACEMENT 21 83 5 26 51 AIR PRESSURE REGULATOR SETTING 21 90 5 27 52 REPLACING SOLENOID VALVES 21 91 5 28 54 ATTACHING AIR SUPPLY 21 92 6 55 APPENDIX A MACHINE SAFETY 21 80 6 1 55 GENERAL SAFETY RULES FOR MACHINE OPERATORS 7 57 APPENDIX B WIRING DIAGRAM 21 84 8 58 APPENDIX C CONTROL BOX WORKS 21 93 9 59 APPENDIX D SOLENOID PNEUMATIC DIAGRAM 21 94 10 60 APPENDIX E CONTROL BOX WORKS 21 9...

Page 4: ...ming maintenance or service on the TSM 21 If trouble occurs in most cases one of the major components is either not starting its function or not completing its function This may lead to a skip or stall in the operational sequence Troubleshooting the TSM 21 is greatly aided by understanding the machine s operational sequence which occurs in this order 1 The Clamp extends to secure the work piece 2 ...

Page 5: ...the operational sequence of the machine 3 Find the description which most closely matches the problem and systematically perform the Diagnostic Procedures listed checking them off as you go Example Page Procedure Clamp comes down as soon as air is attached with Machine power OFF Check clamp Solenoid for function or blockage 12 13 21 11 Note If you are unsure of your observations or if the fault be...

Page 6: ...h ON 3 Depress one of the Safety Buttons with a piece of scrap wood positioned out of the path of both the router and drill bits Position yourself to see both the Router and Drill bits when they extend 4 Press the Foot Pedal and observe the following actions in this order 1 The Clamp extends to secure the scrap wood 2 The Router extends then retracts 3 The Drill extends then retracts 4 The Clamp r...

Page 7: ...ure Regulator and the Router Feed Rate Procedures 21 92 21 90 and 21 32 If the Dry Cycle is successful but a regular cycle fails when routing actual pockets and drilling holes check the Tooling the Motor Operation and the Drive Cylinder Procedures 21 83 21 20 and 21 60 Note For comprehensive diagnostic descriptions and procedures refer to Section IV After testing is complete turn the MAIN Power Sw...

Page 8: ...nuity at rest IE light or sound from tester Drill Motor Porter Cable 7301 Trimmer motor used to drill the Pilot Hole Drive Cylinder A double acting air cylinder which moves the Motor Carriage backwards for the Pocket Router stroke and forwards for the Pilot Drill stroke Pilot Hole The Screw hole drilled by the Drill motor Pilot Valve Provides full pressure to the Clamp cylinder It is controlled by...

Page 9: ...for illustrations SQE Super Quick Exhaust valves which release air pressure from the drive cylinder after the Router and Drill strokes Note Used up to machine SN 62481 only Switches Normally OPEN NO switches Foot Switch Safety Switch Normally CLOSED NC switches Router Stop Switch Drill Stop Switch Web The distance between the deepest part of the pocket and the edge of the material ...

Page 10: ...mp comes down and STAYS DOWN as soon as air is attached with Machine power OFF Check Clamp Solenoid for function 18 19 21 11 Clamp comes down but immediately retracts Machine does not Rout or Drill Check Drill Stop Switch 37 38 21 43 Clamp doesn t hold stock securely Clamp footpad replacement 16 21 01 Internal Air Pressure too low adjust Pressure regulator 51 52 21 90 Router Feed Speed too fast ad...

Page 11: ...e 11 21 10 Clamp doesn t release Machine Routs and Drills Adjust internal Air Pressure 51 52 21 90 Check Pilot Valve for function or blockage up to machine sn 61076 Only 22 24 21 14 Check Drill Stop Switch 37 38 21 43 Check Foot Switch 45 46 21 80 Clamp doesn t release Machine Routs DOES NOT Drill Check Pilot Valve for function or blockage up to machine sn 61076 Only 22 24 21 14 Check Drill Soleno...

Page 12: ... 43 44 21 61 Router doesn t cut pocket Machine Clamps Drills and releases Check Router Stop Switch for function or adjustment 27 29 21 22 Router comes up and STAYS UP as soon as air is attached with Machine power OFF Check Router Solenoid for function or blockage 30 31 21 31 Unclog Router Solenoid 29 30 21 30 Router cuts pocket and STAYS UP Drill doesn t come out and Clamp doesn t release Check Ro...

Page 13: ...s out and stops Router cuts pocket and Clamp DOES NOT release Machine DOES finish cycle when carriage is pushed forward by hand Adjust Air pressure may be too low 51 52 21 90 Check Drill Solenoid for function or blockage 40 41 21 51 Unclog Drill Solenoid 28 39 21 50 Check Router SQE Valve or Solenoid exhaust port for leakage 43 44 21 61 Check Drill SQE Valve or Solenoid exhaust port for leakage 43...

Page 14: ...Page Procedure Machine will not start cycle motors are running Check Air Supply minimum 85 PSI required 54 21 92 Check Safety Switch 47 48 21 82 Check Foot Switch 45 46 21 80 Machine can be cycled with no stock in place Check the Safety Switch 47 48 21 82 Machine cycling too slowly Note A normal cycle is approximately 2 seconds Adjust Air Pressure Regulator 51 52 21 90 Check Drive cylinder for air...

Page 15: ...16 21 01 Check Tooling may be dull 49 50 21 83 Pocket burned or smoking Adjust Router Feed Rate may be too slow 31 32 21 32 Check Tooling may be dull 49 50 21 83 Pocket misaligned with pilot hole Adjust Pilot Hole alignment 45 21 72 Check Drill motor mounting 33 34 21 40 Pocket too close or too far from the edge of the stock WEB adjustment Adjust Web with Router Stop Plate 26 27 21 21 ...

Page 16: ...nto the Clamp Foot and use a flat blade screwdriver to wedge the rest of the Foot Pad into the Clamp Foot 5 1 2 TO REPLACE THE CLAMP FOOT OR CLAMP CYLINDER 1 Connect 85 PSI directly to the Clamp Cylinder to manually actuate it 2 With the shaft fully extended hold the shaft stationary with a wrench and loosen the jamb nut with a wrench Continue holding the shaft stationary with the wrench and use l...

Page 17: ...ush in another 1 2 The appearance of the solenoids may differ See Appendix E page 51 for equivalent illustration on machines SN 61076 and above 1 Disconnect power and air from the machine Remove both air lines from the Clamp So lenoid See Fig 2 Push In rim while pulling out air line Air OUT Line Clamp Solenoid Air IN Line Fig 2 2 Reconnect air to the machine and the Air In line will now be flowing...

Page 18: ...cket Note If this procedure does not correct the problem the Clamp Solenoid will need to be replaced Refer to Procedure 21 91 Replacing Solenoids page 47 48 5 3 Clamp Solenoid Check 21 11 The Clamp Solenoid signals the Pilot Valve to provide full air pressure to the Clamp If the Clamp Solenoid has failed open the clamp will come down as soon as air is attached to the machine without the power bein...

Page 19: ...f it does the Clamp Solenoid has stuck open 4 Swap the air lines back again 5 Perform procedure 21 10 Unclogging the Clamp Solenoid 5 4 Clamp Cylinder Check 21 12 If the Clamp Cylinder clamps or retracts slowly it is having trouble filling or exhausting or it may be faulty If the clamp operates normally with an external air supply look for a crimp in the black air line from the Clamp Cylinder to t...

Page 20: ...tting Clamp Air line Clamp Cylinder Fig 4 4 The Clamp Foot should fully extend quickly Remove the external air supply and the Clamp Foot should fully retract quickly 5 If both clamp actions are smooth and quick the Clamp Cylinder is operating properly Continue troubleshooting the Clamp Cylinder Air Line the Pilot Valve on Mead solenoid machines and the Clamp Solenoid See Fig 5 Castle Inc TSM 21 Di...

Page 21: ...Valve Clamp Exhaust Check 21 13 This procedure applies only to machines up to SN 61076 Air from the Clamp Cylinder is exhausted out of the Pilot Valve Exhaust port This port is located to the left of the Air Pressure Regulator knob If the clamp fails to extend or releases very slowly the Pilot Valve Exhaust Port may be blocked 5 5 1 TROUBLESHOOTING STEPS 1 Open the rear door on the machine The Exh...

Page 22: ...lacement 21 14 This procedure applies only to machines up to SN 61076 The Pilot Valve provides full air pressure to the Clamp Cylinder A leaking Pilot Valve can result in insufficient air pressure to the Clamp regardless of the Pressure regulator setting 5 6 1 TROUBLESHOOTING STEPS 1 Disconnect the Air Out line from the Clamp Solenoid this hose controls the Pilot Valve See Fig 7 Castle Inc TSM 21 ...

Page 23: ...hose the clamp should re lease 5 If the clamp doesn t extend or extends but doesn t release or constantly exhausts re place the Pilot Valve 5 6 2 REPLACEMENT STEPS 1 Disconnect power and air from the machine 2 Remove the two carriage bolts securing the Control Box and pull the box partially out of the rear door 3 Remove the plastic nut that holds the Pressure Regulator assembly to the Control Box ...

Page 24: ...o the machine 5 7 Router Motor Operation 21 20 The Router Motor has its own power switch located on the motor body This switch should be in the ON position as motor operation is controlled by the main Power Switch on the machine Warning Do not run the motor for more than two hours at a time The motor requires a hour cool down period after each two hour period 5 7 1 REMOVING INSTALLING THE ROUTER M...

Page 25: ... Hold the motor face flush with the yellow car riage tabs until the motor has been fully secured by the U Bolt 7 Manually rock the Motor Carriage toward the rear of the machine and make sure that the router bit cleanly fits in the slot on the table top 5 7 2 SERVICING THE ROUTER MOTOR 1 Follow the instructions found in your Porter Cable manual on maintaining the motor This includes information on ...

Page 26: ... Web may be set between 5 8 and 13 16 by adjusting the Router Stop Plate from the top of the machine The factory setting is approximately 7 8 Note If you experience inconsistent web size make sure the lock nut on the Router Stop Plate is secure 5 8 1 WEB ADJUSTMENT STEPS 1 The Router Stop Plate is a black bracket found on the right side of the yellow Clamp Guard 2 It is held in place by a lock nut...

Page 27: ...outer Stop Switch NC 21 22 The Router Stop Switch consists of a magnetic reed switch with wires and a magnet no wires It is Normally CLOSED NC and OPENS at the end of the pocket routing stroke when the Motor Carriage breaks the magnetic field The switch signals two solenoid valves that reverse the direction of airflow in the drive cylinder causing the carriage to retract the Router and extend the ...

Page 28: ...tch should measure as CLOSED 4 Pull the carriage toward the rear of the machine until it stops against the Router Stop Plate The switch should now measure as OPEN 5 If the switch does not OPEN adjust the magnet 1 16 farther away from the switch and repeat step 4 until the switch measures OPEN with the carriage held against the Stop Plate 6 If the switch continuously measures CLOSED regardless how ...

Page 29: ... from the machine Remove both air lines from the Router So lenoid See Fig 12 Push In rim while pulling out air line Router Solenoid Air OUT Line Air IN Line Fig 12 2 Reconnect air to the machine and the Air In line will now be flowing with about 85 PSI Use the Air In line to clean out both open ports on the Router solenoid 3 Disconnect the air supply and reinsert the Air In line back into the Air ...

Page 30: ... 91 Replacing Solenoids page 47 48 5 11 Router Check Solenoid 21 31 The Router Solenoid controls air pressure to the Drive Cylinder which provides the forward motion of the router s cutting stroke If the Router Solenoid has failed open the Router will extend as soon as the air is attached to the machine regardless of whether the power is turned on If the Router Solenoid is clogged the Router may n...

Page 31: ... 21 32 The Router Feed Rate is adjustable to accommodate varying materials and or bit types If the Router Feed Rate is too fast stock slippage poor pocket quality or dulled tooling may result If the Router Feed Rate is too slow pocket burning and premature wear of the tooling may result As a rule of thumb the harder the material the slower the feed rate of the Router Note If the Pressure Regulator...

Page 32: ...l revolutions counter clockwise 4 This setting is typical for hard woods 5 Adjust the Feed Rate to your material by or turn at a time to obtain a clean smooth pocket 6 Counter clockwise increases the Router Feed Rate Clockwise decreases the Router Feed Rate 7 Tighten the Jamb Nut after adjustments are finalized Note If the Router comes up with the Feed rate knob turned fully clockwise the Feed rat...

Page 33: ...ires a hour cool down period after each two hour period The Drill Motor is attached to the Motor Carriage by a bolt that is secured with a black T Knob This bolt may become loose due to vibration causing inconsistent pilot hole boring and or frequently broken drill bits 5 13 1 TIGHTENING THE DRILL MOTOR 1 Open the rear door 2 The Drill Motor is mounted on top of the yellow Motor Carriage See Fig 1...

Page 34: ...es can be handled by your nearest Porter Cable dealer service center or Castle 3 Follow the instructions found in your Porter Cable manual on maintaining the motor This includes information on keeping the motor clean and free of dust maintaining the brushes and replacing the tooling 4 The Drill Motor has two electrical brushes that should be periodically replaced Note During assembly at Castle the...

Page 35: ...ank and the bit can twist independently the bit should be replaced To simplify tooling changes or settings a Bit Gauge is included to record the depth setting most suitable for your purposes See Fig 16 The Bit Gauge is inside the back door of the machine to the left of the router wrenches Proper bit depth varies by application but as a rule of thumb the drill depth only needs to be long enough to ...

Page 36: ... the machine 2 Remove the two carriage bolts that hold the Control Box to the machine Leave the box hanging in place 3 A small rectangular plate anchors the Bar Spring Note how the spring slides between two bolts in this plate Loosen the nuts and remove the old spring and slide in the re placement spring 4 The short elbow at the end should face up toward the inside of the case top Place a plastic ...

Page 37: ...itch then signals both the Drill solenoid and Clamp solenoid to stop airflow which allows the Drill to retract and Clamp to release If the Drill Stop Switch fails or the magnetic field weakens or becomes misaligned the machine will not sense the end of the drill cycle The drill may stay forward in the Pilot Hole causing the cycle to stall or the clamp may extend but immediately release 5 16 1 TEST...

Page 38: ...tinuously measures OPEN regardless of how close the magnet is re place the switch assembly 9 If the switch needs to be replaced the laminate strip on the front of the machine may need to be removed to access the switch retaining screws Pry the laminate free from the case with a sharpened putty knife Contact Castle for a replacement laminate strip 5 17 Unclogging the Drill Solenoid 21 50 All Soleno...

Page 39: ...t power and air to the machine and turn the Power Switch ON 6 Put two boards on opposite sides of the slot on the Table Top press them against the Safety Buttons and depress the Foot Pedal After the Router Stroke air should be flow ing from the Air Out port of the drill valve 7 Turn the Power Switch OFF and repeat steps 5 and 6 several times to ensure all con taminants are expelled then insert the...

Page 40: ... the Drill may not start or complete the pilot hole The appearance of the solenoids may differ See Appendix E page 51 for equivalent illustration for machines SN 61076 and above 5 18 1 TESTING STEPS 1 Detach the air supply from the machine 2 Swap the Air Out lines between the Drill Solenoid and the Router Solenoid See Fig 20 Pilot Valve up to sn 61076 Clamp Exhaust Clamp Solenoid Router Solenoid D...

Page 41: ...age Machines with Serial numbers after 62480 do not have SQE valves therefore it is normal to de tect a puff of air at the exhaust ports of the Router and Drill Solenoids when manually rocking the carriage 5 19 1 TO DETECT A BAD CYLINDER SEAL If the cylinder seal is dry damaged or not seated properly air may bypass the cylinder piston and constantly exhaust out the SQE on the opposite end of the c...

Page 42: ...witch ON 9 Place a piece of scrap wood against the Safety Buttons and depress the Foot Pedal in order to start a normal cycle The router will cut a normal pocket but will stall during the Drill stroke 10 Leave the Power Switch ON Now un plug or turn off the Router motor 11 Listen for constant hissing and feel for leaking air at the open barbs on the SQE valves or at the exhaust valves of the Route...

Page 43: ...ted SQE valves therefore it is normal to detect a puff of air at the exhaust ports of the Router and Drill Solenoids when manually rocking the carriage Note All Solenoid Air Fittings are Push In connections To remove an air line push in the plastic or metal rim of the fitting and pull the air line out To re install push the air line in until it meets resistance and then push in another 1 2 The app...

Page 44: ... Solenoids See Fig 22 7 Disconnect the Air Out lines at the Drive Cylinder SQE valves See Fig 23 8 Repeat Steps 3 and 4 9 The air lines should exhaust air as you manually cycle Make sure air escapes first from the black Router Solenoid line and then from the translucent Drill Solenoid line before the manual cycle is complete 10 This should clear any blockage from the air lines and Drive Cylinder S...

Page 45: ...n the upper left side of the Motor Carriage See Fig 24 2 Tightening the hex nut moves the drill tip left relative to the operator Adjust accordingly Misaligned Pilot hole Hex Nut Drill T Knob Fig 24 5 22 Foot Switch NO 21 80 The Foot Switch is located in the Foot Pedal At rest the Foot Switch is normally OPEN It works in conjunction with the Safety Buttons Safety Switch Closing the Foot Switch whi...

Page 46: ...rminals Fig 25 5 Test for continuity at the wired connections with the switch still in the pedal 6 Without depressing the Spring Plate the switch should read OPEN With the spring plate depressed the switch should read CLOSED Note The switch is wired at the COM and NC terminals because the Spring Plate de presses the button on the switch at rest holding the switch OPEN 7 If the switch fails this te...

Page 47: ... Turn the Power Switch ON 5 24 Safety Switch Safety Buttons NO 21 82 The Safety Switch consists of a reed switch with wires and a magnet no wires It is normally OPEN NO to prevent operation and CLOSES when the Safety Buttons move the Safety Blade between the switch and the magnet If the switch fails or the magnetic field weakens or becomes misaligned the machine will not correctly detect if a cycl...

Page 48: ...between the switch and magnet Otherwise the distance between the switch and magnet may need to be increased by 1 16 5 When pressing the Safety Buttons the switch should measure CLOSED If the switch measures OPEN the distance between the switch and magnet may need to be de creased by 1 16 6 If the switch will not change from OPEN to CLOSED when the Safety Blade is raised de spite adjustment replace...

Page 49: ...n the Router T Knob a few turns to provide enough slack to drop the Router Motor down into your left hand and then out the rear door ALTERNATE METHOD Remove the four bolts and nuts attaching the work top and remove the work top for access to the router 5 Replace the bit A Bit Gauge is provided to record your preferred Router Bit Height Once a preferred setting is selected mark or scribe your setti...

Page 50: ...lt holding the Motor in place See Fig 28 Fig 28 3 Unplug the motor 4 With your left hand loosen the T Knob until it releases the Drill Motor Use your right hand to lift the motor back and then out the rear door 5 Replace the bit A Bit Gauge is provided to record your preferred Drill Bit Extension Once a preferred setting is selected mark or scribe your settings on the aluminum plate D Drill 6 See ...

Page 51: ...ut over sized holes Note It s extremely important that a minimum 85 PSI be provided from your compressor Operating pressure can be especially affected by other machines that share the same air line as your TSM 21 5 26 1 TO RESET THE AIR PRESSURE REGULATOR 1 Open the rear door and locate the Pressure Regulator mounted to the Control Box See Fig 29 Pressure Regulator Knob Router Feed Rate Knob Fig 2...

Page 52: ...he Pressure Regulator setting has been finalized See Procedure 21 32 5 27 Replacing Solenoid Valves 21 91 To replace a solenoid valve follow the steps below 5 27 1 STEPS 1 Disconnect power and air from the machine 2 Disconnect the Router and Drill power cords from the AC outlet 3 Remove the two carriage bolts that hold the Control Box to the machine and pull the box partially out the rear door See...

Page 53: ... Air In and Air Out lines of the solenoid to be replaced Note For SN 61076 and above label then disconnect the air lines then remove the pneumatic fittings from the old solenoid with a 7 16 wrench Note Only disconnect the air lines of the solenoid you are replacing 6 Cut the electrical wires to the solenoid being replaced leaving an inch on the old sole noid 7 Splice in and insulate the wires of t...

Page 54: ...21 92 An air supply with a MINIMUM of 80 PSI must be provided for proper operation of the TSM 21 Pocket Machine 1 From the operator s position the air inlet is the 1 4 NPT fitting located on the left side 2 Use proper thread sealant and install desired attachment method 3 CASTLE recommends the use of a secondary filter method directly in line with the supply at the machine 4 Do not use lubricants ...

Page 55: ...n ten feet when the machine is in operation Always wear protective eyewear and hearing protection when operating or standing near an operating machine Be certain the machine is properly grounded before operating it Operate this machine only when the doors and covers are in their proper position Keep all body parts away from the moving parts of this machine whether it is in operation or at rest Do ...

Page 56: ...ly and power or failure to wait for all motion to stop could result in electrocution or injury When attempting any kind of electrical repair work disconnect the machine from AC mains power Always keep the area around the machine clean and uncluttered Poor housekeeping could result in slips falls or other injuries ...

Page 57: ...op Switch NC Normally Closed Router Solenoid Valve Foot Switch NO Normally Open Router Stop Switch NC Normally Closed 15 16 E L 2 1 G C i r c u i t B o a r d T e r m i n a l S t r i p 16 15 Wood Sensor Switch NO Normally Open 13 14 11 12 9 10 7 8 5 6 3 4 D Black Power Switch White Green Power Cord 24 VAC Transformer 120VAC System Ground Foot Switch Ground Outlet 24 VDC ...

Page 58: ... 93 Note Up to SN 61036 Pilot Valve up to SN 61076 Clamp Exhaust Clamp Solenoid Router Solenoid Drill Solenoid Regulator Knob Air OUT lines Air IN lines Router Feed Rate Knob Fig 32 Castle Inc TSM 21 Diagnostic Manual v2 Page 58 of 63 ...

Page 59: ...Castle Inc TSM 21 Diagnostic Manual v2 Page 59 of 63 9 Appendix D Solenoid Pneumatic Diagram 21 94 Note Up to SN 61036 ...

Page 60: ...above Castle Inc TSM 21 Diagnostic Manual v2 Page 60 of 63 Fig 33 Fig 34 Regulator Knob Router Feed Rate Knob Router Solenoid Drill Solenoid Clamp Solenoid Air OUT lines Air IN lines View from front of machine with work top removed Air IN Lines Exhaust Ports ...

Page 61: ...Castle Inc TSM 21 Diagnostic Manual v2 Page 61 of 63 11Appendix F Solenoid Pneumatic Diagram 21 94 Note SN 61076 and Above ...

Page 62: ...te Serial 58 60 21 93 Drill Motor Operation 33 34 21 40 Drill Settings and Bit Depth 34 35 21 41 Drill Single Coil Bar Spring 36 37 21 42 Drill Solenoid Function check 40 41 21 51 Drill Solenoid Unclogging 38 39 21 50 Drill Stop Switch normally closed NC 37 38 21 43 Drive Cylinder Check 41 42 21 60 Drive Cylinder SQE Super Quick Exhaust valve 43 44 21 61 Dry Cycle Testing 6 7 21 95 Foot Switch nor...

Page 63: ... Function check 30 31 21 31 Router Solenoid Unclogging 29 30 21 30 Router Stop Switch normally closed NC 27 29 21 22 Safety Buttons Safety Switch normally open NO 47 48 21 82 Solenoid Pneumatic Diagram Appendix D F note serial 59 61 21 94 Solenoid Valves Replacing 52 54 21 91 Tooling Check Replacement 49 50 21 83 Web adjustment with the Router Stop Plate 26 27 21 21 Wiring Diagram Appendix B 57 21...

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CASTLE TSM-21, Diagnostic Manual

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