Oh dear. What have I done: Wonky Super Major!

[Colin ThorburnParticipant @colinthorburn94238]

In a bit of a pickle here folks. Hope someone can help me out with a couple of reference photos. I have a sick warco super major. I replaced 3 of the 4 contacters after one burned out. Ok, that’s not all I did: I also put a couple of extension boxes in to make moving the control cabinet a bit easier. I was under the impression I had color coded the ends of every wire I cut and every connection to the contacters. Oops. Now the mill seems to run in reverse ok but nada forward. Head lift goes up and down from the contacter buttons but only down from control box. Here’s a snap of my efforts. If anyone has a super major I’d be over the moon if you could help with a few snaps to help me get this sorted out. Thanks folks.

[HollowpointParticipant @hollowpoint]

I can’t help unfortunately, I don’t have a super major. But it would be worth emailing Warco and explaining the situation. They might be able to get photos or they might even have a wiring diagram.

This kinda situation is exactly why I always photograph everything, before carrying out any electrical work. It’s so easy to get wrong! Especially when it’s as complicated as yours looks. 😬

[Colin ThorburnParticipant @colinthorburn94238]

I went down the diagramming route  for the electrics enclosure. Possibly a mistake there, but everything checks out. I had photos of everything else I touched (spindle & lift motors,switch box), but these have vanished from my phone along  with a whole host of other pics. My current concern is just making sure I have u1 u2 v1 v2 wires to spindle motor back correctly. Currently i have u1 u2 either end of 3 ohm run winding. Switch in series with start 150uf start cap. V1 and v2 across the start winding. Start cap other end to v1 and one end of run cap. Not sure if v1 should be here or what to do with the other end of the switch and run cap. Googling it nit much help.ho hum.

[John HinkleyParticipant @johnhinkley26699]

I don’t know whether these links will help, but might be worth a try.  I Googled The Grizzly equivalent to Warco Super Major mill and got the response that the old, now discontinued. version was called Model G0484, for which the manual is  is still downloadable from here.  There are numerous photos and wiring diagrams which could be of assistance, starting on page 28.

The current version, now called the Model G0755 can be downloaded here.  Again, a wiring diagram and lots of pretty pictures from page 41 onwards.

Hope that helps,

John

 

[Clive FosterParticipant @clivefoster55965]

Can be a lot of work but producing your own function based wiring diagram of the troublesome bits is a great help in figuring things out. Something akin to sort of thing that workshop manuals on more modern cars do.

So, assuming you have a wiring diagram appropriate to the original machine, make your own drawings of all the wires, switches, contactors et al going to the troublesome parts right back to the main power on contactor. Usually with far less of a maze to trace it becomes fairly clear where the problems must lie. Separate one for each problem area. If you don’t have a wiring CAD program scan and print your drawing once done to produce scribble copies that can be binned after making notes if you don’t get it right first time.

Given the fairly extensive modifications you have made you may have to repeat the exercise following your actual wiring. Comparing the two should pin point the issue.

My experience is that creating a functional drawing from the relevant parts of the original diagram is sufficient for the error to be discerned. Don’t try and short cut tho’ as it’s possible to jump to erroneous conclusions part way through drawing. How do I know.

Clive

[Colin ThorburnParticipant @colinthorburn94238]

<p style=”text-align: left;”>Thanks John & Clive. I actually broke out KiCad to do just that but it’s slow going. P28 of the manual John located is actually pretty helpful. I  now have spindle fwd/rev . Rev from the button but fwd only from the button on the contacter . I will persevere and if I get that schematic into a useful state I’ll post it.</p>

[Colin ThorburnParticipant @colinthorburn94238]

Well i didn’t see that coming. When I replaced 3 of 4 contacters i got 1 from warco (last in stock) and 2 from china. Turns out warco sent me a 220v not a 24v coiled one. Swapped a coil from one of the duds and it burst into life. Still got a problem with z axis but at least i have a usable machine now. Thanks again for all the suggestions.

[John HinkleyParticipant @johnhinkley26699]

Colin,

Thanks for coming back and giving us an update on your progress. Glad that you’re back up and running – at least for the most part.  I hope you manage to resurrect the rest of the machine soon.

John

 

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