CASTLE TSM-21 User manual

CASTLE INC PO BOX 750236 PETALUMA CA 94975
WWW.CASTLEUSA.COM
Diagnostic Manual
TSM-21 Pocket Hole Machine with Parker or Humphrey Solenoids
Serial numbers 61076 and above
CASTLE
,
INC.

Table of Contents
1 .............................................................................................................................4 INTRODUCTION
1.1 ........................................................................................................5 HOW TO USE THIS MANUAL
2 ...................................................................................................6 DRY CYCLE TESTING 21.95
2.1 ..................................................................................................................................6 PURPOSE
2.2 DRY TEST TSM-21...................................................................................................................6
3 DEFINITIONS .................................................................................................................................9
4 DIAGNOSTIC DESCRIPTIONS....................................................................................................11
4.1 CLAMP OPERATION..................................................................................................................11
4.2 ROUTER OPERATION................................................................................................................13
4.3 DRILL OPERATION....................................................................................................................15
4.4 OVERALL MACHINE OPERATION AND POCKET ADJUSTMENT.......................................................16
5 PROCEDURES.............................................................................................................................18
5.1 CLAMP FOOT PAD OR CYLINDER REPLACEMENT 21.01 ...........................................................18
5.2 UNCLOGGING THE CLAMP SOLENOID 21.10 ..........................................................................19
5.3 CLAMP SOLENOID CHECK 21.11 ........................................................................................21
5.4 CLAMP CYLINDER CHECK 21.12 .........................................................................................23
5.5 CLAMP EXHAUST CHECK 21.13............................................................................................24
5.7 ROUTER MOTOR OPERATION 21.20 ...................................................................................26
5.8 ADJUSTING THE WEB, ROUTER STOP PLATE 21.21 ...............................................................28
5.9 ROUTER STOP SWITCH (NC) 21.22 ....................................................................................29
5.10 UNCLOGGING THE ROUTER SOLENOID 21.30 ........................................................................31
5.11 ROUTER CHECK SOLENOID 21.31.......................................................................................32
5.12 ROUTER FEED RATE ADJUSTMENT 21.32 .............................................................................33
5.13 DRILL MOTOR OPERATION 21.40 .......................................................................................35
5.14 DRILL SETTINGS AND BIT DEPTH 21.41...............................................................................36
5.15 DRILL SINGLE COIL BAR SPRING 21.42...............................................................................38
2.3 MANUAL OVERRIDE OF SOLENIOIDS............................................................................................8
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5.21 PILOT HOLE ALIGNMENT 21.72...........................................................................................49
5.22 FOOT SWITCH (NO) 21.80................................................................................................50
5.23 RESETTING THE MACHINE 21.81........................................................................................52
5.24 SAFETY SWITCH/SAFETY BUTTONS (NO) 21.82.....................................................................52
5.25 TOOLING CHECK AND REPLACEMENT 21.83 .........................................................................54
5.26 AIR PRESSURE REGULATOR SETTING 21.90 ........................................................................56
5.27 REPLACING SOLENOID VALVES 21.91 .................................................................................57
5.28 ATTACHING AIR SUPPLY 21.92 ..........................................................................................60
6 APPENDIX A – MACHINE SAFETY 21.96.................................................................................61
6.1 GENERAL SAFETY RULES FOR MACHINE OPERATORS................................................................61
7 APPENDIX B – WIRING DIAGRAM 21.84 ................................................................................63
8 APPENDIX C – CONTROL BOX WORKS 21.93 .......................................................................64
9 APPENDIX D – SOLENOID, PNEUMATIC DIAGRAM 21.94 ......................................................65
10 APPENDIX E – INDEX .................................................................................................................66
5.16 21.43 .......................................................................................39
DRILL STOP SWITCH (NC)
5.17 UNCLOGGING THE DRILL SOLENOID 21.50 ...........................................................................41
5.18 21.51..........................................................................................43
DRILL SOLENOID CHECK
5.19 21.60..........................................................................................45
DRIVE CYLINDER CHECK
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5.20 21.61..........................................................48
EXHAUST MUFFLERS ON SOLENOID VALVES

1Introduction
Thank you for making the Castle TSM-21 Screw Pocket Machine a vital part of your shop. The
TSM-21 is designed for use on a wide variety of materials including hardwoods, softwoods,
melamine, particleboard and MDF.
This manual is intended for anyone working with, or performing 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. The Router creates the pocket then retracts
3. The Drill creates the Pilot screw Hole then retracts
4. The Clamp releases the work piece
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1.1 How to Use This Manual
1. Closely observe the behavior of the machine noting which component is involved and
when in the operational sequence the problem is occurring.
2. Go to Section IV-Diagnostic Descriptions, which is organized by 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 behaviour seems irregular you
should “Dry Cycle” test the machine. See Procedure 21.95, page 4.
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2 Dry Cycle Testing 21.95
2.1 Purpose
Dry Cycle testing allows observation of the TSM-21’s mechanical, electrical, and pneumatic
functions without routing pockets or drilling holes.
Caution: Careful observation is essential when troubleshooting or seeking Technical Support
2.2 Dry Test TSM-21
1.
2. Connect air and power to the machine. Turn the machine’s MAIN Power Switch 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 releases the scrap wood
Total elapsed time should be approximately two seconds.
5. If the cycle does not begin, check the Air Supply, the Foot Switch, and the Safety
Switch: Procedures 21.92, 21.80 and 21.82
6. If the cycle stalls with the router extended or if the cycle skips over the router stroke
entirely, check the Router Stop Switch: Procedure 21.22
Locate the ON/OFF switches on the Router and Drill and turn them both off or uplug
the routers.
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•
•
•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
If the cycle stalls with the drill extended or if the clamp starts to extend and then immediately
retracts, check the Drill Stop Switch: Procedure 21.43
If the complete cycle takes significantly longer than two seconds, check the Air
Supply, the Pressure Regulator, and the Router Feed Rate: Procedures 21.92, 21.90
and 21.32
Note: A normal cycle when cutting pockets should take approximately 2 seconds.
If the complete cycle takes significantly longer than two seconds, check the Air
Supply, the Pressure Regulator, and the Router Feed Rate: Procedures 21.92,
21.90 and 21.32
Note: For comprehensive diagnostic descriptions and procedures refer to Section IV.
After testing is complete, turn the MAIN Power Switch OFF and switch both motors back ON or
plug the routers back in to the outlet.
Note: If a dry cycle is preformed to confirm function of the switches and the router bit or
the drill bit stays extended, verify that the carriage plate is not hitting the front of the switch/
magnet. The carriage plate should land in between the switch and the magnet.
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2.3Manual Override on Solenoids
The solenoids can be manually overridden to allow air flow to the cylinder while air is
attached to the machine. This can also be used to flush air through the solenoid to remove
any moisture or debris. The manual override buttons are located on the end of the solenoids
opposite of the air ports. See Fig 1a and 1b.
2.3.1TO TEST SOLENOID FUNCTION AND FOR LEAKS:
1. Unplug the machine, but make sure air is attached.
2. From the rear access door, locate the stack of solenoids below the control box.
3. Depress the red button to allow air to flow through the solenoid to the cylinder to test for
function or listen for air leaks.
2.3.2 TO FLUSH THE SOLENOID:
1. Remove the air line out fitting and the exhaust muffler and press the override button for
several seconds. Air should flow through the solenoid. Reassemble and cut a test
pocket. See FIG. 1a and 1b.
Fig 1a
Fig 1b
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3 Definitions
Term Definition
Air Pressure
Regulator
Used to set the main operational speed of the machine. Factory set at
approximately 75 PSI. / approximately 6 full clockwise turns from stop.
Bar Spring Provides pressure to return the Motor Carriage to neutral after the
Pilot Drill stroke.
Continuity Testing “Visual Indicator” type testers use batteries and a light
bulb.
“Audible Indicator” type testers use batteries and a
beeper or buzzer.
Normally OPEN (NO) switches read no continuity at rest, IE; NO light
or sound from tester.
Normally CLOSED (NC) switches read continuity at rest, IE: light or
sound from tester.
Drill Motor Porter Cable 7301, Bosch PR10E ,or PR20EVS 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.
Pocket The pocket cut in the material by the Pocket Router motor.
Router Motor Porter Cable 6902, Bosch 1617, or 1617EVS used to cut the Pocket.
Router Feed Rate
Valve
Controls the speed at which the Pocket Router moves through the
material when cutting the Pocket.
Note: Should be adjusted AFTER the main operational speed of
the machine has been set with the Air Pressure Regulator.
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Solenoids Electrically controlled air valves which send pressurized air to the
Clamp Cylinder and Drive Cylinder.
See Appendix C & E for illustrations.
Exhaust Muffler The exhaust mufflers on the solenoid valves release air pressure
from the clamping cylinder, and the drive cylinder after the Router
and Drill strokes.
Switches Normally OPEN (NO) switches at rest
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.
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