CASTLE TSM-35 User manual

TSM-35 Screw Pocket Machine Troubleshooting
35.10 Machine will not start:
Confirm that the machine will not turn on – no motor running vs the cycle will not start
!***ALWAYS DISCONNECT POWER AND AIR WHEN CHECKING SWITCHES ***!
•Check the safety interlock switch (See 35.11)
oOne of the most common reasons
oSwitch is a failsafe and will not allow the machine to start if the lid is
up
oOften becomes impacted with sawdust and will not function
Open switch and blow out
•There have been several different types of switches
used over time. Get brand name of switch:
oABB – E03300
oIDEC – E03340
oOmron – E03340 (IDEC and Omron have the same key.)
oTelemechanique – E35001
oSiemens – use E03340 and request Omron type
•Check the contacts at the back of the start and stop buttons (E03000 Stop & E35041 Start)
oSee 35.12 & 35.13
oThis is a continuity check – there should be a change in continuity when the buttons are
depressed. Can be done with no power to the machine.
•Check the air pressure switch (E35420)(See 35.14)
oThe air pressure switch is set at 40 psi at the factory. It can often go bad and be hard to
diagnose.
oThe easiest way to check is to bridge the two wires and see if the machine will turn on.
oWe no longer use the air pressure switch. Customers can keep the bridge in place if they do
not wish to replace.

TSM-35 Screw Pocket Machine Troubleshooting
•Check the transformer (E35713)
o*** CAUTION: ONLY A QUALIFIED ELECTRICIAN SHOULD PERFORM THE
FOLLOWING STEPS. POWER MUST BE SUPPLIED TO THE MACHINE TO CHECK THE
TRANSFORMER. THIS PRODUCES A SHOCKING HAZZARD. DO NOT TOUCH THE CONTROL
BOX COMPONENTS WITH ANYTHING OTHER THAN ELECTIRCAL TESTING PROBES. ***
oThere should be 230V 3ph or 480V 3ph going into the transformer (Check H1 (480V) or H2
(230V) AND H4 at top of transformer)
If no power into the transformer, check main power to the machine.
oThere should be 24V AC coming out of the transformer and entering the board at terminals
1 and 2
oCheck to make sure the fuse is intact (E16224)
•If all switches and transformer check out OK, then problem is with the contactor and/or overload.
(E91024 Contactor / E91827 480V Overload / E94060 230V Overload / E94061 Single phase
overload)
oCheck for loose wires on Contactor and Overload
oIt is recommended to change both components. Currently the Sprecher & Schuh (S & S)
brand we use will need both pieces to be changed, regardless if there is an old S & S in the
machine. The new revision will not work with the old.
o**** Components from different manufacturers cannot be combined. ****

TSM-35 Screw Pocket Machine Troubleshooting
35.11 Test Safety Interlock Switch (NO)
•Disconnect power and air from the machine.
•Unplug the black wire on the pressure switch located in the control box just above the control
board.
•Touch continuity tester to “A1” on the contactor and to the black wire that was removed from the
pin on the pressure gauge.
•When lid is closed, the switch tester should read closed. When the lid is opened, the tester should
read open.
For Machines without the Air Pressure Switch:
•Disconnect power and air from the machine.
•Touch the continuity tested to “A1” on the
contactor and pin #2at the back of the stop
switch.
•When the lid is closed, the switch tester should
read closed. When the lid is opened, the tester
should read open.

TSM-35 Screw Pocket Machine Troubleshooting
35.12 Test Start Switch (NO)
•Disconnect air and power from the machine
•Locate the contact block for the start switch located on the back side of the control box enclosure
door.
•With a continuity tester, touch “-3” and “-4” terminals on the contact block.
•The switch should read (NO) at rest. When the start button is depressed the switch should close.
35.13 Test Stop Switch (NC)
•Disconnect air and power to the machine
•Locate the stop switch contact block on the back of the control box enclosure door.
•Use continuity tester and touch the pins to “-1” and “-2” on the stop switch contact block.
•When the stop switch is pushed in, the continuity tester should read open.
•When the switch is in the out position, the tester will read closed.

TSM-35 Screw Pocket Machine Troubleshooting
35.14 Test Air Pressure Switch (NO)
•Disconnect power and air from the machine.
•Unplug the black and red wires from the pressure switch
•Touch both of the pins on the pressure switch with the tester pins.
•The switch should read open with no air attached to the machine.
•Attach air to the machine and the switch should then read closed.
NOTE:
The air pressure switch is no longer used in the TSM-35. Its removal does not constitute a safety
issue.
To bypass the switch in the system:
•Unplug the black and red wires from the pressure switch
•Cut the terminals off the wires, and strip the insulation
•Twist the ends together lightly
•Used a locknut to secure the wires

TSM-35 Screw Pocket Machine Troubleshooting
35.15 Motor starts, but cycle does not initiate:
•Confirm machine is receiving air.
!*** ALWAYS DISCONNECT POWER AND AIR WHEN CHECKING SWITCHES ***!
•Check the stock sense switch (E10850) and safety blade (C35101)
oCheck switch for continuity: (Also See 35.16)
Remove one wire from the switch
Check for continuity at the switch by placing probes on the screws
and moving the stock sense lever out of the way, then back
oCheck safety blade to make sure it swings and moves out of the way of the
magnet when safety buttons are depressed
•Check the foot pedal switch (E07041 Switch only / E00491 Foot Pedal with Cord)
(Also See 35.17)
oCheck for continuity change when depressed – can check at the switch or
at terminals 3 & 4 on the terminal strip
oJust switch can be changed. Buy from Castle or Grainger part 6X283
•Check to make sure there is power (24V AC) going into the board at terminals 1 & 2
o*** CAUTION: ONLY A QUALIFIED ELECTRICIAN SHOULD PERFORM THE
FOLLOWING STEPS. POWER MUST BE SUPPLIED TO THE MACHINE TO CHECK THE
TRANSFORMER AND CONTROL BOARD. THIS PRODUCES A SHOCKING HAZZARD. DO NOT
TOUCH THE CONTROL BOX COMPONENTS WITH ANYTHING OTHER THAN ELECTIRCAL
TESTING PROBES. ***
oCheck the transformer if no power (E35713)
oThere should be 230V 3ph or 480V 3ph going into the transformer (Check H1 (480V) or H2
(230V) AND H4 at top of transformer)
If no power into the transformer, check main power to the machine
oThere should be 24V AC coming out of the transformer and entering the board at terminals
1 and 2
oCheck to make sure the fuse is intact (E16224)
•Check to make sure that when a cycle is initiated, that there is 24V DC coming from the board to the
clamp solenoid at terminals 11 & 12
o*** CAUTION: ONLY A QUALIFIED ELECTRICIAN SHOULD PERFORM THE
FOLLOWING STEPS. POWER MUST BE SUPPLIED TO THE MACHINE TO CHECK THE
CONTROL BOARD. THIS PRODUCES A SHOCKING HAZZARD. DO NOT TOUCH THE CONTROL
BOX COMPONENTS WITH ANYTHING OTHER THAN ELECTIRCAL TESTING PROBES. ***
oRun a cycle on the machine (put the stock in place, depress the safety buttons, and press the
foot pedal), then check the pins at terminals 11 & 12, then the screws at 11 & 12
If there is no power at the pins, change the board (E35424)
If there is power at the pins, but not at the screws, change the terminal strip
(E21016)

TSM-35 Screw Pocket Machine Troubleshooting
35.16 Test Stock Sense / Safety Blade Switch
•Disconnect power and air to the machine.
•Make sure the case top is shut.
•Locate pins “5” and “6” on the pin strip in the control box.
•Touch continuity tester to “5” and “6” on the pin strip.
•Continuity tester should read open.
•Press in safety buttons under the clamp guard and tester should read closed.

TSM-35 Screw Pocket Machine Troubleshooting
35.17 Test Foot Switch
•Disconnect air and power to the machine
•Locate pins “3” and “4” on the pin strip of the control board.
•Touch continuity tester pins to “3” and “4” on the pin strip and the switch should read open.
•Step on the foot peddle while still touching the pins and the continuity tester should read closed.

TSM-35 Screw Pocket Machine Troubleshooting
35.18 Machine starts, but shuts down when cycle is initiated:
!***ALWAYS DISCONNECT POWER AND AIR WHEN CHECKING SWITCHES ***!
•Check the air pressure switch. Most common reason. (E35420) (See 35.14)
oThe air pressure switch is set at 40 psi at the factory. It can often go bad and be hard to
diagnose.
oThe easiest way to check is to bridge the two wires and see if the machine will turn on.
oWe no longer use the air pressure switch. Customers can keep the bridge in place if they do
not wish to replace.
o
•Check the overload (E91827 480V Overload / E94060 230V Overload / E94061 Single phase overload)
oIncrease the amperage capacity on the overload.
oIf this does not solve the issue, then most likely the problem is with the contactor or
overload.
oIt is recommended to change both components. Currently the Sprecher & Schuh (S & S)
brand we use will need both pieces to be changed, regardless if there is an old S & S in the
machine. The new revision will not work with the old. (E91024 – Contactor)
o**** Contactors and overload components from different manufacturers cannot be
combined. ****

TSM-35 Screw Pocket Machine Troubleshooting
35.19 No cycle - Clamp begins to come down, and immediately goes back
up (flutters):
•Change the drill stop switch (E35010/ E35009 – Strap)
oThis is the most common reason