Service Home TSC-1000 - Troubleshooting Guide - CHC
Last updated: 10/30/2024

TSC-1000 - Troubleshooting Guide

Introduction

Download and fill out the coolant pump Inspection Report Checklist below before replacing any parts.

Coolant pump Inspection Report Checklist

This image shows the following components of the TSC system:

  1. TSC-1000 Pump
  2. Check Valve:
  3. Vacuum Generator:
  4. Precharge Solenoid (40-Taper belt-driven):

    or

    Coolant Union Solenoid (50-Taper or inline):

Output Pressure Reference Chart

This graph shows approximate pressure vs. tool orifice diameters.

Flow Rate Reference Chart

This graph shows approximate Flowrates vs. tool orifice diameters. This data can be used to aid in the selection of an appropriate spindle speeder for your appliaction.

Symptom Table

Symptom Possible Cause Corrective Action
Alarm 151 LOW THROUGH SPINDLE COOLANT There is an electrical fault with the TSC power supply. Inspect the contactors.
There is no incoming voltage. Check the incoming power.
The TSC pressure sensor does not work. Some coolant flow may occur if this is the case. Test and troubleshoot the coolant pressure sensor.

40T and 50T Belted Spindles

Pull studs will not enter into spindle taper

And possibly one of the following alarms:

Alarm 130 Tool Unclamped
Alarm 134 Tool Unclamp Fault

 There is noise being introduced through the IO and pre-charge solenoid. Order service kits 93-3451 & 93-3452 and follow the Low Load Solenoid Valve Kit - Installation procedure.
Excessive noise from pump Gear pump coupler misalignment. Order kit 93-4195 Coolant Gear Pump Coupler Conversion. Follow the Pump Head Coupling - Flexible Coupling Replacement procedure.

Low coolant flow, no alarm.

Low coolant flow, the pump cavitates (cavitation sounds like heavy grit in the pump head, or a suction sound) or is otherwise noisy

 The coolant does not return to the coolant tank fast enough. Remove chip buildup from the coolant return path.
The coolant level drops in the auxiliary filter tank while the machine is in operation. Check for leaks and inspect the gasket.
The auxiliary filter is dirty. Clean or Replace the auxiliary filter.
Air is trapped in the coolant pump. Cycle the pump power.
The vacuum generator, or air bleed valve, valve on the pump does not operate correctly. Clean the vacuum generator assembly, or air bleed valve.
Chips clog the supply hose. Remove all chips from the supply hose, the fittings, and the pipes.
The output hose touches the machine enclosure. Move the coolant output hose. Vibration from the hose can cause noise.
The pickup hose fittings are loose. Tighten the pickup hose fittings.
Gear pump coupler misalignment. Order kit 93-4195 Coolant Gear Pump Coupler Conversion. Follow the  Pump Head Coupling - Flexible Coupling Replacement procedure.

Electrical Fault

Check for a tripped circuit breaker [1] in the coolant pump.

Loose wires can cause arcing. Tighten and inspect the circuit breaker [1] and the contactor [2]. Make sure the screws that hold the wires of the circuit breaker [1] and contactor [2] are secure and tight.

Check the incoming voltage to the TSC unit. The TSC receives power from a separate source, independent from the machine's power. If there is no voltage, check for the tripped breaker at the external power supply. If the breaker is tripped, check for a short to ground at the external power supply connection.

Check the pump for shorts:

Measure the (3) leads to ground in the TSC power cable. If all leads test open to ground, the pump and cable do not have a short.

If the power cable lead test indicates a short, disconnect the cable from the motor. Measure the (3) cable leads on the pump contactor [2] to ground. If any lead on the pump contactor [2] tests short, the pump is at fault. If the pump contactor [2] leads do not test for short, the cable is at fault.

If all leads test OK:

Check the TSC motor for binding that could cause an over amperage condition.

Coolant Pump Operation

Vibrations or signs of rough operation are normal at high pressures.

Move the 1000-PSI coolant output hose away from the machine enclosure.

The oil level in the reservoir rises when the pump is hot and in operation. Check the oil level in the oil reservoir [1] when the pump is cold. Fill it to the cold fill line [2] with 5-30W synthetic oil.

TSC Pressure-Sensor Failure

Coolant Blockage

Remove all chips from the the auger trough [1], and the coolant return drain [2]. Complete these tasks:

Check for leaks in the intake hose from the coolant tank. Make sure that the tank lid gasket is not damaged, and that it is clean. Make sure that the latches are tight and locked. Do not over-tighten the latches. Use the wash down hose on the standard coolant pump to fill the auxiliary filter tank.

Make sure the pump pick-up tube is tightly connected to the tank lid. Cycle the power to the coolant pump to clear the empty chambers of air until the pump runs smoothly.

Drain the auxiliary filter tank. Remove the cover from the auxiliary filter cart.

Clean the auxiliary filter vacuum-generator assembly: Remove the components as shown in the illustration. Remove all of the chips that clog the supply hose in the coolant tank, the fittings, and the pipes.

Pumps without the vacuum generator have a prime line fitting [1] and an air bleed valve [2]. Clean prime line fitting [1] and the air bleed valve [2]. Make sure the prime line fitting [1] and the air bleed valve [2] are not clogged.

Coolant Check Valve Inspection

Shuttle & Ball

This check valve has a ball deflector [2] inside rather than a spring. The ball deflector acts as a shuttle by directing the ball from one location to another--either blocking the coolant or TAB opening.

As coolant flows into the valve, the ball gets pushed and deflected out of the way [3]. When TAB air flows into the valve, the ball gets pushed back down due to both air and gravity [4].

The new shuttle and ball check valve also has a new elbow fitting that is slotted [1]. This elbow fitting allows a small amount of coolant or air pressure through to pressurize the pressure sensor.

Spring & Ball

Coolant pressure can push the ball into the spring and trap it, causing the check valve to fail.  Without a functional check valve, air from the TAB may flow backward through the coolant system and cause the coolant tank to overflow and/or bubble. 

Corrective Action:

Disassemble and visually inspect the check valve for any deformities. Make sure the ball isn't trapped inside the spring. If it is, the spring would be pushing the ball against the countersink of the fitting.

Tool Air Blast (TAB) causes coolant tank overflow

Through Spindle Coolant (TSC) flow diagram.

Electrical Diagram