Interact 1 Mk2 w/ TNC 2500 Gross Positioning Error

All,

We think a part time employee plugged a shop-vac into the 110V receptacle on our mill. The evidence was a blown fuse on the 110V circuit. This has happened before. The one other time this happened we replaced the fuse and everything worked fine. Not this time. We are speculating about the shop-vac because that is what happened last time. (No one has confessed.)

Our problem is this: as soon as we press the I-button the feed contactor (5FC) pulls in and about a half second later the controller faults out with a GROSS POSITIONING ERROR D. All of this happens before we are begin the 'TRAVERSE AXIS' procedure.

We have isolated each axis and tested them individually by following the steps below:

X Axis
* Power down
* Unplug power and control connectors to Y and Z axes
* Power up
* set MP 10 = 1
* set MP 50 = 1
* Press I-Button -> I-button lights up and stays lit
* Press green Start button -> GROSS POSITIONING ERROR C

Y Axis
* Power down
* Unplug power and control connectors to X and Z axes
* Power up
* set MP 10 = 2
* set MP 50 = 2
* Press I-Button -> I-button lights for 1/2 sec. -> GROSS POSITIONING ERROR D

Z Axis
* Power down
* Unplug power and control connectors to X and Y axes
* Power up
* set MP 10 = 4
* set MP 50 = 4
* Press I-Button -> I-button lights for 1/2 sec. -> GROSS POSITIONING ERROR D

There are three different 24VDC circuits and they all read 24.3 to 24.5VDC
TB26&TB39 rectifier output = 24.4VDC
TB9&TB10 PSU1 output = 24.3VDC
TB33&TB34 PSU2 output =24.2VDC
TB5&TB6 Transformer T1 output = 110VAC
3Phase Transformer T2 output = 110V phase-to-phase
(NOTE When we started troubleshooting the L1,L2,L3 lines to the servo drives all read very near 120V phase to phase. Our schematic says T2 should have 105V on the secondary side going to the drives. We moved the primary side wires to 415V and we now have 110V on the secondary side. As far as I know T2 has not been adjusted since we have had this machine so it has probably always worked at 120V)

Can anyone suggest where to look or what our problem may be?

Thanks in advance,
Joey H.