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SYNTEC CNC Maintenance Manual
by：SynTec Incorporation Ver：1.3 date：1999/12/01
SYNTEC CNC Maintenance Manual
Table Of Contents 1. HARDWARE SYSTEM STRUCTURE.............................................................................................3 1.1 INTRODUCTION OF THE SYSTEM STRUCTURE..............................................................................................3 2. MOTHER BOARD TROUBLESHOOTING....................................................................................6 2.1 TROUBLESHOOTING STEPS OF CONTROLLER MOTHER BOARD.....................................................................6 2.2 POSSIBLE REASONS OF FAIL SWITCHING ON .............................................................................................8 2.3 TROUBLESHOOTING OF CPU CARD MEMORIES...........................................................................................9 2.4 USUAL EXTRAODINARY PHENOMENA AND REPLACEMENT STEPS ON MOTHER BOARD.................................10 3. INTRODUCTION OF IO SYSTEM................................................................................................11 3.1 THE STEPS OF I/O TROUBLESHOOTING....................................................................................................12 3.2 BREAKDOWN ANALYSIS AND ELIMIATION OF I/O......................................................................................13 4. SERVO SYSTEM TROUBLESHOOTING.....................................................................................14 4.1 THE STEPS OF SERVO SYSTEM TROUBLESHOOTING...................................................................................15 4.2 HARDWARE BREAKDOWN OF THE SERVO SYSTEM.....................................................................................16 4.3 RELATIVE SERVO ALARM WITH PRECISION..............................................................................................17 5. INTRODUCTION OF PANEL MODULE ......................................................................................18 5.1 THE STEPS OF PANEL MODULE TROUBLESHOOTING..................................................................................19 5.2 BREAKDOWN ANALYSIS AND ELIMIATION OF PANEL MODULE...................................................................20 5.3 REPLACEMENT STEPS OF THE NETWORK.................................................................................................21 6. RENOVATION OF SOFTWARE ....................................................................................................22 6.1 CNC CUSTOMER DATA RESERVE..............................................................................................................23 6.2 INSTALLATION PROCEDURES OF SYSTEM SOFTWARE..................................................................................24 6.3 REINSTALLATION OF SYSTEM SOFTWARE UNDER DOS PROGRAM................................................................25 6.4 CNC CUSTOMER DATA INSTALLATION.......................................................................................................26
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SYNTEC CNC Maintenance Manual
1. Hardware System Structure 1.1 Introduction Of The System Structure
1.
The system structure is as diagram (1), it could divide into below modules: Panel module : 900 Type: the first panel + The second panel 940 Type: the first panel of integration type(combine the first and second panel)
2.
CNC controller BABY series: BABY1 : 1476IPC + SERVO4 + PIO3*1 BABY2 : 1476IPC + SERVO4 + PIO3*2 BABY3 : 1476IPC + SERVO4*2 + PIO3*1 ERK6 series: 1476IPC + SERVO5*n + PIO3*n
3.
Servo system: *. Motor driver + Servo motor *. Transducer + Transducer motor + Encoder
4.
Machine I/O matching: SYNTEC controller provides a machine matching board to decrease the difficulty of the matching. (RELAY1 ,RELAY2) : *. Standard I/O (97-RELAY2) : 40 Input + 12 Relay output *. Optional I/O (PIO3+97-RELAY1) : ( 8I + 15 O)*2
5.
Heavy power matching : *. POWER, SWITCH ON, E.STOP, Oil pressure pump, Cutting liquid ……
3
SYNTEC CNC Maintenance Manual
SYNTEC PC based CNC system structure diagram:
SYNTEC CNC HARDWARE ARCHITECTURE(900T/900M) : SYNTEC 900M O
A
N
Z
U
I
L
!
| M
S
>
9" CRT
BACK SPACE
/
( :
8
9
4
5
6
1
2
0
F1
F2
³s ° Ê
¤o°Ê
F4
F3
F6
F5
F7
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AU X4
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AUX 1
AUX 2
*
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; ,
]
+
S H IF T
INS
3
D EL
SPACE
E NT ER
*1
MPG
HELP
G01 %
Sp indle %
ON
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E
*100 *1000
* 10 A
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Q
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7
CRT module : Dimension : 400(W)*200(H)*300(D) Hole : 195*195*190(M3*6)
F
P
T =
<
RE SET
D
W
V
K
J
R
C
B
Y
X
G
OFF
Second operation panel : Dimension: 400(W)*200(H)*100(D) HOLE : 195*195*190(M3*6)
2 2 2 2 TIME
¤â½ ü
I40..I79 O40..O79
EMERGENCY
I16..I39 First :I80..I87 ,O80..O95 Second :I88..I95 O96..110
S P E 5 I R O V 4 2 O | 3 4 2 2
P I O 2 | 1
I P C
Option I/O: 30 Output + 16 Input
96-WRELAY1
SYNTEC BABY2
C N 29 7 - C N C Standard I/O CN1 12 Output -RELAY2 + 40Input
1
X DRIVER
LIG Power ON ,OFF WAT E.STOP HYD ...
X
HT ER RAULIC ..
I0..I39 ,O0..O11
POWER UNIT
Y DRIVER
Y
Z DRIVER
Z
LIGHT
WATER HYDRAULIC
Inveter
Motor
CHIPS .....
SYNTEC CNC ARCHITECTURE 4
SYNTEC CNC Maintenance Manual
1.2 The Steps Of System Troubleshooting For maintenance of SYNTEC PC based CNC controller, please take the following steps to find out the possible problems. And, turn to the relative pages of this manual: NO
Step 1. Power on Distribution panel power on or not Yes
NO
Step 2. CNC controller power off normally or not Yes
NO
Step 3. I/O action normally or not
Heavy power breakdown of the distribution panel, please according to electric diagram to inspect the problem 1. Breakdown of the CPU card (Chap.2) 2. CNC Power breakdown 3. Monitor module breakdown(Chap5) I/O card breakdown (Chap3)
Yes Step 4. Servo action normally or not
NO
1. Breakdown of the servo motor driver 2. spindle card breakdown (Chap4)
NO
1. Servo problems (Chap4)
Yes Step 5. Machining precision is normal or not
Step 6. Renovation steps of software (Chap 6)
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SYNTEC CNC Maintenance Manual
2. Mother Board Troubleshooting There are three major reasons that the machine could not be switched on: 1. Breakdown of power supply, fail to start the CPU card 2. Breakdown of CPU card, fail to switch on. 3. Breakdown of monitor module, CPU card and power supply normally work, but the monitor is broken down. No screen is shown, and the situation is same as failure of switching on.
CPU Board (AR-B1476/AR-B1047) :
AR-B1047
29EE010 SRAM5
SRAM2
SRAM4
SRAM1
SRAM3
DOC1
AR-B1047 RAM/ROM card AR-B1476 CPU card
1. SY CP RA 2. CP
NT U M/ U
E b R b
C o O o
C ar M ar
N d c d
C CPU : AR ard : (AR-B
2. RA BI st La Gr DO 2. Ad
M/ OS an th in C dr
RO c da e di : es
M( hi rd ,M ng 8M s
ARp o ac ill : B set
B10 n t ces ing SRA
b -B A 14
oa 14 R76
rd description : 76 B1047 ) : AMD 5x86 ,8MB DRAM on board
47) : T he righ sory ,a : SRAM M 512KB
he t nd 5 *2
re han on 12K
ar d e B*
e seven socket on the board ,except corner ,there is a DiskOnChip is or two 512KB SRAM on the board : 1
ting as bellow : ON
CPU boardAR-B1476) : 1
2
3
4
ON
RAM/ROM card(AR-B1047) : 1
2
3
45
6
7
8
2.1 Troubleshooting Steps Of Controller Mother Board When the possible breakdown of motherboard occurs, please take the 6
SYNTEC CNC Maintenance Manual
following steps to find out the problems. NO
Step 1. POWER ON Rack of controller light on
Breakdown of the power supply, replacing the power supply (Chap2.1)
Yes Step 2. Controller could power on, but reset often
Yes
Unstable of the power supply, replacing the power supply ( 或是控制器機箱 )
NO Step 3. No power on action and frame
Yes
Breakdown of CPU card(Chap2.2)
Yes
Breakdown of memories (Chap2.3)
Yes
Breakdown of monitor module (Chap.3)
NO Step 4. Having frame when power on, but no action
NO Step 5. Having action when power on, but no frame
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SYNTEC CNC Maintenance Manual
2.2 Possible Reasons Of Fail Switching On Breakdown of the controller power supply: 1. When switching on, if no screen is shown or there is no action, the CPU card or power supply may be broken down. Please check the power output is OK. 2. Checking the upper red light of the controller to make sure whether it is on or not (upper side of rack). If not, it indicates no power output from the power supply. The power supply may be broken down. Please replace the power supply. 3. Opening the flank cover, checking the +5V of power plug is normal or not by electric multi-tester (red: +5 , black: GND). The normal output of the power supply is +4.95 - +5.1V. When the output of power supply is under 4.8V, then the controller could not be switched on, or reset after operating a while automatically. Please replace the power supply. 4. If the power plug could not be measured, you can measure the power plug of the hard disk (Red and black wire : +5V) to see whether the power output is normal or not (+4.95 - +5.1 V). Breakdown of the monitor module: 1. The monitor module should be broken down if the following conditions occur: power supply is normal, I/O action of panel is normal after 3 minutes, and no any frame. Breakdown of the CPU card: 2. The CPU card may be broken down if the following conditions occur: power supply is normal, but no I/O action of panel after 3 minutes, and no any frame.
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SYNTEC CNC Maintenance Manual
2.3 Troubleshooting Of Cpu Card Memories 1. Analysis of memories: There are three kinds of internal memories on SYNTEC CNC: DRAM, SRAM, DOC, the analysis is as below: DRAM: It solders on the board directly, but no memory function. After switch off, the data will vanish. The reliability is very high, and the breakdown rate is very low. It solders on the board directly. SRAM: Having memory function, after switch off the data is still exist. If the battery breakdown occurs (the battery life is 10 years), the data will be lost. It fixes on RAM/ROM card. DOC: It is FLASH memory equipment of high capacity. The characteristic of the FLASH is rewritable, no needing battery. It could keep the data forever, but if the save times is too many, the it may have problem. (fixed on the board) .
1
When switching on, there is PC switching on frame on the controller. The self-diagnosis action of switching on frame, such as: RAM test, and appearance of final strait-jacket. It should be DOC problem when dwell on the ” Starting DOS “, and could not come into CNC software. Please replace the DOC and frame would be as below: AMI BIOS ….. Main Processor: Base Memory size Math Processor: Ext Memory size Floppy Drive A : Display Type Floppy Drive B : Serial port Processor clock : Parallel 512KB CACHE Memory Starting DOS …
2
When switching on, the controller could come into the normal frame, but cutting program file vanishes after the switch off and could not save. It should be the problem of SRAM battery, please replace the battery or RAM/ROM card.
3
Maintenance method in case of the breakdown of memories (1476 CPU card) : DOC replacement: Take off CPU card and RAM/ROM card. Take off the old DOC and put the new DOC on by the “-“ type screwdriver. Then equip the RAM/ROM card and install the DOC software. RAM/ROM card replacement: Replace the anew RAM/ROM card directly.
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SYNTEC CNC Maintenance Manual
2.4 Usual Extraodinary Phenomena And Replacement Steps On Mother Board Abnormal phenomenon of CPU card: 1. The slots of the motherboard do not contact perfectly: *. After switch on, the frames are all normal, but the spindle card or I/O action is not normal. If the condition still exists after you replace the spindle card and I/O card, it should be not contact perfectly on the slots. Please take off the mother board, clean the gold fingers, and plug it back to slot. 2. Sudden shutdown of the computer : The reasons may be as below : *. Overheat, please check the CPU fan is lost or breakdown. *. Overheat, the vent of controller is block or not. *. Over vibrating on the motherboard. Please enhance the motherboard fixed, or decreasing the vibrating of the machine. Steps to CPU card replacement: 1. Take off the BABY RACK of the controller by the screwdriver. 2. Take off CPU card (the right one of the 4 pieces) , beware the plug position before taking off. 3. Take off RAM/ROM card, replace the old DOC and put the new on. 4. Put back the CPU card to the slot, and connect all plugs. 5. Inspect the power wire, keyboard wire, ad monitor wire is OK or not. (upper side of the controller) , 6. Check the wire of hard disk is Ok or not. 7. CPU fan is Ok or not. (on the CPU card) 8. Switch on again, inspect the action of CPU fan, controller fan is normal or not. 9. See whether the action of the controller is right or not.
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SYNTEC CNC Maintenance Manual
3. Introduction Of Io System The first I/O card (standard equipment): PIO + RELAY2 + HARDKEY The second I/O card (optional equipment): PIO + RELAY1*2
First I/O board(PIO-1) : Z
Y
*100 *1000
*10 A
X
*1
MPG SELECT
MPG
´ M ì ÂI
G01 %
¦Û ° Ê
³s ° Ê
Z+
Y+
X-
ON
X+
OFF Z-
2 2 2 2 TIME
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»»±± ²°
*1
* 10
¿ ï¾ Ü ¸ õ ÅD
¿ ï¾ Ü ° ± ¤î
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* 10 0 0
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¤Á¤ M
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A UX 3
A UX 4
§¨ ¤ ö
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AU X1
A UX 2
Spindle %
°_°Ê
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µ {¦ ¡ ªÅ¶ ]
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EMERGENCY
Second operation panel
CN2
CN1(F) TO CNC JP 1 R L Y 0 +0 + R L Y 0 -0 R L Y 1 +1 + R L Y 1 -1 R L Y 2 +2 + R L Y 2 -2 R L Y 3 +3 + R L Y 3 -3 JP 4 R L Y 4 +4 + R L Y 4 -4 R L Y 5 +5 + R L Y 5 -5 R L Y 6 +6 + R L Y 6 -6 R L Y 7 +6 + R L Y 7 -6 -
CN2(M) TO Machine G N D JP 2 GND
RLY0
IN0 IN1 IN2 JP3 IN3 IN4 IN5 IN6 IN7
RLY1 RLY2 RLY3
RLY4 RLY5
9 7 - C N C - R EL A Y2 SN :
RLY6
RLY7
JP6
RLY8+ 8+ RLY8- 8RLY9+ 9+ RLY9- 9R L Y 1 0 +1 0 + R L Y 1 0 -1 0 R L Y 1 1 +1 1 + R L Y 1 1 -1 1 -
RLY8
IN8 IN9 IN10 I N 1 1 JP 5 IN12 IN13 IN14 IN15
JP7
RLY9 RLY10
CN1
96-W-PIO2
GND GND +5V GND
FUSE
RLY11
Second I/O Board : CN2
JP1 R L Y 0 +0 + RLY0 R L Y 0 -0 R L Y 1 +1 + R L Y 1 R L Y 1 -1 R L Y 2 +2 + R L Y 2 R L Y 2 -2 R L Y 3 +3 + R L Y 3 R L Y 3 -3 JP4 R L Y 4 +4 + RLY4 R L Y 4 -4 R L Y 5 +5 + R L Y 5 R L Y 5 -5 R L Y 6 +6 + R L Y 6 R L Y 6 -6 R L Y 7 +6 + R L Y 7 R L Y 7 -6 JP6 RLY8+ 8+ RLY8 RLY8- 8RLY9+ 9+ RLY9 RLY9- 9R L Y 1 0 +1 0 + R L Y 1 0 R L Y 1 0 -1 0 R L Y 1 1 +1 1 + R L Y 1 1 R L Y 1 1 -1 1 -
CN1(F) TO CNC
220H
IN 0 IN 0 IN 1 IN 1 JP3 IN 2 IN 2 IN 3 IN 3
96-W-RELAY1 IN 4 IN 4 IN 5 IN 5 J P 5 IN 6 IN 6 IN 7 IN 7
SN :
FUSE
+5V GND
JP1 R L Y 0 +0 + RLY0 R L Y 0 -0 R L Y 1 +1 + R L Y 1 R L Y 1 -1 R L Y 2 +2 + R L Y 2 R L Y 2 -2 R L Y 3 +3 + R L Y 3 R L Y 3 -3 JP4 R L Y 4 +4 + RLY4 R L Y 4 -4 R L Y 5 +5 + R L Y 5 R L Y 5 -5 R L Y 6 +6 + R L Y 6 R L Y 6 -6 R L Y 7 +6 + R L Y 7 R L Y 7 -6 JP6 R L Y8 + 8 + R L Y 8 R L Y8 - 8 R L Y9 + 9 + R L Y 9 R L Y9 - 9 R L Y 1 0 +1 0 + R L Y 1 0 R L Y 1 0 -1 0 R L Y 1 1 +1 1 + R L Y 1 1 R L Y 1 1 -1 1 -
CN1(F) TO CNC
IN0 IN0 IN1 IN1 JP3 IN2 IN2 IN3 IN3
9 6 - W -R EL A Y 1 IN4 IN4 IN5 IN5 JP5 IN6 IN6 IN7 IN7
SN :
FUSE
11
+5V GND
CN1
97-PIO3
SYNTEC CNC Maintenance Manual
3.1 The Steps Of I/O Troubleshooting When the possible breakdown of IO module occurs, please take the following steps to make a diagnosis. Step 1. CNC power on succeeds, RELAY1 and RELAY2 green lights are off
Yes
1. Breakdown of the power supply 2. Burnout of fuse 3. Slack of the wires (3.3).
NO Yes
Step 2. Could not see ”I” input point on the diagnosis frame when pressing Aux. panel button (hard key)
1. Breakdown of PIO card(3.2) 2. Hard key no power 3. Slack of wires
NO Step 3. There is no any bright or glitter on the 3 yellow lights of RELAY2 (D37,D38,D39)
Yes
1. Breakdown of PIO card (3.2) 2. Relay no power
NO Step 4. There are some error actions on the I/O points of RELAY1, 2
Yes
1. Contact not well on the contacting position. 2. Interference of noise (3.2)
NO Step 5. There are 1-2 error actions on I/O points of RELAY1, 2 (not by chance)
Yes
12
1. Slack of the wires 2. Breakdown of the RELAY board
SYNTEC CNC Maintenance Manual
3.2 Breakdown Analysis And Elimiation Of I/O SYNTEC CNC I/O breakdowns may have the following types: interference of noise, power breakdown, PCB breakdown, and Relay board breakdown. The detailed description are as below: Step 1. Power breakdown: RELAY1, RELAY2, and hard key all need the power from power supply, and work normally. Therefore, green lights of these 3 boards are not bright, it may the problem of the power supply. Please check that is there any wire slack, breakdown of the power supply, or burnout of the fuse on the board. Step 2. Inspect the second board: When there is no any action on all of I/O, please check whether the green lights on the second board are bright or not. If the power is normal, it may PIO board breakdown, please replace the PIO card. Step 3. Inspect RELAY2: If the 3 yellow lights(D37,D38,D39) of RELAY2 are not bright or no glitter, there is no any action on all I/O, it maybe PIO card breakdown, or RELAY2 breakdown. Step 4. Noise interference: The controller may have some error actions due to noise interference. SYNTEC CNC provides the digital filter setting (parameter 15, setup value: 0.3). The bigger of the parameter setting value and stronger of the noise defense ability, the slower I/O response relatively. When the parameter is set to 3, but the error action is still exist. It should not be the problem of noise interference, and would be not contact well of the contacting points on the wires. Please check the relative wires. Step 5. Input breakdown of relay2 board: There are some abnormal actions on the input points of RELAY2, it should be the breakdown of the RELAY2 board. Please replace the RELAY2. Step 6. Output breakdown of the relay1, 2 relay: 1. The red light of the RELAY board is bright, but there is no any action on the output point of the relay. It should be the relay breakdown, please replace the relay (spares parts) 2. The relay2 action pushed by the PIO, therefore, there is some abnormal action on RELAY board. It may be breakdown of PIO, If the OUTPUT point of the diagnosis frame is “on”, but the corresponding relay board is not bright, it should be PIO breakdown. Please replace the PIO.
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SYNTEC CNC Maintenance Manual
4. Servo System Troubleshooting Description of the servo system: Servo system is composed of CNC spindle card, and servo motor driver.
Servo card(SERVO4) AXIS 1
: AXIS 4 MPG + DA
AXIS 3
AXIS 2
RY5W-K HP2531PC847
AM2631
H P 2 5 3 1 H P 2 5 3 1H P 2 5 3 1 P C 8 4 7
AM2631
HP2531 HP2531HP2531
TL074
AXIS 4
ACTEL 1240
CRISTAL1
PM7541 REF01
74245
IRQ jmp
74245
74688
74245
ON
Fig. SYNTEC CNC servo card
14
1
2
3
4
SYNTEC CNC Maintenance Manual
4.1 The Steps Of Servo System Troubleshooting When the possible breakdown of the servo system occurs, please take the following steps to diagnose the system.
Step 1. CNC power on, Press the E. stop button, Check Alarm message from servo driver NO
Yes
Alarm of the driver Alarm of the motor (4.2)
Yes Step 2. Small turning of the MPG wheel of , alarmed oss pulse �message from CNC.
The alarm action of iss position command�(4.3)
NO Step 3. ollowing error too big �of CNC alarm during cutting.
Yes
The alarm action of ollowing error too big t�(4.3)
NO Step 4. atal following error too big �of CNC alarm during cutting.
Yes
The alarm action of atal error too big�(4.3)
NO Step 5. “loss pulse” of CNC alarm during cutting.
Yes
15
The mechanism is not smooth, could not precise positioning, check is there any jam on mechanism during the cutting.
SYNTEC CNC Maintenance Manual
4.2 Hardware Breakdown Of The Servo System SYNTEC CNC servo system is composed of spindle card (servo4), servo motor , spindle motor, and transducer. The detailed descriptions are as follows: Spindle card: SYNTEC CNC spindle card (SERVO4), the spec is (4+1) axes, control X,Y, Z axes, MPG, spindle encoder, transducer 0-10V output, Servo motor, servo driver: drive X,Y, Z servo motor, X-Y table precise positioning control. Transducer: Spindle speed control, input voltage is 0-10V Analysis of the breakdown: We can divide alarm of the servo systems into two parts: One is the protection of usage, such as over load protection (over current, over voltage….), precision protection (ex: miss position command, tolerance of overshoot is too big ….) ,….another kind of breakdown is belong to hardware breakdown. This section mostly describe the hardware aspect: “Alarm of the servo driver”: When the servo system alarms, please check if the hardware has any problem. Step 1.Open the power control box, to see if any bright alarm exist on the servo driver. Step 2.When there is bright alarm, it indicates the problem is between the driver and motor. Please solve the relative breakdowns according to the content of the bright alarm. Step 3. When there is no any bright alarm, it indicates the problem is in the controller or machine. Please solve the relative breakdowns according to the content of the bright alarm. “Alarm of the spindle inverter”: When CNC controller get the alarm from inverter, it will transfer the message to CRT screen. This moment, open the power unit, could see bright alarm on the inverter. Please solve the relative breakdowns according to the content of the bright alarm.
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SYNTEC CNC Maintenance Manual
4.3 Relative Servo Alarm With Precision The protection of the usage: SYNTEC CNC controller, there is perfectly self -diagnosis on the servo system. Besides the basic ”alarm of the servo driver”, there are several possible problems that is focusing on the machine precision and others, and produce the perfect alarm. We describe that as below: “loss pulse ”: Definition: After one second that CNC controller stop to pass orders, it would check that if the servo positioning precision is within 100 pulse. If it exceed this value, the controller will produce the alarm message ” miss position command”, the possible reasons maybe as below: 1.The mechanism obstruction is too big, servo could not reach precise positioning. Please look over the relative mechanisms. 2. The signal transfer loss, please check the wires are normal or not. “Following error too big“: Definition: During the motion, controller should check the actual servo hysteresis with the theorem value at any time. When the hysteresis exceeds twice of reasonable value, the controller will produce this alarm message “overshooting tolerance is too big”. At the same time, ”stop” cutting, after the vanishment of this condition, we could press “CYCLE START”, and cutting again. Possible reasons: 1. The cutting load is too big, the driver alarm “ overload”. At the same time, opening the power controller box, we could see bright alarm on the driver. 2. There are some problems on transmission mechanism, the driver alarm “ overload”. At this moment, opening the power controller box, we could see bright alarm on the driver. “Fatal following error too big “: Definition: During the motion, controller should check the actual servo hysteresis with the theorem value at any time. When the hysteresis exceeds four times of reasonable value, the controller will produce this alarm message “overshooting tolerance is too big”. At the same time, ”emergency stop” cutting, it need to switch off the machine, then switch on again. Possible reasons: 1. The cutting load is too big, the driver alarm “ overload”. At the same time, opening the power controller box, we could see bright alarm on the driver. 3. Spindle card, or servo motor breakdown, it cause CNC could not control the machine in effective status. Therefore, we need to a emergency stop (spindle card, servo on relay, output: OFF). It need to switch off and switch on again to vanish the alarm.
17
SYNTEC CNC Maintenance Manual
5. Introduction Of Panel Module SYNETC CNC panel module diagram is as below: SYNTEC 900M O
A
N
Z
U
I
L
R > BACK SPAC E
S
F2
³s ° Ê
¤o°Ê
F3
F4
F5
F6
F7
( :
7
8
9
4
5
6
2
3
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¤â°Ê ¿é¤J
»»± ± ²°
*1
¾ ÷ ±ñ Âê© w
µ { ¦¡ ªÅ¶ ]
*1 0
¿ ï¾ Ü ¸ õÅD
¿ ï¾ Ü °±¤î
*100
*1000
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¤Á¤ M
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AUX3
AU X4
§¨¤ö
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AU X1
AUX2
Z
Y+
X-
X+
Z-
°_°Ê
@
*
;
+
SH I F T
,
INS
DEL
SPACE
HELP
*10 0 *1000
*10 A
X
MPG select Z+
E N TE R
# H
E
]
CRT module(First Panel) PC CRT + PC Keyboard
Q
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1
F
P
F8
Y ´ M ì ÂI
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0
F1
&
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D
W
V
K
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9" CRT
C
B
Y
X
G
*1
M PG
G01 %
S pind le %
ON
OFF
Y-
°± ¤ î
2 2 2 2 MPG
EMERGENCY
TIME
I40..I79 O40..O79
Operation Panel : Second panel Hardkey +rotatry switch hardkey : connected to PIO card(CN2) Rotatry switch connected to RELAY2 CN2
I16..I39
SYNETC CNC 900T/900M panel module could divide into below kinds: First panel: It composes of monitor module and letter key, the spec is compatible PC (parameter 3217 keyboard type be set as 3) P.S. SYNTEC CNC character key could connect with the PC keyboard. This function that connect with PC keyboard (parameter 3217 keyboard type is set as 0), is a very nice temporary way when breakdown of customer keyboard. It would not cause the cutting dwell due to keyboard breakdown. SYNTEC CNC monitor could be connected to PC monitor, too. When customer monitor breakdown, replace the PC monitor is a very nice temporary way when breakdown of customer monitor. It would not cause the cutting dwell due to monitor breakdown. Second panel: operating key and switch and so on.
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SYNTEC CNC Maintenance Manual
5.1 The Steps Of Panel Module Troubleshooting When the possible breakdown of the panel module occurs, please take the following steps to diagnose the system. Step 1. POWER ON The control box power on
Step 2. CNC controller power on normally
Phenomenon
Step 3. I/O action normally
Step 4. Breakdown of monitor (5.1 ,5.2 ,5.3)
Step 5. Replace the monitor
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The second panel light is normal 3 yellow light of RELAY2 bright
SYNTEC CNC Maintenance Manual
5.2 Breakdown Analysis And Elimiation Of Panel Module First panel: Condition of monitor breakdown: After switching on 3 minutes, there is no frame, but I/O action of panel is normal, Ex: E.STOP, oil pressure, manual….actions are normal. It maybe breakdown of the monitor, please replace the monitor. Temporary plan: It adopts PC VGA interface for SYNTEC CNC CRT. Therefore, we could use the personal monitor to be a temporary plan, and save the maintenance time. Condition of characters key breakdown: The single key could not appear, it should be the worst connecting of the keyboard mechanism. Please clean tit by the detergent (Ex: WD40). Through this manipulation, if it is still invalid, please replace the button, or replace the whole monitor. Temporary plan:: SYNTEC CNC characters key adopt PC keyboard interface. Therefore, it could use PC the keyboard to be a temporary plan, and save the maintenance time. ( parameter 3217 keyboard type be set as 0) . Second panel: Hardware: After switch on 3 minutes, there is no frame, but the I/O action of the panel is normal. Ex: E.STOP, oil pressure, manual….actions are normal. It maybe breakdown of the monitor, please replace the monitor. Temporary plan: It adopts PC VGA interface for SYNTEC CNC CRT. Therefore, we could use the personal monitor to be a temporary plan, and save the maintenance time. Condition of hardware key breakdown: Single key: The key could not appear, it should be the bad connection of the keyboard mechanism. Please clean tit by the detergent (Ex: WD-40). Through this manipulation, if it is still invalid, please replace the button, or replace the whole monitor. Whole keys: Hardware undergoes I/O scan by matrix point way on PIO card. When all of the keys are invalid, it may due to the lost of the +5V power hard key PCB, or I/O card breakdown. Partial keys: SYNTEC CNC hard key undergoes I/O scan by matrix point way on PIO card. Therefore the disability of these partial keys at the same time, it should be breakdown of the PIO card.
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SYNTEC CNC Maintenance Manual
5.3 Replacement Steps Of The Network The network may break by using, or lost by other reason. The network replacing steps are as follows: Step 1: Tear off the old network. Step 2: Clean the metal surface by the vaporization detergent thoroughly. Step 3: Check the network dimension, it need be smaller than metal frame. Step 4: Smear super paste over metal pieces. Step 5: Tear off a small piece of paste from the backside of network, press it from up to down by heaving force. It needs to keep paste closely.
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SYNTEC CNC Maintenance Manual
6. Renovation Of Software When the controller need toe renovate files by user, please take the following steps: Step 1. Reserve system data
Yes
Reserve parameter file (6.1) Ladder reserve Reserve the user data
Yes Step 2. Renovate new CNC system software
Renovate system software (6.2)
NO Step 3. Renovate the machine action logic 更新機台參數
Yes
Renovate ladder Renovate parameter (6.4)
NO Step 4. Installing the controller software on the customer PC
Yes
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PC software install Special PC parameter setting (6.3)
SYNTEC CNC Maintenance Manual
6.1 Cnc Customer Data Reserve
1. 2. 4.
SYNTEC CNC controller is a PC-based controller. Therefore, all kinds of software of the controller can undergo renovating or spare data by the floppy. For example: controller software, mechanical parameters, Ladder …., all could renovate the software by floppy. Collocate the data transfer of Internet, we could get the lowest cost to save and reserve data. We analyze as below: When we change CPU card, or renovate the system software, we must reserve the original customer data of the CPU card to floppy. The steps are as below: Reserve the customer Ladder, parameters, tool data …., the steps are as below: Confirm system parameter 3223 switching on system management function, and setting to be 1. Confirm system parameter 3213 setting the drive number in correct drive source. Put the spare disk into the floppy. 5. Using the leftward key of left side F1, and changing to the highest layer of the main bill ”F1 Machine setting, F2 Program edit….”. 6. Pressing the rightward key of right side F5, and changing to the next layer of the main bill ”F1 Parameter setting, “F2 Diagnose function….”. 7. Pressing F2 [Diagnose function], and changing to the next layer of the main bill ”F1 PLC status, F2System data….”. 8. Pressing F5 [System management], and changing to the next layer of the main bill ”F1 Installing software, F2 Sparing system....”. 9. Pressing F5 [System reserve], CNC would copy the customer data into disk (note) automatically. Note: 1. When we reserve the data, not including the user cutting program. The cutting program is out on the SRAM of the RAM/ROM card. Therefore, if we change RAM/ROM card, these parts of data need to reserve specially. 2. Please press F2 ”program logic” frame under main bill. 3. F5 ”File management” 4. F5 “Out to floppy” copy the files into the floppy one by one.
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SYNTEC CNC Maintenance Manual
6.2 Installation Procedures Of System Software Step 1. The production of installation disk: 1. SYNTEC CNC software could be compressed into one disk, the file name is: Model_ Machine type_ Serial number (Ex: 900.me.637 or 940.tew.670) 2. Compressing it into C drive (or Windows table). By executing extraction, we could get one \ disk \*.* sub catalog. 3. Please copy all files of \ disk \*.* into blank disk. 4. Please check the root catalog of the installing disk including below files: cncpack.exe defapp.exe setup.bat XXXX.YYY XXXX: system name; YYY : version number
Step 2. Installation of the system software into the controller : 1. Confirm system parameter 3223 switching on system management function, and setting to be 1. Confirm system parameter 3213 setting the drive number in correct drive source. 2. Put the installing disk into the floppy. 3. Using the leftward key of left side F1, and changing to the highest layer of the main bill ”F1 Machine setting, F2 Program edit….”. 4. Pressing the rightward key of right side F5, and changing to the next layer of the main bill ”F1 Parameter setting, “F2 Diagnose function….”. 5. Pressing F2 [Diagnose function], and Pressing F5 [System management]. 6. Pressing F1 [Installing system], the controller starts to inspect the correct or not on the disk. After 3 minutes, and the data is correct, according to controller index to switch off and then switch on. 7. After switch on, the controller will execute all installing action. 8. After installing software, the controller will execute switching on action. 9. From the right up side of the switching on frame, we could see the version number of the software.
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SYNTEC CNC Maintenance Manual
6.3 Reinstallation Of System Software Under Dos Program Time of Use: When installing into personal computer or failing to switch on the controller, and only DOS program can be used to start the installation, then the necessary steps are set below: Step 1. The production procedures of installation disk: 1. SYNTEC CNC software could be compressed into one disk, the file name is: Model_ Machine type_ Serial number (Ex: 900.me.637 or 940.tew.670) 2. Compressing it into C drive (or Windows table). By executing extraction, we can get one \ disk \*.* sub catalog. 3. Please copy all files of \ disk \*.* into blank disk. 4. Please check the root catalog of the installing disk including below files: cncpack.exe defapp.exe setup.bat …… XXXX.YYY XXXX: system name; YYY : version number
Step 2. Installation of the system software into the PC : 1. Switch on and change to DOS ( or switching disk of DOS ) 2. Put the switching disk into the controller floppy. 3. Executing the setup program of root catalog on the disk Command format is: Setup Object drive Source drive Ex: Put disk into drive B, we want to install into drive C. Setup 1. B:\setup c: b: from drive b: install into c: Setup 2. Installing program will extract from disk to drive C ( C:\CNC\*.* ) Setup 3. After setup completely installs program, switch off and then switch on .(note) Note: For PC, the start steps of CNC software: 1.Pease under DOS, and change to C:\CNC 2.Key in CNC /M /P, and press ”ENTER”, then it could start CNC software.
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SYNTEC CNC Maintenance Manual
6.4 Cnc Customer Data Installation When replacement the CPU card, we need to reinstall spare customer data, and the steps is as below: 1. Put the spare customer ladder, parameter, tool data …into the disk. 2. Put the spare disk into floppy. 3. Using the leftward key of left side F1, and changing to the highest layer of the main bill ”F1 Machine setting, F2 Program edit….”. 4. Pressing the rightward key of right side F5, and changing to the next layer of the main bill ”F1 Parameter setting, “F2 Diagnose function….”. 5. Pressing F2 [Diagnose function], and changing to the next layer of the main bill ”F1 PLC status, F2System data….”. 6. Pressing F5 [System management], and changing to the next layer of the main bill ”F1 Installing software, F2 Sparing system....”. 7. Pressing the right key of F5 side, and changing to the next layer of the main bill ”F1 PLC program install, F2 System parameter install…”. 8. Selecting the relative action, CNC will copy the customer data from the disk to CNC.
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