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MANUALS

The CNC-7's Maintenance Functions

This chapter contains a description of the different buttons and commands used to perform tests, alignments and other Maintenance procedures. The organization of this chapter as well as the buttons themselves, follow the same layout as the rest of the CNC-7 System. To perform any Maintenance function, the user needs first to be logged into the Maintenance account, and to type "maint" from keyboard to switch the system into Maintenance mode (Only users with the proper privilege will be permitted access to this mode). The screen will then display a menu with all different Maintenance functions. At the end of this chapter is included a troubleshooting section, which contains some hints for diagnosing problems (or perceived problems) that you might encounter in initially using your CNC-7.

Maintenance mode command

MAINT

The MAINT keyboard command takes the system out of NC mode, into the Maintenance mode. This mode presents you with a menu which allows you to perform any of several adjustment, tune-up, and testing functions. Entering Maintenance mode can only be done from the Maintenance account (See logging into the system). In addition, certain highly critical maintenance functions, can only be done from the highly privileged SERVICE account. Please see the section on setting up operator accounts for more information on the SERVICE account. The purpose of the Maintenance account is to allow only highly privileged users to access the Maintenance functions, which require access to the electronics, and which may contain procedures which are not deemed safe in the hands of any and all machine users. Note that the machine may not be running (Program in Progress) when you go into Maintenance mode. You must first STOP the machine before you can enter Maintenance mode. Once the required Maintenance procedures are completed, the NC command (or button) can be used to return the system to NC mode.
See also: NC
Keyboard command: MAINT

TMS alignment functions

The TMS alignment functions are provided to assist in the alignment and verification of the TMS system. This button displays the TMS alignment menu. The menu contains several procedures which may be performed by pressing the corresponding buttons.
The correct sequence of operations when executing TMS alignment should start with the button from the top left corner of the screen and perform the functions towards the right on the first line of buttons. Then Align Cassette Right-Front, followed by the Save button to store the new parameters in the Machine file. After this, use the buttons Check Cassette Alignment to verify the overall alignment of the system.
Before any alignment or when a problem is suspected from the associated hardware, the Sensors Status button may be used to display and exercise the involved sensors and mechanisms.
For machines equipped with two stationary cassettes, there is a button which can be used to select whether the alignment functions impact the first or second magazine location.
The remaining buttons on the screen provide support to all alignment functions and are self explanatory.

Set Piston Height button

The Set Piston Height button is used to align the Transfer Pistons Up position referred to the granite. This is important to level all the pistons to the same height.
See also: Transfer Collet Select

Align Transfer Assembly button

This button provides a way to perform the correct setting of the Transfer Assembly for all stations. Mainly the purpose of this is to assure that the tool will be delivered and received properly during tool change.
See also: Transfer Collet Select

Check Transfer Piston Height button

This button is used to verify and if required, adjust the Magazine Holder. The proper set up prevents the transfer piston from hitting the magazine when picking up or returning tools.
See also: Transfer Collet Select

Set Z axis Tool Change Down button

This button is used to enter and verify new values for ZATCD. This is the position of the spindle collet when it goes down for a tool change, so its correct set up prevents the transfer piston from smashing the spindle's collets.
See also: Save ZATCD and TPOS

Check Cassette Alignment Left-Front button

This button is provided as a convenient way to check and eventually realign the Magazine. The magazine should be first aligned using "Align Cassette Right-Front" function and then Right-Rear. If this check shows that the alignment is not good enough, verify the magazine, realign it if necessary and recheck.
The same applies to the other check functions.
See also: Align Cassette Right-Front, Transfer Collet Select

Check Cassette Alignment Left-Rear button

This button is provided as a convenient way to check and eventually realign the Magazine. See "Check Left-Front" for a more detailed description.
See also: Align Cassette Right-Front, Transfer Collet Select

Check Cassette Alignment Right-Rear button

This button is provided as a convenient way to check and eventually realign the Magazine. Function primarily used in conjunction with the other similar ones.
See also: Align Cassette Right-Front, Transfer Collet Select

Check Cassette Alignment Right-Front button

This button is to be used to align the Transfer Collet to the Cassette. It should be the first one used to align the magazine, and again if the checking with the others show that realignment is required. It is also used to compute the new TPOS parameter that will be saved in the Machine Data File.
See also: Save ZATCD and TPOS button, Transfer Collet Select

Check Cassette Alignment button

The Check Cassette Alignment button is used to exercise the tool changer and determine whether the magazine is correctly aligned or not. This function picks and returns a tool to the magazine, and at the same time offsets the table. Any misalignment will be shown on the display as a correction value to be used for realignment. All the other TMS alignment function should be executed first.
See also: TMS Alignment

Check Piston Down and Park Table button

This button may be used at the end of any TMS alignment session to insure that the Transfer Pistons are down and to park the table. Normally it is not necessary to use it because after normal exit from any alignment function the pistons are automatically retracted.

Test Box button

The Test Box button enables and disables the standard alignment box, which can be plugged to the I/O board in the computer enclosure on the back of the machine. When this button is active (White color) and the Box is connected, the user can jog the table or raise the Transfer Collets from either the screen buttons or the Test Box. When the button is inactive (Black color) the Test Box is ignored even if it is connected to the machine.

Transfer Collet Select buttons

This buttons allow any alignment to be executed on individual or group of stations as well as all of them simultaneously. Usually this buttons are used to select the desired stations to work with before starting a new alignment option.

Save button

The Save button is used to store into the Machine Data File the new ZATCD and TPOS along with related parameters. It should be pushed after running options "Set Z Axis Tool Change Down" and "Align Cassette Holder" which actually determine the parameters to be used. If Save is pushed prior to computing new values for ZATCD or TPOS, the Machine File will not be updated and a message will indicate so. Otherwise a popup message will indicate whether the update was successful or not. For machines equipped with two stationary cassettes, the TPOS for both the first and second cassettes will be written to the Machine file.
See also: Set Z Axis Tool Change Down, Align Cassette Right-Front

Dual Cassette Magazine Select

The Magazine select button is used only on machines equipped with two stationary TMS cassettes. This button is used to allow the TMS alignment functions to be used with either the first or second TMS magazine. On any other toolchanger configuration, this function is unused.
See also: X_TMS, NUMCAS

MCH Alignment button

The MCH alignment procedure is provided for adjusting the rotary MCH cassette holder for those machines so equipped. A description of the cassette leveling adjustment and a stepper motor alignment procedure is provided. The cassette leveling adjustment is performed to insure the cassette is parallel (level) with the granite. This adjustment should be checked prior to performing the stepper motor alignment procedure that follows. The stepper motor alignment procedure aligns the stepper motor and cassette housing. This alignment assures the cassette housing doesn't move as a consequence of energizing the stepper motor. Misalignment is evidenced by a small but noticeable movement of the cassette housing when the locking pin is raised just prior to rotation.
See also: X-TMS

Sensors Status Display button

The Sensors Status Display screen allows verification of the status of the Piston Up and Tool in Collet sensors for hardware debugging or testing. The "Open Transfer Collet" button on this screen opens and closes all the collets. The "Transfer Pistons up" button raises and lowers the transfer collets. At the same time, display "buttons" show the status of the position detectors. The lasers are turned on so if the beams are manually interrupted, this condition is displayed on the screen. The "park" button may be used to position the table on a convenient location. It should only be pushed with the transfer pistons down.

Sensor Status Display "button"

These display "buttons" show the status of the position detectors. The background color changes from black to white when the corresponding sensor is activated. At the same time the label text changes to indicate the new condition.

Open Transfer Collet button

This button opens and close all transfer collets at the same time, thus allowing verification of their operating condition.

Open Transfer Collet button

This button raises and lower all transfer collets. At the same time the position indicator "buttons" display the current position.

Z-Axis Adjustments button

Z-Axis Adjustment functions are provided to assist in the alignment, tune-up, and verification of the Z axis. This button displays the Z-axis maintenance menu. The menu contains several procedures which may be performed by pressing the corresponding button. Some maintenance procedures apply only to machines equipped with independent Z-axes. Some other procedures apply only to machines equipped with the conventional rocker shaft type Z-axis. The menu will display the procedures appropriate for the type of machine. The Z-Axis Adjustments button is located on the Main Maintenance menu.

Z-Axis Switches button

Z-Axis Switches displays the status of each of the switches located on the Z-axis spindle assemblies. When a switch is actuated (blocked), the corresponding box will turn white and "ON" will be displayed, otherwise the box will be dark and "OFF" displayed. The Z-axis switches display is provided to aid in the mechanical alignment of the Z-axis assembly and may also be useful as a diagnostic tool. The Z-Axis Switches display applies only to machines equipped with independent Z-axes. The Z-Axis Switches button is displayed on the Z-axis adjustments maintenance menu for those machines so equipped.

Z-Axis APOS button

Z-Axis APOS displays the actual position of each spindle. The position is displayed as an elevation relative to the lower limit of Z-Axis travel as defined by the "ZTRAVEL" VSB command. The displayed elevation should increase (become more positive) if the spindle is raised, or decrease if the spindle is lowered. The Z-Axis APOS display may be useful as a diagnostic tool in cases where faulty position feedback from the encoder is suspected. This display applies only to machines equipped with independent Z-axes. The Z-Axis APOS button is displayed on the Z-axis adjustments maintenance menu for those machines so equipped.

Set Tip Sensor Depths button

Set Tip Sensor Depths displays the status of each of the depth control tool tip sensor pods located on the front of the worktable. This procedure is provided to establish the plunger actuation depth for each tool tip sensor pod, and should be performed whenever a sensor pod is installed or replaced. Depth values upon input are converted into Z-axis encoder units. For greater accuracy, depth values may be input and are displayed at a resolution greater than that of the Z-axis encoder. This often results in the displayed value being slightly different than the input value due to the rounding that occurs when the depth is converted into lower resolution encoder units. The difference in depth due to rounding is quite small and may be ignored for normal operations. The Set Tip Sensor Depths procedure applies only to machines equipped with independent Z-axes. The Set Tip Sensor Depths button is displayed on the Z-axis adjustments maintenance menu for those machines so equipped.

Adjust Spindle Collet button

Adjust Spindle Collet displays the procedures for adjusting Non-locking and Locking type spindle collets. This adjustment is performed when a collet is installed, as part of routine maintenance, or any time proper operation of the spindle collet is in doubt. The Non-Locking Collet and Locking Collet buttons located on the Collet Adjustment page are provided to select either the Non-locking or Locking collet adjustment displays. The Continue button displays the next page of the selected procedure should it consist of more than one page. The Adjust Spindle Collet button is displayed on the Z-axis adjustments maintenance menu.

Sliding Pressure Foot button

The Sliding Pressure Foot button is provided to verify proper operation of the sliding pressure foot. Pressing the button toggles the pressure foot off and on. When ON is displayed, the bottom of the pressure foot is released and should slide freely. When OFF is displayed, the bottom of the pressure foot should be locked in position. Operation of the sliding pressure foot should be checked after replacing the pressure foot, following any maintenance that might affect pressure foot operation, or any time proper operation of the pressure foot is in doubt. Sliding Pressure Feet apply only to machines equipped for routing. The Sliding Pressure Foot button is displayed on the Z-axis adjustments maintenance menu for those machines so equipped.

Freq. Converter Tune-up button

The Freq. Converter Tune-up button displays the frequency converter tune-up menu. Depending on the converter type installed on the machine, either the Excellon or the PTI frequency converter tune-up menu will be shown. The menu includes the tune-up procedures appropriate for the type of converter. Menu items are displayed from left to right, and should be performed in that order. The menu also includes a button for entering the type of spindle presently installed on the machine. Spindles are grouped by their maximum RPM capability (110K spindles, 100K spindles, etc.). The spindle type is initially set to one of spindle models capable of running at the maximum RPM setting of the machine, which is established by VSB. If more than one spindle model is available for a particular maximum RPM, pressing the Select Spindle Type button will cause the "Spindle Type:" display to switch to the next spindle model available for that RPM. Upon each push of the button the next model spindle will be displayed. When the list of available spindles is exhausted or if only one model spindle is available for the given RPM, the original spindle model will be redisplayed. The Freq. Converter Tune-up button is displayed on the Z-axis adjustments maintenance menu.
IMPORTANT: Frequency converter logic board jumpers and tune-up procedures may vary between the different spindle models available for a given RPM. Insure that "Spindle Type" is set for the spindle presently installed on the machine before attempting any of the tune-up procedures.

Set-up button - Excellon Freq. Converter

The Set-up procedure is used to configure the Excellon frequency converter FCC-1 circuit board jumpers for the type of spindle presently installed on the machine. Initial settings are also given for the VS and FMAX pots, in preparation for the tune-up procedures that follow. This procedure should be performed if the FCC-1 board is replaced or the machine is retrofit with different spindles. The Set-up button is displayed on the Excellon Frequency converter tune-up menu.

FMAX Adjustment button - Excellon Freq. Converter

The FMAX Adjustment procedure is provided for adjusting the Excellon frequency converter FMAX pot. The FMAX pot adjusts the RPM output of the converter to assure the spindles run at the proper speed. This procedure should be performed following any maintenance to the converter or if the machine is retrofit with different spindles. The Slope 1 and 2 pots should also be adjusted following this procedure. The FMAX Pot Adjust button is displayed on the Excellon Frequency converter tune-up menu.

Slope 1 and 2 Preset button - Excellon Freq. Converter

The Slope 1 and 2 Preset procedure is provided for pre-adjusting the Excellon frequency converter VS1 and VS2 (Slope 1 and 2) pots. The Slope pots adjust the voltage output of the converter. If the FCC-1 board is replaced or the machine is retrofit with different spindles, this procedure should be performed in order to avoid excessive current levels and possible damage to the converter or spindles. The Slope 1 and 2 Final adjustment procedure should be performed after making this adjustment. The Slope 1 and 2 Preset button is displayed on the Excellon Frequency converter tune-up menu.

Slope 1 and 2 Final adjustment button - Excellon Freq. Converter

The Slope 1 and 2 Final adjustment procedure is provided for making the final adjustments to the Excellon frequency converter VS1 and VS2 (Slope 1 and 2) pots. The Slope pots adjust the voltage output of the converter. If the FCC-1 board is replaced or the machine is retrofit with different spindles, the Slope 1 and 2 Preset procedure should be performed prior to making this adjustment to avoid possible damage to the converter or spindles. The Slope 1 and 2 Final adjustment button is displayed on the Excellon Frequency converter tune-up menu.

Verify Decel Ramp button - Excellon Freq. Converter

The Verify Decel Ramp procedure is used to verify the Excellon frequency converter spindle deceleration ramp time. The ideal deceleration ramp time is displayed along with the actual ramp time for decelerating the spindles from maximum RPM. Although there is no adjustment, the ideal and actual ramp times should be similar. This procedure should be performed following any adjustments to the converter and may also be useful as a diagnostic tool. The Verify Decel Ramp button is displayed on the Excellon Frequency converter tune-up menu.

Set-up button - PTI Freq. Converter

The Set-up procedure is used to preset the PTI frequency converter logic board Boost pot (R58) and Maximum Voltage pot (R97). This procedure is usually only necessary when the logic board is replaced. The Set-up button is displayed on the PTI Frequency converter tune-up menu.

Spindle RPM adjustment button - PTI Freq. Converter

The Spindle RPM procedure is provided to adjust the PTI frequency converter minimum and maximum speed pots. This adjusts the RPM output of the converter to assure the spindles run at the proper speed. The RPM adjustment should be checked periodically, and should also be performed following any maintenance to the converter or if the machine is retrofit with different spindles. The Spindle RPM button is displayed on the PTI Frequency converter tune-up menu.

Slope 1&2 adjustment button - PTI Freq. Converter

The Slope 1&2 adjustment procedure is provided for adjusting the PTI frequency converter Slope 1 and Slope 2 pots. The Slope 1 pot adjusts the voltage output of the converter's low RPM range, the Slope 2 pot adjusts the voltage output of the high RPM range. The Slope 1&2 adjustment should be checked periodically, and should also be performed following any maintenance to the converter or if the machine is retrofit with different spindles. The Slope 1&2 adjustment button is displayed on the PTI Frequency converter tune-up menu.

Voltage Trip adjustment button - PTI Freq. Converter

The Voltage Trip adjustment procedure is provided to adjust the PTI frequency converter Voltage Trip pot (R40). This adjustment is used to set the converter overvoltage threshold at a point slightly above the level required to operate the spindle motors. This assures the spindles do not "trip off" during normal operation, while still providing adequate overvoltage protection. The Voltage Trip adjustment should be checked periodically, and should also be performed following any maintenance to the converter or if the machine is retrofit with different spindles. The Voltage Trip adjustment button is displayed on the PTI Frequency converter tune-up menu.

Current Trip adjustment button - PTI Freq. Converter

The Current Trip adjustment procedure is provided to adjust the PTI frequency converter Current Trip pot (R48). This adjustment is used to set the converter overcurrent threshold at a point slightly above the level required to operate the spindle motors. This assures the spindles do not "trip off" during normal operation, while still providing adequate overcurrent protection. The Current Trip adjustment should be checked periodically, and should also be performed following any maintenance to the converter or if the machine is retrofit with different spindles. The Current Trip adjustment button is displayed on the PTI Frequency converter tune-up menu.

Compensate Drill Depth button

The Compensate Drill Depth procedure is provided for adjusting the ZIF board Drill Depth Compensation pot. The pot is adjusted to assure the Z-axis drills to a uniform depth across the range of drilling feedrates. Without depth compensation, the Z-axis has a tendency to drill slightly deeper as the drilling feedrate is increased. This procedure should be performed if the ZIF board is replaced or if the drill depth is not consistent at different feedrates. The Compensate Drill Depth procedure applies only to machines equipped with the rocker shaft type Z-axis. The Compensate Drill Depth button is displayed on the Z-axis adjustments maintenance menu for those machines so equipped.

Spindle Alignment button

The Spindle Alignment button displays the spindle alignment menu. Procedures are provided for adjusting the pressure feet and spindle heights. Related adjustments dependent upon machine type are also provided. The menu items are displayed from left to right and should be performed in that order. The Spindle Alignment button is displayed on the Z-axis adjustments maintenance menu.

Pressure Foot Height button

The Pressure Foot Height procedure describes the mechanical adjustment of the pressure foot. The pressure foot is adjusted so that the bottom of the foot is at the proper distance relative to the nose of the spindle collet. This procedure should be performed following pressure foot replacement or after performing any other maintenance that would disturb this adjustment. For independent Z-axis equipped machines, the depth control flag adjustment should also be checked and adjusted if necessary after adjusting the pressure foot height. The Pressure Foot Height button is displayed on the spindle alignment maintenance menu.

Travel Limit Flag button

The Travel Limit Flag procedure is provided to adjust the Z-axis travel limit flag on machines equipped with independent Z-axes. The flag is adjusted so the spindle will actuate the limit switches at the proper height. This procedure should be performed following replacement of the Z-axis spindle assembly, or after performing any other maintenance that could disturb the adjustment. The home pulse adjustment should also be checked and adjusted if necessary following adjustment of the travel limit flag. This procedure applies only to machines equipped with independent Z-axes. The Travel Limit Flag button is displayed on the Z-axis adjustments maintenance menu for those machines so equipped.

Home Pulse button

The Home Pulse procedure is provided for adjusting the home pulse position on machines equipped with independent Z-axes. The position is adjusted so that the home pulse will occur at the proper distance from the limit switch. This procedure should be performed following replacement of the Z-axis spindle assembly, or after performing any other maintenance that could disturb the adjustment. The pressure foot height and travel limit flag adjustments should be checked and adjusted if necessary prior to making this adjustment. The home offset adjustment should also be performed following this adjustment. This procedure applies only to machines equipped with independent Z-axes. The Home Pulse button is displayed on the Z-axis adjustments maintenance menu for those machines so equipped.

Home Offset button

The Home Offset procedure is provided for adjusting the home offset on machines equipped with independent Z-axes. The home offset establishes the proper height of the spindle above the tooling plate. The UPPER LIMIT buttons displayed on the home offset page allow the spindle to be positioned both above and below the normal drilling lower limit. The home offset is adjusted properly if the alignment tool installed in the spindle just contacts the tooling plate when the UPPER LIMIT reads zero. This procedure should be performed following replacement of the Z-axis spindle assembly, or after performing any other maintenance that could disturb the adjustment. The pressure foot height, travel limit flag and home pulse adjustments should be checked and adjusted if necessary prior to making this adjustment. This procedure applies only to machines equipped with independent Z-axes. The Home Offset button is displayed on the Z-axis adjustments maintenance menu for those machines so equipped.

Depth Control Flag button

The Depth Control Flag procedure is provided for adjusting the depth control flag on machines equipped with independent Z-axes. The flag is adjusted so that the depth control switch will actuate with the proper amount of pressure foot compression. This procedure should be performed following replacement of the Z-axis spindle assembly, pressure foot, or after performing any other maintenance that could disturb the adjustment. The pressure foot height adjustment should be checked and adjusted if necessary prior to making this adjustment. The procedure applies only to machines equipped with independent Z-axes. The Depth Control Flag button is displayed on the Z-axis adjustments maintenance menu for those machines so equipped.

Spindle Height button

Spindle Height describes the procedure for the initial mechanical alignment of all of the spindles. The spindles are adjusted so that they are all at a uniform height above the work surface. The procedure should be performed if all spindles/spindle assemblies have been replaced. If only some of the spindles/spindle assemblies have been replaced, it may be possible to adjust only those spindles. Refer to Process Specification PS2-0082 Z-axis Adjustments, for further details. The Spindle Height procedure applies only to machines equipped with the rocker shaft type Z-axis. The Spindle Height button is displayed on the spindle alignment maintenance menu for those machines so equipped.

Transducer Adjustment button

The Transducer Adjustment procedure is provided in order to perform the mechanical and electrical transducer adjustments. These adjustments assure that the spindles will be at the proper elevation above the worktable when the Z-axis is commanded to a particular position. This procedure should be performed following replacement of the transducer or ZIF board, after performing any maintenance that would affect the mechanical heights of the spindles, or if the Z-axis positions are either too high or too low. The Transducer Adjustment procedure applies only to machines equipped with the rocker shaft type Z-axis. The Transducer Adjustment button is displayed on the spindle alignment maintenance menu for those machines so equipped.

Z-axis Servo button

The Z-axis Servo button displays the Z-axis servo menu. Procedures are provided for adjusting the Excellon Z-axis servo amp and ZIF board Position Gain pots. Menu items are displayed from left to right and should be performed in that order. The Z-axis Servo procedures apply only to machines equipped with the rocker shaft type Z-axis. The Z-axis Servo button is displayed on the Z-axis adjustments maintenance menu for those machines so equipped.

Tachometer Adjustment button

The Tachometer Adjustment procedure is provided for adjusting the Excellon Z-axis servo amplifier Tachometer pot. The tachometer pot adjusts the velocity of the Z-axis so that it will drill at the proper feedrate. This procedure should be performed following replacement of the servo amplifier or servo amplifier TAC-1 board, or if the Z-axis is not drilling at the proper feedrate. The Tachometer Adjustment procedure applies only to machines equipped with the rocker shaft type Z-axis. The Tachometer Adjustment button is displayed on the Z-axis servo maintenance menu for those machines so equipped.

Position Gain Adjustment button

The Position Gain adjustment procedure is provided for adjusting the ZIF board Position Gain pot. The position gain pot is adjusted to achieve the fastest pull in of the Z-axis at the top of the drill stroke without overshooting. This procedure should be performed following replacement of the ZIF board. The adjustment should also be checked if the machine displays intermittent "Z axes out of position" messages while drilling. The Position Gain Adjustment procedure applies only to machines equipped with the rocker shaft type Z-axis. The Position Gain Adjustment button is displayed on the Z-axis servo maintenance menu for those machines so equipped.

Signal and Current Balance Adjustment button

Signal and Current Balance adjustment describes the procedure for adjusting the Excellon Z-axis servo amplifier Signal Balance, Current Balance and Function Generator Offset pots. This adjusts the amplifier so the Z-axis will not drift out of position when zero velocity is commanded. This procedure should be performed following replacement of the servo amplifier or servo amplifier TAC-1 board. The Signal and Current Balance Adjustment procedure applies only to machines equipped with the rocker shaft type Z-axis. The Signal and Current Balance Adjustment button is displayed on the Z-axis servo maintenance menu for those machines so equipped.

Servo Amplifier Adjustments button

Servo Amplifier Adjustment functions are provided to assist in the tune-up and verification of the X/Y/T and Z axis servo amplifiers. This button displays the Servo Amplifier maintenance menu. The menu contains several procedures which may be performed by pressing the corresponding button. The menu items along the top line are displayed from left to right, and should be performed in that order. Some maintenance procedures apply only to machines equipped with independent Z-axes. Some other procedures apply only to machines equipped with the conventional rocker shaft type Z-axis. For machines equipped with independent Z-axis assemblies, maintenance procedures are provided for adjusting the IMEC X/Y/T and Z axis servo amplifiers. For machines equipped with the rocker shaft type Z-axis, procedures are provided for adjusting the Excellon X/Y axis servo amplifiers. Procedures for adjusting the Excellon Z-axis servo amplifier may be accessed via the Z-axis Servo button displayed on the Z-axis Adjustments maintenance menu. The Servo Amplifier Adjustments button is located on the Main Maintenance menu.

Axis Slew button

The Axis Slew procedure is provided to slew the X/Y/T or Z axis back and forth without requiring position feedback from the encoder. The procedure may be used for encoder tune-up or as a diagnostic tool if intermittent or unreliable position feedback from the encoder is suspected. X/Y axis slew is available for all machines, Z-axis slew is applicable only on independent Z-axis equipped machines and T-axis slew is applicable on the autoload equipped machines. The Axis Slew button is displayed on the Servo Amplifier maintenance menu.

DAC Adjustment button

The DAC Adjustment procedure is provided for adjusting the STAC board DAC output. This adjustment assures the proper STAC board velocity output for the desired speed. The procedure allows the DAC Offset and Gain pots to be adjusted for each axis individually. The X/Y axis DAC adjustment is available for all machines, the Z-axis DAC adjustment applies only to machines equipped with independent Z-axes and the T-axis DAC adjustment applies only to machines equipped with autoload. This procedure should be performed following replacement of the STAC board. It may also be desirable to verify the DAC output prior to performing the servo amplifier adjustments. The DAC Adjustment button is displayed on the Servo Amplifier maintenance menu.

DAC Test button

The DAC Test procedure is provided for testing the STAC board DAC outputs. A canned triangle wave output routine is included for checking the DAC output throughout the entire voltage range. Specific DAC output voltages may also be verified by turning ON and OFF individual DAC input bits. Each bit may be turned ON and OFF individually to verify proper operation. The procedure may be useful as a diagnostic tool if incorrect DAC output is suspected at intermediate voltage levels. An indication of this might be if an axis occasionally does not appear to be moving at the proper speed, or if it does not accelerate or decelerate smoothly. The X/Y axis DAC test is available for all machines, the Z-axis DAC test applies only to machines equipped with independent Z-axes and the T-axis DAC test applies only to machine equipped with autoload. The DAC Test button is displayed on the Servo Amplifier maintenance menu.

Set-up button

The IMEC servo amplifier or personality module is configured and pre-adjusted at the IMEC factory for use in the Excellon drilling machine. Additional set-up or pre-adjustments should not be required prior to installation. To verify the initial set-up or pre-adjustment of an amplifier or personality module, identify the model number of the amplifier or module, then refer to the corresponding IMEC Custom Feature Specification Sheet. A copy of this document is included with each amplifier or personality module shipped from IMEC. Jumper locations, switch settings and pre-adjustment instructions are provided. Following replacement of the amplifier or personality module, the maintenance procedures should be performed for making the final adjustments to the Current (I) Limit, Velocity Offset, Velocity Loop and Command Gain pots. The Set-up procedure applies only to independent Z-axis machines equipped with IMEC servo amplifiers. The Set-up button is displayed on the Servo Amplifier maintenance menu for those machines so equipped.

Current Limit Pot Adjustment button

The Current Limit Adjustment procedure is provided for adjusting the X/Y/T or Z-axis IMEC servo amplifier Current (I) Limit pot. The current limit pot adjusts the maximum amount of current output by the servo amplifier. This procedure should be performed if the servo amplifier is replaced. Adjusting the Current Limit may affect other servo amplifier adjustments. The Velocity Offset, Velocity Loop and Command Gain adjustments should be verified following this procedure. The Current Limit procedure applies only to independent Z-axis machines equipped with IMEC servo amplifiers. The Current Limit button is displayed on the Servo Amplifier maintenance menu for those machines so equipped.

Velocity Offset Pot Adjustment button

The Velocity Offset Adjustment procedure is provided for adjusting the X/Y/T or Z-axis IMEC servo amplifier Velocity Offset pot. The pot adjusts the zero velocity output of the servo amplifier. It is adjusted so that the axis will hold steady when zero velocity is commanded. This procedure should be performed if the servo amplifier is replaced. Adjusting the Velocity Offset may affect other servo amplifier adjustments. The Velocity Loop and Command Gain adjustments should be verified following this procedure. The Velocity Offset procedure applies only to independent Z-axis machines equipped with IMEC servo amplifiers. The Velocity Offset button is displayed on the Servo Amplifier maintenance menu for those machines so equipped.

Velocity Loop Gain Pot Adjustment button

The Velocity Loop Gain Adjustment procedure is provided for adjusting the X/Y/T or Z-axis IMEC servo amplifier Velocity Loop Gain pot. The pot adjusts the gain of the amplifier to obtain maximum control of the axis without oscillation. This procedure should be performed if the servo amplifier is replaced or the axis emits the sound of oscillation. The adjustment might also be checked if the machine displays the "Bad chipload of tool geometry - Excessive drill depth variance" message, which could occur if the gain is adjusted too low. Adjusting the Velocity Loop Gain may affect the Command Gain adjustment. The Command Gain adjustment should be verified following this procedure. The Velocity Loop Gain procedure applies only to independent Z-axis machines equipped with IMEC servo amplifiers. The Velocity Loop Gain button is displayed on the Servo Amplifier maintenance menu for those machines so equipped.

Command Gain Pot Adjustment button

The Command Gain Adjustment procedure is provided for adjusting the X/Y/T or Z-axis IMEC servo amplifier Command Gain pot. The pot adjusts the output of the amplifier so that the axis will move at the proper speed. This procedure should be performed if the servo amplifier is replaced, or the axis does not move at the proper speed. The adjustment might also be checked if the machine displays the "Bad chipload or tool geometry - Excessive drill depth variance" message, which could occur if the speed is adjusted too low. The Command Gain procedure applies only to independent Z-axis machines equipped with IMEC servo amplifiers. The Command Gain button is displayed on the Servo Amplifier maintenance menu for those machines so equipped.

Tachometer Adjustment button

The Tachometer Adjustment procedure is provided for adjusting the X/Y axis Excellon servo amplifier Tachometer pot. The pot adjusts the velocity of the axis so it will move at the proper speed. This procedure should be performed following replacement of the servo amplifier or servo amplifier TAC-1 board, or if the axis does not move at the proper speed. The Tachometer Adjustment procedure applies only to rocker shaft type Z-axis machines equipped with Excellon servo amplifiers. The Tachometer Adjustment button is displayed on the Servo Amplifier maintenance menu for those machines so equipped.

Signal Balance Adjustment button

The Signal Balance Adjustment procedure is provided for adjusting the X/Y axis Excellon servo amplifier Signal Balance pot. The pot adjusts the amplifier so the axis will not drift out of position when zero velocity is commanded. This procedure should be performed following replacement of the servo amplifier or servo amplifier TAC-1 board, or if excessive position error always exists when the axis is stationary (APOS and DPOS displayed on the CRT never quite agree). The Signal Balance Adjustment procedure applies only to rocker shaft type Z-axis machines equipped with Excellon servo amplifiers. The Signal Balance Adjustment button is displayed on the Servo Amplifier maintenance menu for those machines so equipped.

Current Balance Adjustment button

Current Balance Adjustment describes the procedure for adjusting the X/Y axis Excellon servo amplifier Current Balance pot. The Current Balance pot is preset at the factory and should not normally require further adjustment unless the seal has been broken or the servo amplifier TAC-1 board has been replaced. The Current Balance Adjustment procedure applies only to rocker shaft type Z-axis machines equipped with Excellon servo amplifiers. The Current Balance Adjustment button is displayed on the Servo Amplifier maintenance menu for those machines so equipped.

Diameter and Depth Sensors, alignment and test functions

This functions are provided as a tool in the alignment and verification of the laser sensors based system. This button displays the sensors alignment menu. The menu contains several procedures which may be performed by pressing the corresponding buttons. All tools needed are included on this screen. These include buttons, the keyboard command window, and machine status windows which are necessary to set the machine up, perform the required alignments, and finally check the entire system performance. The first step should be a general hardware checking that can be done with the button SENSORS STATUS. This is useful, among other things, to verify that the sensors are turned on, can be raised up and down, the position switches are properly set, and the laser beams and associated electronics work correctly. This last one is done by introducing a small piece of paper into the sensor window to interrupt the beam and looking at the status of that station on the screen. The next step is to align the sensors with the SENSOR ALIGNMENT button. This is done one station at the time, selecting it with the SELECT STATION button and placing a tool in the spindle collet either manually or using TMS if ATC is on, and the button DO A TOOL CHANGE or the keyboard command window. The following operation is to find the beam location on the Z axis referred to the top of the sensor. The button COMPUTE DEPTH LOCATION will start the procedure that performs this routine. Again, this process is done on individual stations. The two previous steps should be repeated if necessary, until the operator is confident that the results are consistent and accurate enough. They are only required after sensors installation or when the mechanical system that holds them has been moved. Upon completion of the preceding steps, the new parameters computed by the system must be permanently stored in the machine data file with the button SAVE SENSORS LOCATION that will do the update and inform of the results of it. If this option is not used after the alignment procedures, those parameters will be lost and the operator will have to start from the beginning again. The buttons DIAMETER AND RUNOUT TEST and DEPTH TEST are intended to perform hardware testing. They exercise the entire hardware involved by taking continuous readings and presenting the data on the screen in a way that permits verification of repeatability and spread. Finally, some other support buttons are provided which may be useful under certain conditions. They are RESET, PARK and HOME WORKTABLE, as well as the usual buttons for exit and help.

Save button

The Save button is used to store into the Machine Data File the new sensors location on the work table (X and Y coordinates), as well as the beam's depth from the top of the sensor. It should be pushed after running options "Sensor Alignment" and "Compute Depth Location" which actually determine the parameters to be used. If Save is pushed prior to computing new values, the Machine File will not be updated. Otherwise a popup message will indicate whether the update was successful or not.
See also: Sensor Alignment, Compute Depth Location, Diameter and Depth Sensors alignment and test functions.

Sensor Alignment button

This function is to be used to determine the location of the beam's focus. The machine will find the position of the beam and display it on the screen. On machines that allow adjustments on the Y axis, the sensor should be moved until the position is within the range specified for that machine. The X axis is fixed and does not require any alignment. However, when this option is run, the X and Y coordinates are saved in memory for later Machine File update. On machines equipped with fixed sensors, this function should still be run in order to compute the beam's location that will be saved into the Machine file. Always run this function first after sensors installation and before taking any diameter or depth readings to insure that the tool will go into the sensors instead of hitting its top.
See also: Save Sensors Location, Diameter and Depth Sensors alignment and test functions.

Compute Depth Location button

This is used to determine the offset from the surface of the laser sensor to the beam. It should be executed for all the stations one by one and then the computed parameters saved into the Machine File. To execute, follow the directions given on the screen. It is also recommended that this procedure be done several times until a good degree of confidence on the parameters read is achieved.
See also: Save Sensors Location, Diameter and Depth Sensors alignment and test functions.

Sensors Status Display button

The Sensors Status Display screen allows verification of the status of the sensors and the depth beam for hardware debugging or testing. The "Pods Up" button on this screen raises the sensors up and back down. At the same time, display "buttons" show the status of the position detectors. Also the lasers are turned on so if the beams are manually interrupted, this condition is displayed on the screen ( In tip check mode). The "park" button may be used to position the table on a convenient location.
See also: Diameter and Depth Sensors alignment and test functions.

Raise Depth Pods button

This button raises and lower all sensor pods. At the same time the position indicator "buttons" display the current position.
See also: Diameter and Depth Sensors alignment and test functions.

Diameter test button

By pushing this button, the machine will take continuous diameter readings for the selected spindle and display the tool diameter in statistical mode to permit sensor confidence checks. This function should only be used after the sensors are properly aligned. During execution of this test, the tool is driven to the lowest Z axis position to assure that the beam will always be interrupted (unless the tool is missing or broken). Therefore, do not use it to find the diameter of a tool (use the TOLCHK button instead).
See also: Sensor Alignment, Diameter and Depth Sensors alignment and test functions.

Depth test button

By pushing this button, the machine will take continuous depth readings for all the selected spindles and display the relative travel distance in statistical mode to permit sensor confidence checks. This function should only be used after the sensors are properly aligned. When more than one station is selected, the tools in the collet should be large enough to compensate for differences of the sensors location on the Y axis. This is because all the readings are taken at the same time, and if the tool on one station is smaller than the sensors misalignment on the Y axis, it will miss the beam producing a message.
See also: Sensor Alignment, Diameter and Depth Sensors alignment and test functions.

Scheduled Maintenance

This Maintenance menu provides support of the Scheduled Maintenance system as described in it's own chapter of this manual. This menu entry presents you with a page from which you can display, make changes and test all maintenance procedures set in the machine.

Display Schedule

This button produces a "view" type display, which has buttons on the bottom for scrolling, searching, etc. All the maintenance procedure items scheduled for that machine are listed in order one after the other. Every item appears as a block of information taking several lines of text on the screen.

Display Pending Maintenance

Use of this button will bring up a display screen that lists all the messages corresponding to items currently pending. That means these maintenance procedures should be executed as soon as possible. Once done, they may be removed with the button Clear Pending Maintenance or the keyboard command "MNT_SCH clear".
See also: Clear pending maintenance
Keyboard command: MNT_SCH SHOW

Schedule edit

Pressing the Edit Scheduled Items button displays the Edit Items page. From this page items may be viewed, edited, added or deleted. Buttons are provided to select the desired item for display. Press the Item Number button to enter a specific item number, or press the Next Item button to display the next item in the schedule. The elements associated with the item are displayed in a spreadsheet format. To make a change, touch the box containing the desired element. A sub-page will then display to provide information concerning the element and to prompt for input. Entering new data or Quit returns back to the Edit Items page. The Add Item button displayed on the Edit Items page allows any number of additional items to be added to the schedule. To add a new item just follow the directions given on the screen and answer the questions by selecting from the list of options normally provided. After entering the desired items, press Quit to return back to the Edit Items page. A Delete Item button is provided on the Edit Items page for removing any unwanted items. Pressing this button will cause the ARE YOU SURE? popup to display. Selecting YES will remove the presently displayed item. The Quit button exits the Edit Items page and returns back to the schedule menu page.

Clear Pending Maintenance

This button and the keyboard command "MNT_SCH clear" popup a window on the screen displaying the first line of text of every message in the pending maintenance list. At the same time the user is asked to confirm deletion of the message or quit. After that the user's privilege level is checked and the message removed.
See also: Display Pending Maintenance
Keyboard command: MNT_SCH CLEAR

Check for Due Maintenance

The system software automatically checks for due maintenance at certain strategic times during machine operation as explained in Maintenance Schedule Description and notifies the operator of any pending maintenance. However, if for any reason a check is desired at any time, this button will do just that. This could be useful after changing scheduled items to make sure that everything is correct.

Restart Schedule

At the time a new item is entered into the Maintenance Schedule File, the machine's run time and program time clocks are saved if that item uses machine time as reference. Obviously, if that schedule file is copied to another machine which has different clock values, those values must be changed for the new machine. This is done with this button. It should be used always after installing a schedule file on a new machine, a machine that did not have maintenance schedule before, or any time the clock values are lost which could be the case if the hard disk is reformatted or replaced and there is no system backup disk available.

Other Maintenance functions

The following additional functions are available in Maintenance mode, and can be accessed from the Maintenance menu.

Calibrating the touch screen

This function is used to calibrate the size and position of the touchscreen with respect to the monitor it is mounted on. When this function is selected, a message will be displayed in the middle of an otherwise blank screen. Plus signs ("+") will appear in different locations of the screen, which you are to touch with a small but DULL object (such as a pencil). Each time that you touch the plus sign, the plus sign will disappear and be redisplayed in a different location. This will continue until the system gathers enough information to calibrate the screen. When calibration terminates (after a minimum of four touches), the main Maintenance menu will be redisplayed. The system should be rebooted to reload the calibration values into the active memory.
NOTE: The CNC-7 supports both the AccuTouch and DuraTouch touch screens. During initial install, the system will identify the type of screen automatically. If you suspect that your machine may have changed types of touchscreens from one type to the other, then you should delete the "ts_calib.dat" file from the SYSTEM directory, and rerun the touchscreen calibration.
NOTE: You should reboot after calibrating the touchscreen.

Servo Pull-in, TACH graphics

PULTAC

This command is used to display on-screen graphics indicating the performance of the servo system as pertains to pull in of XY moves. This function is to be used from NC mode, NOT FROM MAINTENANCE MODE. The function is normally limited to use by the MAINTENANCE operator only. The command PULTAC will cause a popup display to be presented which includes a title, a display range area, a graphic charting area, and five buttons. The command is intended to be used with part programs which contain a series of XY moves to be studied. These part programs are made up using standard facilities such as the text editor. When the popup displays, the NC system will be put into Single Cycle mode. Each press of the STEP button will cause the system to perform one cycle of the part program. The graphical area will then display a chart for the indicated axis. The X or Y button toggles between displaying data for either the X or Y axis, so that both axes' moves may be analyzed. The IN and OUT buttons are used to magnify the scale of the graphical display for the SAME DATA. IN will ZOOM IN, magnifying the scale by a factor of two. OUT will ZOOM OUT, condensing the scale by a factor of two. QUIT exits from the window. The Chart will record two different graphs, one shows the position relative to target, or pull-in, as a white line approaching a grey zero line. The system will also display calculated velocity, or TACH, as a yellow line. The TACH line is intentionally reversed to make it easier to see in relation to the pull-in. Data is collected by the master STAC board, and will indicate samples occurring each 1ms interval after the distance to target becomes less than 32766 System Bits, or approx 0.32 inch on a 1 micron scale. Data will be charted each 1ms from this point for approximately 280ms. The display range area, located above the Chart, will indicate the axis and the range of the display in System Bits. The TACH line is intentionally scaled up by a factor of four to make it more readable. If the program is stepped all the way to end of program, the program can be restarted, and the moves reevaluated by simply pressing STEP again.
See also: Servo Stats

Machine enable/disable command

CONTROL,us/ls/x/y,on/off

This command is used to enable and disable the Upper or Lower Structure or the X or Y axes of the machine. This command is useful during Maintenance of the machine, as it is sometimes helpful to only run one part or another of the machine during testing of the machine. Disabling the Upper structure includes all sensors in that area, plus the Z-axis. Drill strokes and other Upper structure machine functions will simply be ignored by the system. Disabling the Lower structure also includes all sensors in this area, such as machine air, table clamps, and so on. Homing and XY movement functions will simply be ignored and simulated. Disabling or enabling the lower structure will also disable or enable the X and Y axes. Disabling an X or Y axis will cause the system to ignore that axis during homing and part program moves, such as drilling and parking. This is useful when doing certain machine calibration operations such as leadscrew compensation. Enabling the X or Y axis while the lower structure is disabled is dangerous and should be avoided.
** This function is only available from the SERVICE account **
See also: HOME
Keyboard command: CONTROL,us/ls/x/y,on/off

XY Scale offset computation command

OFFSET,X#Y#

Step pinning

This command is used to calculate the scale offset, used to compensate the exact position of the scales as physically mounted in the machine. This command is for use on linear scale machines ONLY, and should not be needed on rotary encoder equipped machines. The command calculates the difference between APOS and a desired position, called a Magic Number, which is the location of a step pin bushing as provided on tooling plate drawings. Generally, this location is provided in INCH, Version 1, so it is helpful to set the machine up accordingly. Step Pinning is generally done by jogging the table to the step pin coordinates using the J command, then turning off the servos and manually turning the leadscrews until the step pin fits freely into the step pin bushing. At this point, the OFFSET command is entered, and the system will calculate the new scale offset. The difference between APOS and DPOS is then added to the CURRENT scale offset value, and the result is stored in memory, and displayed in the Machine Status box for a period of 30 seconds. The table must be rehomed after using the OFFSET command. An optional XY coordinate can be entered with the OFFSET command, which is compared against APOS, otherwise DPOS is used if no coordinate is entered. The new scale offset value IS NOT automatically written to the MACH.DAT file, you must do this manually by editing the MACH.DAT file, as stored in the SYSTEM directory.
See also: SOF
Keyboard command: OFFSET(,X#Y#)

T Scale offset computation command

TOFFSET,#

This command is used to calculate the T axis scale offset on an autoload equipped machine, used to compensate the exact position of the scales as physically mounted in the machine. The command calculates the difference between the TAPOS and a desired position, called a Magic Number, which is the location of a T axis step pin bushing as provided on tooling plate drawings. Generally, this location is provided in INCH. Step Pinning is generally done by jogging the transporter to the T axis step pin coordinates using the JT command, then turning off the servos and manually moving the transporter until the T axis step pin lines up with the mark on the front edge of transporter. At this point, the TOFFSET command is entered, and the system will calculate the new T axis scale offset. The difference between TAPOS and TDPOS is then added to the CURRENT scale offset value, and the result is stored in memory, and displayed in the Machine Status box for a period of 30 seconds. The table must be rehomed after using the TOFFSET command. An optional T coordinate can be entered with the TOFFSET command, which is compared against TAPOS, otherwise TDPOS is used if no coordinate is entered. The new T axis scale offset value IS NOT automatically written to the MACH.DAT file, you must do this manually by editing the MACH.DAT file, as stored in the SYSTEM directory.
See also: TSOF
Keyboard command: TOFFSET(,#)

TMS exerciser

LCXR,on/off

This command is used to enable the TMS exerciser. The TMS exerciser is a canned routine which "walks" a tool from the first tool position in it's group through the last tool position in it's group. This is useful for checking "bottom line" performance of the TMS system. The TMS exerciser affects all selected stations, and may be operated from keyboard commanded toolchanges, or from a part program. To operate the exerciser, simply turn on the exerciser and command a toolchange. After the tool is walked to the end of the group, it will be placed in the spindle collet. Please be sure to remove the other tools from the affected groups to avoid crashing tools into one another. The exerciser remains enabled until you disable it, or until you reboot the system.
See also: TMS
Keyboard command: LCXR,on/off

Setting the system clock

The system clock will be set as part of a software installation, and is set from the value of the battery powered clock installed on the I-IO board each time that the system powers up. Should it become necessary to reset the battery clock (due to replacing the battery, or a time change like daylight savings time), a menu item is provided to do this. When you select this function from the Main Maintenance menu, the system will display the current values of the system clock, and the battery powered clock on the I-IO board. You have the option at this point to either accept the current value of the battery powered clock as the correct system time, or to enter a new value to be loaded into both the system time and the battery clock.

Troubleshooting

Problems you might encounter

This section is meant to give you help in the event that problems arise in the use of your CNC-7. It is meant to describe common problems that might be encountered in the field, and which can be partially or totally corrected by the user or Service Engineer. These areas might describe real problems which can happen, and real or perceived problems which result from a misunderstanding of how the system operates. This section of the CNC-7 Reference Manual first became available in the Rev 1.5 revision of the manual. If you become aware of other troubleshooting items that should be included, please forward them to Excellon Technical Support, and they will be considered for inclusion in the next edition of this manual.

Device is disabled

When installing system options, such as DNC-1.3, the paper tape reader, or a 3.5 inch DOS microfloppy, you may find that even after you've successfully installed all of the hardware and software, that the device can not be accessed. Instead, you get a message such as "This device is disabled". This is because the optional devices are disabled when the machine ships from the factory so that the operator will not try to select a device which is not available, causing problems or system lockup. To enable the device, you must edit the file DEVINFO.DAT in the SYSTEM directory and reset the device disable bit in the device bits mask. For example, if the device description for DNC looked like:
00010007 FFFFFFFF FFFFFFFF XM: FILESERVER /dev/dnc/ In this example, you'll need to reset the disable bit, which is the "1" in the field "00010007". This should be changed to "00000007" to enable the device.
It is not necessary to reboot after this edit.
See also: DEVINFO.DAT

Disk Problems

File System Check

Should problems develop with the hard disk file system (such as corrupted or lost files), the Operating System does have a feature of trying to restore the file system. This procedure is called FSCK, for File System Check and Repair. When you shut the machine down normally (see Power Down), the machine cleans up and closes it's files safely. If an abnormal shutdown occurs (such as a power interruption, hard reset, or crash), the system will detect this at the next power up. If the system detects and abnormal shutdown on it's next boot, it puts the file system through an FSCK procedure to make sure that the system is intact. This happens automatically, and except for requiring an extra boot, does not inconvenience the operator. If however, the disk system is corrupted enough that a normal boot does not take place, you may need to perform the FSCK manually. To do this, you must get the system to the REGULUS prompt, and enter Super User mode. This can be reached a variety of ways, depending on how badly damaged the hard disk is. There are three main possibilities: You boot the system up, and the system enters Single User mode, listing one or more problem conditions on the console. In this case, you are already in Super User mode. You boot the system "normally", and get to the front page, but the system behaves strangely. To get to Super User mode, log in as the SERVICE account, and type the command "quit" (lower case) followed by a RETURN. Once the CNC displays terminate, enter Super User mode with the command "su" (lower case). The system won't boot at all. In this case, you must boot and run the file system check and repair from the floppy disk. To do this, insert the boot disk into the floppy drive in the rear of the computer enclosure, set DIP switch number 2 on the CPU board to OPEN (all others CLOSED), and press the RESET button on the computer enclosure. Answer all questions (Format Winchester?, and Install System?) with N for NO. You are now in Single User Super User mode. Type one of two commands: "fsck" (lower case), followed by a RETURN, if you booted from hard disk. If you booted from floppy, you'll need to use the command "fsck /dev/win" (lower case). The check will report any found problems, and may alert you to problems detected. If any problems are detected, the system will generally ask you if you want to delete the affected areas. Answer "y", since those areas are too badly damaged to recover anyway. If FSCK reports any problems, a second pass of FSCK will be required. To run this, type "fsck -s", or "fsck -s /dev/win" if you booted from floppy. This will rebuild the free list of available sectors. Once both procedures are complete, set DIP switch 2 back to CLOSED (on the CPU board), and press the RESET button located on the computer enclosure. A normal boot should now take place.

Disk Errors Reported by System

If you notice disk errors occurring in your system, first be careful to check where the errors have come from. The error messages will appear in the Machine Status box, and will also be recorded in the MESSAGES log file. These errors are hard errors which the system was not able to recover even after several retries to read or write the bad area of the disk. The message you will see will look something like this:
CMD=Disk 0x00 0x000000 ...
The second parameter of this message (0x000000) is the bad sector which produced the error. BE SURE that the number shown is LESS THAN 0x1FFFFF. Only these numbers refer to the hard disk, higher numbers, like 0x201234 or 0x324742 indicate floppy disk errors, and not hard disk errors. Once it has been determined that you have a disk error, you need to map out the bad sector from use so that this section of the disk is avoided in the future. To do this, you can either reformat the system hard disk and manually add this sector to the list of bad sectors (See Installing the System), or you can add it by hand. To add the bad sector by hand, you will first need to get the system into single user state. To do this, boot the system up normally, and then force an improper shutdown by pressing the RESET button on the computer enclosure. When the system reboots and complains about an improper shutdown, it will ask you to press RETURN in order to begin repairing the filesystem. DO NOT PRESS RETURN at this point. Instead, enter the password SBE and THEN press RETURN. The system will exit out to REGULUS so you can perform the repair. Add the bad sector to the system's list by entering the BADBLK command as follows:
/etc/badblk 0x000000 (this is the number from the disk error message)
If there are multiple bad sectors reported, you can either use several BADBLK commands (on for each one), or you can place all sector numbers on one line, separated by spaces (not commas). Once this is done, repair the filesystem with the command:
/etc/fsck -vsy
You should now reboot your system. NOTE: Depending on WHERE the bad sector was, the system may have to delete files where the bad block occurred. Although in most cases the system will probably perform well at this point, it is possible that a file will be deleted which makes the system unusable. If this occurs, reload the software from the floppies WITHOUT FORMATTING, and the bad sector will be avoided. NOTE: MAKE SURE THAT YOU RECORD THE BAD BLOCK FOR FUTURE REFERENCE. This way, you can re-enter the number manually if it later becomes necessary to reformat the hard disk. You'll save yourself the effort of having to "rediscover" the bad sector later on.

Corrupted System on Hard Disk

Because the system resides on a hard disk, there is always the possibility that the system on the hard disk can be corrupted. Although this is unlikely, it is possible, and if it happens the results can be quite strange depending on what is corrupted and how badly. If you suspect that your system has been corrupted, you'll need to force the system through a file system check to find out. The easiest way to force a file system check is to boot the system up, and then go through an "improper" shutdown, and then reboot. You can do this by pressing the RESET button on the computer enclosure after the system is booted and running. After reloading the Operating System, the system will detect an improper shutdown, and will report the problem. You'll be asked whether or not you want to perform a disk corruption test. Entering "y" will cause the system to first go through the major system directories and verify the checksums of all files in those directories which have not been intentionally updated since the system was installed. If a problem is found, it will be reported. Essentially ANY problem reports should be treated as corruption of the system on the hard disk. The reports will look like this:
Checking files in "/cnc/bin" error: /core computed checksum is -1738002962
The reports from the test indicate that a file has changed since the installation of the system, and that the change was not "intentional". In other words, the file changed without some part of the system making a change to the file for a known reason. Whether or not the corruption test is run, and whether or not there are any problems, the system will run a file system check and repair procedure which will attempt to correct any problems with the structure of the file system itself. What to do if you have problems:
If you have corrupted files on the system, this is a fairly serious matter. If possible, the machine should IMMEDIATELY be taken out of production to avoid any damage to your product, and corrective action should be taken. You should record the directory and file for which the problem is reported, "/cnc/bin" and "core" in the above example. You should then try to correct the problem in the following sequence:
1) Reinstall the system from the distribution floppies without formatting the hard disk.
2) If that fails, reinstall the system and reformat the hard disk. BE SURE THAT YOU HAVE A GOOD SYSTEM BACKUP DISK BEFORE REFORMATTING THE HARD DISK. This will avoid losing the critical system specific information during the formatting process.
3) If that fails, replace the hard disk drive, disk controller, and/or disk cables and repeat at step 2. It is also possible that disk corruption problems can be caused by CPU, power supply, or software problems, although these are considerably more rare. If the above steps fail to correct the problem, and you have not already called for factory assistance, now is the time to call.

bk_page

Automatic System Backup functions

System Backup functions

Backup of the System

This Maintenance menu provides support of the Automatic System Backup functions as briefly described in the first chapter of the User Reference Manual. This menu entry presents you with a page from which you can format and list System backup diskettes, save to and restore from these diskettes, and test the System Backup floppy disk drive. You also have the capability of duplicating diskettes, including software diskettes. During most of the operations described in this section, the first thing that the system will do is to do an integrity test on the file structure of the floppy disk. This is done to assure that the disk structure has not been damaged, and to repair it if it has and if possible. This menu also contains functions for saving and restoring the USER, LOGIN, and MATERIALS directories via the System Backup floppy drive.

Format system backup diskettes

This button allows you to create blank system backup floppies. In doing this, the diskette is formatted, and a blank (empty) file system is created on it. Before using this function, be sure that the diskette is inserted properly into the floppy drive (located in the rear computer enclosure), and that the diskette is not write protected. This function will verify whether you really want to use it or not, but you should use this function with caution!!!
Keyboard command: BACKUP FORMAT

Test System Backup floppy drive

This button allows you to perform a disk drive test on the System Backup floppy disk drive. This test is the same test used by the system to test the hard disk drive during formatting in order to create a bad block list. To run this test, you will need a diskette which the system can used for the test. All contents of this diskette will be destroyed during the test. The test will format the diskette, and then do a read/write test to verify each block on the disk. Error counts for read and write, as well as progress messages are displayed. This function will verify whether you really want to use it or not, but you should use this function with caution!!!
Keyboard command: BACKUP TEST

List system backup diskettes

This button allows you to get a directory listing of a system backup floppy. This will show the names of all files on the diskette, in the long directory listing format (see the Regulus manual for further details). This listing will show things like the file name, creation date, and protection status. The listing will show all files, plus directories and subdirectories. At the end of the directory listing, a report will show how much of the diskette is presently used. Before using this function, be sure that the diskette is inserted properly into the floppy drive (located in the rear computer enclosure), and that the diskette is not write protected.
Keyboard command: BACKUP LIST

Save system info to backup floppy

This button allows you to save crucial system information (those files stored in the SYSTEM directory /cnc/data) to the backup floppy. The system's log files are not written to the backup floppy. Pressing this button will cause any system files which have been changed to be written out to the backup floppy. Using this button is usually only necessary when you are creating multiple backup floppies, since a "backup save" is automatically performed at power down. Before each file is copied to the floppy, the system checks to see if the file already exists on the floppy. If so, the name of the file on the floppy is changed to have a ".BAK" extension, so "password.dat" would become "password.BAK". After the name change (if required), the file is copied from the hard disk to the floppy. This gives you one extra level of protection, in case you accidentally change an important file, and shut the system down so that the file on floppy is overwritten. As long as you don't change the file AGAIN, you can restore from floppy and then rename the file from "password.BAK" to "password.dat". Before using this function, be sure that the diskette is inserted properly into the floppy drive (located in the rear computer enclosure), and that the diskette is not write protected. This function will verify whether you really want to use it or not, but you should use this function with caution!!!
Keyboard command: BACKUP SAVE

Save user info to backup floppy

This button allows you to save user information (those files stored in the USER, LOGIN, and MATERIALS directories) to the backup floppy. No system information is written out by this function. The primary use of this function is to save the contents of these user directories for later restore after reformatting the hard disk. The function clears all files currently on the floppy, and then creates subdirectories USER, LOGIN, and MATERIALS. The contents of each of the corresponding hard disk directories are copied to these. NOTE: The capacity of the floppy disk is roughly 1.4 megabytes. This function makes no attempt to handle saving of more than this amount of data. If you run into this, it probably indicates that you are trying to archive TOO MUCH DATA on the machine itself - the machine was never intended to act as mass storage. Before using this function, be sure that a diskette is inserted properly into the floppy drive (located in the rear computer enclosure), and that the diskette is not write protected. This function will verify whether you really want to use it or not, but you should use this function with caution!!!
Keyboard command: BACKUP USAVE

Restore system info from backup floppy

This button allows you to restore crucial system information from the backup floppy to the hard disk. Pressing this button will cause all files stored on the floppy to be copied to the SYSTEM directory /cnc/data, except the DATESTAMP file, which only notes time of last floppy update. This function would be required if, for instance, the system's hard disk was replaced or formatted. After these files are restored from the floppy, the Extended Installation procedure will be run (See Extended Installation) which will merge the restored files COMMANDS.TAB and DEVINFO.DAT with the master files for the current revision. The files on the backup disk cannot be used directly (without running Extended Installation), because they might be from a different software revision than what's currently on the hard disk. Before using this function, be sure that the diskette is inserted properly into the floppy drive (located in the rear computer enclosure), and that the diskette is not write protected. This function will verify whether you really want to use it or not, but you should use this function with caution!!!
Keyboard command: BACKUP RESTORE

Restore user info from backup floppy

This button allows you to restore user information from the backup floppy to the hard disk. Pressing this button will cause all files stored on the floppy subdirectories USER, LOGIN, and MATERIALS to be restored to the corresponding directories on the hard disk. See "Saving User Information", above. Before using this function, be sure that the diskette is inserted properly into the floppy drive (located in the rear computer enclosure), and that the diskette is not write protected. This function will verify whether you really want to use it or not, but you should use this function with caution!!!
Keyboard command: BACKUP UREST

Duplicating diskettes

This button allows you to duplicate diskettes. This function can be used for duplication of AUTOPATCH, SYSTEM BACKUP, SYSTEM SOFTWARE, SERVICE KEY, and SYSTEM LOG diskettes. NOTE: Excellon STRONGLY recommends that you duplicate your software diskettes. Reasons why this is important are listed in the CNC-7 User Reference Manual. When you select this function, you will be instructed to insert the diskette to be copied FROM, and the contents of the diskette will be copied to a working area on the hard disk. After this, you will be instructed to insert the diskette being copied TO, and the contents will be written back out to the new floppy after formatting the new diskette. NOTE: This duplication procedure is a general purpose copy procedure that painstakingly copies each sector on the disk one at a time. So it doesn't really matter what is on the disk, or how many files there are. Duplication takes approximately 20 minutes per diskette, 10 minutes to read the diskette to the hard disk, and 10 minutes to copy it back to the new diskette. This function will verify whether you really want to use it or not, but you should use this function with caution!!!
Keyboard command: BACKUP DUP

Check Hard Disk File System

FSCK

This button allows you to perform a hard disk surface analysis. During this analysis, any hard disk errors like "Duplicate Block" or "Missing Block" will be reported as problems. After the analysis, a NOTICE page is displayed. If you see any above described errors in your hard disk, you should follow the NOTICE instructions to repair your hard disk.
Keyboard Command : BACKUP FSCK

Report Hard Disk Usages

DF

This button allows you to perform a hard disk usage analysis. During this analysis, it reports the used disk space in block, unused disk space in block and the percentage on the used disk space.
Keyboard Command : BACKUP DF

bk_apat

Installing an AutoPatch

AutoPatch

CNC-7 software is shipped on sets of multiple diskettes, called Distribution Sets. An update for a machine to a new revision will be sent as a Distribution Set, and includes all known fixes as well as new features. Any one level of software functionality is called a Revision, or "Rev", such as "Rev 1.9". When bugs are fixed within a release, Excellon releases what is called a "sub-release", e.g.: 1.9b. This system would fix all known problems in Rev 1.9, but contains all of the same basic features - no more, no less. Anyone updating from an earlier revision will receive the current sub-release which fixes all identified bugs. If your machine is running one revision of software (e.g.: Rev 1.9b), and a problem is resolved in 1.9 after that point, a new sub-release will be made (e.g.: Rev 1.9e). This sub-release includes all of the same features, but perhaps a few additional bug fixes. If you were to order an upgrade in order to get those fixes, you would be sent an "AutoPatch" disk - one disk which contains ONLY the fixes made to Rev 1.9. After installation, this disk should be stored with your diskette copies of Rev 1.9b in a safe place, and should be reinstalled if you have occasion to reinstall your software from diskettes. When you select this function, you will be asked to insert your AutoPatch diskette. After assuring that this AutoPatch disk is for this revision of software, all of the fixes will be installed onto the hard disk. After installation of the AutoPatch, you should remove the AutoPatch disk and replace the System Backup Diskette into the System Floppy drive. This function will verify whether you really want to use it or not, but you should use this function with caution!!!
Keyboard command: BACKUP APAT

System Log

This Maintenance menu provides support of the System Log files as described in it's own chapter of this manual. This menu entry presents you with a page from which you can format and list the log disks, as well as allowing you to release today's log entries to the SYSTEM directory so that they can be viewed and backed up, and a function to write the log files to the System Floppy so they can be sent in to the Excellon Factory for analysis. The Format and List functions on this page are EXACTLY the same as those on the SYSTEM BACKUP menu, since both functions use the 3.5 inch high-density floppy drive located in the rear enclosure of the machine. The RELEASE TODAY'S LOG, SAVE LOG FILES, and MACHINE PERFORMANCE STATISTICS functions are described below.

Making up a Log Disk

Under certain circumstances, you may wish to make up a Log Disk, to send into Excellon for the purpose of diagnosing a problem with the system. To make up a Log Disk, you must enter first log into a Maintenance account, and then enter Maintenance mode using the keyboard command MAINT. Once in Maintenance mode, press the button labeled SYSTEM LOG to display the SYSTEM LOG menu. You'll need a blank 3.5 inch high density computer disk, which you must insert into the System floppy drive at the rear of the machine in the Computer enclosure. After inserting the diskette, press the FORMAT SYSTEM FLOPPY button to format the floppy diskette (see description, above), This will prepare the diskette to receive files. Press the SAVE LOG FILES button to copy the System Log files to the Floppy drive. Once this operation is complete, you may wish to list the Log disk with the LIST CONTENTS button. After completing the above steps, you now have a Log disk that can be sent in to Excellon for analysis. Remove it from the System floppy drive, and reinsert the System Backup floppy before closing the door to the computer enclosure. Send the diskette to Excellon Automation, attn: Tech Support for Analysis.

Save Log files to System floppy

This button allows you to save the System Log files (stored in the SYSTEM directory /cnc/data) to the backup floppy. The other information stored in this directory (such as the MACH.DAT file) will not be copied to the floppy drive. Pressing this button will cause all System Log files contained in this directory to be written out to the backup floppy. They include the standard CONSOLE, MESSAGES and STATS files, as well as some "debugging" files useful for Excellon to analyze machine behavior and possible problems. Some of these are "debugdmp" and "SMRDATA.SAV". Before using this function, be sure that the diskette is inserted properly into the floppy drive (located in the rear computer enclosure), and that the diskette is not write protected. This function will verify whether you really want to use it or not, but you should use this function with caution!!!
Keyboard command: BACKUP LOGSAVE

Machine Performance Statistic graphs

This button allows you to get graphical displays of how the machine is running, based on the information contained in the log files. The system is currently able to display graphs on hit rate (hits/minute) and on dynamic runout. Note that these graphs represent the behavior of the machine over a 24 hour period, for any one day saved in the log files. The page contains buttons to select which graph is to be viewed, and one to select which day is to be viewed. Log file day numbering is used, e.g. day 1 is today (may need to be released before viewing), day 2 is yesterday, etc. It also contains START and QUIT buttons. In addition, a legend will be displayed to show what the graph displays, and what the range (in the Y axis) or the graph is. The graph always represents 24 hours, from midnight the previous day to midnight this day. Gradations on the graph indicate hours and magnitude of the measurement. When runouts are plotted, a separate graph is drawn for each spindle, using a different color. NOTE: Dynamic runout and static runouts are not necessarily related! NOTE: This function is part of the Rev 3.2 Option Bundle.
Keyboard command: MCH_STAT

Release Today's Log

This button allows you to Release Today's Log for access by the Display program, or for backup to the System Floppy as described above. The Log files for the current day are normally not accessible by the user, since they are still open and in the process of being created. Pressing this button temporarily closes and reopens these files, moving them to the SYSTEM directory where they can be accessed by the user. The names of the created files will be CONSOLE.1, MESSAGES.1, and STATS.1. See the Log File chapter for further information. This function is not necessary unless you wish to access today's log files. If you never use this function, the log files visible in the SYSTEM directory will begin with CONSOLE.2, which is the console activity file for yesterday.
Keyboard command: LOGREL

Special System log

SYSLOG

This button allows you to enable or disable special system logging of special diagnostic events and/or statistics. Categories are available to log this additional information only when it's necessary, thereby conserving the CNC-7's speed and disk space unless needed. The various categories available to this command are described in the Special System log section of the Log files chapter. Please see that section. This function can be activated through the button, in which case you will be prompted to enter a category (followed by any optional parameters) or to turn the special logging OFF. The function can also be activated by the command "syslog", which may be entered from the keyboard or inserted into the MACH.DAT file.
** This function is only available from the SERVICE account **
Keyboard command: SYSLOG (you will be prompted) SYSLOG,ON,#(,#...) SYSLOG,OFF
See also: Special System log (Log files chapter)

TSI Pressure Foot Calibration

The TSI Pressure Foot Calibration functions are provided to assist in the validation and calibration of TSI pressure feet, either as part of a machine build, pressure foot replacement, or recalibration. This button displays the TSI Calibration menu. The menu contains basically two procedures for calibrating TSI for "standard" or "small" tools. The definition of what is considered a "standard" or "small" tool is arbitrary and can be changed by the user. The menu also contains a function for adjusting TSI sensitivity values and a procedure for displaying the raw data values read from the hardware. Upon successful completion, the procedures will load the new calibrated values into memory, as well as writing them to the MACH.DAT file so that the calibration values are available at next reboot. This button is located on the Main Maintenance menu.

TSI Standard Tool Calibration

This procedure is used to calibrate the TSI system for standard tools. The procedure uses the toolchange system, and requires that a "good" and "bad" standard tool be loaded into the tool changer. It will pick up the good tool, and take a reading, then pick up a bad tool, and also take a reading. A minimum voltage difference is required between the good and bad tools, and failure to reach this minimum difference will be noted if it occurs. The procedure will need you to move the heads being calibrated over a stack of panels at a specific test height in order to take it's readings.

TSI Small Tool Calibration

This procedure is used to calibrate the TSI system for small tools. The procedure uses the toolchange system, and requires that a "good" and "bad" small tool be loaded into the tool changer. It will pick up the good tool, and take a reading, then pick up a bad tool, and also take a reading. A minimum voltage difference is required between the good and bad tools, and failure to reach this minimum difference will be noted if it occurs. Note that this threshold is different for standard and small tool sizes. The procedure will need you to move the heads being calibrated over a stack of panels at a specific test height in order to take it's readings.

TSI Sensitivity adjustment

This procedure is used to adjust the sensitivity of the TSI system for large and standard tools. The procedure displays the percentage change required for confidence check (verification of good drill after toolchange) and differentiation between good and bad drills. Separate values are available for standard and small tools, and a separate value is used for each pressure foot. You touch a button indicating which category you wish to change, and then enter the new percentage for the selected spindles on the pop up keypad. Spindle selection is done from the main TSI adjustment page. After entering a new value, the software will update the MACH.DAT file, and will adjust the reference values in memory and in the MACH.DAT file.

TSI Raw Data report

Sometimes it is useful to know exactly what raw data values are being seen by the computer, for example, to know if the cables are connected properly, and if the AtoD board is functioning properly. The TSI Raw Data report displays the exact values read via the AtoD board for each of the selected spindles in decimal. This is a display only page, and does not allow any alteration of the system or data.

Depth Control Problems

Faulty machine set-up or hardware problems may cause one of the messages listed below to be displayed in the Machine Status window. There are often many different conditions that could conceivably result in a particular message being displayed. A partial list of some of the more likely causes is provided for each message. In describing the messages the following terms are used:
Depth Control Switch: A switch and flag arrangement located in each spindle assembly. The switch is designed to activate when the pressure foot touches down on the material during a drill stroke or rout position plunge. When activated, the switch enables a Z axis position counter which is then used to determine the absolute elevation of the top of the material.
Tool Tip Check: After changing tools and at the beginning of each part program run, a tool tip check is performed where the machine inserts the tip of the tool into the tool tip sensor pod located at the front of the worktable. This is done to determine the elevation of the tool tip relative to the pressure foot.
The following messages may display while performing depth controlled drilling or routing:
Depth control switch activated-Check switch adjustment: n This message is displayed if the depth control switch is already activated prior to the drill stroke or rout position plunge.
Possible causes:
o Flag is adjusted too close to the switch o Switch is inoperative or blocked by foreign material o Pressure foot is not fully extended
Depth too low - Check stack thickness and commanded depth: n An absolute depth is computed based upon the commanded depth into the material, the elevation of the top of the material, and the relationship between the tool tip and pressure foot. The drill stroke or rout position plunge is terminated and the above message is displayed if the computed absolute depth is determined to be deeper than the maximum allowable depth.
Possible causes:
o Stack is not thick enough to drill or rout at the commanded depth o Tool ring is set improperly making the tool too short
No material detected-Deselect spindle(s) not in use: n This message is displayed if the top of the material is not detected before the spindle reaches the maximum allowable depth.
Possible causes:
o No material is present at a selected station o The flag is not engaging with the depth control switch
Bad chipload or tool geometry - Excessive drill depth variance: n This message is displayed if the machine detects an abnormally large variance at the bottom of a drill stroke, either too deep or too shallow. The amount of allowable variance (before this message will be triggered) is set by the VSB command ZDEPTH-TOL.
Possible causes:
o Z-axis badly out of tune o Failed Z-axis motor or resolver
The following messages may display during the Tool Tip Check:
Depth pod not up - Check pod: n This message is displayed if the tool tip sensor pod did not raise for the Tool Tip Check.
Possible causes:
o The pod is mechanically stuck in the down position o Faulty depth pod up/down sensor switch
Depth pod not down - Check pod: n This message is displayed if the tool tip sensor pod is not fully retracted before or after the Tool Tip Check.
Possible causes:
o The pod is not fully retracted for mechanical reasons o Faulty depth pod up/down sensor switch
Depth pod activated - Check pod: n This message is displayed if the tool tip sensor pod is already activated prior to performing the Tool Tip Check.
Possible causes:
o LED type pods: The plunger is stuck in the down position o Laser sensor pods: The laser beam is obstructed
Depth counter not zero - Check depth control switch: n This message is displayed if the Z axis position counter (enabled by the depth control switch) is non-zero prior to performing the Tool Tip Check.
Possible causes:
o The flag is adjusted too close to the depth control switch o The switch is inoperative or blocked by foreign material o The pressure foot is not fully extended
Depth counter did not count - Check depth control switch: n This message is displayed if the Z axis position counter (enabled by the depth control switch) contains zero when the tool tip is inserted into the tool tip sensor pod.
Possible causes:
o The flag is not engaging with the depth control switch
Tool too long - Check ring set or for collet to ring seating: n This message is displayed if the tool tip protrudes below the bottom of the pressure foot at the point the depth control switch first activates.
Possible causes:
o Tool is ring set improperly making it too long o The tool was picked up improperly during the last toolchange and is not seated in the spindle collet o The flag is adjusted too far away from the depth control switch
Tool missing or broken - Check the tool: n This message indicates that no tool was detected for a selected spindle.
Possible causes:
o Tool is missing or broken o Tool is ring set improperly making it too short
Inconsistent Depth readings - Increase band and/or inspect sensors: n This message indicates that the machine was unable to take a consecutive set of depth readings which are within the band dictated by the VSB command DPCHK-READS. Either the band is too small, or there is some mechanical/electrical problem.

Other Machine Problems

Machine Messages Explained

Clogs on # # ... Where #... indicate the stations containing the clogged tools. This message is put in the STATS log file on end of program and upon tool change after clogged tools were detected and indicates that debris from the drilling process is attached around the tool. Correcting Tool Seating: # # ... Where #... indicate the stations being fixed. This message may appear on the screen while the machine is adjusting tools' heights during a tool change on ringless tools equipped systems in Automatic Tool Change mode. Can't Correct Tool Seating. Check Tools: # # ... Where #... indicate failed stations. Possible mechanical problem has been found. Tools, spindles and tool transfer jaws should be inspected. Correct Tool Seatings: # # ... Where #... indicate the stations to be fixed. This message prompts the operator to adjust tools' heights during a tool change on ringless tools equipped systems in Manual Tool Change mode. Problem Moving Z axis - Check Spindles # # ... Where #... indicate the troubled stations. This message, usually displayed during tool change or check, shows spindles which failed to reach final position after being commanded up or down. This could be due to mechanical spindle system problems causing binding or electrical related malfunctioning that prevent the servos from moving the spindles. Stopped by: Depth/Insert pod up: # # ... Where #... are the pods detected up. If the tool check or insert remover pods are detected to be unexpectedly up, this message is displayed. Also, the work table is immediately stopped if it is moving. Inspect the referred pods and associated components to determine the cause of this problem. If the pods are down, check the switches attached to each of them for possible misalignment. Broken tool(s) detected: Refer to Broken Tool Report This message is displayed upon end of program when there have been broken tools replaced during part-program execution and the broken tool report/recovery option is installed on the machine.. Verifying Depth Control accuracy: # # ... Where #... are the affected stations. During tool tip check for depth controlled drilling or routing, the machine may take several sets of readings until the accuracy indicated in the machine configuration is achieved. When this happens, this temporary message is shown. Clipped TMG beam depth - Station: # Depth: # Where the affected station and an absolute Z axis position are indicated. This message is displayed during tool diameter check under some particular circumstances, such as large tool diameter, in which case the diameter reading can not be taken at the desired height on the tool's flute