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MANUALSThe CNC-7's Maintenance FunctionsThis 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.
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.
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.
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.
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.
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.
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. 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. 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.
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.
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.
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. 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.
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.
Sensors Status Display buttonThe 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 buttonThis button opens and close all transfer collets at the same time, thus allowing verification of their operating condition. Open Transfer Collet buttonThis button raises and lower all transfer collets. At the same time the position indicator "buttons" display the current position. Z-Axis Adjustments buttonZ-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 buttonZ-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 buttonZ-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 buttonSet 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 buttonAdjust 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 buttonThe 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. Set-up button - Excellon Freq. ConverterThe 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. ConverterThe 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. ConverterThe 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. ConverterThe 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. ConverterThe 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. ConverterThe 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. ConverterThe 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. ConverterThe 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. ConverterThe 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. ConverterThe 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 buttonThe 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 buttonThe 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 buttonThe 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 buttonThe 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 buttonThe 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 buttonThe 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 buttonThe 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 buttonSpindle 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 buttonThe 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 buttonThe 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 buttonThe 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 buttonThe 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 buttonSignal 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 buttonServo 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 buttonThe 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 buttonThe 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 buttonThe 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 buttonThe 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 buttonThe 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 buttonThe 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 buttonThe 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 buttonThe 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 buttonThe 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 buttonThe 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 buttonCurrent 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 functionsThis 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. 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.
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.
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. Raise Depth Pods button
This button raises and lower all sensor pods. At the same time
the position indicator "buttons" display the current position. 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).
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.
Scheduled MaintenanceThis 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 ScheduleThis 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". Schedule editPressing 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. Check for Due MaintenanceThe 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 ScheduleAt 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 functionsThe 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. 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.
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.
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.
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.
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. Setting the system clockThe 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 encounterThis 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: Disk Problems
File System CheckShould 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:
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: bk_pageAutomatic System Backup functions
System Backup functions
Backup of the SystemThis 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!!!
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!!!
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.
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!!! 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!!!
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!!!
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!!! 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!!!
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. 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.
bk_apatInstalling 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!!! System LogThis 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 DiskUnder 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!!! 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.
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.
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. TSI Pressure Foot CalibrationThe 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 CalibrationThis 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 CalibrationThis 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 adjustmentThis 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 reportSometimes 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:
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 because the machine may not dip the tool any farther
into the sensor pod. If the tool is not large, say more than 0.180",
check the alignment, specially the machine parameter ZAUXTRVL.
Broken tool detected in station(s) # # ...
Where #... are the affected stations.
This message means just what the text says. It is displayed during
program execution when a tool is detected broken.
Clogged tool detected in station(s) # # ...
Where #... are the affected stations.
This message indicates tools found clogged during program execution
on machines equipped with clog detector hardware.
Block - IPP time-out - Program cannot continue
While executing a part-program, the machine reads command blocks
from an Intermediate Part Program named IPP.PP, which resides on
the hard disk after being created the first time every particular
job is executed. If a read failure occurs, this message is displayed
and execution is aborted. In this case the intermediate
file may be corrupted, or an associated problem has occurred, such
as hard disk malfunction.
"text" parameter is out of range
Where "text" is the name of a tool data command.
If a tool command is issued, such as T500S50, which includes tool
data values not allowed, this message is returned by the system.
Can't with this tool in collet - put it away first
Some machine operations are not allowed while a tool is in the
collet, such as turning auto tool change on/off. If a command is
executed by the operator under these circumstances, this message
reminds to put the tool away first.
Tool check needed
If the machine is commanded to execute a move that requires
the tools to be previously tip checked, for example sending the
spindles down to rout position after turning depth control on
with tools in the collets,
this message reminds the operator that tip check must be done first.
Remove Tool from Transfer Collet
When aligning the TMS cassette with the corresponding Maintenance
function, the tool may fail to go into the cassette. In this case,
this tool must be manually removed from the transfer collet and
placed back into the cassette.
Laser sensor fault detected. Clean the TMG lenses
Machines equipped with laser tool detector may produce a fault
signal when the sensors are turned on before tool check. If
cleaning the lenses does not eliminate the problem, a hardware
problem may have occurred, which could be in one of the sensors
(The one that shows a red light on the sensor) or the 'Diameter
Check Board'.
Tool diameter counter did not count. Check tool length
While executing any Diameter Check Alignment maintenance function,
the machine runs the tool across the laser beam and a dedicated
hardware counter provides information for computing diameter and
runout. If the beam is not intercepted by the tool, which could
happen if it is short, the counter does not count. If the tool has
its normal length, there may be a problem with the Diameter Check
hardware, including the counters (Located on the Motion Controller
Board).
Bad tool # ... (see machine status) - Waiting START button
Where #... are the affected stations.
After a tool has been found defective (Bad Diameter, runout or
broken) during tool change, the machine may stop waiting for the
operator to take an action. If this is the case, this message is
shown in the Machine Program Status Window. Details of the problem
are simultaneously displayed in the Machine Status Windows.
Laser sensor 'Out of Lock' detected
This message indicated a hardware problem in the first versions
of the TMG system. It is obsolete now, so it should never be
displayed.
Laser sensor beam obstructed :#. Clean the TMG lenses
Where #... are the affected stations.
Before passing the tool across the laser beam during tip check
operations, the machine makes sure that the beam is not obstructed.
If it is, this message is shown and the machine stops. In this
case, if cleaning the lenses does not eliminate the problem, check
the indicated sensor pods for malfunctioning.
Laser sensor inconsistent readings station #. Possible bad tool
Where #... are the affected stations.
After taking every diameter/runout reading during tool check, the
system uses some additional information to verify the accuracy of
the reading. If it is considered not reliable, at least two more
readings are taken and compared with each other. If these readings
are inconsistent, the machine is unable to determine the correct
diameter/runout. This problem may occur if the tool has debris
built around the flute. If this is not the case, the sensor pod
should be suspected.
Bad tool, Wrong Diameter: # # ...
Where #... are the affected stations.
This message, displayed after tool check, simply indicates the
tools that failed to pass the diameter test.
Bad tool, Excessive Runout: # # ...
Where #... are the affected stations.
This message, displayed after tool check, simply indicates the
tools that failed to pass the runout test.
Questionable tool, Runout in Warning Range: # # ...
Where #... are the affected stations.
If the runout detected in a tool is larger than expected but not
enough to reject the tool, this temporary message is displayed and
logged. To determine when a tool is questionable, the system uses
parameters contained in the machine configuration file.
Checking for dirty collets on Station: # # ...
Where #... are the affected stations.
A tool may have excessive runout because the spindle collet has
trapped debris while dropping/picking up tools. In an effort to
eliminate this problem, the machine re-chucks the tool during the
tool check operations. While this is in progress, this message
informs the operator of those machine actions.
Beam Interrupted. Check sensors, related boards and loose cables
This message may be displayed during Diameter Check Alignment,
one of the Maintenance functions, when the laser beam is
unexpectedly interrupted. If the beam is not physically obstructed,
the indicated hardware is producing a false signal.
Laser Sensor Beam was not interrupted. Check tool and involved hardware
This is another message that may be displayed during Diameter Check
Alignment, while exercising tip checks. It means that the system did
not see the tool. If the tool is properly set, the hardware associated
with diameter check is malfunctioning.
Can't move, it will hit sensor's wall. Realign sensor: #
Where #... is the affected station.
This message may be displayed during tool check operations, right
after tip check and before diameter check. For this last operation,
the tool must be positioned inside the sensor pod, between the laser
beam and the internal sensor's wall. Because in this position the
tool may be very close to the wall, there is the potential risk of
hitting the sensor with the tool. To prevent this, the system limits
the travel to a maximum safe area. If an attempt is made to trespass
this safety limit, the operation is aborted and indicated with this
message. This problem can only occur if the beam location
(specially on the Y axis) is not correct. The Beam Alignment function,
in the Diameter Check Alignment maintenance page should be performed.
Because at this point the machine has an incorrect set up parameter,
this maintenance function should be executed with care to avoid
damaging the sensor or the tool.
Exceeded number of retries in Tool Tip Check
In same cases, as part of the recovery process, such as after
re-chucking the tool or re-aligning a ringless tool, the system needs
to redo all tool check sequences for maximum accuracy. However, if
this is the case, the total number of retries is kept to no more than
three times and this occurrence logged with this message.
Right/Left axis servo fault - Check servo amplifier
Front/Rear axis servo fault - Check servo amplifier
Z axis servo fault - Check servo amplifier: # ...
Where #... are the affected stations.
Immediately after detecting a fault signal from the servo amplifiers,
the system stops all machine moves and displays this message, which
will stay on the screen until the faulty condition goes away.
An inspection of the indicated servo system and associated components
should be performed.
Doing multiple reads for maximum TMG accuracy: #...
Where #... are the affected stations.
Due to the alignment of the spindles to the tool check pods
(This alignment may vary due to factors like temperature, etc.)
the system separates all active stations into groups which are
tip checked individually. These groups are made up of stations
with similar alignment. By doing this, greater accuracy is
achieved for depth control.
Depth control, Diameter/Runout/Flute or Controlled Penetration not enabled
At least one of the run time options indicated by this message must
have been turned on before the operator manually commands a tool check.
CHECK IF PISTON IS DOWN AND PARK TABLE
This message is part of one of the TMS maintenance functions, intended
to direct the operator during execution.
TOO MANY # TOOLS INDICATED
Where #... is the number of tools.
This message may be displayed while the machine is being configured
during boot up if the maximum number of tool sizes indicated
for that machine is greater than expected. In this case, enter the
correct value in the machine description file.
NOT ENOUGH # TOOLS INDICATED
Where #... is the number of tools.
This message may be displayed while the machine is being configured
during boot up if the maximum number of tool sizes indicated
for that machine is less than expected. In this case, enter the
correct value in the machine description file.
Dead pressure foot detected on station(s) # ...
Where #... are the affected stations.
On machines equipped with Microwave Broken Tool Detector in the
pressure foot, this message indicates that at least one failing
pressure foot has been detected. Inspect those indicated pressure
feet for malfunction.
Broken Tool: # ...
Where #... are the affected stations and additional information.
This message is logged into the Statistics and Broken Tool Report
files when appropriate, after any tool is detected to be broken.
Additional information is also saved, such as hole location. Specially shaped drillsSome drill bit manufacturers have begun shipping special "multilayer" drills, which have a tapered flute after a short length of "true diameter" flute. Generally, these drills taper off in diameter after about 1.0mm (0.04 inch) so that the entire flute is not in contact with the hole wall. Problem is that without adjustment, these drills will give trouble to the diameter checking system, since it measures the diameter at a specific point along the flute of the drill (in the Z axis). The Z-axis position depends on the diameter of the drill (using a fixed drill point angle), and then upon an offset applied to all diameters. The default value for this offset is 0.02 inch (0.50mm). With the "multilayer" drills, the drill will be measured too high, giving false readings. To correct this, you'll need to reduce the offset to a smaller value, perhaps 0.02 inch. You may need to experiment to find the exact value. This offset is entered though the DIAM-Z-OFFSET,# VSB command, and should be placed in the MACH.DAT file somewhere toward the end of the file. The system must be rebooted after making the edit. Also, to prevent the pressure foot from touching the laser sensor, the Z axis position is clipped to the maximum travel down of the spindle for tool check. This could cause erroneous diameter and runout readings and messages like "Inconsistent readings" especially on large tools. Dumping System information
Lockup of the screen
DEBUGDMP.DATThe CNC-7 has an added debug facility which causes the system to dump certain important pieces of data to the disk. This is done whenever the system detects what it thinks is a problem, such as a system screen lockup or other similar catastrophic problem. In the event that a problem is detected, a task called DEBUGDMP is run, which creates a file called "debugdmp.dat" in the SYSTEM directory. This file contains a dump of the current processor status (ps), as well as the current date and time, and several key variables related to the particular dump type being made. The dumped variables are not described here, since they require too much knowledge of the internals of the system to be useful to the user. However, this information, combined with the system log files, can be VERY useful to someone at the factory trying to diagnose a problem you may be experiencing. When you create a log file disk (see System Log section), this file will be written to the log file disk so that the information can be analyzed by Excellon at the factory. Servo StatisticsThe CNC-7 automatically collects data relating to servo system performance during normal drilling operations. Statistical data summarizing XY servo performance is written to the STATS log file at end of program. This information may be useful for diagnosing problems with the machine or for monitoring trends. For information regarding the Servo Statistics Log, please refer to the Servo Statistics Log section of the Log Files chapter. DNC Debug fileIn case of severe DNC problems which are unexplainable and expected to be hardware related, it may be useful to find out what the DNC software thinks has happened during a DNC transfer. This is best accomplished using a Data Line Monitor (DLM), and then having the data recorded by the DLM analyzed by someone familiar with the DNC-1.3 protocol. However, in some cases this is not practical or possible. In these cases, you can use the /tmp/DNCDEBUG.LOG file, which is created at the start of any DNC-1.3 file transaction. This file stores all unusual DNC-1.3 protocol events, such as checksum errors and time-outs, whether or not the problem is eventually recovered. This file can be read out of the system disk after a transmission failure, and sent back to Excellon Torrance for evaluation. To recover this file, log in as the SERVICE account, and type the command "quit" (lower case) followed by a RETURN. The /tmp/DNCDEBUG.LOG file can be moved to the SYSTEM directory using the command "dcp /tmp/DNCDEBUG.LOG /cnc/data/DNCDEBUG.LOG". From there, you can return to the CNC-7 displays with the "adm2" command, and use the CNC-7's standard file handling utilities to print or copy the file. The data in this file, accompanied by a DETAILED explanation of the symptoms of the problem, and copies of all files involved, can be very helpful in diagnosing the source of the problem. Reporting problems to Excellon
Technical SupportAny problems you have with your system which you cannot resolve should be reported to Excellon via Excellon's Technical Support team. This team is staffed with highly trained experts who can handle most problems directly, and know who to consult on issues which require input from other members of Excellon team. Tech Support's number is 1-800-EXCELLON (392-3556). When you call, be prepared with the name of your company, the machine type, serial number, the current software revision, and as EXACT a description of the problem as you can obtain. It is best to have the person who noticed the problem talk directly with Tech Support. Try not to go through another person, as things get lost in the translation. Messages are important, so write them down when trying to resolve a problem. A report like "I tried to use the editor, but got a message", or "The paper tape reader doesn't work" doesn't give the problem solvers any information to work with, delaying you getting a solution. Any problem must be able to be reproduced back at the factory before it can be solved, so the more information you can supply, the better. The log file system is often helpful here. On complex or difficult to reproduce problems, it is helpful to send in a diskette with the system log files stored on it. These log files record every activity for a certain amount of time, and can be used to diagnose and duplicate difficult problems. Once it has been reproduced, it can be solved. A description of how to create a log file disk to send in to the factory is described in the System Log section of this chapter. The Excellon Technical Support team is there to help you with your questions and/or problems, and they are anxious to help you with whatever you are facing, but they need the best information you can give them. Autoload maintenanceThe Autoload maintenance provides six different tools to adjust the sensor sensitivity, to align the sensor mounting locations, to tune the elevator motor drive to reach the maximum output voltage/current, to verify board presented switches, to align all elevators and plates positions and update them in the machine file, to test barcode unit. Elevator Sensor Sensitivity
Adjust Sensitivity on Elevator SensorsElevator Sensor Sensitivity provides the procedures to adjust the UPPER OVERTRAVEL, TOP, INDEX and BOTTOM sensors to have the right sensitivity. The NEXT PAGE and the PREVIOUS PAGE buttons are used to read through procedures. The ELEVATOR UP, DOWN and STOP buttons are used to manually move the elevator up or down to any location. ALL elevator sensors feedback are disabled. The elevator will not stop automatically on the overtravel, top and the bottom sensors triggered condition. Elevator Sensor Alignment
Elevator I/O Test
Elevator Sensor Position AlignmentElevator Sensor Alignment provides the procedures to first verify four input sensors feedback from the elevator and then to align the mounting position of INDEX sensor. The NEXT PAGE and the PREVIOUS PAGE buttons are used to read through procedures. The ELEVATOR UP button is used to move the elevator up until the next highest panel is blocking the TOP sensor and the elevator will stop. The ELEVATOR DOWN button is used to move the elevator rail down by one slide. Elevator Motor Output
Elevator Motor Drive Tune-Up
Elevator Motor Output provides the procedures to tune the elevator
motor drive to reach the maximum output voltage and current.
Hand Motor Drive Tune Up
Hand Motor Drive Tune Up provides the procedures to tune the hand
motor drive to reach the maximum output voltage and current.
Board Present SensorBoard Present Sensor displays the sensor status of the sensor switch located underneath the hook assembly and the sensor switches located above all tooling plates. For the SYSTEM-1000 station, only the one sensor switch located above the tooling plate is available. Motorized Hand Sensor StatusMotorized Hand Sensor Status displays the PLC ERROR, Ready to Scan, Slider limit switches and Board At Hand sensor status. For Double Hands system, a hand selection popup is executed before displaying this page. Once the selection is made, a RIGHT HAND or LEFT HAND will be displayed on this page. Autoload SYSTEM-2000 Position Alignment and Update
Save SYSTEM-2000 Autoload positions to MACH.DAT
Autoload SYSTEM-2000 Position Alignment and Update is provided for easy realignment
on SYSTEM-2000 autoload related positions. It includes the manual mode operation
buttons, a Park button and two Y coordinate absolute jog and incremental
jog buttons.
READ BARCODE LABEL
READ_BCRREAD BARCODE LABEL button triggers the barcode unit and scans barcode until a GOOD READ or the time-out occurred. The time-out period is set at the 2 1/2 seconds. The decoded barcode content will be displayed in the popup button window and stay there until the button window is touched or for up to four seconds. Any invalid barcode scanning will result in no characters following the "BAR CODE :" display in the popup button window. Autoload SYSTEM-1000 Position Alignment and Update
Save SYSTEM-1000 Autoload positions to MACH.DAT
Autoload SYSTEM-1000 Position Alignment and Update is provided for easy realignment
on SYSTEM-1000 autoload related positions. It includes the manual mode operation
buttons, a Park button, a Table Load/Unload Position button and two Y
coordinate absolute jog and incremental jog buttons.
vis_maintServo Controlled Vision AlignmentThe Servo Controlled Vision Calibration functions are provided to assist in the validation and calibration of the camera mounting mechanism and Vision Pod device, either as part of a machine build, parts replacement, or recalibration. This section applies to machines equipped with servo controlled variable focus and magnification only. This button displays the Vision Calibration menu. The menu contains several procedures for aligning the camera mounting and determining the location of the Vision Pod on the work table. These procedures, listed in the recommended order of execution are: Mechanical Slide Alignment, Optics Alignment, Pod Mapping and Pod Location Calibration. The first one will permit an approximation to the camera assembly perpendicularity, while the second will help to complete it. Pod Mapping executes a sequence of functions to determine the exact distance from the Air Gauge to the glass fiducials. Finally, the last procedure is intended to establish the location of these fiducials on the work table. The menu also contains support functions for additional operations that may be required as part of the main procedures. Upon successful completion, the procedures will save the new calibrated values into memory, as well as writing them to specific files so that the calibration values are available at next reboot or when the user calls for a new set up. This button is located on the Main Maintenance menu. Mechanical Slide Alignment
The viewing device must be perpendicular to the image in order
to achieve specified accuracy.
Optics Alignment
The viewing device must be perpendicular to the image in order
to achieve specified accuracy.
Pod Mapping
This maintenance function is used to determine the Air Gauge/Glass Fiducials
relationship.
Pod Location Calibration
This maintenance function is used to determine the location of the
Glass Fiducials on the work table.
Air Gauge Test
This Maintenance Option allows for testing of the AtoD board,
air gauge and transducers.
rpfi_maintPressure Foot Inserts AlignmentThe removable pressure foot inserts calibration functions are provided to assist in the alignment, verification and testing of the mechanisms involved in removing and replacing the inserts, which are normally done as part of a tool change. This section applies to machines equipped with these special inserts only, whether they are equipped with single or multiple inserts (This last version usually has 3 inserts per station). The Pressure Foot Insert Alignment button on the main maintenance page displays the Calibration menu. The menu contains several procedures for aligning the Transfer Holders to the spindles, the Park Holders to the Transfer Holders, the spindles' height, machine data file update, Transfer Holders actuation switches, vacuum valve and sensor actuation and verification, and several support functions which may be required from inside this menu. All provided functions may be executed directly from this menu. Also, they are intended as aids to the standard alignment procedures, so there is no specific sequence of operations to be followed. Moreover, in most cases the same functions may be used for verification and testing as well as alignment. Jog Pods Under SpindlesThis function jogs the table to position the transfer pods under the spindle's collet. It may be used to verify the spindle/pod alignment when used along with button 'Raise Pods, Lower Spindles'. If a correction is needed, new X and Y locations may be entered with button 'Enter Pods Location'. Also, the spindle height (Z axis position when commanded down) may be changed with button 'Enter Spindle Height'. Then use this function again to reposition the work table. After a correction has been made, it should be made permanent saving it with button 'Save New Locations'. Jog Pods Under Park StationsThis function jogs the table to position the transfer pods under the parking stations. It may be used to verify the transfer pod/parking station alignment when used along with button 'Raise Pods, Lower Holders'. If a correction is needed, new X and Y locations may be entered with button 'Enter Park Holders Location'. Then use this function again to reposition the work table. After a correction has been made, it should be made permanent saving it with button 'Save New Locations'. Raise Pods, Lower Spindles
This button simultaneously commands the transfer pods up and spindles down
or viceversa. The spindles are lowered down to the same position as for
an actual tool change insert transfer.
Raise Pods, Lower Holders
This button simultaneously commands the transfer pods up and park holders
down or viceversa.
Raise Pods
This button simply commands the transfer pods up and down. It is useful
to exercise the pods' solenoids, air lines, position sensor switches, etc.
The state of the switches is indicated by the display "buttons" on the
same screen.
Lower Park Holders
This button simply commands the park holders up and down. It is useful
to exercise the mechanism's solenoids, air lines, etc.
Enter Pods Location
This button allows for new X and Y locations to be entered when the pods'
locations under the spindles need to be changed. This would normally
be done as part of an alignment.
Enter Park Holders Location
This button allows for new X and Y locations to be entered when the pods'
locations under the park holders need to be changed. This would normally
be done as part of an alignment.
Enter Spindle Height
This button allows for a new Z axis location to be entered when the
spindle height needs to be changed. This would normally
be done as part of an alignment in which case inserts should be present on
top of the transfer holders.
Save New LocationsAfter any correction has been made to the table position or spindle height for insert transfers (Buttons: "Enter Pods Location", "Enter Park Holders Location" and "Enter Spindle Height") they should be permanently saved into the machine description file. This can be accomplished with this function, which will do whatever is necessary to store the new values into the file). Vacuum ON/OFF
This button turns the vacuum pump on and off. It may be used for checking
the involved pneumatics. For example, if inserts have been placed on the
pods, the created vacuum should trigger the display "button" on the screen
called "Vacuum Sensor Inactive/Active" indicating that the system is working
properly. If there is a leak, the sensor will indicate so. If at least one
of the inserts is missing, the sensor should be "inactive".
Also, when this button is used along with "Raise Pods, Lower Spindles" and
"Raise Pods, Lower Holders", an actual "manual" insert transfer may be
exercised.
Vacuum Sensor Status
This display "button", changes color and label every time the pneumatic
vacuum sensor is activated (Only while the vacuum is ON) indicating that
the vacuum system is working properly (pump, hoses, etc). Because this
sensor is used to detect the presence of an insert on the pod, this
should be placed on it first in order to close the circuit.
Pod Up/DownThis display "buttons", turn white and change the message whenever the transfer pods are in the up position (For example after been commanded with button "Raise Pods"). If one or more of them do not do this, it would indicate a problem with the pods' solenoid or sensor switch. iotestI/O Sensor status display
IOTEST
The I/O Sensor status display provides four different page displays which
can be used to help diagnose machine problems and to verify the correct
operation of the machine's sensors. The I/O Sensor status display can be
activated from the Maintenance Menu or from the keyboard with it's keyboard
command.
The display consists of four possible pages, each activated from buttons
located along the right side of the display. The four page displays available
are described in the following sub sections. In addition, a QUIT button allows
you to exit the display, and return to the previous page or menu.
Input Sensor displayThe Input sensor display puts up small boxes within a larger rectangle, each one representing an active input sensor. Inside the box is printed the names of the various sensors, eliminating the need to know the particular hardware polarity, bit assignment, port address, or filtering. If the sensor is triggered, the sensor box will be displayed as black text on a white background. If not triggered, it will be displayed as white text on a black background. Output Sensor displayThe Output Sensor display is very similar to the Input Sensor display, except that it displays output sensors rather than input sensors. Again, If the sensor is triggered, the sensor box will be displayed as black text on a white background. If not triggered, it will be displayed as white text on a black background. I/O Port displayThe I/O port display displays each port in a small rectangle located within a larger rectangle. Those toward the top are input ports, those toward the bottom are output ports. In each box is displayed the name of the port, its I/O address, and it's current value in Hexadecimal and (decimal). If you touch the box containing the port name, the bits of the current state are "blown up" into a bit pattern written along the bottom of the large rectangle. This shows you the state of each individual bit, whether it is ON (a one) or OFF (a zero). The box containing the port which is "blown up" will be displayed as black text on a white background, as opposed to the normal white text on black background. This display is a little "closer" to the hardware, in that you display raw bit values, without regard for their interpretation by the system as any particular function. STAC I/O displayThe STAC I/O display shows the STAC board I/O space. You are allowed to select which of the STAC (servo control) boards in the system you wish to examine, and the system will respond by giving you a display of I/O on that STAC board. The information for each STAC board includes: Axis numbers, names of axes, values of counters 1 and 2 (in hex), DAC output value (in hex), APOS and DPOS (relative to HOME, in scale counts). Also shown are the bit expansions (with labels) for the board's general purpose inputs, outputs, and status register. As much as possible, this display shows data exactly as read from the hardware, with no pre-digestion. As such, be careful in interpreting the data, since bits may be active high or active low. Also, please note that bit definitions may change depending on which STAC board is being looked at, or on the exact configuration of options on your machine. I/O Sensor names
The sensor names are intended to be specific, but in case they're not
reasonably clear, we've included a list of some of the sensors to give
you the general idea along with a short description of their functions.
Hardware configuration
JumpersThis section shows the jumper configuration as used in the major boards of the CNC-7 control system. At this time, this section describes the 2 and 4 megabyte CPU boards, and the MLAN-E Ethernet controller. Excellon's Engineering drawings for the configuration of these boards are provided to assist you in verifying or correcting the jumper configurations. These boards are commercial products which are intended for a variety of applications. These jumper configurations reflect their configuration as used within Excellon CNC-7 systems. The Two megabyte version of the CPU is used in all CNC-7 systems not equipped with Ethernet. The Four megabyte version is used only with Ethernet, and the additional MLAN-E Ethernet controller card is also required. Protection EditorThis page contains a list of functions which will allow you to edit user access privileges. These access privileges are how you control which operators are able to do what in the system, limiting their access to those functions or files you don't want them to be able to use. This page is available from the Maintenance Menu, and provides functions which can be used to display a summary of all operator accounts in the system, display detailed information about one operator account at a time, display the access privileges to all the system's devices, or display the access privileges to all the system's functions. In addition, there are functions for editing the components of a user account, editing device access privileges, editing command access privileges, or adding a new user. This set of functions should allow you to perform the most commonly needed protections functions, such as setting up an operator account, changing privilege levels, or modifying which functions the operator has access to. In some cases, you may need to type in new values, such as when entering a new privilege level. In some cases you may need to select a user name. Selecting a user is done via a special select page which lists all available operator names in the system, displaying one button with each name in it. Pressing the button will select or deselect that operator for the function. Note that access to system functions is controlled by assigning a privilege level to each operator. Each system device or command, in turn, specifies which privilege levels have access to it. In the case of commands, there is only one set of access privileges - you either can use it on your level or you can't. In the case of system devices, there is a read and write privilege, meaning that you can separately control which operators can read and/or write from each device. It may be desirable, for example, to allow most operators to read from floppy disks, but only allow a few to write to them. It is possible to have multiple operators on the same privilege level. Simply stated, this means that all operators on level 5 (for example) have access to all the same commands and devices. Therefore, when you display the detail on an operator, it will tell you what other operators are on this privilege level. When editing privileges of commands or devices, you touch user names to grant or deny access privileges. It is important to understand that if you have three users, say SALLY, FRED, and JOE on the same level, that if you grant access to something for one of them, you grant it to all. Same is true for denying access. Hence, when you touch the button for JOE, and it lights up, the buttons for SALLY and FRED will light up as well. There are some types of editing which are currently not supported by the Protection Editor. These include: (1) Deleting a user - If this becomes necessary it can be done by editing the PASSWORD.DAT file and deleting the line for that user. (2) Editing device bits - To enable or disable a device, edit the DEVINFO.DAT file and edit the required line. (3) Changing the name of a user - If this is necessary, edit PASSWORD.DAT. Display all UsersThis function will give you a summary of all users currently defined in your system. One line will be displayed for each user, listing his name, language, and privilege level. Passwords are not displayed here. The display is presented using the File Display Program, which allows you to page through a multiple page display, and search for items of interest. This function is available from the Protection Edit menu, which can be accessed from the Maintenance Menu. Display one User
This function will give you a detailed explanation of the access privileges of
one operator. When you select this function, you will be presented with a
user selection screen, which will allow you to select one user by touching his
name. On entering SELECT, the system will display a report listing his name,
language, privilege level, readable and writable system devices, and commands
which this user can execute.
The display is presented using the File Display Program, which allows you to
page through a multiple page display, and search for items of interest.
Display devices
This function will give you a report on the access privileges of the various
devices in the system. When you select this function, the system will display
a report listing the name of each device (e.g.: USER), and which operators have
read and/or write privileges to them.
Display commands
This function will give you a report on the access privileges of the various
commands in the system. The report is trimmed to not display functions which
are unusable on this system, and to not list VSB commands. When you select this
function, the system will display a report listing each command (e.g.: FSB), and
which operators are allowed to execute that command.
Edit a User
This function will allow you to edit a user account, including his password,
language, or privilege level. When you select this function, you will be
presented with a user selection screen, which will allow you to select one user
by touching his name. On entering SELECT, you will be shown each item, and will
have a chance to enter a new value, or press RETURN or QUIT only if the item
is to remain unchanged.
Edit a Device
This function allows you to edit access privileges to a device. When you select
this function, you will be asked for the name of the device (e.g.: USER). If
found, you will be shown a screen showing which operators have read access to
that device. You can touch the screen granting or denying access privileges to
the various operators. Note that you may have multiple operators assigned to the
same privilege level - so their access is tied together. After you press SELECT
(to commit changes) or QUIT (to not make changes), you will be presented with
a similar screen, this one used to edit write access privileges to the same
device.
Edit a Command
This function allows you to edit access privileges to a command. When you select
this function, you will be asked for the name of the command (e.g.: FSB). If
found, you will be shown a screen showing which operators have access to
that command. You can touch the screen granting or denying access privileges to
the various operators. Note that you may have multiple operators assigned to the
same privilege level - so their access is tied together. You may then press SELECT
(to commit changes) or QUIT (to not make changes).
Add a UserThis function allows you to add a new user to the system. When you select this function, you'll be asked for the user name, password, privilege level, and language. After you've entered all of these things, you'll be allowed to enter another user name, and keep adding. When you've added all users to the system you intend to, press QUIT. Add a User Directory
Create new User Directory
This function creates new User Directories which can then be used by you
for your own purposes. For example, you might want to create a working
directory which is private to each of the operators on your system. You
might want to create a directory to hold cassette files, one for part
programs, one for autoload job queues, etc.
When you select this function, you'll be asked for the name of the
new directory. The name should be less than 12 characters. When you enter
a name, the directory will be created and initially given the characteristics
and protections of the USER directory (which you can then change). The new
directory is immediately usable - you don't have to reboot.
After you've added a name, you'll be allowed to enter another name, and
keep adding. When you've added all new directories to the system you
intend to, press QUIT.
ald_toolTooling Plates Alignment
Tooling Plates Alignment using Air GaugeTooling Plate Alignment page is provided to assist the tooling plate alignment procedures described in document PS20253. Please refer to this document for all buttons and their usages. An air gauge device is required to do the alignment. Jog in Tooling Plates AlignmentJog buttons in the Tooling Plate Alignment are used to move the X,Y or a chosen spindle's Z axes to set positions. They work as the ABSOLUTE JOG. +/- in Tooling Plate AlignmentThe +/- button in the Tooling Plate Alignment are used to move the X, Y or chosen spindle's Z axes incrementally/decrementally with a preset offset which is entered using the Jog Inc./Dec. Units buttons. The X and Y axes are used the same Jog Inc./Dec. Units button and the Z axes has a different one. Save and Go buttons in Tooling Plate AlignmentThe Save buttons in the Tooling Plate Alignment are use in saving four different positions into the memory. Once they are saved , the Go buttons will be used to move the X, Y or Z axes back to these saved positions. The four different pairs of Save and Go buttons are currently used in move spindle to the Clear position, move spindle to the Down position, Move the table to the Front alignment position ( which include both the X and Y move ) and move the table to the Back alignment position. Z axis up position in Tooling Plate AlignmentThis button will move all spindles to the home position. Choose spindle in Tooling Plate Alignment
This button is used to select a spindle to work with. A previous used
spindle will move up before the chosen spindle move down.
SYSTEM-1000 Multilayer Tooling Plate Alignment Procedures
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