Maincon / Software - NGC - Troubleshooting Guide

Transcription

1 Maincon / Software - NGC - Troubleshooting Guide LAST UPDATED: 12/14/2018 Introduction Use this document to troubleshoot the Maincon PCB and software update problems on a machine with the Next Generation Control. If you can not find the scenario that matches your situation, please submit an error log ([SHIFT] + [F3]) to service@haascnc.com. Note: If necessary the error log command ([SHIFT] + [F3]) can be initiated while the program is running. MainCon PCB The Next Generation Control Maincon PCB includes the units for Video, Main, and Motion controller. It accommodates 16 motion control channels. No need to add extra MOCON for the applications that require more channels. This board communicates with the I/O PCB via serial communication through a single RJ45 cable using the RS422 system. The Next Generation Control includes ports for linear scale encoders. Communication with the front panel is done via RJ45 cable and includes the video signals for the LCD display. Page 1 of 10 pages

2 Maincon Function Reference Page 2 of 10 pages

3 1-16 Encoder Input 9A - 13A Scale Encoder Input 1-16 Amplifier Command J2 Wifi Antenna J3 Power Input from PSUP J4 HDMI Output J7 Ethernet / Dual USB, J8 Dual USB 1. RJ45 cable Ethernet input 2. USB cable to going to SKIBF PCB at J23 3. Not used 4. Not used 5. Not used J9 RJ45 cable to SKIBF PCB J28 J12 WIFI module power. J13 Not Used J14 RJ45 cable to I/O PCB J2 J16 Not Used BT1 System Battery Page 3 of 10 pages

4 NGC Boot Troubleshooting The illustration shows the NGC control boot sequence. If the Boot sequence stops at: Stage 1 Test the +5V / +12VDC voltage levels at J3. Power off / on a few times and check that voltages stay consistent. If the voltage levels are not consistent, the low volt power supply could be at fault. Caution: When testing for voltage be careful not to short out the red and black leads. This can cause damage to the Maincon PCB or the low volt power supply. Check for loose connections at the Wi-Fi module PCB connector and also at J12. Check the RJ-45 cable and connector from the Maincon PCB to the SKBIF PCB. Check the Low Volt power supply to SKBIF PCB, and connections to the LCD. Refer to the LCD AND SKBIF TROUBLESHOOTING GUIDE. Stage 2 Check all the connections at the Maincon PCB. Check for loose connections at the Wifi module. Power off, and disconnect all the cables going to the Maincon PCB except (J9) SKIBF cable and (J3) Low Volt power supply input. Stage 3-8 Check processor / software compatibility chart below. Reload the software using the Clean Install method (Option 5). Note: If the problem is intermittent, generate an error report and the report to the service department. Stage 9 Alarm 9972 FPGA CONFIGURATION FAULT at boot up. Check the software release notes for updates. Reload the software using the Clean Install method (Option 5). Page 4 of 10 pages

5 Hardware and software Version Compatibility Table Note: Do not upgrade to the current software from software version or lower. You need to upgrade to first then you can upgrade to the current software version. Hardware Compatible Software Version Hardware PN# TP# NGC Main PCB NGC maincon PCB with Q7_4GB emmc module to current (see note*) A, B, B, F, F N/A NGC maincon PCB with Q7_8GB emmc module and higher C, D, C, A, A NGC maincon PCB with Q7_16GB emmc module and higher B, B Y/D Contactor Y/D contactor with feedback cables and higher A, A Page 5 of 10 pages

6 Symptom Table Maincon / Software - NGC - Troubleshooting Guide Page 6 of 10 pages

7 Maincon / Software - NGC - Troubleshooting Guide SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION The Time/Date or Activation will reset intermittently. The system battery is defective. Measure the system battery voltage, if the voltage is b 3.0 VDC replace the battery. Refer to Next Generation Control - Main Control PCB - Battery Replacement 1. Power Off the machine. 2. Disconnect the WIFI module connector at 3. Power On the machine. If the machine boo correctly, reseat the WIFI module connecto J12 and also on the WIFI module PCB [1]. A loose cable connection to the WIFI module PCB is causing the processor to hang. The machine display will not turn on. The control won't boot up or hangs at the Haas logo after a software update. The screen on the control flickers or goes blank when the servos are on. The cable from the SKBIF to the Maincon PCB is defective. Refer to the Next Generation Control - SKBIF / LCD M - Troubleshooting Guide for more troubleshooting information. The software version is not compatible with the processor installed. Check the processor part number and make sure tha correct software version was installed. See the Hardw and software Version Compatibility Table. The software did not load correctly. Use a SanDisk Extreme USB 3.0 USB device to load software. Reload the software using option 5) Perform Software Install. Refer to: Next Generation Control Software Update - Clean Installation. The cable from the SKBIF to the Maincon PCB is defective. Test the RJ-45 cable that connects to J28 on the SKB PCB and J9 on the Maincon PCB using a network ca tester. Refer to Network Cable Tester Tool procedure The connector on the SKBIF PCB has a broken solder joint or is not soldered correctly. Check the solder on the J28 header connector on the PCB. Make sure that it is soldered correctly. Replace SKBIF PCB if the connector is not soldered correctly. The connector on the Maincon PCB has a broken solder joint or is not soldered correctly. Check the solder on the J9 header connector on the Maincon PCB. Make sure that it is soldered corre Replace the Maincon PCB if the connector is not sold correctly. Page 7 of 10 pages

8 Machines with software version prior to The control freezes, blank monitor, black screen, keypad not working, won't boot sometimes, random shutdowns, or software alarms. The parameters for the Q7 module on the Maincon PCB are outdated. The updated parameters have been incorporated into software version (TP 21894). Update software to the latest version. If the symptoms contin updating the software, download the error log with [S + [F3] and it to Haas Service Department. Alarm NON RESETTABLE SOFTWARE ERROR Alarm RESETTABLE SOFTWARE ERROR The software encounter an error. Download the error log with [SHIFT] + [F3] and e-ma Haas Service Department. Alarm 9972 FPGA CONFIGURATION FAULT. The FPGA software did not get loaded correctly during the software update. Use a SanDisk Extreme USB 3.0 USB device to load software. Reload the software using option 5) Perform Software Install. Refer to: Next Generation Control - Software Update - Clean Installation. Alarm SOFTWARE VERSION MISMATCH The configuration files loaded to the control do not match the software version on the machine. Make sure the configuration file that is being loaded m the software version matches the software the software version on the machine. 1. Download the configuration file from the po 2. Add the.zip extension and unzip the files. 3. open the _cv.xml file in notepad 4. search for keyword: Software Version mak version on the machine. If the configuration file is correct: Try reloading the configuration files again. to: Next Generation Control - Configuration Download/Load If that does not work reload the software u option 5) Perform Clean Software Install. R to: Next Generation Control - Software Up Clean Installation. The Z Axis does not jog and can not do a tool change after a software update. Option 5 Clean Software Install was selected for software update and theserial_number.fs file in the configuration folder is missing. The software was updated to the latest version from a machine that had software version or lower. Make sure the Factory Settings File box is checked w you download the configuration files. Make sure theserial_number.fs file is in the configuration folder. Load software first then you can upg to the current software version. This version is located portal. Page 8 of 10 pages

9 1. Press [POWER OFF]. 2. Put the USB memory device into the contr Note: The USB memory device must c your Haas Control Key and the correct configuration files. Alarm IO BOARD CONFIGURATION MISMATCH Alarm NON RESETTABLE SOFTWARE ERROR The new configuration files were not updated before the software update. 3. Press [POWER ON]. 4. Press [DIAGNOSTIC]. 5. Use the arrow keys to go to I/O Config [2] the Diagnostics tab [1]. 6. Press [F3] to Update Config Table [4]. 7. Press [RESET] to continue. If the alarm do clear, cycle the machine power. The Main Crc and the Factory Crc [3] are now the same. [ERROR] appears during a software update or platform version update. The USB is not being read. 1. Press [POWER OFF]. 2. Do the software update again with a differe USB memory device. The software binary is corrupted. Re-download the software from the portal and try the with the new files. Machines with of later, during a software update you get the following USB error: "The system check detected the USB connector is inserted into the wrong port on the skbif or main board..." The USB cable on the Maincon or SKIBF PCB is connected to the wrong location. Make sure the USB cable going to the SKIBF PCB is connected to the correct location, #2, on the Maincon (See above diagram). Page 9 of 10 pages

10 Maincon / Software - NGC - Troubleshooting Guide PCB Component Inspection Intermittent symptoms or alarms can be caused by component failure. Below is a list of possible failures: 1. Missing solder on all or some components pins 2. Poor solder 3. Solder bridges 4. Wrong component installation (orientation) 5. Missing components Note: Some PCB's have unused circuits and are missing components intentionally, look for broken off components. 6. Broken components 7. Broken pins on IC's 8. Bent pins on the connectors Use a magnifying glass to inspect the circuit components on the front and back of the Maincon PCB. Below are the circuit component zones to inspect: 1. Inspect for bent pins inside the connectors, also look for loose header connectors. 2. Inspect for a loose battery, broken battery tabs, repair if needed. Note: Do not replace the Maincon PCB. Refer to NEXT GENERATION CONTROL - MAIN CONTROL PCB BATTERY REPLACEMENT for repair instructions. 3. Inspect for bent or missing pins inside the connectors, also look for loose header connectors. 4. Inspect the E-net module for loose connections or broken wires. 5. Inspect all solder joints and surface mount components on the back of the Maincon PCB. Page 10 of 10 pages