[njohns98]

Hello,

I have been working with a Cincinnati Milacron Arrow 1000 with Acramatic 2100 control for a few months now. Machine works great and runs smooth. A few days ago while cleaning out chips, I accidentally jogged it into the Y limit switch before alignment. It through the standard fault and turned off the drives. When trying to turn it back on to move it off the switch, it faulted a few more times and then wouldn't even attempt to turn the drives on (the software also froze up and I couldn't navigate to different screens).

I decided to fully shut down the machine and manually move it off the limit switch. When turning back on, it now fails the startup diagnostics for the Bridge Board (RT), Conv. Servo, High Density I/O, Pendant/Panel (MSL), and Realtime Processor.

During the diagnostic there are popups that say:

[S_CURPOS_DSP[0]]. Value Size is Zero
Application startup timeout. The exe name is CNC.EXE
[S_CURPOS_PGM[0]]. Value Size is Zero
Application startup timeout. The exe name is RAP.EXE


What I have tried so far:

Reseated all of the cards connected to the Bridge Board
After the machine is on, the "Real Time Fail" and "Workstation Fail" LEDs are illuminated on the Bridge Board


This has happened once before a month ago when the air supply shut off while it was running. I couldn't get it to boot up again, went home for the weekend, then it started up with no issues on Monday. I have seen only two threads about similar problems, but they occurred when powering on the machine after a long period of no use. I also have around 15 manuals for the machine and the different hardware, but haven't found anything useful in them.

Just to summarize, the machine was running fine, ran into a fault, froze up, and now won't bootup properly.

If anyone has incite or has suggestions on places to look for solutions, that would be majorly appreciated.

[gwood]

NJohns98,
Might start with https://www.cnczone.com/forums/cinci...ply-issue.html
Afterward reading that post; you may want to: With power off remove the WSCPU And RTCPU Assemblies and check the voltage on the CR 2032 Batteries; DO NOT remove them!
If they measure under 3.01 VDC look at posts regarding the loss of CMOS BIOS settings and re-flashing or restoring the BIOS settings.
The Overtravel SW killed the Drives like an E-stop; which does cause a power fluctuation.

[njohns98]

gwood,

The RTCPU battery is at 3.9V and the WSCPU battery is 3.1V

I'm in the process of pulling all the boards, cleaning the contacts, and reseating them to see if that helps. I'll also run through the other things mentioned on the other thread.

Thanks!

[njohns98]

After checking my multimeter against a powersupply, found it was super off the mark. With a different (more accurate) multimeter, I'm reading 3.1V on the RTCPU and 2.9V on the WSCPU.

[njohns98]

I have replaced the battery and am fairly sure I need to reset the CMOS BIOS settings. Tried calling the Fives tech support number that was listed in some other threads, but it just rang for 20 minutes. I'll try again tomorrow. If anyone has the BIOS settings for the 3-424-2123A02 workstation cpu board that would be very helpful. I've seen people say that it is in the reference manual, but I've gone through all the ones I have and none have a section on CMOS BIOS settings.

[gwood]

Here is the Attached PDF WSCPU_Bios: 34242123A02_Award4.51(H3-SSD-Correction).PDF

Do Not change the RTCPU Battery unless you have the board powered up on a bench with an AT-PS2 Power supply!
If so or if the battery gets too low; then it will need to be re-flashed, or set up on a bench with the correct settings.

The TS# for Fives is 859-534-4750

[maver1ck]

Looks like Greg posted while I was typing this, so will scale back my response a little bit.

If you changed your BIOS battery, yes, you most likely lost the BIOS configuration and will need to set it up again, however, based on your initial post I would also suspect an issue with your RT BIOS is likely. Since you indicated the first diagnostic failure was Bridge Board (RT), this usually indicates your WS board BIOS was OK (although if you changed the battery since then, it no longer would be).
.
Most of the other alarms you mentioned are essentially caused by a communication failure between the boards (although the extent of these alarms depends on what software/hardware is in your machine).

[njohns98]

Update: I've had a few conversations with a tech at Fives who had me reload the software settings using the uninstall window. Still had errors, so he sent me the files to flash the RTCPU board. I've reformatted a floppy to a MS-DOS startup disk on a windows XP computer and added the files from the Fives tech. They sent me the RTCPU settings to use when flashing, which I set up, but when I boot it up with the floppy attached, the computer reads "DISK BOOT FAILURE. INSERT SYSTEM DISK AND PRESS ENTER"

Here are the files that are on the floppy (combination of what was sent to me and what was there after formatting). Any thoughts on what the issue is?

[gwood]

NJohns, The Dos Bootable Disk should boot after proper formatting; then the bat. file should execute.
Bill O at fives should be able to help ???

[njohns98]

Bill was super helpful!

Turns out the settings for flashing the RTCPU BIOS needed to be modified to get the floppy drive working properly (also needed to use a second one because the first one was having issues). Successfully flashed the BIOS and reinstalled all the board.

Starts up with no errors, but the machine power will turn on for a few seconds then shut off without any error messages.

I also tested the power supply and saw it was a bit under voltage. I could see why this could cause this problem because of a power drop when everything turns on, but I would still expect to see an error message.

[gwood]

Nikolas,
1) Do you mean the control starts up; then shuts down by itself with no alarm?
2) The control boots OK and the Drives Start-up; then the drive fault with no alarm?

If the 2nd are there any fault LEDs on the Drives exactly when this happens when watching them?
GWood

[njohns98]

Control boots just fine/no errors. When I hit the button to turn the drives on before aligning the machine, they turn on for a couple seconds then shut off.

[njohns98]

Installed new power supply, but still the same problem.

Another thing of note: When the machine was running before, every time we turned it on, a keyboard error pop up would appear on the desktop screen that would need to be closed before the CNC software would boot up. The keyboard hardware diagnostic would also say "missing." Since the problems started, that pop up hasn't been showing up. The diagnostic still says failed though

[njohns98]

Update:

I was able to get the drives to power on properly by jumping P41-11 and P40-2 on the output board (this could have also been determined by testing continuity across them to avoid multiple machine startups). This bypasses the overtravel switches, which I was then able to probe to figure out the X overtravel switch circuit was open. I inspected the switch and it was stuck in the depressed position. After cleaning and actuating it a few times the switch releases properly.

Now that the drives turn on, there is a new problem. I immediately get a foldback error from the drives pop up on the display. Checking the drives, the X and Z axis drives had the foldback light on. After manually spinning the X ballscrew, the X axis drive foldback light has turned off, but once the machine power is turned on (drives powered up), the foldback error still appears for the Z axis and the X axis servo starts to slowly jog towards the home switch with no user input (slow enough that I barely noticed). Any thoughts on what might be the issue now?

Just a recap of the original issue: machine was working perfectly until hitting the Y overtravel switch while cleaning out chips. That resulted in a bootup error. I reflashed/set the BIOS in both the realtime and workstation CPU boards with information I received from Fives. They also had me reload the Acramatic software using the uninstall menu.

[gwood]

You need to use your Control Diagrams 9120xxxxy to figure out the test points to measure the Brake Voltage going to the Z-Brake after the drives are started with no Foldback.
If you reloaded the machine parameters or switched the software without making a backup *.BCK file; then you may have lost them.
This could cause improper drive settings in the control that could cause the drives to imbalance a nd shut down with an Overcurrent (Foldback) Alarm.
Uninstall backs up the current Machine Data Parameter file onto the hard drive; but if you did other things before it may have been wiped or corrupted.
Talk to Biil-O who retires End of June....

[njohns98]

I've managed to get the drives to turn on properly by going through and fixing some of the settings that were reset. I also reinstalled the software from a floppy that came with the machine that was the most recent. It now will go through the alignment cycle, but at the end alarm 39-2 pops up saying: Y Axis TPA/Home Failure.


I ran the align cycle while viewing the i/o board display in programware. It shows that the Z, Y, then X axis all feed until they hit their TPA switch (turning the inputs on). Then, it moves off and slowly feeds until the TPA switches trigger again (all 3 still turn on). Finally, it rapidly moves all 3 axis off and back onto the TPA switches, but the Y switch does not turn back on.

[gwood]

You will need to adjust the "Align Trim" value for the Y-Axis. After the fault you can zero the handwheel;
then activate the Y-Axis handwheel and slowly move the Y-axis using .001" increments until the switch makes; then goe .010" further.
If you go more than .100" from when the TPA switch closes, you could trip the overtravel switch; which kills the drives.
After adjusting the trim incrementally from what it was and "Committing" it; you'll need to realign the axes to see if the fault clears itself.
Once you get the machine to align with no faults use rapid traverse override and feedrate pot, and "Distance to Go" to
perform an air tool change with no tool in the pocket. Stop with "feedhold" if the distance to go show it will crash into the tool drum
when moving Z-axis down! Also the key in the spindle should be pointing to the right at 3 O'Clock,
I this look good try a real tool change with a tool.
If all looks good make a new Backup BCK file to save your changes onto the hard drive, and one to the applicable Floppy, RS232, or Ethernet drive;
off the machine for safe keeping.

[njohns98]

I have managed to get the Mill up and running again. I had to revert to some old settings that were on a floppy drive, but it fixed the issues. Weirdly, it seems the settings were for an arrow 500, so I had to go through all the settings and put them back to the correct values based on a printout I have. It struggled with homing initially and I had to play with some of the homing values in each of the axis to make sure the encoder found its home position.

All seems to be working now, but for some reason, the door lock won't unlatch. The only time it does is when I increment the tool changer when the spindle is empty. It looks like it tries to hold the spindle at the zero degree position when the door is closed. Must be a setting somewhere that I need to fix. If anyone knows what it might be, let me know.

[njohns98]

Believe I fixed the door issue. The runoff setting for the tool changer was on which prevented programs from starting (alarm 39-58). Once I fixed that setting, the door unlocks like before.

Thanks for the responses gwood! I didn't see that the thread had looped to a second page, so I'm only reading the last few just now, but they are still very helpful!