DC3IO and CNC10 Limit sensor failure

[SchmidtFAB]

I have a Kasaga Knee mill that has a DC310 Board and running CNC10 V2.3.

I know this might be kind of a long write up but I going crazy trying to narrow down what is wrong with the machine to get it fixed.

I was in the middle of running a program when the entire machine stopped responding and started showing Error code
428 Check MPG Cable
405 Lubricant level low
407 Y- Limit (#3) tripped
407 Z+ limit (#6) tripped
MPG offline

A few things to note
-The Lubricant level sensor hasnt worked since I have owned the machine and was bypassed as a NC circuit, never had a issue with this in the last 4 years.
-I have never had a MPG connected to the machine
- The machine was almost perfectly centered in its travel when this happened, running a program that had already produced 3 parts that day prior to these errors.

I have tried verifying the power to DC3IO board and from what I can tell its getting the correct 5v and 12v power.
I have tested the com power coming out of the board into the Limit switch circuits and the return circuit seem to all test good. To include the Lub level circuit.

After doing some searching on the forums I found how to get to the screen that shows the status of all inputs. It looks like all Limit switches are reading tripped.

I have also noticed from that screen that none of the Control panel buttons are readying correctly. when I push the X+ jog button the computer is reading it as if Im pushing the Coolant flood button, and such with allot of the other buttons. Most buttons just don't do anything.

Im thinking that something on the DC3IO board has failed but I dont want to send it in to Centroid for them to tell me there is nothing wrong with it.

Any help someone might be able to provide in narrowing down what has gone wrong would be greatly appreciated.

[cncsnw]

You should post a current Report. Then we could tell what you have in Parameter 178; how your limit inputs are configured in Machine Configuration; what jog panel type you have selected in Control Configuration; and many other useful things.

On the Alt-i screen, an "okay" limit switch or E-stop input (closed, not tripped) will be green. A tripped limit switch or pressed E-stop (open input) will be red.

If you are seeing a steady red dot for multiple inputs which all have either closed switches or jumper wires, then you probably have something wrong with your 5VDC power supply, or the 0VDC distribution (i.e. the connection from the DC3IO power supply to the bottom of terminal block TB1).

If you are seeing a steady red dot for one input that has a jumper wire to close it to 0VDC, then there is a problem with that jumper wire circuit [where does it get its 0VDC?]; or, much less likely, you have a damaged input circuit on the DC3IO.


BTW, it is "DC3IO", as in "dee see three eye oh": a DC servo drive, three axes, with integrated Inputs and Outputs.

[SchmidtFAB]

I tryed pulling a report but it keeps giving me a Failed to copy files message.
Is there a particular screen that I can get a picture of, that would show the Parameters information that you would be interested in?

I have attached a photo of the Alt-i screen. Im starting to thinking there is allot of the inputs that all lost signal at the same time.

Trying to identify what connection from the DC3IO power supply to TB1 that you referenced? What exactly would I be looking for to test?

Thank you for your help

[cncsnw]

On further thought, if your system is a basic mill that does not use the "auxiliary" inputs on pin headers H9 and H12, then most or all of the 0VDC connections come directly from the DC3IO board, via terminals on the Phoenix plugs H13 and H14.

Take the cover plate off the front of the DC3IO unit so you can see the indicator LEDs.

Check the three LEDs on the left edge, just below the fiber sockets: DF, PLC_OK and XVCC.
Also check the four LEDs on the bottom edge, just to the right of the analog trim pots: +5V, -12V, +12V and USV.
It is probably expected that USV will be out, if the emergency stop contactor is open. The others should all be lit.

If you are positive that you have a good supply of 5V and 12V power going into J10 at the top left, but any of the XVCC, +5V, -12V or +12V LEDs are not lit, then there is a problem on the DC3IO board, and it needs to go to the factory for repair or swap-out.

[SchmidtFAB]

Ok I think I have rechecked all that.

I have good power readings from the 12v and 5v going into J10

The DF light is on
The PLC ok light is on
The XVCC light is off

The +5v, -12V, +12V, and USV lights at the bottom are on

Just to verify that is as far as i can go with troubleshooting, at this point I need to send the DC3IO board in to be checked or replaced?

Thank you for your assistance, I really just wanted to be certain before I pulled the board out, that there might not be something wrong somewhere else.

[cncsnw]

The XVCC light is off
...
Just to verify that is as far as i can go with troubleshooting, at this point I need to send the DC3IO board in to be checked or replaced?

See page 7 of the attached DC3IO manual.

[SchmidtFAB]

I have really appreciated all the assistance you have provided,
I have installed the new DC3IO board received from centroid. Everything seems to be booting up correctly and the Inputs look to be correct on the Alt-i screen.

Now I am still facing the problem that the button control panel mounted next to the screen is responding to button pushes all weird. For example the start cycle button does nothing but if I push the INCR/Cont button it thinks Im pushing the cycle start button. Any suggestions on where to start trouble shooting?

[cncsnw]

You probably have the wrong console type selected on the Control Configuration screen:
F1/Setup -> F3/Config -> "137" -> F1/Control

Assuming that you have M400S serial number 20691, you should set "Console Type" = "Uniconsole-2".

[SchmidtFAB]

Thank you, that fixed it. I have no idea how that would of changed, I have never touched anything in those settings.

Everything seems to be working as it should now.