Restoring an old workstation - harddrive failure

[mavenblueprint]

Did you run the command

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CNC7CONV -CC

in the C:\CNC7 directory?

Ah, I have not previously, I didn't realize that applied for the v5 install as well.

OK so I ran that and an empty CNC7.CFG was created ( checked via editor ).

Next I ran CNC7M4 which got to CPU7 initialization

but ran into an "Error opening CNC7.PLC"

and the resulting screen

C:\CNC7 dir doesn't seem to contain this file

Did I miss a step somewhere for configuration / installation ?

[cncsnw]

At this point, what you really need is a backup copy of your machine-specific PLC program, configuration settings, parameter values, etc..

There were many variants of Magnum/Phoenix router tables, with different PLC I/O units, or with no PLC I/O unit at all; and with different uses for the PLC I/O where it was present.

If you don't want your PLC to do anything at all, you can create a source file (perhaps calling it "NULL.SRC" and putting it in the C:\PLC directory) with the following content:

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MEM1 = MEM1 AND / MEM1
OUT75 = MEM1
OUT76 = MEM1

... then compile it, from a command prompt in the C:\PLC directory, with the command:

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PLCCOMP /I NULL.SRC

That should create a CNC7.PLC file in the C:\CNC7 directory, adequate to let you start up CNC7.

[mavenblueprint]

At this point, what you really need is a backup copy of your machine-specific PLC program, configuration settings, parameter values, etc..

There were many variants of Magnum/Phoenix router tables, with different PLC I/O units, or with no PLC I/O unit at all; and with different uses for the PLC I/O where it was present.
....

Hmm since the PLC stuff is machine specific I decided to take a step back and try a different path than starting from scratch.

I erased my 128MB CF card, installed MS-DOS 6.22 fresh again and then "installed" from the CNC7 v4.0 Centroid branded floppy disk using:

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xcopy A: C: /S /V

rebooted

Since this floppy contains, what I assume, the machine-specific PLC information there were no errors during bootup. Here's the floppy contents of the PCL dir:

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...
├── PLC
│   ├── 6THGEN.PLC
│   ├── 6THGEN.SRC
│   ├── CHKLIST.MS
│   ├── MAGNUM.PLC
│   ├── MAGNUM.SRC
│   ├── PLCCOMP.DEF
│   ├── PLCCOMP.EXE
│   └── PLCDBUG.EXE
...

This seemed to have mostly worked but pressing F7 failed to launch CNC7UTIL.EXE. I looked at the contents of CNC7 v5.27.zip you provided and it looked like the CNCM4.BAT (v5.27) was updated quite a bit compared to C.BAT (v4.0) including how CNC7UTIL is loaded.

Next step was to update to CNC7 v5.27 and see what happens.
Loaded up CNC7, pressed F7 Util, F2 Update and let the installer run.

This ended in the same error as previously "Insert the MillWrite disk in the floppy drive", ignored it and ejected the install floppy.

This showed the CNC v4.0 software so I rebooted and had to change which CNC7 program is being loaded:

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edit AUTOEXEC.BAT
replaced C.BAT with CNC7M4

CNC7 v5.27 is loading and booted up correctly so I took the PC back into the shop and connected to the cables.

I was able to recover the "Software Unlock Parameters" from a really old piece of paper and enter those in the setup ( F1 > F3 > F3 > ALT+F1 )
It seems the last hurdle is setting home based on what I'm seeing now is with what's likely all part of missing C:\CNC7\CNC7.HOM

When CNC7 starts up I see the "Z+ limit (#5) tripped" ( nothing obviously physically blocking the mill from moving around )

Next, I attempted to jog X, Y and Z axis independently and got similar/related errors ( without any movement )

X axis jog via pendant

Y axis jog via pendant

Z axis job via pendant

Looking at the manual and CNC7 output which says it's using AS.CNC ( which I can't locate on the drive ) nor C:\CNC7\CNC7.HOM.

Am I on the right path here? I'm not sure if I'm supposed to create CNC7.HOM myself somehow or somehow change the home XYZ vs physical XYZ positioning of the tool so that they aren't the identical?

[cncsnw]

If it says "Z+ Limit (#5) tripped", then it is likely that your Z+ limit switch circuit is open. If you are positive that the switch is not tripped, then perhaps it is not connected to the PLC, or you have a broken wire somewhere, or the switch has failed open.

The currently-loaded CNC job file name is entirely irrelevant at this point.

Whether you have a CNC7.HOM file, and whether it is correct, is not relevant until you get your limit switch circuits closed, and get to where you can jog all three axes in both directions using just the jog buttons.

Since you are using a CNC7 version earlier than 8.00, you do not have the benefit of the Alt-i display for PLC input status; but you do have a PLC Diagnostic utility on the Utility menu: F7/Utility -> F6/PLC Diag. You may or may not have the supporting files to make that work, but if you can get into it (perhaps just running PLCDBUG.EXE from the DOS prompt) then you should be able to use a "watch all" screen to see what your PLC inputs are doing.

It appears from your cabinet picture that you do have a full set of six limit switches, wired to both the drive and the PLC. If that is the case, then INP1 through INP6 should all be closed (0, green). If any are not closed, then it is a given that the drive will not move in that direction, and you will get either a "limit tripped", "full power w/o motion", or "position error" message.

[mavenblueprint]

If it says "Z+ Limit (#5) tripped", then it is likely that your Z+ limit switch circuit is open. If you are positive that the switch is not tripped, then perhaps it is not connected to the PLC, or you have a broken wire somewhere, or the switch has failed open.

The currently-loaded CNC job file name is entirely irrelevant at this point.

Whether you have a CNC7.HOM file, and whether it is correct, is not relevant until you get your limit switch circuits closed, and get to where you can jog all three axes in both directions using just the jog buttons.

Thanks for confirming and providing detail. That was my hunch based on https://www.centroidcnc.com/dealersuppo ... ads/22.pdf and how to setup CNC7.HOM and now that file exists and indeed it's

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M92/Z
M26/Z
M91/X
M26/X
M92/Y
M26/Y

Of course that doesn't change above issue with Z+ limit (#5) tripped and X/Y axis full power w/o motion errors.
I'll start looking into your suggestions next.

Since you are using a CNC7 version earlier than 8.00, you do not have the benefit of the Alt-i display for PLC input status; but you do have a PLC Diagnostic utility on the Utility menu: F7/Utility -> F6/PLC Diag. You may or may not have the supporting files to make that work, but if you can get into it (perhaps just running PLCDBUG.EXE from the DOS prompt) then you should be able to use a "watch all" screen to see what your PLC inputs are doing.

It appears from your cabinet picture that you do have a full set of six limit switches, wired to both the drive and the PLC. If that is the case, then INP1 through INP6 should all be closed (0, green). If any are not closed, then it is a given that the drive will not move in that direction, and you will get either a "limit tripped", "full power w/o motion", or "position error" message.

In the past post you provided the files and suggested an upgrade to CNC7 v7.17 which I was going to do next. Would it be better to go straight to CNC7 v8 or is there some kind of incompatibility after CNC7 v7 for some machines?
Searching the forums, I saw you provide a link in a previous post http://www.cncsnw.com/823_823.zip but it doesn't seem to host the files anymore. Do you know where one might find this download (if it's relevant here ) ?

[cncsnw]

If your computer has at least 32MB of memory installed, then you should be able to run v8.23 if you want to.

That file is still on my web server. I don't know why Chrome won't download it if you just click on it. I was able to pull down a good copy by right-clicking and choosing "Save link as...".

[mavenblueprint]

Since you are using a CNC7 version earlier than 8.00, you do not have the benefit of the Alt-i display for PLC input status; but you do have a PLC Diagnostic utility on the Utility menu: F7/Utility -> F6/PLC Diag. You may or may not have the supporting files to make that work, but if you can get into it (perhaps just running PLCDBUG.EXE from the DOS prompt) then you should be able to use a "watch all" screen to see what your PLC inputs are doing.

Update to 7.17 went smoothly however pressing F7/Utility -> F6 PLC Diag shows a blank black screen for a second and then goes back to the utility screen. :/

Next, I tried the manual run of PLCDBUG.EXE from DOS but got null errors when using either of the available SRC files:

Both the 6THGEN.SRC and MAGNUM.SRC failed the same way:

If your computer has at least 32MB of memory installed, then you should be able to run v8.23 if you want to.

That file is still on my web server. I don't know why Chrome won't download it if you just click on it. I was able to pull down a good copy by right-clicking and choosing "Save link as...".

This machine only has 8MB of RAM and it appears to be failing ( have to press F1 to skip NMI check due to a checksum error ). I finally found someone in France that appears to have 2 sticks of this type of RAM but obviously won't get me to 32MB. I'll have to see if there's a way to find compatible RAM.

Out of curiosity, I attempted to update to CNC7 v8.23 after using using your suggestion to download the files and indeed CNC7 never finishes loading. So now I switched back to CNC7 v7.17.

On a separate note, I'm getting odd behavior/error while outputting a report to any floppy ( I tried many different kind older and newer ). Each time the same thing happens: CNC7 starts and writes about 3 files and then fails saying either insufficient space on floppy or inability to access the floppy. Inserting into my external USB floppy drive makes the floppy no longer readable or usable.

Is there a way to configure CNC7 to write the report to C: instead of A: ?

[cncsnw]

If I had to guess, those are probably 72-pin EDO SIMMs. You do not need to match the brand or the chip numbers; just the type.

You might be able to use the DOS ASSIGN command to redirect A: to a directory on C:.

[mavenblueprint]

If I had to guess, those are probably 72-pin EDO SIMMs. You do not need to match the brand or the chip numbers; just the type.

You might be able to use the DOS ASSIGN command to redirect A: to a directory on C:.

As usual, you are correct and the 72-pin RAM fit and allowed for the CNC7 v8.23 to be installed and run successfully.

Though I'm not sure PLC actually loaded/installed correctly based on this output:

ALT+I does now show the following output (power OFF to cabinet/machine):

and this is what it looks like once power is ON:

Here's the first set of errors in the error logs:

How does one connect the onscreen lights (i.e INP5 being red) to the physical components in the cabinet? I thought one way would be via schematic but I currently have a M-39 and a M-400 paper schematics which do not match the M-10 designation that CNC7 displays (they appear to be fairly similar and having the SERVO1/QUADDRV1 boards).

The errors indicated an issue in the job panel/pendant so I removed it just to see what happened.

Doing so I ended up getting into a state I haven't experienced before.

It was a sudden power/electricity cycling and likely the related SERVO1 board DF and UV lights flickering during these cycles. The DF light flickered in sync with the sound of power/electricity cycling and although you can't see it in the video as well the UV light was doing the same despite being already very dim. Based on http://www.cncsnw.com/Drives.htm#SERVO1 I assume there's bad wiring and/or other components.

Here's the video of the power cycling ( at 0:19-0:20 it's a bit hard to see but the DF and UV LED lights do flicker ):

[centroid467]

You should check logic power quality going into your servo drive. It looks like it has the old Toko supply that we phased out. Check the ripple and sagging under load of the DC output with an oscilloscope (if available) or DMM (in both DC and AC modes).

CNCSNW might have better or more specific advice.