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840D not booting, need help swapping NCU 572 Board

Created by: the_cnc_guy at: 6/20/2013 8:59 PM (12 Replies)

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6/20/2013 8:59 PM	Rate (0)
the_cnc_guy Posts: 18 Rating: (0)	We have a 5axis CNC mill with an older 840D ( 1997 ) control. We started getting random cummunications errors on the HMI but now we cant even boot. All the staus LEDs are on the 7-segment display is showing "8". I think this is the initial lamp test. The HMI and keyboard are on a common purple profi bus cable and there is an external PLC connected with its own cable. The PLC has a SF led on. I have a new NCU coming tomorrow but I know its not as easy as just swapping the boards. There is a PCMICA card which I think I need to move to the new board. Also all the data in the old board needs to be transferred to the new one. Any help would be great!! TIA the_cnc_guy
the_cnc_guy Posts: 18 Rating: (0)
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6/20/2013 9:05 PM	Rate (0)
Ekalavya Posts: 2964 Rating: (484)	Hello, Have you tried clearing the NC that is the S3 rotary swtich(keeping the positionzero to One)and checked.....all data will get lost... If it is with same card you can put the PCMCIA card that is the system software card in new one,after these clear your NC and PLC and then Load your archive backups NC and PLC.. By these time by know your machine will be the healthy status.....hope if you have backups in good condition.... Check it out and revert back. Regards, Prakash
Ekalavya Posts: 2964 Rating: (484)
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6/20/2013 9:19 PM	Rate (0)
the_cnc_guy Posts: 18 Rating: (0)	As far as backups go, I have floppy disks which came with the machine. I know have have made sight parameter adjustments when re-aligning the machine. These are basically adjusting the axis zero positions. If I clear the NC, what, if any, data do I lose? Also, is there a procedure to re-load the floppy disk data back. Done with the HMI menus? Service menu? Other? Thanks for the help!
the_cnc_guy Posts: 18 Rating: (0)
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6/21/2013 1:05 PM	Rate (0)
Ekalavya Posts: 2964 Rating: (484)	Hello, When you clear NC ....yes ofcourse the data will go off and it will restore the factory setting... Does your 840D is with PCU 50 / MMC103 You can restore you backups if you have it. check this link for the :-Creating /restoring the NCPLC arechive backups /tf/WW/en/Posts/60254#top NC PLC clearing steps... /tf/WW/en/Posts/45967#top Check it out and revert back... Regards, Prakash
Ekalavya Posts: 2964 Rating: (484)
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6/21/2013 2:25 PM	Rate (0)
the_cnc_guy Posts: 18 Rating: (0)	Thanks Prakash, Our 840D has an MMC102. This morning everything powered up normal so I immediatly started to make backup archives of PLC and NC data. This is what I did: 1- services 2- data out 3- series startup 4- left only "PLC" checked 5- entered filename for PLC archive 6- pressed archive seemded to work ok. at the end got "job done" message next 7- checked only "NC" 8- entered filename for NC archive 9- pressed archive worked up until reached act_initial.ini then got error #1019 Floating point arithimc error at address -55679741 in channel 0 task 1 FPU state 1 Tried three times always the same. Anyways, I think the PLC data is the most important one. I think the last saved NC data was 2006. What is in NC data? Just programs and offsets? Thanks again for your help.
the_cnc_guy Posts: 18 Rating: (0)
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6/21/2013 2:42 PM	Rate (0)
Ekalavya Posts: 2964 Rating: (484)	Hello, Fine thanks for the update.....why do you get the error? check this FAQ for information. http://support.automation.siemens.com/WW/view/en/592955 Regards, Prakash
Ekalavya Posts: 2964 Rating: (484)
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6/21/2013 3:47 PM	Rate (0)
APC Tech Team Posts: 391 Rating: (50)	Have you unloaded the tool from the spindle before making the NC archive ? The NC archive contains (taken from the manual): Machine data Setting data Option data Global (GUD) and local (LUD) Tool and magazine data Protection zone data R parameters Work offsets Compensation data Display machine data Workpieces, global part programs and subroutines Standard and user cycles Definitions and macros Drive Data so if you have ever changed any of these data after 2006 you'd better make a new NC archive.
APC Tech Team Posts: 391 Rating: (50)	Last edited by: APC Tech Team at: 6/21/2013 3:55 PM
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6/21/2013 4:33 PM	Rate (0)
the_cnc_guy Posts: 18 Rating: (0)	I have been trying to backup the NC archive but get error everytime. As soon as I get to "act_initial.ini" I get the floating point error. The backup doesnt stop. It does make it to the end butI'm not sure if I can trust the data. Note, the PLC and MMU backups worked ok. I'm wondering if the error is due to bad memory on the NCU. I have a new NCU coming tomorrow. The current NCU seems to work ok for about an hour then starts locking up. I will compare todays NC backup with the 2006 using a hex editor and see if all the data is more or less there. Tomorrow I will have to install the replacement NCU ( used ) and tryto get the archived settings back into it. Worries me a bit. I know after I remove the first one, I have 15mins before its data is lost so if I cant get the replacement working, I'll have both units not working. Anyways, Thanks for the help
the_cnc_guy Posts: 18 Rating: (0)
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6/22/2013 7:13 AM	Rate (0)
Ekalavya Posts: 2964 Rating: (484)	Hello, Looks like your NC backups have problem....do you have any other NC backups with you. Try loading it and check. Regards, Prakash
Ekalavya Posts: 2964 Rating: (484)
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6/26/2013 11:42 PM	Rate (0)
the_cnc_guy Posts: 18 Rating: (0)	Before swapping the NCU, I replaced the Batt/Fan unit. NCU is no longer shutting down. I think maybe the old fan was turning but not getting to full speed. So no fan alarm but running hot. Fingers crossed, ran for one whole day so far. Thanks again for the help guys!
the_cnc_guy Posts: 18 Rating: (0)
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