Fanuc 15TF, Stack Overflow, remote buffer, CNC processor NMI
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  1. #1
    Join Date
    Mar 2014
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    FINLAND
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    Default Fanuc 15TF, Stack Overflow, remote buffer, CNC processor NMI

    Hello all!
    I recently bought a Takisawa TS-25 3-axis CNC lathe. I've been getting familiar with the machine and have encountered some problems.

    I can contact the machine via CD4A RS-232 port, transfer files, backup parameters, use tape mode and drip feed.

    The machine has a Remote Buffer card and as it has a c-axis with live tools and as I get it, the remote buffer offers faster execution of short G1's as there is no true look ahead in the control and G05.1 doesn't work (inappropriate G-code error)


    Anyway, what happens is that when I put the machine to Tape mode, press cycle start and start transfer from PC, the program starts to 'move' and after a few seconds the hydraulics disengage and Trap 15 error screen comes up and IPL mode appears. That happens without a re-boot and the machine starts up normally after power cycle. If I do this with wrong stop bit setting for example, control doesn't crash.

    Error leds seem to be like on this one: https://www.*******.com/forums/fanuc...tml#post823937 and the remote buffer card ha "waiting command from CNC controller led status.

    And if I try to transfer file from CNC to PC via remote buffer (channel 10), the transfer doesn't start and the control pretty much hangs and only way to reset it is by power cycle. If I try to punch parameters via channel 10 (Remote Buffer), the punch starts but after about 1s, hydraulics turn off, control hangs completely and nothing is transferred.

    Initially the status was that parameter punch crashed the control but nothing happened in tape mode or when trying to transfer the software. I suspected that the CD4 UART chips where gone and replaced them and only after that I managed to experience the Trap 15 issue.

    Please find the parameter list below. Seems I can't have the list I pulled out from the machine a couple days ago with current comm settings, I can get proper list if needed, but don't think it's a comm issue.

    Any help is greatly appreciated!

    Code:
    &FWPARAMETER        :%
    N0P00001000
    N3P00000000
    N10P00000000
    N11P00000011
    N12A1P00000000A2P00000000A3P00000000A4P00000000A5P00000000A6P00000000
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    N104P183642
    N105P0
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    N108P0
    N109P0
    N1000P00000001
    N1001P00000000
    N1002P00000000
    N1004A1P00000000A2P00000000A3P00000000A4P00000000A5P00000000A6P00000000
    N1005A1P00000000A2P00000000A3P00000000A4P00000000A5P00000000A6P00000000
    N1006A1P00001000A2P00000000A3P00000111A4P00000000A5P00000000A6P00000000
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    N1008A1P00000000A2P00000000A3P00000000A4P00000000A5P00000000A6P00000000
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    Seems I messed with the error led url. It's: https://www.*******.com/forums/fanuc...tml#post823937


    Also, see the attached pics for the machine configuration. Inerested also if the option parameters match with the machine parameters. There is an attached robot interface, so there can be differences because of that, too.
    Attached Thumbnails Attached Thumbnails trap15.jpg   14.jpg   24.jpg   34.jpg   44.jpg  


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    TRAP15 alarm means a trouble with the system software.

    There are several differences in the option/configuration parameters in the file you attached when compared to the list shown in the 14.jpg picture you posted. Incorrect option/configuration parameters could be the cause of the system software not operating properly and resulting the TRAP15 alarm. You need to get the correct option/configuration parameters loaded.

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    Thank you Vancbiker for the answer! Seems there might be a possibility that nothing is trashed then?

    As far as I know, there has been the added robot interface and if I've understood correctly, tool control and setter has been added after the initial purchase and they might explain the different option parameters, at least for some part?

    Could it be that the remote buffer is set to be used with the robot? If that would be the case, I think that the robot interface should be removed as I don't have any use for it.

    Do you know anyone who could help with the option parameters?
    Attached Thumbnails Attached Thumbnails interface.jpg   label.jpg  

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    I have never worked on a 15 with the remote buffer board. I'll try to look that up and see what it may possibly be used for.

    Usually if a Fanuc tech changes option/configuration parameters they will mark the hard copy sheet with the updated values. I would expect that to be the case if the remote buffer board were added after the machine was sold/installed.

    Where did the parameter file list you posted come from? Is it an old backup from this machine at some point when it was operational? I have run into cases where someone has reloaded a parameter file from a different machine which results in all kinds of strange problems. Sometimes people think that a parameter file from a different machine is OK as long as the control model is the same. This is not a true assumption.

    The label in the picture you posted is from a digital output module for the I/O rack. It will be one of the yellow modules in the picture of I/O rack you posted.

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    Thank you!
    The remote buffer (and DNC2) function are both listed in the 34.jpg listed above.

    The parameter list is from the machine itself. I bought the machine from a school and I don't think that they would of had a need to load params from another machine as there is also history of some maintenance made by the Takisawa importer during the years. I contacted them earlier about machine properties, but didn't really receive any answers even I dind't expect to have them for free.

    Have I understood correctly that the Op values in the sheet are hex values and need to be converted binary and OP1->9100, OP2->9102 etc.? If I got it right, seems some are completely different... But I also find it unwise to directly replacing them as the control could go brick if the differences are correct?

    By the way. I have two different ladder diagrams. There is the original one and there is a note label that says "Original ladder, not useful" and the latter one has marks that tell me that it was installed by the importer. I believe this was done after adding the digital I/O module.
    I sent some questions related to this to the importer, too, but am not really expecting any answer from them...

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    My 2 cents: I agree that it is likely a wrong option configuration. You also should figure out which ladder is actually running; if you have an dynamic ladder display (visible in the pmc display), you could compare that with the two printed versions.
    I have the option list for that control; the hard part is selecting which option needs specific hardware and also may be dependent on software version (displayed on SYSTEM CONFIG screen).
    So, lets start with the software version that you have.

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    Please find the modules and software screens from system config.

    Also, I initially described the problem incorrectly. When I transfer file through channel 10 while at edit mode, then the trap error appears, but if the machine is in tape mode, the control hangs completely. Not sure if this has any relevance but though to share it anyway.
    Attached Thumbnails Attached Thumbnails sw_sysconf.jpg   mod_sysconf.jpg  

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    our software version is A31AD (15A-TF level up).
    These are the options present from your parameter list:
    bit description
    N9100P00001001 0 Simult. cntrld. axis exp.
    3 Skip function
    N9102P00100110 1 Inch/metric conversion
    2 Canned cycle
    5 Cutter comp. C
    N9103P00000100 2 Chamfer/corner rounding
    N9104P00000100 2 Multiple repetitive cycle
    N9105P00000100 2 Manual handle feed 1st
    N9107P01100011 0 Spindle speed output, analog
    1 Constant surface speed
    5 Tool life management (1st parm)
    6 2nd Aux. function
    N9108P00101000 3 Tool length measurement
    5 Rdr/punch interface A (1st parm)
    N9109P00001000 3 Tool offset memory B
    N9111P00011001 0 Custom macro (1st parm)
    3 Expanded part program editing
    4 Custom macro, 200 variables
    N9112P01000000 6 Custom macro (2nd parm)
    N9116P00010000 4 Tool life management, 512 pairs
    N9117P11000101 0 CNC window B
    2 Tape reader rewind - RS232C
    6 Cylindrical interpolation
    7 Polar cord. interpolation
    N9118P00010000 4 Rdr/punch interface B (3rd parm) and Rdr/punch
    interface A (3rd parm)
    N9120P00000001 0 Part program 40 M
    N9122P00000010 1 Tool life management (2nd parm)
    N9125P10000000 7 Tool offset meas. B
    N9126P00001000 3 Work coordinate system preset
    N9130P10000011 0 Auto process selection
    1 Animated drawing
    7 C-axis FAPT
    N9133P00000001 0 Remote buffer interface (2nd parm)
    N9137P00001000 3 DNC1 Interface
    N9144P00001000 3 DNC2 interface function

    Maybe there is a problem in the Remote Buffer board. Is the problem new? Was anything changed since the last time it worked?

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    Thank you for your effort!

    So it seems to you that the config is correct for the installed modules?

    I have nothing but vague info from the machines history. Nothing from the party that used/administered the machine and the condition is as is I originally bought it, despite the replaced UART chips.

    The next step would then be to test the Remote Buffer card, I guess the "easiest" method would be to locate someone with a machine that has the same unit installed and send mine to be tried in his/her working environment?

    Are there any other parameters that might affect the behavior? Also, I'm wondering why the G05.1 isn't present in the system?

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    G05.1 is an option not enabled in your control:
    High precision contour (requires J986).G05.1; HPCC w/o RISC. Cannot have J704 (HPC w/RISC); use 9035 or 904x servo software. REQUIRES SUBCPU.
    J986 = 9116 bit 2, (also not turned on) Multi buffer 15 blocks;;Special w/o sub cpu but all features of AA01 + rotary head features J728 & J729.
    Now you see how hard it is to do the correct combination of options.
    I can't tell the part # of your Remote Buffer board (A16B-2200-017X); I don't seem to have one.
    Look at how your comm ports are set up on the control.

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    Thank you memoryman! You've been most helpful!

    The RB card no is A16B-2200-0170/11A.

    I made a test and gave the board some gentle heat. The result is that trap error etc. isn't happening anymore and neither is any reaction to transmission. Seems like some soldering issue is a probable cause of the issue. Might as well be some failing/failed component, I guess.
    It seems that the board communicates with the CNC controller, though, as if I remove the card, there will be an error that 'remote buffer not available'.

    Luckily the "punch panel" / RS232 through CD4A transmission works and I can drip feed using that so I can get the machine operational and think of the remote buffer later.


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