[TorrentBoilers]

Hello to everyone!

First of all,sorry for my bad English...

I working as production supervisor in a company named "Torrent Boilers",located in Greece and we built cast iron boilers.

The company i am working have a Cincinnati millacron matrix 6 with acramatic 950
This machine was lacking maintenance untill i join the company and get the position i have already.
Last month we change the main module E/R simodrive ( the machine have the 6SN1145-1BA02-0CA0 VERSION D and we change it with another same type but it was version XE )
The company order the B axis feedback cable cause this one be on machine right now is not in good contition as the machine preservative told us...

Since when we change the E/R module we have a huge problem with the machine...The first 2-3 days the machine working great but then,suddently the CRT and machine computer makes reboot!!!
I sent an e-mail to a technician in FIVES ( http://www.fivesgroup.com/ ) and he told us to check the DC voltages and AC voltages in 2 power supplies at the bottom drawer and maybe the problem is the noice filter cause if the BOH board sees noice above 5 millivolts it will not let certain things come alive and more often that not it picks the CVC board ( monitor ) cause its the lowest priority board.

Did anyone have the same problem at the past?
Any suggestion what we have to look to solve this problem?

Thanks in advance

George Petsis

[meckardt55]

I agree, it sounds like a power supply going bad. You need to put a scope on the power supplies at the BOH board to see what it looks like at the board level. BE VERY CAREFUL BECAUSE THE TEST PINS ARE VERY CLOSE TOGETHER. Look in the control reference manual for the info on this. You can also go to the TOOL BOX section and see if all the boards pass. You should also look at the AC voltage to the control and tighten all electrical connections on the machine.

Mike CNC Machine Services INC | Cincinnati Milacron MachinesCNC Machine Services

[TorrentBoilers]

Thanks for the fast reply meckardt55 !!!

I have to call an technician who made the maintenance at this machine since it arrives to Greece....

Any other suggestion or opinion be accepted.

[meckardt55]

Let us know what you find out.

Mike CNC Machine Services INC | Cincinnati Milacron MachinesCNC Machine Services

[TorrentBoilers]

When i have the solution i post it here meckardt55

I have to notice that this problem shows only with the hydraulic ON if this means something...

[meckardt55]

Take a look at the electrical prints, I think that the control uses it's 5 VDC power supply to provide power to the encoder. If you have a short to ground in the new cable or anywhere it could pull down this power supply and cause your problem.


Mike CNC Machine Services INC | Cincinnati Milacron MachinesCNC Machine Services

[TorrentBoilers]

Today i get a video of BOH module when machine makes the usual reboot ( I dont know if this video help any specialist to understand something about the reboot problem )

https://www.youtube.com/watch?v=v4-w...ature=youtu.be

Tommorow i try to find time to use the tool box diagnostic...For any update i keep posting here.

[meckardt55]

Put a scope on the power supplies, I think you may have one of the supplies dipping and causing a control re-start. The green lights on the BOH is for the power supplies and I did not see anyone of them flash. It could be a very quick flash of a power supply that only a scope would catch. What was moving when the control re-set?? Any correlation with anything moving on the machine??? You also need to look at the servo side (IDS) and the lights on the left panel (encoder power light).

Mike CNC Machine Services INC | Cincinnati Milacron MachinesCNC Machine Services

[TorrentBoilers]

meckardt55, I try to use tool box yesterday cause i have enough time,after i read the Vickers manual... I get a message " Not enough good boards",so, i am waiting next week the encoder B axis feedback cable from France for change it.
Once the cable found in my hands, I will call the conservator with oscilloscope to measure the power supply at motherboard...

I attach 2 pictures from the BOH card and the screen from my effort to use tool box...



PHOTO_20150205_071551_zpsa3cb7b3d.jpg Photo by braintrauma | Photobucket


PHOTO_20150205_070903_zps4c25b806.jpg Photo by braintrauma | Photobucket

[meckardt55]

So what did you find the problem was???

Mike CNC Machine Services INC | Cincinnati Milacron MachinesCNC Machine Services

[TorrentBoilers]

At friday 21 of February we change the B-axis feedback cable and from tommorow we have to test the machine if the problem causes from cable or not...Maybe the problem was the cable cause i find a few drops of water in the plug...

I will update the topic soon.

[meckardt55]

What did you find???

Mike CNC Machine Services INC | Cincinnati Milacron MachinesCNC Machine Services

[TorrentBoilers]

I didn't find something....the problem still exists after we change the B axis feedback cable.

I call an electrician to visit us this wednesday, with a 7 channel scope, to measure the power supply when the machine works...

[TorrentBoilers]

Update...

Yesterday an electrician vitit our company with a Fluke scope and we measure and calibrate the voltage at power supply and BOH board...i can upload pics from the voltages if any request that...
We get measures from the voltages from the motherboard behind the crt and it was ok as the manual suggest...
Then we saw the video i upload already and we thinking that maybe is posible the BOH board "cut" the power in CVC board,or the CVC board is not in good condition ( we notice that CVC board was repaired at the past but i dunno why and when this repair held )
Another suggestion was,the supply card in motherboard behind the crt have some problem...anyway,i wanna change the noice filter soon...

[meckardt55]

You need to keep the scope on the power supply to see what happens when the control re-boots. You must look at each voltage when the control re-boots to see if you are getting a quick voltage drop that re-sets the control. The power supplies will look normal until the control re-boots. Did you do this???

Mike CNC Machine Services INC | Cincinnati Milacron MachinesCNC Machine Services

[TorrentBoilers]

The tecnician do this once but as he said he need more than one scope to do this you suggest cause maybe the power supply cut the power in different point every time ( 5v,12v,15v)
The day when tecnician came,the machine makes only 3 reboots,( some days it makes 30-40 reboots),so he dont have the chances to have a lot of measures
We saw the video i get from the reboot and we notice that when the machine reboot,the power failure led is off but the reset led is on,so he thinking the problem is not the power supply but is the BOH or the CVC boards.
We try after the power calibration to use tool box again but we get the same msg ( not enough good boards),so we try to do the bootstrap diagnostic,we let the recomented cards and we take off the other cards but we get "system failure" msg,( maybe we take off a necessary board).
After we get system failure msg,we stop trying to do diagnostics again cause we dont want to do further damage in machine.

[meckardt55]

You need to find out why it is telling you "not enough good boards" this may be the problem. A bad board could be pulling down the data bus which would cause it to re-set. I would still try to rule out the power supplies. You can also heat up the control cabinet with a heat gun to see if it is heat related. Then you can try to narrow it down by heating one section of the control boards at a time. Do you have any spare boards that you can change out??

Mike CNC Machine Services INC | Cincinnati Milacron MachinesCNC Machine Services

[TorrentBoilers]

No,i do not have spare boards...I try to do the "bootstrap diagnostic" just to find out witch board is not good but i fail (maybe i try it again at the future)
The heat is cabinet is only 25-30 degrees celcious...i place 2 thermometers already,one in main power supply and one in motherboard and both they show the same temperature.

[Strange179]

We also have a machine with an Acramatic 950 and we're having almost the exact same issue. The machine will be going along fine and then *poof* control reboot (hydraulics and servos off). For us this almost always seems to happen at a spindle event. Spin up, stop, reverse (for tapping), or change speed. We just had the spindle drive out to Siemens because it had a bad board but the problem is still occurring. We've also been told by Siemens that it's most likely an instability in the 5V supply to the control and that the BOH board sees a drop, thinks the power is going out and shuts down the control to protect it. Of course, the power isn't going out so the control immediately begins the boot process. We've tried to trap this voltage fluctuation on a storage scope but have yet to have any success. It's just not predictable. Some days it will do this 10 times in a day. Some days maybe once. We tried replacing the big 5V supply in the drawer below the control but only seemed to make the problem worse (or maybe it just had a bad day that day). I'm definitely interested in any solutions you may come up with.

Justin