Memex Automation Inc. Fanuc CNC Backup Instruction Manual

Transcription

1 Memex Automation Inc. Fanuc CNC Backup Instruction Manual

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3 1 Table of Contents Table of Contents... 1 Procomm Plus version 4.8 Configuration... 3 Serial Cable Connection... 6 Memory Card Usage... 8 What Data Can be Archived... 9 CNC Parameter settings for RS-232 communications CNC Parameters Related to Memory Card Communications How to Backup and Restore ALL Data in your CNC Series 0 models A/B/C/D Using the RS-232 interface Series 16/18/21 models A/B/C, Powermate models D/H Using the RS-232 interface Series 15 models A/B Using the memory card Using the RS-232 interface Series 16i/18i/21i/0i models A/B, Powermate i models D/H Using the memory card Using the RS-232 interface Series 15i model A Using the memory card Using the RS-232 interface How to Backup and Restore Programs in your CNC Series 0 models A/B/C/D Using the RS-232 interface Series 16/18/21 models A/B/C, Powermate models D/H Using the RS-232 interface Series 15 models A/B Using the RS-232 interface Series 16i/18i/21i/0i models A/B, Powermate i models D/H Using the memory card Using the RS-232 interface Series 15i model A Using the RS-232 interface How to Backup and Restore CNC Parameters in your CNC Series 0 models A/B/C/D Using the RS-232 interface Series 16/18/21 models A/B/C, Powermate models D/H Using the RS-232 interface Series 15 models A/B Using the RS-232 interface Series 16i/18i/21i/0i models A/B, Powermate i models D/H Using the memory card Using the RS-232 interface Series 15i model A... 64

4 2 Using the RS-232 interface How to Backup and Restore PMC Parameters in your CNC Series 16/18/21 models A/B/C, Powermate models D/H Using the RS-232 interface Series 15 models A/B Using the RS-232 interface Series 16i/18i/21i/0i models A/B, Powermate i models D/H Using the memory card Using the RS-232 interface Series 15i model A Using the RS-232 interface Open Systems Backup and Restore using the Basic Operation Package (BOP) References... 75

5 3 Procomm Plus version 4.8 Configuration The following setup information applies to ProComm Plus 2.0 for Windows 95/98 through version 4.8 for Windows 95/98/2000/XP. NOTE: It is possible that you may experience timeouts when uploading a program using drip feed to the CNC while using ProComm Plus Version 4.8. ProComm's default delay time is to wait 20 seconds after an XOFF command and then abort. Symantic has provided a solution to this on their web pages. For further explanation, please visit their Tech Support site at enter a search for that version of Procomm product and open the FAQ section for that product. 1. After installing ProComm Plus, launch the application by double clicking on the appropriate icon or selecting the appropriate item from the Start button. If you need any additional help on installing or launching the application, please refer to the ProComm documentation that accompanied the software. This is the main screen of ProComm Plus. Clicking the SETUP button will bring up the screens used to change the communications parameters. 2. By clicking the SETUP button the following screen appears. Click on the System" tab followed by the "Modem Connection" button. Next, select "direct connect Com1" from the "Current Modem / Connection" drop down box. To configure the Com1 port, click on the "Modem/Connection Properties " button.

6 4 3. After selecting the "Modem/Connection Properties " button, you should see the following screen. Set your to match the following:

7 5 Click on "OK" to accept the settings and close the window 4. Clicking on the "Data" tab of the Setup screen allows you to set the type of transfer to be used. Click on the "Transfer Protocol" button. To communicate with the CNC, you should select ASCII from the "Current Transfer Protocol" drop down box. Set the remaining fields in this window to match those shown below. Click on "OK" to accept the settings and close the window

8 6 Serial Cable Connection The GE Fanuc CNC controls have a minimum of one serial communication port available for communications. This port is designed to conform to the basic requirements of the EIA232C standard. Connection to an EIA232 or EIA574 compliant device can be accomplished using a null modem cable. Communication Cable Diagrams EIA232C Null Modem Cable This cable, utilizing a DB25P connector to a DB25S connector, uses Control Codes also known as Software Handshaking. Controls and PG systems use serial inter-face. NOTE: Pin #25 has 24 volts power supply on it. Do not use for normal interface connection or damage to the control may occur. EIA232C to EIA574 Null Modem Cable This cable can be used for interfacing between IBM-compatible computers and GE Fanuc controls. This cable uses a DB25P connector to a DB9S connector. This is the most commonly used cable for communications and is available from GE Fanuc or easily fabricated.

9 7 SD RD DB25P (male) 2 3 DB9S (female) 2 3 RD SD SG 7 5 SG RS 4 7 RS CS 5 8 CS DR 6 1 CD CD 8 4 ER ER 20 6 DR FG: Frame ground SD: Send data RD: Receive data RS: Request to send CS: Clear to send DR: Data set ready SG: Signal ground ER: Equipment ready CD: Received line signal detector

10 8 Memory Card Usage Three types of memory cards can be used with our CNC and Power Mate controls: 1. ATA Flash Rom 2. SRAM (Static Ram Access Memory), which are battery-backed. 3. FlashROM (called FROM for the rest of this document), which do not require battery backup. Which type of memory card do you need? The Pros and Cons of each type of card are given below. We recommend SRAM or ATA Flash. The SRAM works with a larger variety of controls, but requires a small battery on the card to retain its memory and should not be used as a permanent storage device. ATA Flash is lower cost and can be used for permanent storage of backup files, but is newer technology and therefore works with a smaller number of controls. Memory Card Type ATA Flash SRAM FROM Works with i series controls Yes Yes Yes Works with 15/16/18/21-B and 20/21-A controls No Yes Yes Works with PowerMate-C/D/E/F/H/I controls No Yes Yes Can read/write from a Yes Yes No Fast Write Time Yes Yes No Plug and Play for WIN95 and newer Yes No No Low Cost Yes No Yes Requires battery to retain backup data No Yes No Files can be deleted individually Yes Yes No Can be formatted on Yes Yes No Requires special drivers No No Yes GE Fanuc Part Numbers 44A G09 (8MB) 44A G01 (2MB) 44A G02 (4MB) 44A G10 (16MB) 44A G03 (4MB)

11 9 What Data Can be Archived The system software that operates GE Fanuc CNC controls is stored in EPROM. They are essentially fixed and unchangeable. The CNC is shipped from GE Fanuc ready for the machine builder to customize for his application. The files needed for final operation are contained in non-volatile RAM, or battery backedup RAM. The data stored here can be lost for a variety of reasons and therefore must be saved externally on permanent media. It is recommended that all user data be kept both on a computer diskette or CD-ROM as well as on paper to ensure that it will be available in time of need. User Files Long term archival: 1. CNC Parameters (including servo parameters) 2. Pitch Error Compensation (if used) 3. PMC Parameters (or Diagnostic Data on FS-0 Controls) This data seldom changes after installation of the machine tool. However, the archive must be updated whenever changes are made Data that changes regularly. 1. Tool Offsets 2. Work Offsets 3. Dynamic Tool Offsets 4. Macro Variables 5. Tool Form Data 6. CAP Tool Data 7. CNC Part Programs This data should be backed up any time maintenance is performed that might cause a memory loss. Data normally stored in EPROM but may be stored in RAM format: 1. PMC ladder program 2. Macro executor programs File Naming When user data is saved to a diskette, it should be remembered that in an average plant there may possibly be multiple machines and controls of the same model. This means that there will be multiple versions of this data. There should be a complete set for each machine on which a GE Fanuc control is applied. It is important to realize that even identical machines may have different parameter data based on any number of factors. The existence of so much similar data can easily cause problems if not addressed from the beginning, so some type of

12 10 system for naming and archiving files must be created. For example, when backing up the data, you will be asked what to name the resulting data file on disk. GE Fanuc recommends that you use a unique name such as the machine serial number, brass tag or asset number, combined with an extension that helps label the type of data being backed up. By using the first eight (8) characters to identify the machine and the extension to identify the file type, much confusion can be avoided. For example, the filename BT CNC could be used to name the CNC parameter file for machine BT

13 11 CNC Parameter settings for RS-232 communications The parameter tables on the following page can be used as a reference when setting up the various models of CNC control for RS-232 communications. These parameters tell the control which port to use and the device type (in this case, RS-232). These parameters also determine that the number of data bits will be 8, the number of stop bits 2, that EVEN parity will be used as well as a baud rate of 4800bps set. These settings coincide with the ProComm configuration explained earlier in this manual. Additionally, these parameters also unlock the custom macro protection, allowing the download of the macro programs. When setting CNC parameters ensure that the Parameter Write Enable (PWE) setting is set to 1 on the control settings screen. PWE PWE Setting from series 16i-MA control

14 12 Control Series 10/11/12/15A/15B/15i Parameters Port 1 Port 2 P 0000 ****1010 ****1010 P P P 0011 ******00 ******00 P 2201 ******00 ******00 P P P P P P P P Control Series 0A/0B/0C/0D Parameter Port 1 Port 2 P ******1 P 0010 ***0**** ***0**** P ****** P ******1 P P P P TVON 0 0 ISO 0,1 2 I/O 1 1 PWE 1 1 TAPEF 0 0 Control Series 16/18/20/21-ABCi / 0i Parameter Port 1 Port 2 P 0000 ******10 ******10 P ,1 2 P ***0**1 P P P ***0**1 P P P 3202 ***0***0 ***0***0

15 13 CNC Parameters Related to Memory Card Communications 1. Select the MDI mode on the operator panel for the CNC. 2. Go to the Offset/Setting screen. 3. Set I/O channel = 4. or 1. Select the MDI mode on the operator panel for the CNC. 2. Place the CNC into an Emergency Stop condition. 3. Set your control so that Parameter Write is enabled. 4. For series 18i set parameter 20 = 4, series 15i set 20=4. These settings will let you upload and download files to the cards the same as you would to a and there is also an additional menu called all IO with additional I/O functionality. IO Channel Setting IO Channel Setting from series 16i-MA control

16 14 How to Backup and Restore ALL Data in your CNC One of the most common procedures on CNC controls during maintenance is to backup all of the data possible before working on a CNC system. In this manner, a maintenance person can easily restore the control to the original state should a problem be encountered during the maintenance activity. Series 0 models A/B/C/D This series of controls is restricted to using the RS-232 interface for all data backup and restore operations. Using the RS-232 interface To Transfer Programs from CNC to From the CNC Side, do the following: 1. Select EDIT mode. 2. Select the PROGRAM screen. 3. Depress I/O key. 4. Prepare the to receive file (See appropriate section on ProComm for receiving a file on the ). 5. To output an individual program, enter the Letter O and the part program number OR to output all programs enter To Transfer Program from to CNC From the CNC side, do the following: 1. Select EDIT mode. 2. Select the PROGRAM screen. 3. Depress I/O softkey. 4. Depress READ softkey. 5. Send file from (See appropriate section on ProComm for sending from ). To Transfer Parameters from CNC to From the CNC side, do the following: 1. Select EDIT mode. 2. Select the PARAMETER menu. 3. Prepare to receive the file (See appropriate section on ProComm for receiving a file on the ). 4. Hold down EOB key and simultaneously depress OUTPUT START key.

17 15 NOTE: Failure to press the EOB key and OUTPUT START will result in an incomplete parameter file being downloaded. Transfer Parameters from to CNC From the CNC side, do the following: 1. Set Parameter Write Enable (PWE) to Select EDIT mode. 3. Select the PARAMETER menu. 4. Depress INPUT key. 5. Send the parameter file from the (See appropriate section on ProComm for sending from ). 6. When the transfer is complete, turn CNC OFF and back ON to use the new parameter set. Also verify that PWE is set to 0. NOTE: To upload and download PMC parameters (Diagnostics) and offsets, the procedures are the same as for the system parameters. The only difference is that you must be on the CNC Diagnostic Page for transferring PMC parameters and the Offset Page for transferring offsets.

18 16 Series 16/18/21 models A/B/C, Powermate models D/H The primary method for archiving data from this series of control is through the RS-232 port. Newer models B/C controls may have MCIA memory card slots located in the control rack and are accessible through the boot mode. For instructions on using the boot mode backup procedures for the model A/B controls, see the section for 16i/18i/21i/0i controls. Using the RS-232 interface First set the CNC parameters as per the settings in the section labeled CNC Parameter Settings for RS-232 Communications Punching CNC Parameters (CNC --> ) Set up the CNC for communications as per CNC Parameter Setting for RS-232 Communication. Perform the following steps on the and CNC as follows: Launch Procomm Plus 4.8 Select File Receive from the toolbar Designate a name and directory for the saved data CNC Select EDIT mode. CNC Press SYSTEM key. CNC Hit softkeys [PARAM], [OPRT], [+], [PUNCH],[EXEC]. (You will see the parameters scroll up on the screen.) (The CNC will flash OUTPUT on the lower section of the CRT.) Reading CNC Parameters (CNC <-- ) Set up the CNC for communications as per CNC Parameter Setting for RS-232 Communication. Perform the following steps on the and CNC as follows: Launch Procomm Plus 4.8 CNC Select MDI mode and press ESTOP CNC Set PWE to 1. CNC Press SYSTEM key.

19 17 CNC Hit softkeys [PARAM], [OPRT], [+], [READ], [EXEC]. Select File Send from the toolbar Designate the name and directory for the file to send (You will see the parameters scroll up on the screen.) (The CNC will flash INPUT on the lower section of the CRT.) CNC Power the CNC off then on to have the new parameters take effect. Punching CNC Part Programs (CNC --> ) Set up the CNC for communications as per CNC Parameter Setting for RS-232 Communication. Perform the following steps on the and CNC as follow Launch Procomm Plus 4.8 Select File Receive from the toolbar Designate a name and directory for the saved data CNC Select EDIT mode. CNC Press PROG key CNC To output current program hit softkeys [PRGRM], [OPRT], [+], [PUNCH],[EXEC] CNC To output all programs input O-9999 and hit [+], [PUNCH], [EXEC]. (You will see the program scroll up on the screen.) ( The CNC will flash OUTPUT on the lower section of the CRT.) Reading CNC Part Programs (CNC <-- ) Set up the CNC for communications as per CNC Parameter Setting for RS-232 Communication. Perform the following steps on the and CNC as follows: Launch Procomm Plus 4.8 CNC Select EDIT mode and turn program protect key off. CNC Press PROGRAM key. CNC Hit softkeys [PRGRM],[OPRT], [+], [READ], [EXEC].

20 18 Select File Send from the toolbar Designate the name and directory for the file to send (You will see the parameters scroll up on the screen.) (The CNC will flash INPUT on the lower section of the CRT.) Punching PMC Data (CNC --> ) Perform the following steps on the and CNC as follows: Launch Procomm Plus 4.8 Select File Receive from the toolbar Designate a name and directory for the saved data CNC Select EDIT mode. CNC Go to the PMC side and select I/O. CNC Select Channel 1 for Port 1 and Channel 2 for Port 2. CNC Set Device to OTHERS CNC Set Data kind to type desired --- ALL/LADDER/PARAM. Set Function to WRITE. CNC Press the SPEED softkey. CNC Select 4800 Baud (depending on computer setup). CNC Select Parity 0, Stop bits 1, Write code ASCII. CNC Press < and EXEC softkeys to initiate download. (The CNC screen will flash executing and count up until complete.) Reading PMC Data (CNC <-- ) Launch Procomm Plus 4.8 CNC Select MDI mode and press ESTOP CNC Set PWE to 1. CNC Go to the PMC side and select I/O. CNC Select Channel 1 for Port 1 and Channel 2 for Port 2 CNC Set Device to OTHERS.

21 19 CNC Set Function to READ. CNC Press the SPEED softkey CNC Select 4800 Baud. CNC Select Parity 0, Stop bits 1. CNC Press < and EXEC softkeys. (Executing should flash) Select File Send from the toolbar Designate the name and directory for the file to send (You will see the parameters scroll up on the screen.) (The CNC will flash INPUT on the lower section of the CRT.)

22 20 Series 15 models A/B The series 15 model A control is restricted to using the RS-232 interface whereas the series 15 model B control additionally offers a MCIA memory card slot in the control rack. For more information refer to GE Fanuc Manual GFZ Series 15/150 Model-B Maintenance Manual. Using the memory card (Not available on series 15 model a) The table below lists the functions and corresponding memory card types that can be used. Cards must be of TYPE 1 or 2 as defined in the Personal Computer Memory Card International Association (MCIA) standard, version 2.0 or later, or the Japan Electronic Industry Development Association (JEIDA) standard, version 4.1 or later. The format conforms to the DOS FAT file system. The memory card has a maximum storage capacity of 32M bytes.

23 21 Accessing the Boot System Insert the SRAM Memory card into the MCIA slot in the control rack. Turn the power on while holding down the page up/down keys Note: If you are using a 9 small MDI unit, turn the power on while holding down cursor keys up and down keys instead of the page up/down keys. SYSTEM DATA SAVE The SYSTEM DATA SAVE screen enables the saving of user files, such as PMC ladder files. System files, such as executive software cannot be saved. To save SYSTEM DATA use the following procedure. Press a cursor up/down key to choose the desired function. Position the cursor to a desired function, then press the INPUT/INSERT key.

24 22 The ROM files in flash memory are listed together with the number of management units (128KB management units) in each file. Use the cursor keys to position the cursor to the file to be saved to the memory card. Then, press the INPUT/INSERT key. The INPUT FILE NAME (CAN: RESET) message appears in the message field. Enter the name of the desired file on the memory card, then press the INPUT/INSERT key. To abandon saving, press the RESET key. To end the processing, position the cursor to END, then press the INPUT/INSERT key. The main menu appears again. SRAM DATA BACKUP To save a complete image of the data stored in SRAM memory, select FILE DATA BACKUP from the System Monitor screen (selection 4).

25 23 From the File Data Backup screen, select STORE FILE. To execute batch restoration, select LOAD FILE. To terminate the processing, select END. To select the processing, press a cursor key to position the cursor, then press the INPUT/INSERT key. When the batch saving or restoration of a file is selected, the size of the system s backup RAM is displayed on the screen. To execute the selected processing, press the INPUT/INSERT key. To cancel the processing, press the CAN key. (See the detailed description given below.) NOTE The backup data is saved to file FILEx.BAK, where x is a value of 1 to 4. The original data can be saved in up to four files. If a single memory card cannot hold all the original data, the data can be saved using up to four memory cards. Existing FILEx.BAK files on a memory card may be overwritten if a file of the

26 24 same name is stored. The names of the files already on the memory card can be listed in the FILE DIRECTORY field of the SYSTEM DATA LOADING screen. To execute the batch saving of backup data, perform the following steps: 1. Select the STORE FILE function on the initial screen. 2. When the SET IC CARD NO.1 & HIT INPUT KEY message appears in the message field, mount the first memory card. Then, press the INPUT/INSERT key. To cancel the processing, press the RESET key. The initial screen appears again. 3. While data is being saved, the STORE TO IC CARD message blinks. Once saving has been completed, the STORE FILE COMPLETE and HIT INPUT KEY messages appear in the message field. When the INPUT/INSERT key is pressed, the initial screen appears again. If the first memory card cannot hold all the data to be saved, the SET IC/CARD NO.2 & HIT INPUT KEY message appears in the message field. Mount the second memory card without turning the power off, then press the INPUT/INSERT KEY. 4. The backup data can be saved using up to four memory cards by performing step (3) repeatedly. If four memory cards cannot hold all the data, the FILE DATA SIZE ERROR and HIT INPUT KEY messages appear in the message field. When the INPUT INSERT key is pressed, the initial screen appears again. NOTE Once batch saving starts, requests to replace the memory card are repeated until all the backup data has been normally saved (using up to four memory cards). To stop the processing, press the RESET key while the SET IC CARD NO.x & HIT INPUT KEY message is displayed. Data is stored on the memory cards under the following file names: First memory card: Second memory card: Third memory card: Fourth memory card: FILE1.BAK FILE2.BAK FILE3.BAK FILE4.BAK Note that a file on a memory card can be overwritten. If the specified name of a file to be saved duplicates that of a file already on the card, the old data will be overwritten.

27 25 To execute the batch restoration of backup data, perform the following steps: 1. On the initial screen, select the LOAD FILE function. 2. The SET FILE1.BAK & HIT INPUT KEY message appears in the message field. Mount the first memory card containing FILE1.BAK, then press the INPUT/INSERT key. To cancel the processing, press the RESET key. The initial screen appears again. 3. While data is being restored, the LOADING FROM IC CARD message blinks. Once data restoration has been completed, the LOAD FILE COMPLETE and HIT INPUT KEY messages appear in the message field. When the INPUT/INSERT key is pressed, the initial screen appears again. 4. Backup data stored using up to four memory cards can be restored by performing step (3) repeatedly. If all the required data cannot be restored from all of the four memory cards, the FILE DATA SIZE ERROR and HIT INPUT KEY messages appear in the message field. When the INPUT/INSERT key is pressed, the initial screen appears again. NOTE: The function for saving or restoring a file in batch mode of the boot system assumes that the backup RAM (file SRAM) used for saving and that used for restoration are of the same size. So, this function should be used in the following cases: 1. To restore a file when file all clear must be executed (the file SRAM module is not replaced) 2. To restore a file when the file SRAM module must be replaced and when the size of the new backup RAM is the same. If this function is used for any other purpose, such as restoring SRAM into a module of a different size after an upgrade, file restoration may not be performed correctly. In the case of a memory upgrade, use the RS-232 option to backup and restore the control. Similarly, if an error (a RAM parity error, for example) is found in the contents of the backup RAM during batch saving, file restoration may not be performed correctly and the RS-232 method must be used.

28 26 Using the RS-232 interface PUNCHING CNC PARAMETERS (CNC --> ) Connect the cable to the computer and the serial port on the CNC Set up the CNC for communications as per CNC Parameter Setting for RS-232 Communication. Perform the following steps on the and CNC as follows: Launch Procomm Plus 4.8 Select File Receive from the toolbar Designate a name and directory for the saved data CNC Go into EDIT mode. CNC Press the <, SERVICE, CHAPTER, PARAMETER, >, PUNCH, ALL keys. ( The CNC will flash PNCH on the lower portion of the CRT. ) ( The will display the text and count lines until finished.) READING CNC PARAMETERS ( --> CNC) Set up the CNC for communications as per CNC Parameter Setting for RS-232 Communication. Perform the following steps on the and CNC as follows: Launch Procomm Plus 4.8 CNC Go into EDIT mode. CNC Press ESTOP. CNC Press the <, SERVICE, CHAPTER, PARAMETER, >, READ, ALL keys. Select File Send from the toolbar Designate the name and directory for the file to send (You will see the parameters scroll up on the screen.) (The CNC will flash INPUT on the lower section of the CRT.) CNC Power the CNC off and then on to have the new parameters take effect.

29 27 PUNCHING CNC PART PROGRAMS (CNC --> ) Set up the CNC for communications as per CNC Parameter Setting for RS-232 Communication. Perform the following steps on the and CNC as follows: Launch Procomm Plus 4.8 Select File Receive from the toolbar Designate a name and directory for the saved data CNC Go into EDIT mode. CNC Press the <, PROGRAM, CHAPTER, TEXT, >, >, PUNCH, Oxxxx, EXEC keys (where xxxx is the desired program no.). (The CNC will flash PNCH on the lower portion of the CRT.) (The will display the text and count lines until finished.) READING CNC PART PROGRAMS ( --> CNC) Set up the CNC for communications as per CNC Parameter Setting for RS-232 Communication. Perform the following steps on.the and CNC as follows: Launch Procomm Plus 4.8 CNC Go into EDIT mode. CNC Press the <, PROGRAM, CHAPTER, TEXT, >, >, READ, ALL keys Select File Send from the toolbar Designate the name and directory for the file to send (You will see the parameters scroll up on the screen.) (The CNC will flash INPUT on the lower section of the CRT.) PUNCHING PMC PARAMETERS (CNC --> ) Perform the following steps on the and CNC as follows: Launch Procomm Plus 4.8 Select File Receive from the toolbar

30 28 Designate a name and directory for the saved data CNC Press ESTOP. CNC Press the CNC/PMC button to go into the PMC side CNC Press PRM, KEEPRL and set K17.7 = 1. CNC Press <, SYSPRM and set PG CHANNEL = 1 (for Port 1) or 2 (for Port 2). CNC Press the <, I/O, FDCAS, OUTPUT, PARAM, ADD keys. (The CNC will flash EXECUTING on the lower portion of the CRT.) (The will display the text and count lines until finished.) READING PMC PARAMETERS ( --> CNC) Perform the following steps on the and CNC as follows: Launch Procomm Plus 4.8 CNC Press ESTOP. CNC Press the CNC/PMC button to go into the PMC side. CNC Press PRM, KEEPRL and set K17.7 = 1. CNC Press <, SYSPRM and set PG CHANNEL = 1 (for Port 1) or 2 (for Port 2). CNC Press <, EDIT, PASWRD, ENAON, <, <, I/O, FDCAS, INPUT, EXEC keys. Select File Send from the toolbar Designate the name and directory for the file to send (You will see the parameters scroll up on the screen.) (The CNC will flash INPUT on the lower section of the CRT.)

31 29 Series 16i/18i/21i/0i models A/B, Powermate i models D/H These controls can use several different methods to backup data that is in the control. Memory cards are the fastest method, and can be used in the boot mode or in the CNC Screen Mode. RS-232 communications are also available on this control series. Using the memory card There are two ways to backup and restore using a Memory Card with the I series controls, boot mode SRAM backup, and ALL I/O. However, please note that this ability only exists in i-series and newer controls. Refer to the Maintenance Manual for a specific CNC control for further explanation. The user data that should be archived can be accessed through the following operations: Boot mode SRAM backup is used to make a complete backup of all files contained in Volatile Memory. ALL I/O is used to backup individual files in the machine such as programs, or offsets that may have changed. BOOT MODE BACKUP and RESTORE SRAM Boot Mode Backup and Restore SRAM is used for transferring a complete image of all SRAM data (i.e. CNC parameters, part programs, etc.) through the use of a memory card only. This method should not be used to backup controls that are already exhibiting memory related errors such as RAM parity errors since this method makes an exact copy of the memory image which may contain the error. In the case where you need to backup a control that is exhibiting memory errors, use RS-232 backup methods. To use this method, Press and hold the right two softkeys and turn power on to the control. 1. Insert the MCIA card into the slot on main CPU or on the I Series, into the slot located on the front of the MDI/CRT unit. 2. Using the softkeys under display go down until SRAM BACKUP is highlighted. 3. Choose SELECT and it will display two choices select SRAM BACKUP to send SRAM data from CNC to a file or to select individual files on the card that will be called SRAM****.***. This will backup all

32 30 battery backed memory on the Memory Card (parameters, programs, offsets, pmc parameters, work shifts, pitch error comp, and etc). 4. Choose SELECT again and you will be asked Backup SRAM Data OK? Select YES to continue or NO to return to previous menu. 5. This data can then be stored on a from the card as a backup. It is recommended that the data be transferred to a hard drive or floppy drive. To restore the data should the machine should loose its battery backed memory, follow steps 1 through 5, choosing RESTORE SRAM in step 4 to load files from the memory card to the CNC. 6. After the file loads choose SELECT again to complete that function. Once finished, select END which will return you to the previous menu and allow you to exit the system. Note: 1. Any attempt to backup a second machine to the same card may result in files being overwritten. 2. The data backup or image, must match the physical size of the SRAM module in the CNC. For example, a SRAM backup from one machine that is 256k in size, cannot be restored to a second machine that requires a SRAM file that is 512k in size. 3. These files are in a binary format which cannot be read with a word processor. SYSTEM DATA BACKUP System Data Backup is used for transferring an image of system data such as the PMC Ladder. Follow Steps 1 and 2 from above then: 1. Using softkeys under the display cursor, down until SYSTEM DATA SAVE is highlighted and hit the select key. 2. From this menu user files which are the pmc-r* or the macro executer files can be saved. After selecting the correct file to save, confirm a second time and the CNC will download it to the Memory card. The first file will be labeled PMC-R*.000, the second PMC-R*.001, etc. Restoring the data is similar except selecting SYSTEM DATA LOADING, followed by SELECT. 3. A directory listing of the files on the card will be displayed. Select the file to load (to page down to the next group of files hit the right arrow key), choose SELECT and confirm the operation desired. 4. Once the file has loaded, choose SELECT to move to the next function. Continue until all the files requested have been loaded. Next,

33 31 select END and confirm. The CNC will then reboot and return to it s standard operating mode. CNC SCREEN INPUT AND OUTPUT (Excludes 0i-Model A) CNC screen Input and Output is used to transfer the CNC parameters from the CNC side of the control or to edit the file offline. Parameters 1. Power up the CNC and select the SYSTEM key. 2. Select EDIT mode on operators panel. 3. Select PARAM soft key then the OPRT softkey and the + softkey. 4. To punch out (download) the parameters to the card, select PUNCH, then ALL and the CNC will output a file called CNCPARAM.DAT to the MCIA card. This file is always put out with the same name so there can only be one of these files on the card or it will be written over. 5. To read (upload) the file into the CNC, follow steps 1 to 3, selecting READ, then EXEC. The CNC will access the MCIA card, find the file named CNCPARAM.DAT and load it into the control. Note that there can only be one file named CNCPARAM.DAT on the card. Note: This file can be edited with a word processor, saved back to the card as a text file and be reloaded in to the CNC. ALL IO input and output All IO Page Input and Output is used to transfer data such as programs, parameters, offsets, etc. from the I/O screen. Depending on the control model, this can be done using a memory card or by RS-232. To access the ALL IO screens: 1. The CNC must be powered up, not in Emergency Stop and in EDIT mode to use this function. 2. The key sequence is SYSTEM, followed by the + key until the menu option select ALL IO appears. 3. Additionally, the menus for programs, parameters, offsets, etc., will be visible. Continue to press the + key until the menus for macro variables and pitch error appear.

34 32 Parameters Punching (output) 1. Access the ALL IO menu screen and select PARAM, OPRT, then PUNCH. 2. Input the name to be used for the file in a MS-DOS 8+3 format (for example, BT CNC). Then select F NAME, followed by EXEC, and the CNC will put the parameters on the card with that file name ( if no file name is entered then CNCPARAM.DAT will be created automatically). Reading (input) 1. Access the ALL IO menu screen and select PARAM, OPRT, then F READ. 2. The file can be input using one of two methods: a. Select F READ, then page up and down to find you file on the card and input the file number and F SET, and EXEC. b. Select N READ, input the file name, select F NAME, and hit EXEC. Programs Punching (output) 1. Access the ALL IO menu screen and select PRGRM, OPRT, then PUNCH. 2. Input the name to be used for the file in a 8+3 format and hit F NAME. Next, input the program number to punch and press O SET, then EXEC. The CNC will output the program to the card with that file name ( with no file name entered, the CNC will create a file using O plus the program # for the file name) Reading (input) 1. Access the ALL IO screens and select PRGRM, OPRT, then F READ. 2. The files can be input using one of two methods: a. Select F READ, then page up and down to find the desired file on the card and input the file number. Next, press F SET, followed by EXEC and the program will load in with the program number in the file (if a program number was entered and the O SET pressed before pressing EXEC above otherwise it will be entered with the new program number). b. Select N READ, input the file name, select F NAME, and press EXEC. The program will load in with the program number in the file (if a program number was entered and the O SET pressed before

35 33 pressing EXEC above otherwise it will be entered with the new program number). Tool Offsets Punching (output) 1. Access the ALL IO menu screen and select OFFSET, OPRT, then PUNCH. 2. Input the name to be used for the file in a MS-DOS 8+3 format. Then select F NAME, followed by EXEC, and the CNC will put the offsets on the memory card with that file name ( with no file name you will get TOOLOFST.DAT for a file name). Reading (input) 1. Access the ALL IO menu screen and select OFFSET, OPRT, then F READ. 2. The files can be input using one of two methods: a. Select F READ, then page up and down to select the correct file on the memory card. Next, input the file number, followed by F SET, then EXEC. b. Select N READ, input the file name, select F NAME, then EXEC. MACRO VARIABLES Punching (output) 1. Access the ALL IO menu screen and select MACRO, OPRT, then PUNCH. 2. Input the desired name for the file in a 8+3 format, press F NAME, and then EXEC. The CNC will put the parameters on the memory card using that file name ( with no file name the CNC will use MACROVAR.DAT for that file). Reading (input) 1. Access the ALL IO menu screen and select MACRO, OPRT, then F READ. 2. The files can be input using one of two methods: a. Select F READ, then page up and down to find the correct file on the card. Next, input the file number and select F SET, then EXEC. b. Select N READ, input the file name, select F NAME, then hit EXEC.

36 34 PITCH ERROR COMP Punching (output) 1. Access the ALL IO menu screen and select PITCH, OPRT, then PUNCH. 2. Input the name to be used for the file in an 8+3 format. Next, select F NAME, then EXEC and the CNC will put the parameters on the card using that file name ( with no file name the CNC will use PITCHERR.DAT for the file name) Reading (input) 1. Access the ALL IO menu screen and select PITCH, OPRT, then F READ. 2. The data can be input using one of two methods: a. Select F READ, then page up and down to find the correct file on the card. Next, input the file number followed by F SET, then EXEC. b. Select N READ, input the file name, select F NAME, then EXEC. Using the RS-232 interface Punching CNC Parameters (CNC --> ) Set up the CNC for communications as per CNC Parameter Setting for RS-232 Communication. Perform the following steps on the and CNC as follows: Launch Procomm Plus 4.8 Select File Receive from the toolbar Designate a name and directory for the saved data CNC Select EDIT mode. CNC Press SYSTEM key. CNC Hit softkeys [PARAM], [OPRT], [+], [PUNCH],[EXEC]. (You will see the parameters scroll up on the screen.) (The CNC will flash OUTPUT on the lower section of the CRT.) Reading CNC Parameters (CNC <-- )

37 35 Set up the CNC for communications as per CNC Parameter Setting for RS-232 Communication. Perform the following steps on the and CNC as follows: Launch Procomm Plus 4.8 CNC Select MDI mode and press ESTOP CNC Set PWE to 1. CNC Press SYSTEM key. CNC Hit softkeys [PARAM], [OPRT], [+], [READ], [EXEC]. Select File Send from the toolbar Designate the name and directory for the file to send (You will see the parameters scroll up on the screen.) (The CNC will flash INPUT on the lower section of the CRT.) CNC Power the CNC off then on to have the new parameters take effect. Punching CNC Part Programs (CNC --> ) Set up the CNC for communications as per CNC Parameter Setting for RS-232 Communication. Perform the following steps on the and CNC as follow Launch Procomm Plus 4.8 Select File Receive from the toolbar Designate a name and directory for the saved data CNC Select EDIT mode. CNC Press PROG key CNC To output current program hit softkeys [PRGRM], [OPRT], [+], [PUNCH],[EXEC] CNC To output all programs input O-9999 and hit [+], [PUNCH], [EXEC]. (You will see the program scroll up on the screen.) ( The CNC will flash OUTPUT on the lower section of the CRT.) Reading CNC Part Programs (CNC <-- )

38 36 Set up the CNC for communications as per CNC Parameter Setting for RS-232 Communication. Perform the following steps on the and CNC as follows: Launch Procomm Plus 4.8 CNC Select EDIT mode and turn program protect key off. CNC Press PROGRAM key. CNC Hit softkeys [PRGRM],[OPRT], [+], [READ], [EXEC]. Select File Send from the toolbar Punching PMC Data (CNC --> ) Designate the name and directory for the file to send (You will see the parameters scroll up on the screen.) (The CNC will flash INPUT on the lower section of the CRT.) Perform the following steps on the and CNC as follows: Launch Procomm Plus 4.8 Select File Receive from the toolbar Designate a name and directory for the saved data CNC Select EDIT mode. CNC Go to the PMC side and select I/O. CNC Select Channel 1 for Port 1 and Channel 2 for Port 2. CNC Set Device to OTHERS CNC Set Data kind to type desired --- ALL/LADDER/PARAM. Set Function to WRITE. CNC Press the SPEED softkey. CNC Select 4800 Baud (depending on computer setup). CNC Select Parity 0, Stop bits 1, Write code ASCII. CNC Press < and EXEC softkeys to initiate download. (The CNC screen will flash executing and count up until complete.)

39 37 Reading PMC Data (CNC <-- ) Launch Procomm Plus 4.8 CNC Select MDI mode and press ESTOP CNC Set PWE to 1. CNC Go to the PMC side and select I/O. CNC Select Channel 1 for Port 1 and Channel 2 for Port 2 CNC Set Device to OTHERS. CNC Set Function to READ. CNC Press the SPEED softkey CNC Select 4800 Baud. CNC Select Parity 0, Stop bits 1. CNC Press < and EXEC softkeys. (Executing should flash) Select File Send from the toolbar Designate the name and directory for the file to send (You will see the parameters scroll up on the screen.) (The CNC will flash INPUT on the lower section of the CRT.)

40 38 Series 15i model A The series 15i control introduced the capability to use ATA Flash memory cards for backup and restore operations as well as SRAM memory cards that were available on the series 15 model A/B. The backup and restore operations are the same for both the 15i model A and the 15 model A/B controls. For more information refer to GE Fanuc Manual GFZ Series 15i/150i Maintenance Manual Using the memory card The table below lists the functions and corresponding memory card types that can be used. Cards must be of TYPE 1 or 2 as defined in the Personal Computer Memory Card International Association (MCIA) standard, version 2.0 or later, or the Japan Electronic Industry Development Association (JEIDA) standard, version 4.1 or later. The format conforms to the DOS FAT file system. The memory card has a maximum storage capacity of 32M bytes.

41 39 Accessing the Boot System Insert the SRAM Memory card into the MCIA slot in the control rack. Turn the power on while holding down the page up/down keys Note: If you are using a 9 small MDI unit, turn the power on while holding down cursor keys up and down keys instead of the page up/down keys. SYSTEM DATA SAVE NOTE: The SYSTEM DATA SAVE screen enables the saving of user files only, such as PMC ladder files. System files, such as executive software cannot be saved. Press a cursor up/down key to choose the desired function. Position the cursor to a desired function, then press the INPUT/INSERT key.

42 40 The ROM files in flash memory are listed together with the number of management units (128KB management units) in each file. Use the cursor keys to position the cursor to the file to be saved to the memory card. Then, press the INPUT/INSERT key. The INPUT FILE NAME (CAN: RESET) message appears in the message field. Enter the name of the desired file on the memory card, then press the INPUT/INSERT key. To abandon saving, press the RESET key. To end the processing, position the cursor to END, then press the INPUT/INSERT key. The main menu appears again. SRAM DATA BACKUP To save a complete image of the data stored in SRAM memory, select FILE DATA BACKUP from the System Monitor screen (selection 4).

43 41 From the File Data Backup screen, select STORE FILE. To execute batch restoration, select LOAD FILE. To terminate the processing, select END. To select the processing, press a cursor key to position the cursor, then press the INPUT/INSERT key. When the batch saving or restoration of a file is selected, the size of the system s backup RAM is displayed on the screen. To execute the selected processing, press the INPUT/INSERT key. To cancel the processing, press the CAN key. (See the detailed description given below.) NOTE The backup data is saved to file FILEx.BAK, where x is a value of 1 to 4. The original data can be saved in up to four files. If a single memory card cannot hold all the original data, the data can be saved using up to four memory cards. Existing FILEx.BAK files on a memory card may be overwritten if a file of the

44 42 same name is stored. The names of the files already on the memory card can be listed in the FILE DIRECTORY field of the SYSTEM DATA LOADING screen. To execute the batch saving of backup data, perform the following steps: 1. Select the STORE FILE function on the initial screen. 2. When the SET IC CARD NO.1 & HIT INPUT KEY message appears in the message field, mount the first memory card. Then, press the INPUT/INSERT key. To cancel the processing, press the RESET key. The initial screen appears again. 3. While data is being saved, the STORE TO IC CARD message blinks. Once saving has been completed, the STORE FILE COMPLETE and HIT INPUT KEY messages appear in the message field. When the INPUT/INSERT key is pressed, the initial screen appears again. If the first memory card cannot hold all the data to be saved, the SET IC/CARD NO.2 & HIT INPUT KEY message appears in the message field. Mount the second memory card without turning the power off, then press the INPUT/INSERT KEY. 4. The backup data can be saved using up to four memory cards by performing step (3) repeatedly. If four memory cards cannot hold all the data, the FILE DATA SIZE ERROR and HIT INPUT KEY messages appear in the message field. When the INPUT INSERT key is pressed, the initial screen appears again. NOTE: Once batch saving starts, requests to replace the memory card are repeated until all the backup data has been normally saved (using up to four memory cards). To stop the processing, press the RESET key while the SET IC CARD NO.x & HIT INPUT KEY message is displayed. Data is stored on the memory cards under the following file names: First memory card: Second memory card: Third memory card: Fourth memory card: FILE1.BAK FILE2.BAK FILE3.BAK FILE4.BAK Note that a file on a memory card can be overwritten. If the specified name of a file to be saved duplicates that of a file already on the card, the old data will be overwritten. To execute the batch restoration of backup data, perform the following steps:

45 43 1. On the initial screen, select the LOAD FILE function. 2. The SET FILE1.BAK & HIT INPUT KEY message appears in the message field. Mount the first memory card containing FILE1.BAK, then press the INPUT/INSERT key. To cancel the processing, press the RESET key. The initial screen appears again. 3. While data is being restored, the LOADING FROM IC CARD message blinks. Once data restoration has been completed, the LOAD FILE COMPLETE and HIT INPUT KEY messages appear in the message field. When the INPUT/INSERT key is pressed, the initial screen appears again. 4. Backup data stored using up to four memory cards can be restored by performing step (3) repeatedly. If all the required data cannot be restored from all of the four memory cards, the FILE DATA SIZE ERROR and HIT INPUT KEY messages appear in the message field. When the INPUT/INSERT key is pressed, the initial screen appears again. NOTE: The function for saving or restoring a file in batch mode of the boot system assumes that the backup RAM (file SRAM) used for saving and that used for restoration are of the same size. So, this function should be used in the following cases: 1. To restore a file when file all clear must be executed (the file SRAM module is not replaced) 2. To restore a file when the file SRAM module must be replaced and when the size of the new backup RAM is the same. If this function is used for any other purpose, such as restoring SRAM into a module of a different size after an upgrade, file restoration may not be performed correctly. In the case of a memory upgrade, use the RS-232 option to backup and restore the control. Similarly, if an error (a RAM parity error, for example) is found in the contents of the backup RAM during batch saving, file restoration may not be performed correctly and the RS-232 method must be used. Using the RS-232 interface PUNCHING CNC PARAMETERS (CNC --> ) Connect the cable to the computer and the serial port on the CNC

46 44 Set up the CNC for communications as per CNC Parameter Setting for RS-232 Communication. Perform the following steps on the and CNC as follows: Launch Procomm Plus 4.8 Select File Receive from the toolbar Designate a name and directory for the saved data CNC Go into EDIT mode. CNC Press the <, SERVICE, CHAPTER, PARAMETER, >, PUNCH, ALL keys. ( The CNC will flash PNCH on the lower portion of the CRT. ) ( The will display the text and count lines until finished.) READING CNC PARAMETERS ( --> CNC) Set up the CNC for communications as per CNC Parameter Setting for RS-232 Communication. Perform the following steps on the and CNC as follows: Launch Procomm Plus 4.8 CNC Go into EDIT mode. CNC Press ESTOP. CNC Press the <, SERVICE, CHAPTER, PARAMETER, >, READ, ALL keys. Select File Send from the toolbar Designate the name and directory for the file to send (You will see the parameters scroll up on the screen.) (The CNC will flash INPUT on the lower section of the CRT.) CNC Power the CNC off and then on to have the new parameters take effect. PUNCHING CNC PART PROGRAMS (CNC --> ) Set up the CNC for communications as per CNC Parameter Setting for RS-232 Communication.

47 45 Perform the following steps on the and CNC as follows: Launch Procomm Plus 4.8 Select File Receive from the toolbar Designate a name and directory for the saved data CNC Go into EDIT mode. CNC Press the <, PROGRAM, CHAPTER, TEXT, >, >, PUNCH, Oxxxx, EXEC keys (where xxxx is the desired program no.). (The CNC will flash PNCH on the lower portion of the CRT.) (The will display the text and count lines until finished.) READING CNC PART PROGRAMS ( --> CNC) Set up the CNC for communications as per CNC Parameter Setting for RS-232 Communication. Perform the following steps on.the and CNC as follows: Launch Procomm Plus 4.8 CNC Go into EDIT mode. CNC Press the <, PROGRAM, CHAPTER, TEXT, >, >, READ, ALL keys Select File Send from the toolbar Designate the name and directory for the file to send (You will see the parameters scroll up on the screen.) (The CNC will flash INPUT on the lower section of the CRT.) PUNCHING PMC PARAMETERS (CNC --> ) Perform the following steps on the and CNC as follows: Launch Procomm Plus 4.8 Select File Receive from the toolbar Designate a name and directory for the saved data CNC Press ESTOP. CNC Press the CNC/PMC button to go into the PMC side CNC Press PRM, KEEPRL and set K17.7 = 1. CNC Press <, SYSPRM and set PG CHANNEL = 1 (for Port 1) or 2 (for Port 2).