SYNTEC CNC

Maintenance Manual

by：SynTec Incorporation
Ver：1.3
date：1999/12/01
 SYNTEC CNC Maintenance Manual

Table Of Contents

1. HARDWARE SYSTEM STRUCTURE 3

1.1 INTRODUCTION OF THE SYSTEM STRUCTURE 3

2. MOTHER BOARD TROUBLESHOOTING 6

2.1 TROUBLESHOOTING STEPS OF CONTROLLER MOTHER BOARD 7

2.2 POSSIBLE REASONS OF FAIL SWITCHING ON 8
2.3 TROUBLESHOOTING OF CPU CARD MEMORIES 9
2.4 USUAL EXTRAODINARY PHENOMENA AND REPLACEMENT STEPS ON MOTHER BOARD 10

3. INTRODUCTION OF IO SYSTEM 11

3.1 THE STEPS OF I/O TROUBLESHOOTING 12

3.2 BREAKDOWN ANALYSIS AND ELIMIATION OF I/O 13

4. SERVO SYSTEM TROUBLESHOOTING 14

4.1 THE STEPS OF SERVO SYSTEM TROUBLESHOOTING 15

4.2 HARDWARE BREAKDOWN OF THE SERVO SYSTEM 16
4.3 RELATIVE SERVO ALARM WITH PRECISION 17

5. INTRODUCTION OF PANEL MODULE 18

5.1 THE STEPS OF PANEL MODULE TROUBLESHOOTING 19

5.2 BREAKDOWN ANALYSIS AND ELIMIATION OF PANEL MODULE 20
5.3 REPLACEMENT STEPS OF THE NETWORK 21

6. RENOVATION OF SOFTWARE 22

6.1 CNC CUSTOMER DATA RESERVE 23

6.2 INSTALLATION PROCEDURES OF SYSTEM SOFTWARE 24
6.3 REINSTALLATION OF SYSTEM SOFTWARE UNDER DOS PROGRAM 25
6.4 CNC CUSTOMER DATA INSTALLATION 26

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 SYNTEC CNC Maintenance Manual

1. Hardware System Structure

1.1 Introduction Of The System Structure

The system structure is as diagram (1), it could divide into below modules:
1. Panel module :
900 Type: the first panel + The second panel
940 Type: the first panel of integration type(combine the first and second panel)

2. CNC controller
BABY series:
BABY1 : 1476IPC + SERVO4 + PIO3*1
BABY2 : 1476IPC + SERVO4 + PIO3*2
BABY3 : 1476IPC + SERVO4*2 + PIO3*1
ERK6 series:
1476IPC + SERVO5*n + PIO3*n

3. Servo system:
*. Motor driver + Servo motor
*. Transducer + Transducer motor + Encoder

4. Machine I/O matching: SYNTEC controller provides a machine matching board to

decrease the difficulty of the matching. (RELAY1 ,RELAY2) :
*. Standard I/O (97-RELAY2) : 40 Input + 12 Relay output
*. Optional I/O (PIO3+97-RELAY1) : ( 8I + 15 O)*2

5. Heavy power matching :

*. POWER, SWITCH ON, E.STOP, Oil pressure pump, Cutting liquid ……

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 SYNTEC CNC Maintenance Manual

SYNTEC PC based CNC system structure diagram:

SYNTEC CNC HARDWARE ARCHITECTURE(900T/900M) :

SYNTEC 900M
O N A B C

CRT module :
RESET

G X Y Z D F
U V W

R
I

M
J
|
K

S
!
T
L
&
P

E
$
Q

H
# Dimension :
> < = % @ *

9" CRT
BAC K
SPA CE
/
:
(
[
)
]
;
,
SHI FT
400(W)*200(H)*300(D)
7 8 9
4 5 6
+ INS DEL

Hole : 195*195*190(M3*6)
1 2 3 SPA CE

0 ENT ER HELP

F1 F2 F3 F4 F5 F6 F7 F8

Z *10 *100
Y
A *1000
´M­ì
ÂI
¦Û°Ê ³s°Ê ¤o°Ê
¤ â°Ê
¿é¤J
»» ± ±
²°
¾÷±ñ
Âê©w
µ{¦¡
ªÅ¶]
X *1
Second operation panel :
Z+ Y+ *1 *10 ¿ï¾Ü
¸õ ÅD
¿ï¾Ü
°±¤î
MPG SELECT MPG G01 % Spindle %
Dimension:
X- X+
*100 *1000 ³æ¸`
ÂI¿O
400(W)*200(H)*100(D)
°õ¦æ

Z- Y-
ON OFF
HOLE : 195*195*190(M3*6)
¥[¤u AUX 3
¤Á¤M AUX4
²G

¥ D¶b
AUX1 AUX2
2 2 2 2
°_°Ê °±¤î §¨¤ö Âà

¤â½ü TIME EMERGENCY

I40..I79 I16..I39
O40..O79

First :I80..I87 ,O80..O95

Second :I88..I95 O96..110

S I
96-W- Option I/O:
P P P
E
5 I I C RELAY1 30 Output
R O SYNTEC
V 4
O
2 BABY2 + 16 Input
2
O |
4 3
|
2 1 CN2 97-CNC Standard I/O
2 CN1 12 Output
-RELAY2
1 + 40Input
LIGHT I0..I39 ,O0..O11
Power
ON ,OFF WATER
E.STOP HYDRAULIC
X .....
DRIVER X

LIGHT
Y
POWER UNIT
DRIVER Y

Z WATER
DRIVER Z
HYDRAULIC

Inveter Motor
CHIPS
.....

SYNTEC CNC ARCHITECTURE

4
 SYNTEC CNC Maintenance Manual

1.2 The Steps Of System Troubleshooting

For maintenance of SYNTEC PC based CNC controller, please take the following steps
to find out the possible problems. And, turn to the relative pages of this manual:

NO
Step 1. Power on Heavy power breakdown
Distribution panel of the distribution panel,
power on or not please according to
electric diagram to inspect
the problem
Yes
NO
Step 2. CNC controller 1. Breakdown of the CPU
power off normally or card (Chap.2)
not 2. CNC Power breakdown
3. Monitor module
breakdown(Chap5)
Yes
NO
Step 3. I/O action I/O card breakdown
normally or not (Chap3)

Yes
NO 1. Breakdown of the
Step 4. Servo action servo motor driver
normally or not 2. spindle card
breakdown (Chap4)

Yes

Step 5. Machining NO 1. Servo problems

precision is normal or (Chap4)
not

Step 6. Renovation steps

of software (Chap 6)

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 SYNTEC CNC Maintenance Manual

2. Mother Board Troubleshooting

There are three major reasons that the machine could not be switched on:
1. Breakdown of power supply, fail to start the CPU card
2. Breakdown of CPU card, fail to switch on.
3. Breakdown of monitor module, CPU card and power supply normally work, but the
monitor is broken down. No screen is shown, and the situation is same as failure of
switching on.
CPU Board (AR-B1476/AR-B1047) :

AR-B1047 29EE010

SRAM5 SRAM2

SRAM4 SRAM1
SRAM3 DOC1

AR-B1047 RAM/ROM card

AR-B1476 CPU card

1. SYNTEC CNC CPU board description :

CPU board : AR-B1476
RAM/ROM card : AR-B1047
2. CPU board(AR-B1476) : AMD 5x86 ,8MB DRAM on board

2. RAM/ROM(AR-B1047) : There are seven socket on the board ,except

BIOS chip on the right hand corner ,there is a DiskOnChip is
standard accessory ,and one or two 512KB SRAM on the board :
Lathe ,Milling : SRAM 512KB*1
Grinding : SRAM 512KB*2
DOC : 8MB
2. Address setting as bellow :
ON
CPU boardAR-B1476) :
1 2 3 4
ON
RAM/ROM card(AR-B1047) :
1 2 3 4 5 6 7 8

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 SYNTEC CNC Maintenance Manual

2.1 Troubleshooting Steps Of Controller Mother Board

When the possible breakdown of motherboard occurs, please take the

following steps to find out the problems.

NO
Step 1. POWER ON Breakdown of the power
Rack of controller light supply, replacing the
on power supply (Chap2.1)

Yes

Yes
Step 2. Controller could Unstable of the power
power on, but reset often supply, replacing the
power supply
( 或是控制器機箱 )
NO

Yes
Step 3. No power on Breakdown of CPU
action and frame card(Chap2.2)

NO

Yes Breakdown of memories

Step 4. Having frame (Chap2.3)
when power on, but no
action

NO

Step 5. Having action Yes Breakdown of monitor

when power on, but no module (Chap.3)
frame

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 SYNTEC CNC Maintenance Manual

2.2 Possible Reasons Of Fail Switching On

Breakdown of the controller power supply:

1. When switching on, if no screen is shown or there is no action, the CPU card or
power supply may be broken down. Please check the power output is OK.
2. Checking the upper red light of the controller to make sure whether it is on or not
(upper side of rack). If not, it indicates no power output from the power supply.
The power supply may be broken down. Please replace the power supply.
3. Opening the flank cover, checking the +5V of power plug is normal or not by
electric multi-tester (red: +5 , black: GND). The normal output of the power supply
is +4.95 - +5.1V. When the output of power supply is under 4.8V, then the controller
could not be switched on, or reset after operating a while automatically. Please
replace the power supply.
4. If the power plug could not be measured, you can measure the power plug of the
hard disk (Red and black wire : +5V) to see whether the power output is normal or
not (+4.95 - +5.1 V).

Breakdown of the monitor module:

1. The monitor module should be broken down if the following conditions occur:
power supply is normal, I/O action of panel is normal after 3 minutes, and no any
frame.

Breakdown of the CPU card:

2. The CPU card may be broken down if the following conditions occur: power supply
is normal, but no I/O action of panel after 3 minutes, and no any frame.

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 SYNTEC CNC Maintenance Manual

2.3 Troubleshooting Of Cpu Card Memories

1. Analysis of memories: There are three kinds of internal memories on SYNTEC CNC:
DRAM, SRAM, DOC, the analysis is as below:
DRAM: It solders on the board directly, but no memory function. After switch off, the data
will vanish. The reliability is very high, and the breakdown rate is very low. It solders on
the board directly.
SRAM: Having memory function, after switch off the data is still exist. If the battery
breakdown occurs (the battery life is 10 years), the data will be lost. It fixes on
RAM/ROM card.
DOC: It is FLASH memory equipment of high capacity. The characteristic of the FLASH is
rewritable, no needing battery. It could keep the data forever, but if the save times is too
many, the it may have problem. (fixed on the board) .

1 When switching on, there is PC switching on frame on the controller. The self-diagnosis
action of switching on frame, such as: RAM test, and appearance of final strait-jacket. It
should be DOC problem when dwell on the ” Starting DOS “, and could not come into CNC
software. Please replace the DOC and frame would be as below:
AMI BIOS …..
Main Processor: Base Memory size
Math Processor: Ext Memory size
Floppy Drive A : Display Type
Floppy Drive B : Serial port
Processor clock : Parallel
512KB CACHE Memory
Starting DOS …

2 When switching on, the controller could come into the normal frame, but cutting program
file vanishes after the switch off and could not save. It should be the problem of SRAM
battery, please replace the battery or RAM/ROM card.

3 Maintenance method in case of the breakdown of memories (1476 CPU card) :

DOC replacement: Take off CPU card and RAM/ROM card. Take off the old DOC and put
the new DOC on by the “-“ type screwdriver. Then equip the
RAM/ROM card and install the DOC software.
RAM/ROM card replacement: Replace the anew RAM/ROM card directly.

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 SYNTEC CNC Maintenance Manual

2.4 Usual Extraodinary Phenomena And Replacement Steps On Mother

Board

Abnormal phenomenon of CPU card:

1. The slots of the motherboard do not contact perfectly:
*. After switch on, the frames are all normal, but the spindle card or I/O action is not
normal. If the condition still exists after you replace the spindle card and I/O card, it
should be not contact perfectly on the slots. Please take off the mother board, clean
the gold fingers, and plug it back to slot.
2. Sudden shutdown of the computer : The reasons may be as below :
*. Overheat, please check the CPU fan is lost or breakdown.
*. Overheat, the vent of controller is block or not.
*. Over vibrating on the motherboard. Please enhance the motherboard fixed, or
decreasing the vibrating of the machine.

Steps to CPU card replacement:

1. Take off the BABY RACK of the controller by the screwdriver.
2. Take off CPU card (the right one of the 4 pieces) , beware the plug position
before taking off.
3. Take off RAM/ROM card, replace the old DOC and put the new on.
4. Put back the CPU card to the slot, and connect all plugs.
5. Inspect the power wire, keyboard wire, ad monitor wire is OK or not. (upper side of
the controller) ,
6. Check the wire of hard disk is Ok or not.
7. CPU fan is Ok or not. (on the CPU card)
8. Switch on again, inspect the action of CPU fan, controller fan is normal
or not.
9. See whether the action of the controller is right or not.

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 SYNTEC CNC Maintenance Manual

3. Introduction Of Io System

The first I/O card (standard equipment): PIO + RELAY2 + HARDKEY

The second I/O card (optional equipment): PIO + RELAY1*2

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 SYNTEC CNC Maintenance Manual

First I/O board(PIO-1) :

Z *10 *100
Y
A *1000
X *1 ´M­ì
³s°Ê
¤â°Ê » » ±± ¾÷±ñ µ{¦¡
ÂI ¦Û°Ê ¤o°Ê
¿é¤J ²° Âê©w ªÅ¶]

MPG SELECT MPG G01 % Spindle %

*10 ¿ï¾Ü ¿ï¾Ü
Z+ Y+ *1
¸õÅD °±¤ î

X- X+ ³æ¸`
*100 *1000 ÂI¿O
ON OFF °õ¦æ

Z- Y-
¥[¤u
¤Á¤M AUX3 AUX4
²G

2 2 2 2 °±¤î §¨¤ö
¥D¶b
AUX1 AUX2
°_°Ê Âà

¤â½ü TIME EMERGENCY

Second operation panel

CN2
CN1(F) CN2(M)
TO CNC TO Machine
JP1
GND JP2
RLY0+ 0+
RLY0 GND
RLY0- 0-
RLY1+ 1+ IN0
RLY1
RLY1- 1- IN1
RLY2+ 2+ RLY2 IN2 JP3
RLY2- 2- IN3
RLY3+ 3+ RLY3 IN4
RLY3- 3- IN5
JP4 IN6
RLY4+ 4+
RLY4 IN7
RLY4- 4-
97-CNC-RELAY2
RLY5+ 5+ RLY5 IN8
RLY5- 5- SN : IN9
RLY6+ 6+ RLY6 IN10
CN1
RLY6- 6- IN11
RLY7 JP5
RLY7+ 6+ IN12
RLY7- 6- IN13
JP6
RLY8+ 8+ IN14
8- RLY8 IN15
RLY8-
9+ JP7
RLY9+ RLY9 96-W-PIO2
9- GND
RLY9-
10+ GND
RLY10+ RLY10 FUSE
10- +5V
RLY10-
RLY11+ 11+ RLY11 GND
RLY11- 11-

Second I/O Board :

CN2
220H

JP1 CN1(F)
RLY0+
RLY0-
0+
0- RLY0 TO CNC IN0
IN0
RLY1+ 1+
RLY1 IN1
RLY1- 1-
IN1
RLY2+ 2+ RLY2 JP3
IN2
RLY2- 2-
IN2
RLY3+ 3+ RLY3
IN3
RLY3- 3-
IN3
JP4
RLY4+ 4+
4- RLY4
RLY4- 96-W-RELAY1
RLY5+ 5+ RLY5
SN : IN4 JP1 CN1(F)
RLY5- 5- 0+
RLY6+ 6+ RLY6 IN4 RLY0+
RLY0- 0- RLY0 TO CNC IN0 CN1
RLY6- 6- IN5 IN0
IN5 JP5 RLY1+ 1+
RLY7+ 6+ RLY7 RLY1 IN1
IN6 RLY1- 1-
RLY7- 6- IN1
JP6 IN6 RLY2+ 2+ RLY2 JP3
IN2
RLY8+ 8+ IN7 RLY2- 2-
RLY8 RLY3 IN2
RLY8- 8- IN7 RLY3+ 3+
IN3
RLY9+ 9+ RLY3- 3-
RLY9 IN3 97-PIO3
RLY9- 9- JP4
10+ RLY4+ 4+
RLY10+ RLY10 FUSE +5V RLY4
10- RLY4- 4-
RLY10- GND 96-W-RELAY1
RLY11+ 11+ RLY11 RLY5+ 5+
RLY5 IN4
11- RLY5- 5- SN :
RLY11- IN4
RLY6+ 6+ RLY6
RLY6- 6- IN5
RLY7 IN5 JP5
RLY7+ 6+
RLY7- 6- IN6
JP6 IN6
RLY8+ 8+ IN7
RLY8
RLY8- 8- IN7
RLY9+ 9+ RLY9
RLY9- 9-
RLY10+ 10+ RLY10 FUSE +5V
RLY10- 10- GND
RLY11+ 11+ RLY11
RLY11- 11-

3.1 The Steps Of I/O Troubleshooting

When the possible breakdown of IO module occurs, please take the

following steps to make a diagnosis.

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 SYNTEC CNC Maintenance Manual

Step 1. CNC power on 1. Breakdown of the power

succeeds, RELAY1 and Yes supply
RELAY2 green lights 2. Burnout of fuse
are off 3. Slack of the wires (3.3).

NO
Yes
Step 2. Could not see 1. Breakdown of PIO
”I” input point on the card(3.2)
diagnosis frame when 2. Hard key no power
pressing Aux. panel 3. Slack of wires
button (hard key)

NO

Step 3. There is no any 1. Breakdown of PIO

bright or glitter on the 3 Yes card (3.2)
yellow lights of RELAY2 2. Relay no power
(D37,D38,D39)

NO

Step 4. There are some Yes 1. Contact not well on

error actions on the I/O the contacting
points of RELAY1, 2 position.
2. Interference of noise
(3.2)

NO

Step 5. There are 1-2 1. Slack of the wires

error actions on I/O Yes 2. Breakdown of the
points of RELAY1, 2 RELAY board
(not by chance)

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 SYNTEC CNC Maintenance Manual

3.2 Breakdown Analysis And Elimiation Of I/O

SYNTEC CNC I/O breakdowns may have the following types: interference of noise,
power breakdown, PCB breakdown, and Relay board breakdown. The detailed description
are as below:

Step 1. Power breakdown: RELAY1, RELAY2, and hard key all need the power from
power supply, and work normally. Therefore, green lights of these 3 boards are not bright,
it may the problem of the power supply. Please check that is there any wire slack,
breakdown of the power supply, or burnout of the fuse on the board.
Step 2. Inspect the second board: When there is no any action on all of I/O, please check
whether the green lights on the second board are bright or not. If the power is normal, it
may PIO board breakdown, please replace the PIO card.
Step 3. Inspect RELAY2: If the 3 yellow lights(D37,D38,D39) of RELAY2 are not bright or
no glitter, there is no any action on all I/O, it maybe PIO card breakdown, or RELAY2
breakdown.
Step 4. Noise interference: The controller may have some error actions due to noise
interference. SYNTEC CNC provides the digital filter setting (parameter 15, setup value:
0.3). The bigger of the parameter setting value and stronger of the noise defense ability,
the slower I/O response relatively. When the parameter is set to 3, but the error action is
still exist. It should not be the problem of noise interference, and would be not contact
well of the contacting points on the wires. Please check the relative wires.
Step 5. Input breakdown of relay2 board: There are some abnormal actions on the input
points of RELAY2, it should be the breakdown of the RELAY2 board. Please replace the
RELAY2.
Step 6. Output breakdown of the relay1, 2 relay:
1. The red light of the RELAY board is bright, but there is no any action on the
output point of the relay. It should be the relay breakdown, please replace the relay
(spares parts)
2. The relay2 action pushed by the PIO, therefore, there is some abnormal action on
RELAY board. It may be breakdown of PIO, If the OUTPUT point of the
diagnosis frame is “on”, but the corresponding relay board is not bright, it should
be PIO breakdown. Please replace the PIO.

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 SYNTEC CNC Maintenance Manual

4. Servo System Troubleshooting

Description of the servo system: Servo system is composed of CNC spindle

card, and servo motor driver.

Servo card(SERVO4) :

AXIS 4
AXIS 1 AXIS 2 AXIS 3 MPG + DA

RY5W-K
HP2531 PC847 AM2631 HP2531 HP2531 HP2531 PC847 AM2631 HP2531 HP2531 HP2531

CRISTAL1 TL074
PM7541
ACTEL
1240

AXIS 4
REF01

74245 IRQ jmp 74245 74688 74245

ON
Fig. SYNTEC CNC servo card 1 2 3 4

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 SYNTEC CNC Maintenance Manual

4.1 The Steps Of Servo System Troubleshooting

When the possible breakdown of the servo system occurs, please take the
following steps to diagnose the system.

Step 1. CNC power on, Alarm of the driver

Press the E. stop button, Yes Alarm of the motor (4.2)
Check Alarm message
from servo driver
NO

Yes
Step 2. Small turning of The alarm action of “miss
the MPG wheel of , position command” (4.3)
alarmed “loss pulse ”
message from CNC.

NO

Step 3. “Following error The alarm action of

too big ” of CNC alarm Yes “following error too big t”
during cutting. (4.3)

NO

Step 4. “Fatal following Yes The alarm action of

error too big ” of CNC “Fatal error too big”
alarm during cutting. (4.3)

NO

Step 5. “loss pulse” of The mechanism is not smooth,

CNC alarm during Yes could not precise positioning,
cutting. check is there any jam on
mechanism during the cutting.

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 SYNTEC CNC Maintenance Manual

4.2 Hardware Breakdown Of The Servo System

SYNTEC CNC servo system is composed of spindle card (servo4), servo motor , spindle
motor, and transducer. The detailed descriptions are as follows:
Spindle card: SYNTEC CNC spindle card (SERVO4), the spec is (4+1) axes, control X,Y,
Z axes, MPG, spindle encoder, transducer 0-10V output,
Servo motor, servo driver: drive X,Y, Z servo motor, X-Y table precise positioning
control.
Transducer: Spindle speed control, input voltage is 0-10V

Analysis of the breakdown:

We can divide alarm of the servo systems into two parts: One is the protection of usage,
such as over load protection (over current, over voltage….), precision protection (ex: miss
position command, tolerance of overshoot is too big ….) ,….another kind of breakdown is
belong to hardware breakdown. This section mostly describe the hardware aspect:

“Alarm of the servo driver”:

When the servo system alarms, please check if the hardware has any problem.
Step 1.Open the power control box, to see if any bright alarm exist on the servo driver.
Step 2.When there is bright alarm, it indicates the problem is between the driver and motor.
Please solve the relative breakdowns according to the content of the bright alarm.
Step 3. When there is no any bright alarm, it indicates the problem is in the controller or
machine. Please solve the relative breakdowns according to the content of the bright
alarm.

“Alarm of the spindle inverter”:

When CNC controller get the alarm from inverter, it will transfer the message to CRT
screen. This moment, open the power unit, could see bright alarm on the inverter. Please
solve the relative breakdowns according to the content of the bright alarm.

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 SYNTEC CNC Maintenance Manual

4.3 Relative Servo Alarm With Precision

The protection of the usage: SYNTEC CNC controller, there is perfectly self -diagnosis
on the servo system. Besides the basic ”alarm of the servo driver”, there are several possible
problems that is focusing on the machine precision and others, and produce the perfect alarm.
We describe that as below:
“loss pulse ”:
Definition: After one second that CNC controller stop to pass orders, it would check that if
the servo positioning precision is within 100 pulse. If it exceed this value, the
controller will produce the alarm message ” miss position command”, the possible
reasons maybe as below:
1.The mechanism obstruction is too big, servo could not reach precise positioning. Please
look over the relative mechanisms.
2. The signal transfer loss, please check the wires are normal or not.
“Following error too big“:
Definition: During the motion, controller should check the actual servo hysteresis with the
theorem value at any time. When the hysteresis exceeds twice of reasonable value, the
controller will produce this alarm message “overshooting tolerance is too big”. At the
same time, ”stop” cutting, after the vanishment of this condition, we could press
“CYCLE START”, and cutting again.
Possible reasons:
1. The cutting load is too big, the driver alarm “ overload”. At the same time, opening the
power controller box, we could see bright alarm on the driver.
2. There are some problems on transmission mechanism, the driver alarm “ overload”. At
this moment, opening the power controller box, we could see bright alarm on the driver.
“Fatal following error too big “:
Definition: During the motion, controller should check the actual servo hysteresis with the
theorem value at any time. When the hysteresis exceeds four times of reasonable value,
the controller will produce this alarm message “overshooting tolerance is too big”. At
the same time, ”emergency stop” cutting, it need to switch off the machine, then switch
on again.
Possible reasons:
1. The cutting load is too big, the driver alarm “ overload”. At the same time, opening the
power controller box, we could see bright alarm on the driver.
3. Spindle card, or servo motor breakdown, it cause CNC could not control the machine in
effective status. Therefore, we need to a emergency stop (spindle card, servo on relay,
output: OFF). It need to switch off and switch on again to vanish the alarm.

18
 SYNTEC CNC Maintenance Manual

5. Introduction Of Panel Module

SYNETC CNC panel module diagram is as below:

SYNTEC 900M
O N A B C RESET

G X Y Z D F
U V W

R
I

M
J
|
K

S
!
T
L
&
P

E
$
Q

H
# CRT module(First Panel)
= % @ *

PC CRT + PC Keyboard
> <

9" CRT
BACK / ( ) ;
SPACE SHIFT
: [ ] ,

7 8 9 + INS DEL

4 5 6
1 2 3 SPACE

0 ENTER HELP

F1 F2 F3 F4 F5 F6 F7 F8

Z *10 *100
Y
A *1000
´M­ì
ÂI
¦Û°Ê ³s°Ê ¤o°Ê
¤â°Ê
¿é¤J
»»± ±
²°
¾÷±ñ
Âê©w
µ{¦¡
ªÅ¶]
X *1
Operation Panel : Second panel
Z+ Y+ *1 *10 ¿ï¾Ü
¸õÅD
¿ï¾Ü
°±¤î
MPG select MPG G01 % Spindle %
Hardkey +rotatry switch
X- X+
*100 *1000 ³æ¸`
ÂI¿O
hardkey : connected to PIO
°õ¦æ ON OFF
Z- Y- card(CN2)
¥[¤u
¤Á¤M
²G
AUX3 AUX4
Rotatry switch connected
2 2 2 2
°_°Ê °±¤î §¨¤ö
¥D¶b
Âà
AUX1 AUX2
to RELAY2 CN2
MPG TIME EMERGENCY

I40..I79 I16..I39
O40..O79

SYNETC CNC 900T/900M panel module could divide into below kinds:
First panel: It composes of monitor module and letter key, the spec is compatible PC
(parameter 3217 keyboard type be set as 3)
P.S. SYNTEC CNC character key could connect with the PC keyboard. This function that
connect with PC keyboard (parameter 3217 keyboard type is set as 0), is a very nice temporary
way when breakdown of customer keyboard. It would not cause the cutting dwell due to
keyboard breakdown.
SYNTEC CNC monitor could be connected to PC monitor, too. When customer monitor
breakdown, replace the PC monitor is a very nice temporary way when breakdown of customer
monitor. It would not cause the cutting dwell due to monitor breakdown.

Second panel: operating key and switch and so on.

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5.1 The Steps Of Panel Module Troubleshooting

When the possible breakdown of the panel module occurs, please take the
following steps to diagnose the system.

Step 1. POWER ON The

control box power on

Step 2. CNC controller

power on normally

Phenomenon The second panel light is

Step 3. I/O action
normally normal
3 yellow light of RELAY2
bright

Step 4. Breakdown of
monitor
(5.1 ,5.2 ,5.3)

Step 5. Replace the

monitor

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5.2 Breakdown Analysis And Elimiation Of Panel Module

First panel:
Condition of monitor breakdown: After switching on 3 minutes, there is no frame, but I/O
action of panel is normal, Ex: E.STOP, oil pressure, manual….actions are normal. It
maybe breakdown of the monitor, please replace the monitor.
Temporary plan: It adopts PC VGA interface for SYNTEC CNC CRT. Therefore, we
could use the personal monitor to be a temporary plan, and save the maintenance time.
Condition of characters key breakdown: The single key could not appear, it should be the
worst connecting of the keyboard mechanism. Please clean tit by the detergent (Ex: WD-
40). Through this manipulation, if it is still invalid, please replace the button, or replace
the whole monitor.
Temporary plan:: SYNTEC CNC characters key adopt PC keyboard interface. Therefore,
it could use PC the keyboard to be a temporary plan, and save the maintenance time.
( parameter 3217 keyboard type be set as 0) .
Second panel:
Hardware: After switch on 3 minutes, there is no frame, but the I/O action of the panel is
normal. Ex: E.STOP, oil pressure, manual….actions are normal. It maybe breakdown
of the monitor, please replace the monitor.
Temporary plan: It adopts PC VGA interface for SYNTEC CNC CRT. Therefore, we
could use the personal monitor to be a temporary plan, and save the maintenance time.
Condition of hardware key breakdown:
Single key: The key could not appear, it should be the bad connection of the keyboard
mechanism. Please clean tit by the detergent (Ex: WD-40). Through this manipulation, if
it is still invalid, please replace the button, or replace the whole monitor.
Whole keys: Hardware undergoes I/O scan by matrix point way on PIO card. When all of
the keys are invalid, it may due to the lost of the +5V power hard key PCB, or I/O card
breakdown.
Partial keys: SYNTEC CNC hard key undergoes I/O scan by matrix point way on PIO
card. Therefore the disability of these partial keys at the same time, it should be
breakdown of the PIO card.

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5.3 Replacement Steps Of The Network

The network may break by using, or lost by other reason. The network replacing steps
are as follows:
Step 1:
Tear off the old network.

Step 2:
Clean the metal surface by the vaporization detergent thoroughly.

Step 3:
Check the network dimension, it need be smaller than metal frame.

Step 4:
Smear super paste over metal pieces.

Step 5:
Tear off a small piece of paste from the backside of network, press it from up to
down by heaving force. It needs to keep paste closely.

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6. Renovation Of Software

When the controller need toe renovate files by user, please take the
following steps:

Step 1. Reserve parameter file

Reserve system data Yes (6.1)
Ladder reserve
Reserve the user data

Yes
Step 2. Renovate system software
Renovate new CNC (6.2)
system software

NO

Step 3. Renovate ladder

Renovate the machine Yes Renovate parameter
action logic (6.4)
更新機台參數

NO

Step 4. Yes PC software install

Installing the controller Special PC parameter
software on the setting
customer PC
(6.3)

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6.1 Cnc Customer Data Reserve

SYNTEC CNC controller is a PC-based controller. Therefore, all kinds of software of the
controller can undergo renovating or spare data by the floppy. For example: controller software,
mechanical parameters, Ladder …., all could renovate the software by floppy. Collocate the
data transfer of Internet, we could get the lowest cost to save and reserve data. We analyze as
below:
When we change CPU card, or renovate the system software, we must reserve the
original customer data of the CPU card to floppy. The steps are as below:
Reserve the customer Ladder, parameters, tool data …., the steps are as below:
1. Confirm system parameter 3223 switching on system management function, and setting
to be 1.
2. Confirm system parameter 3213 setting the drive number in correct drive source.
4. Put the spare disk into the floppy.
5. Using the leftward key of left side F1, and changing to the highest layer of the main bill
”F1 Machine setting, F2 Program edit….”.
6. Pressing the rightward key of right side F5, and changing to the next layer of the main
bill ”F1 Parameter setting, “F2 Diagnose function….”.
7. Pressing F2 [Diagnose function], and changing to the next layer of the main bill ”F1
PLC status, F2System data….”.
8. Pressing F5 [System management], and changing to the next layer of the main bill ”F1
Installing software, F2 Sparing system....”.
9. Pressing F5 [System reserve], CNC would copy the customer data into disk (note)
automatically.

Note:
1. When we reserve the data, not including the user cutting program. The cutting program
is out on the SRAM of the RAM/ROM card. Therefore, if we change RAM/ROM card,
these parts of data need to reserve specially.
2. Please press F2 ”program logic” frame under main bill.
3. F5 ”File management”
4. F5 “Out to floppy” copy the files into the floppy one by one.

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6.2 Installation Procedures Of System Software

Step 1. The production of installation disk:

1. SYNTEC CNC software could be compressed into one disk, the file name is: Model_
Machine type_ Serial number (Ex: 900.me.637 or 940.tew.670)
2. Compressing it into C drive (or Windows table). By executing extraction, we could get
one \ disk \*.* sub catalog.
3. Please copy all files of \ disk \*.* into blank disk.
4. Please check the root catalog of the installing disk including below files:
cncpack.exe
defapp.exe
setup.bat
XXXX.YYY XXXX: system name; YYY : version number

Step 2. Installation of the system software into the controller :

1. Confirm system parameter 3223 switching on system management function, and setting
to be 1. Confirm system parameter 3213 setting the drive number in correct drive
source.
2. Put the installing disk into the floppy.
3. Using the leftward key of left side F1, and changing to the highest layer of the main bill
”F1 Machine setting, F2 Program edit….”.
4. Pressing the rightward key of right side F5, and changing to the next layer of the main
bill ”F1 Parameter setting, “F2 Diagnose function….”.
5. Pressing F2 [Diagnose function], and Pressing F5 [System management].
6. Pressing F1 [Installing system], the controller starts to inspect the correct or not on the
disk. After 3 minutes, and the data is correct, according to controller index to switch off
and then switch on.
7. After switch on, the controller will execute all installing action.
8. After installing software, the controller will execute switching on action.
9. From the right up side of the switching on frame, we could see the version number of
the software.

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6.3 Reinstallation Of System Software Under Dos Program

Time of Use: When installing into personal computer or failing to switch on the
controller, and only DOS program can be used to start the installation, then the
necessary steps are set below:

Step 1. The production procedures of installation disk:

1. SYNTEC CNC software could be compressed into one disk, the file name is: Model_
Machine type_ Serial number (Ex: 900.me.637 or 940.tew.670)
2. Compressing it into C drive (or Windows table). By executing extraction, we can get
one \ disk \*.* sub catalog.
3. Please copy all files of \ disk \*.* into blank disk.
4. Please check the root catalog of the installing disk including below files:
cncpack.exe
defapp.exe
setup.bat
……
XXXX.YYY XXXX: system name; YYY : version number

Step 2. Installation of the system software into the PC :

1. Switch on and change to DOS ( or switching disk of DOS )
2. Put the switching disk into the controller floppy.
3. Executing the setup program of root catalog on the disk
Command format is:
Setup Object drive Source drive
Ex: Put disk into drive B, we want to install into drive C.
Setup 1. B:\setup c: b: from drive b: install into c:
Setup 2. Installing program will extract from disk to drive C ( C:\CNC\*.* )
Setup 3. After setup completely installs program, switch off and then switch
on .(note)

Note:
For PC, the start steps of CNC software:
1.Pease under DOS, and change to C:\CNC
2.Key in CNC /M /P, and press ”ENTER”, then it could start CNC software.

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6.4 Cnc Customer Data Installation

When replacement the CPU card, we need to reinstall spare customer data, and the steps is
as below:
1. Put the spare customer ladder, parameter, tool data …into the disk.
2. Put the spare disk into floppy.
3. Using the leftward key of left side F1, and changing to the highest layer of the main bill
”F1 Machine setting, F2 Program edit….”.
4. Pressing the rightward key of right side F5, and changing to the next layer of the main
bill ”F1 Parameter setting, “F2 Diagnose function….”.
5. Pressing F2 [Diagnose function], and changing to the next layer of the main bill ”F1
PLC status, F2System data….”.
6. Pressing F5 [System management], and changing to the next layer of the main bill ”F1
Installing software, F2 Sparing system....”.
7. Pressing the right key of F5 side, and changing to the next layer of the main bill ”F1
PLC program install, F2 System parameter install…”.
8. Selecting the relative action, CNC will copy the customer data from the disk to CNC.

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