EZ-Trak DX2 Startup Questions

[jmorris@mailmds]

We just installed a used DX2 and did the 480 to 208 Volt power conversion.
When the PC tries to boot, we get the following displayed on the monitor:

Award Modular BIOS v 4.51PG
Green PCI/ISA System
Pentium-S CPU@75MHz
Memory Test: 8192K OK
Plug and Play Bios Ext. v1.0A
Detecting IDE Primary Master... None
CMOS Checksum Error. Defaults Loaded
Press F1 to continue Del to setup
09/04/97 - i430TX-W83977-2A59IA1BC-5U

A Machinetek post suggested checking/replacing the Bios battery. We have found that it does indeed need to be replaced. Will this alone solve the problem or do we need to reconfigure the BIOS? Any suggestions on doing this?
Is there a way to connect a regular keyboard to have full access to the controller? Where is a good place to buy a manual?

Thank you,
Jon

[NC Cams]

With the battery dead or dying on the motherboard, the BIOS won't stay active. Thus, each and every time you try to boot the machine, the thing will ask/force you to reset/reconfigure the BIOS to get the parameters appropriately.

When/if you replace the battery, the boot-up problem should go away.

When you reset the bios, make sure that you turn LBA "OFF". Also set any 'write cache before exit' to "ON".

Look on the back of your control pendant. Advise if there are DIN pins there - there should be 3 or 4. If there are, you can plug in a keyboard there buy you also have to "swap plugs" back and forth - some of the keys on the small OEM keyboard aren't easily found on the regular computer keyboard.

I have a diagram at work that I have to follow to make the swap so I unfortunately can't advise readily right here and now.

Manual: which version of software do you have??? There are versions 5, 6 and a beta of ver 7 that some folks have access to.

Check on this website via an "Eztrak" search - I seem to recall someone posting a copy of a manual as a PDF attachment at one time or another.

[machintek]

Yes, once the BIOS/CMOS is corrected, the machine should boot. Because you have a baby pentium, I am suspecting that you may have a CIB (control in a box) either a Cutler Hammer, or a newer BMI. The mother board is a half size, all in one, industrial unit. Some have a coin style lithium battery and some have a DALLAS REAL TIME CLOCK chip. the again, you may have a old pentium. You have to look.
Did you want a programming manual or a maintenance manual?
Again, it would need to be specific to your level of software or the internals of your machine.

George

[jmorris@mailmds]

First of all... Thanks for all the help. The machine is booting up now and we have a standard keyboard working.

When we try to home each axis, the Z axis runs away. We removed the front cover and it looks like there is a clamp that is used to engage the Z axis. The nut is so tight on the ball screw that we cannot rotate it up to the clamp. Likewise, the quill feed is so tight that we cannot lower the quill. To make matters worse, we do not have a quill feed lever. The machine did not come with one. We thought that it would not be neccessary with the three axis machine. Any suggestions on how to get these two together?

Because the Z runs away, we have not been through the X and Y yet. However, the X and Y encoders seem to be working fine.

We do need manuals, How can I tell what level of software we have?
Many Thanks,
Jon

[Steve@Reliance]

I just ended up with a manual for a Sereis I DX. I have an SX II. What are the differnces in the machines and controls, And will this manual help me?

[NC Cams]

Hit F8 and hold it while booting. This will ask you if you want to load each and every program as you go thru the autoexet.bat file.

Say NO to anything that looks like it has the word EXTRAK or EZLOAD in it. When finatlly booted at the O/S level, you should see a C:\ DOS prompt.

At this point, anyone proficient in DOS should be able to 'see' the date version of the Eztrak software being used.

If you're lucky, they loaded DOSSHELL which when typed at the C:\ prompt will enable you do have a WYSIWYG screen that makes this process much easier. If not, it can be loaded separately off of a DOS 6 install disk.

As an alternate method, you can also exit to DOS from the Eztrak software but I can never rememeber how to do it.

Sounds like you need to undo some hamfisted modification that the previous mill owner performed.

BTW: you'd better plan on changing the current limiting breaker to the spindle motor. When you convert from 480 to 208, you DOUBLE the current draw potential to the motor. Initially, the breaker will fault when the motor sees some loading.

We simply reset ours and kept on cutting. HOWEVER, Do that ONCE too often and the damn thing will eventually NOT reset. Change the breaker NOW or else you will have to do it later, usually in the middle of a hot job when NOBODY IS OPEN who has the breaker.

If your machine is like ours was, it uses a Telemechanique (sic) breaker which was NOT AT ALL easy NOR CHEAP to find.

[jmorris@mailmds]

NC CAMS, I will try your suggestions for the software revision/manuals.

I did change out the current overload. I sourced an Allen Bradley part the was very available, affordable and a direct replacement. You will need 1 each of 193-EA1FB and 193-EPM1.

The Z axis problem is now solved. Each axis seems to be fully functioning, i.e. limits, jog, homing.

The original keyboard does not seem to be working. I have connected a wireless keyboard and it works fine.

At this point, the spindle is not turning. I think it is due to a low lube alarm. The tank is empty. I have a 5G bucket of Mobile DTE 26. Is that okay for lubing the ways?

I would also like to find hardware manuals for this Bridgeport EZTrak DX2 machine. Does anybody have suggestions on where to find them?

[jmorris@mailmds]

It looks like I have the EZTrak software version 3.85.3. Does anybody have a suitable software manual for this?

[jmorris@mailmds]

A maintenance manual would be much appreciated too!

jmorris@mailmds.com

Thanks!

[NC Cams]

The software version I have is dated mid 1990's and it is version 5.

Version 3 software might be an early Southwest Industries machine. MACHINETEK George would be the expert who could verify this or not. I could be wrong.

Have you tried EMI yet??? Their stuff is highly regarded for value (by them) so expect to pay heavily for the manual(s) from them. If you give them the serial number, they should be ablt to give you more insight into what generation machine you have - if you can get past the secretary.

In the mean time, try Machinmanuals.net.

[machintek]

The DX and SX were very different in the motherboard and the DX had a hard drive. The version you have is the first good version for the 3 axis machine. The Southwestern Industries machines did not have a CRT/monitor. They had an LED readout. Later they were sold as Proto traks.
A 3 axis SX machine is rare. I typically do not go past version 3.02 for an SX machine, 2 axis. It just runs better and it has a screen saver to prevent burn in of the CRT.
Versions, 5, 6 and 7 (beta) have more bells and whistles as the numbers go up, such as mill arc slot, importing DX files, and engraving.
Keep an eye on your parameters (backlash, pitch error, etc). The versions prior to yours had a habit of changing them for no reason.
As the machine boots and the BMDC finishes counting down, the version will be briefly displayed. I know the EZPATH will display the version by pressing the minus key after homing. Do not remember if the TRAK will do it, but I do not think so.
Try this though. Go to RUN, load a program, and press the minus key. It will display the program in G and M code as converted by the BMDC internally. You see, the machine is really a G & M code machine.

George

[jmorris@mailmds]

Topping off the lube reservoir solved the spindle problem. Apparently, it is interlocked to a low level sensor. The spindle run fine and sounds pretty good. Now, all I have to do is figure out how to program it and get some more Kwik Switch 200 tooling.
Does anybody have electronic version of software manuals?

Thanks for all the help so far!