Tsuagami Lathe with Fanuc Controlller not communicating

[dangittj]

We have a Tsugami S25 SuperSwiss Turn lathe with a Fanuc Series O or OO Controller that we moved to one of our other facilities and it stopped working.

The machine is connected to the computer using a regular 25 pin parallel cable over LPT1, using an old version of ProComm to send the files.

Im not sure how this worked originally, as ProComm can't even send over the parallel port. The machine was just boxed up and sent out, no configuration changes were made as far as I can tell. All the operators have said it's the exact configuration, but i can't figure out how in the hell it worked before and how to get it to work. The cable they have given me is the same one they used in the original facility, and it is not bad, I have hooked it up to a cable tester and it is working.

I have tried using a null modem adapter and a 25-9 serial converter (working on the theory that maintenance lost them in the move) but both of these combinations cause the controller to immediately error out like it is not connected.

Any help would be greatly appreciated.

[angelw]

We have a Tsugami S25 SuperSwiss Turn lathe with a Fanuc Series O or OO Controller that we moved to one of our other facilities and it stopped working.

The machine is connected to the computer using a regular 25 pin parallel cable over LPT1, using an old version of ProComm to send the files.

Im not sure how this worked originally, as ProComm can't even send over the parallel port. The machine was just boxed up and sent out, no configuration changes were made as far as I can tell. All the operators have said it's the exact configuration, but i can't figure out how in the hell it worked before and how to get it to work. The cable they have given me is the same one they used in the original facility, and it is not bad, I have hooked it up to a cable tester and it is working.

I have tried using a null modem adapter and a 25-9 serial converter (working on the theory that maintenance lost them in the move) but both of these combinations cause the controller to immediately error out like it is not connected.

Any help would be greatly appreciated.

What is the error you get when using the Null Modem Cable?

Many not familiar with Fanuc Comms, mistake the DB25 Female connector at the machine as a parallel port; this is not the case.

Check the following parameters and cable pin out.

#0002
Bit 0 = 1 for 2 Stop Bits
Bit 2 = 0 for RS-232 Input

#552 = 10 (4800 Baud) starting point

Machine Control Set Page Settings
I/O = 0
ISO Format

Cable pin out. This will depend on whether the PC has a 9 or 25 pin serial port.

Machine Side------------------------PC Side
DB25 Male--------------DB9 Female----------DB25 Female
2--------------------------2-------------------3
3--------------------------3-------------------2
7--------------------------5-------------------7

4
| bridged
5

6
|
8 all bridged
|
20

Configure the PC software as follows:
Handshaking Method = Xon Xoff
Baud Rate = 4800
Data Bits = 7
Parity = Even
Stop Bits = 2

Communication with your machine should will work unless there is a problem with the controller or PC Comm Port.

Regards,

Bill

[dangittj]

Ok, go that error fixed a day or two ago. I found the settings for ProComm and was able to procure the right cable (we actually ended up using a 25 pin serial to a null modem adapter to a 25-9 converter)

The problem now is that while the program doesn't have a problem sending small files, on large files the controller throws up a PS 87 alarm

(When entering data in the memory by using reader/puncher interface, though the read terminate command is specified, input is not interrupted after 10 characters read.)

and only picks up part of the program. I have checked the memory and program space and there appears to be plenty available. Is there some setting in ProComm that we need to change? (As far as I can tell, this version of procomm doesn't have any kind of buffer overflow protection or setting)

[angelw]

Ok, go that error fixed a day or two ago. I found the settings for ProComm and was able to procure the right cable (we actually ended up using a 25 pin serial to a null modem adapter to a 25-9 converter)

The problem now is that while the program doesn't have a problem sending small files, on large files the controller throws up a PS 87 alarm

(When entering data in the memory by using reader/puncher interface, though the read terminate command is specified, input is not interrupted after 10 characters read.)

and only picks up part of the program. I have checked the memory and program space and there appears to be plenty available. Is there some setting in ProComm that we need to change? (As far as I can tell, this version of procomm doesn't have any kind of buffer overflow protection or setting)

This is a Handshaking issue. Either the machine side is not sending a DC3, Ascii character 19, Xoff, or the PC software is not acknowledging it. Make sure the PC software is set to Xon Xoff handshaking.

I'd be dubious using a cable set up as you described. With software handshaking you only need 3 wires, Send, Receive, and Signal Ground, plus the hardware pins at the machine end bridged to satisfy it's Uart.

Assuming that you end up with a 25 pin male connector at the machine end of your cable, and a 9 pin female at the PC end with the cable assembled with all its adapters, use a multimeter to check that pin 2 is connected to pin 2 and pin 3 to pin 3. If pin 2 to 2 is not connected, no handshake signal will be received by the PC

Have you been able to set the Comms parameters of Pro Comm to those I described in my previous post? If you cant set to Xon Xoff, no handshaking will occur and you will get the error you're getting.

If you can't get hold of another Comms package in a hurry for the purpose of comparison with the software you have now, your PC should have an application called Hyper Terminal, accessible through Windows menu system:

START
|
ALL PROGRAMS
|
ACCESSORIES
|
COMMUNICATION

Its not the most intuitive program to set up and to get going, but I'm sure you'll work it out. Configure the Comms parameters of the program as follows:

Handshaking Method = Xon Xoff
Baud Rate = 4800
Data Bits = 7
Parity = Even
Stop Bits = 2

Try to send a program using a software package that you know for sure can be set as I've described and see what happens. If you do that, and you're sure the software is set correctly, and you still get the error, look carefully at the cable.

Regards,

Bill

[dcoupar]

If your PC is running Windows, you can eliminate many "buffer overflow" errors by turning off the FIFO buffers for the COM port you're using.

Go into Control Panel - System - Hardware - Device Manager - expand the Ports (COM & LPT) - right-click on the port you are using and select Properties.

In the Properties dialog, click the Port Settings tab, then click Advanced. You should see two slider bars for Receive and Transmit buffers. Slide them both to Low(1), then un-check the Use FIFO buffers check-box.

OK all the way out of Control Panel and restart your PC.