Troubleshooting the relays on machines equipped with the old style Opto I/O boards.

Electrical diagrams to be used as reference: V4.1 The old style Opto I/O board measure about 4.0x3.5. On all dual X axis router models (Stealth, PRO, Barracuda,) there are 2 Opto I/O boards located right underneath the CNC controller. On the single X axis models (Viper, LX) there is only one board. Please refer to the picture below for help in identifying the old style Opto I/O board:

Relay functions: - each servo amplifier has a corresponding fault relay, mounted along with all others inside the electrical cabinet. They monitor the fault status of that respective servo amp and are labeled K2, K3, K4, and K5. On some of the early implementations, there were no labels on these relays but the order in which they were mounted was always K2, K3, K4, K5, K6, K7, K8. (please note that the numbering sequence starts from 2. K1 label is affixed on the main contactor. During different design stages the machines were also equipped with two different brand name relays: FINDER (blue in color) or OMRON (beige in color). Functionally they are absolutely identical; they can be mixed but are not interchangeable. If you decide though to replace one brand with the other one, you must replace the whole unit (relay + socket). HINT: Under normal working conditions, K2 (XA), K3 (Y), K4 (Z) and K5 (XB) get energized the moment you press the Power Enable button on the door, indicating there are no fault conditions on none of the servo amplifiers. This status is indicated by a green LED on the relays socket (FINDER) or a green LED on the relay itself (OMRON). Additionally, on the OMRON relays, the energized status is indicated by a red whiteness tab which will be visible on the little window on the relays top. Should a fault condition occur on a servo amp, the corresponding relay will turn OFF (de energize). - K6 = master fault relay, monitoring all fault conditions on any of the servo amps. Gets energized after pressing Power Enable button and only if no faults are present on any of the servo amp (K2, K3, K4, K5 are all ON) - K7 = servo enable relay, gets energized only at the end of initialization cycle - K8 = spindle ON relay, energized only when there is a request for the spindle to turn ON (Start Spindle in Material Cut Menu (F2) or when a job is started) - K9 = Z axis brake release relay. Gets energized practically simultaneously with K7 (in fact is 50ms after the Servo ON signal has been enabled) Getting started: - turn the power to the machine ON and press the Power Enable button (the green button on the door). If everything is OK, the following components should be in a status as described below: - all 4 fault relays (K2, K3, K4, K5) should be energized (ON) indicating there is no fault condition on the servo amplifiers.

K6 should be ON K7 comes ON at the end of the boot up cycle, when the message Flexicam Ready is displayed on the keypads LCD display.

Should you need to troubleshoot the relays please identify the symptom and refer to the attached flowcharts. HINTS: 1. When checking for +24V potential, all measurements are in reference to ground (GND). 2. When checking for 0V potential, all measurements are in reference to +24V

Servo Amps not enabled / Old style I/O board

Symptom: Flexicam Ready on the keypad, but servo amplifiers are not enabled Old style I/O board implementation
NO K7 is ON?

NO

Are Servo Amps Enabled?

YES

YES

Machine is working fine Get back to work you lazy bum

NO

K7-14 0V?

YES

NO

LED10 on I/O_A and K6 are ON?

YES

NO

K7 pin11 0V?

Check wiring between K7-14 and servo amps YES

See E-Stop message Troubleshooting flowchart

Check grounding of K7-11 Is voltage on IO_A-10 24VDC?

Bad K7 Replace it with a new one

NO

YES

Replace I/O board NO

K6-11 24VDC?

YES

Check wiring between I/O_A-10 and K6-11 NO

K6-14 24VDC?

YES

Replace K6

Check wire between K6-14 and K7-A1

E-Stop Message on the keypad / Old style I/O board

NO

LED I/O_A-10 ON?

YES

NO

K6 ON?

YES

May have servos not enabled but no E-Stop message on the keypad

NO

Terminal A1 XPS-AL Module 24VDC?

YES NO
Pin I/O_A-17 24VDC?

YES

Check Keypad E-Stop circuit

NO

Terminal 23 XPS-AL Module 24VDC?

YES

Check wiring from I/O_A-17 for broken wire or bad contact Check wiring from terminal 23 of XPS-AL module to +24V

Check PMDI ribbon cable Try a new PMDI card

NO

Terminal 24 XPS-AL Module 24VDC?

YES

Replace XPS-AL Module

NO

K2-14 24VDC?

YES

NO

K2-11 24VDC?

YES NO

K3-14 24VDC?

YES

Check wiring between K2-11 and XPS-AL-24

Replace K2

NO

K3-11 24VDC?

YES NO

K4-14 24VDC?

YES

Check wiring between K2-14 and K3-11

Replace K3

NO

K4-11 24VDC?

YES NO

K5-14 24VDC?

YES

Symptom: E-Stop Message on the handheld controller Servo amplifiers not enabled Old Style I/O board implementation

Check wiring between K3-14 and K4-11

Replace K4

Check wiring between K5-14 and K6-A1

NO

K5-11 24VDC?

YES

Check wiring between K4-14 and K5-11

Replace K5

Spindle doesnt start / Old style I/O board Symptom: Spindle doesnt start neither through Material Cut Menu nor when a job is started Old style I/O board implementation
NO
K8 relay ON?

YES

NO

Led 3 on I/O_A board ON?

YES

NO

Contact between K8-11 and K8-14 Closed?

YES

Restart the machine and make sure is homed

NO

Pin K6-21 24VDC?

YES

Replace K8 If terminals 21 and 24 are empty try moving the wires from 11 to 21 and from 14 to 24

Check wiring between K8-14 and spindle inverter pin S1 and between K8-11 and spindle inverter pin SC

Check wiring between Pin I/O_A-3 and K6-21

NO

Pin K6-24 24VDC?

YES

Replace K6

NO

Pin K8-A1 24V?

YES

Check wiring between K6-24 and K8-A1

Replace K8