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Section 14: Communications
Communications
Character Code
The CNC 88 can send or receive either EIA or ASCII character codes. The EIA
code output is intended for output to a tape punch only. The communications
described in this section are intended for the ASCII mode.
Initial Connection When the CNC 88 is in the command mode (ENTER NEXT COMMAND is on the
screen), it constantly monitors the RS-232 port for incoming data. When data
is detected, the CNC 88 switches to the terminal mode and subsequent input/
output is through the RS-232 port. Also, the user can direct the CNC 88 to send
its output to the RS-232 port by entering the proper CD command.
The
initial communication
to
the machine
requires
the
following
communications parameters:
7 Data Bits
Even Parity
1 Stop Bit
Compatible Baud Rate (i.e. 2400 at both the computer and the machine).
Machine Grounding
The machine grounding may affect the communications capabilities. The
machine MUST be properly grounded for best communication results. The
FADAL VMC shall be grounded using any method listed in article 250 of the
National Electrical Code. The minimum grounding method recommended by
FADAL Engineering is detailed in the Installation chapter of the VMC
Maintenance Manual. Inadequate grounding will result in a wide range of hard-
to-diagnose problems in communications, positioning, spindle motion, etc.
Termination
If the MANUAL key is pressed while the control is in the terminal mode,
communication will be terminated. This is also accomplished at the computer
terminal by typing the word BYE.
Handshaking
Handshaking uses one of two available software protocols:
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XON/XOFF Protocol
DC1-READER ON (ASCII 17) DC2-PUNCH ON (ASCII 18)
DC3-READER OFF (ASCII 19) DC4-PUNCH OFF (ASCII 20)
While punching (or outputting) a program, the CNC receives either a DC3 or
DC4, and the transmission pauses. When a DC1 or DC2 is received,
transmission is resumed.
XMODEM Protocol
132-byte packet with 128 bytes of data and 4 control bytes, including a 1-byte
checksum.
How to Send a File
Using XMODEM for
DNCX
The following listing provides an outline for implementing XMODEM protocol.
Data is sent 128 bytes at a time. Program lines are concatenated with other
lines until there are 128 bytes to send (including carriage returns). Four control
bytes are added to the 128 bytes to complete a packet. The first three bytes are
1) CHR$(1); 2) Block Number (from 0-255, starting at 1); 3) 255 - Block
Number. The 128 data bytes are next, followed by a checksum byte.
The procedure for sending data is based on ACKs and NAKs. ACK means
acknowledged, or success. NAK means not acknowledged, or failure. An EOT
is sent if an unrecoverable error or end-of-file has occurred. The logic is better
described in sample code than in words.
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EXAMPLE:
SUB DNC ()
' SETUP VALUES
' TRANSMIT BLOCK - [3-128-1], 1ST IS CONTROL BYTE
SENDBLOCK$ = CHR$(1) + STRING$(131, 32)
' BLOCKNUMBER WILL BE INCREMENTED TO 1 IN FIXBLOCK
BLOCKNUMBER% = 0
' TIMES BLOCK WAS BEEN TRANSMITTED, 3 FOR ERROR
XMITEDCOUNTER% = 0
RECDNAK% = 0
RECDACK% = 0
SENDFLAG% = 0
EOT$ = CHR$(4)
NAK$ = CHR$(21)
ACK$ = CHR$(6)
STARTCHAR% = 4
CALL CLEARPORT
NEXTBLOCK:
CALL NEXTDNC(DATA$)
IF DATA$ = "" THEN GOTO SPACEFILL
BACKTOSLOW:
DATA$ = DATA$ + CHR$(13)
DATALENGTH% = LEN(DATA$)
SELECT CASE STARTCHAR% + DATALENGTH%
CASE IS > 132
CANFIT% = 132 - STARTCHAR%
LEFTOVER% = DATALENGTH% - CANFIT%
MID$(SENDBLOCK$, STARTCHAR%, CANFIT%) = LEFT$(DATA$, CANFIT%)
GOSUB BEGINSENDING
MID$(SENDBLOCK$, 4, LEFTOVER%) = RIGHT$(DATA$, LEFTOVER%)
STARTCHAR% = 4 + LEFTOVER%
CASE 132
MID$(SENDBLOCK$, STARTCHAR%, DATALENGTH%) = DATA$
GOSUB BEGINSENDING
STARTCHAR% = 4
CASE ELSE
MID$(SENDBLOCK$, STARTCHAR%, DATALENGTH%) = DATA$
STARTCHAR% = STARTCHAR% + DATALENGTH%
END SELECT
GOTO NEXTBLOCK
SPACEFILL:
' SPACE FILL REST OF BLOCK, TERMINATING CR
MID$(SENDBLOCK$, STARTCHAR%, 131 - STARTCHAR% + 1) =
STRING$(131 - STARTCHAR%, CHR$(32)) + CHR$(13)
GOSUB BEGINSENDING
FINISHUP:
CALL DWELLSENDING
CALL CLEARPORT
QUITING:
CLOSE
EXIT SUB
BEGINSENDING:
CALL FIXBLOCK
BEGINSENDINGSKIP:
CALL CHECKFORABORT
' WAS LAST BLOCK ACKED OR NAKED?
IF RECDACK% OR RECDNAK% THEN RECDACK% = 0: GOTO ZXREADYTOSEND
ZXREADYTORECD:
CALL WAITTILGOT(STOP$)
SELECT CASE STOP$
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EXAMPLE:
CASE IS = EOT$
GOTO QUITING
CASE IS = NAK$
RECDACK% = 0
RECDNAK% = 1
IF SENDFLAG% THEN
' BLOCK WAS SENT BUT NOT RECEIVED, RE-TRANSMIT UP TO 3 TIMES
SELECT CASE XMITEDCOUNTER%
CASE IS = 0, 1
XMITEDCOUNTER% = XMITEDCOUNTER% + 1
CASE ELSE
CALL MHSENDDATA(PORT%, EOT$, ECODE%)
IF ECODE% THEN ERROR ERRTRANSMIT%
GOTO FINISHUP
END SELECT
END IF
GOTO ZXREADYTOSEND
CASE IS = ACK$
IF SENDFLAG% THEN
' BLOCK WAS SENT AND RECEIVED
SENDFLAG% = 0
XMITEDCOUNTER% = 0
RECDNAK% = 0
RECDACK% = 1
RETURN
END IF
END SELECT
ZXREADYTOSEND:
CALL DWELLSENDING
CALL MHSENDDATA(PORT%, SENDBLOCK$, ECODE%)
IF ECODE% THEN ERROR ERRTRANSMIT%
SENDFLAG% = 1
' WAIT FOR ACK
GOTO ZXREADYTORECD
END SUB
SUB FIXBLOCK
' SET BYTES 2 AND 3 FOR HEADER, 132 HOLDS CHECKSUM
BLOCKNUMBER% = BLOCKNUMBER% + 1
IF BLOCKNUMBER% > 255 THEN BLOCKNUMBER% = 0
MID$(SENDBLOCK$, 2) = CHR$(BLOCKNUMBER%)
MID$(SENDBLOCK$, 3) = CHR$(255 - BLOCKNUMBER%)
CSUM% = 0
FOR I = 1 TO LEN(SENDBLOCK$) - 1
CSUM% = CSUM% + ASC(MID$(SENDBLOCK$, I))
NEXT I
MID$(SENDBLOCK$, 132) = CHR$(CSUM% MOD 256)
END SUB
NEXTDNC:
' RETURNS NEXT ASCII LINE TO SEND
DATA$ = "" IF END OF FILE
DWELLSENDING:
' WAIT UNTIL TRANSMISSION BUFFER IS EMPTY
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Commands
CNC 88 Commands
All of the CNC 88 commands may be issued from the computer terminal. The
MANUAL key is simulated by a control/E (05 hex or ENQ character). The line
delete function is accomplished by the @ key and the backspace function is
accomplished by the underline key. The TA and PU commands have special
requirements and features discussed below.
Tape Input
The following is a description of the two possibilities to initiate data input.
a. From the keyboard, enter the commands: CD, (Baud Rate #) and TA,1
b. While in the command mode if a DC2 is received from the RS-232 port,
a TA,1 is assumed by the CNC.
The following events are required to successfully complete the transfer of an
NC program.
1) The CNC 88 starts by issuing a DC1 control character. Terminals such as
the teletype with the AUTO mode respond to DC1 by turning on the tape
reader. If the sending device has a tape reader that does not respond to
DC1, the operator must start the reader after the TA,1 command has been
issued. The TA,1 command will send a DC3 to activate the tape reader.
2) The next data sent must be a “%” character followed by a CR control
character, to signal the start of NC program data.
3) The terminal must now send the body of the NC program. Lines of the
program must be separated by a CR control character. An LF character is
optional. After all lines are sent, one or more TO commands followed by
one or more FO commands may be sent to build the tool and fixture data
tables.
4) The terminal must conclude the NC program data by sending a “%”
character followed by a CR control character.
5) An optional checksum may follow. The checksum is sent as a string of
characters consisting of one to four numeric digits(0-9) and terminated by
a carriage return. The checksum may be generated by a high level
language like BASIC. An example follows:
10 REM update checksum after sending character C$
20 CK + CK = ASC (C$)
30 If CK9999 Then CK=CK-9999
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Note:
a. CK is set to zero before the “%” Character is sent in step 20 above.
b. CK includes all characters sent up to, but excluding, the first character
of the checksum.
c. The only control character included in the checksum is the CR (i.e. the
LF character is not counted).
d.
If a null line (only a CR) is sent, the CR must not be included in the
checksum.
6) At the completion of a successful TAPE input, when no CHECKSUM is
received, the CNC displays the message “TAPE INPUT TERMINATED”.
When a CHECKSUM is correct, the message “TAPE IS GOOD” is displayed.
PU Command
The following is a description of two ways to initiate data output:
a. From the keyboard, type CD, (baud rate #) and press ENTER then type
PU and press ENTER.
b. While in the command mode if a DC1 is received from the RS-232 port,
a PU is assumed by the CNC.
The PU command has two modes of transmission. The first assumes that the
remote device is a “dumb” terminal such as a punch or a teletype. This mode
is initiated by the PU command (with no parameters). The CNC 88 transmits
the NC program as follows:
1) A DC2 control character is sent. Some terminals respond to this by turning
on the tape punch.
2) Approximately 300 NULL characters (leader) are sent next (when punch
tape format is selected). Leader is transmitted only at baud rates 600, 300,
150, and 110.
3) The data portion is then opened with a “%” character followed by LF and
CR characters.
4) The body of the NC program is transmitted next with LF and CR characters
terminating each line.
5) After the NC program, TO and FO commands are output (if selected) to
download the tool and fixture data tables.
6) The data is finally closed with a “%” character followed by LF and CR
characters.
7) The last line sent is the checksum as described in the TA command.
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The second mode assumes that the remote device is programmable and is
prepared to receive the NC data in the order described below. This mode is
invoked by the PU,,,1 command. The order is as follows:
1) The CNC 88 sends one null character and waits for a DC1 or DC2 from the
remote device.
2) The remote device then sends a DC1 or DC2 when it is ready to receive
data.
3) The CNC 88 responds with ten lines of data.
4) The remote device must process the data received in step 3.
5) Steps 2 through 4 must be repeated until the end of file is detected. The
end of file is indicated by a line consisting of a single “%” character. All
lines are terminated by LF only.
6) After the end of file, the CNC 88 sends the checksum as described above.
DNC Mode
DNC mode is generally used when a program is too big for the memory of the
CNC control. CAD/CAM software usually posts a program too big to fit into the
CNC memory, either the program is sectioned and stored, or it is sent DNC.
DNC mode does not store a program in the control. The control receives
program code via the RS-232 port in blocks. Enough program code is sent to
fill a buffer for the machine tool to perform. Once the machine has performed
the code, it looks to the buffer for more information. When the buffer starts to
empty, the control talks to the units sending the code to refill or keep filling the
buffer so that the machine can have a continuous run. Since the DNC program
does not remain in the control, certain differences to the code are as follows:
a. NO O word program identification numbers are allowed.
b. NO comments are allowed.
c. NO user defined subroutines (L01-L89) are allowed.
d. Fixed subroutines are allowed during DNC.
e.
Sequence numbers are optional.
f.
The program should be ended with either an M0 or with NO code at all.
g. Macro statements (see Section 18) ARE allowed.
Using FADAL communications software such as Assist, ProSend, or CNC
Memory Manager in the DNC mode, a server program can be accessed by
encoding a drive, path and filename within the program. During DNC the
program lines indicating the path and filenames may NOT have line sequence
numbers.
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EXAMPLE:
N1 G0 G90 S3000 M3 E1 X0 Y0
N2 H1 Z.1 M7
C:\ASSIST\CNCDATA\MOLD.CNC
N3 G0 G90 H0 Z0
N4 M0
Note: A % sign is not required in sub program
DNC Protocols
The control may use either one of two types of handshaking protocols.
1) DNC, the standard protocol is XON/XOFF.
a. This protocol uses DC1 through DC4 to control data flow.
b. When the machine cannot continue to receive data, or the buffer is full,
the XOFF stop signal is sent. When transmission can resume, the XON
start signal is sent.
c. This protocol is used for normal DNC operations.
2) DNCX, Xmodem protocol is used at a baud rate setting of 9600 baud or
above.
a. X modem protocol sends data in blocks of 128 bytes.
b. After sending each block a CHECKSUM is performed. These blocks are
used to report errors that may occur during transmission.
c. X modem protocol requires the use of the DNCX command during DNC
operations.
d. DNCX must be used with computer software or a device that can send a
file at X modem protocol.
e. DNCX command is available with the 1400-3 processor only.
RS-232-C Interface
Connection
Data and command input to the CNC is normally via the keyboard on the VMC
pendant. However, the CNC can be instructed to receive its input from the RS-
232-C interface. Likewise, data normally sent to the CRT can also be directed
to the interface. This interface is set up in the data terminal equipment (DTE)
mode per the Electronic Industries Association (EIA) Standard numbered RS-
232-C published by:
Electronic Industries Association
Engineering Department
2001 Eye St. N.W.
Washington, D.C. 20006
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Table 1 shows the circuits that are implemented in the CNC’s RS-232-C
interface. In this table, DCE, stands for Data Communication Equipment. The
DCE is normally a telephone modem. If the user wishes to connect a computer
or a data terminal directly to the CNC, it must be determined whether the
device is set up as DTE or DCE.
If the device is DCE, a commercially available 9 wire cable will be satisfactory.
The CNC requires the socket housing (female) connector at its end of the cable.
If the device is DTE, the user must make or buy a modem bypass cable (also
called a null modem).
Two versions of a null modem are shown in tables 2 and 3. Table 2 is for simple
3 wire cabling. Table 3 is for equipment that uses the DTR circuit to indicate
conditions, such as buffer full. This condition requires a brief pause in
transmission from the CNC (see handshaking). If the CNC finds its DSR line low
for more than 1 second it ceases transmission until it is reconnected.
The CNC RS-232-C interface has a programmable baud rate. It can be
changed by use of the CD command (see Section 8, Commands, for more
details). When the CNC is powered on, the initial baud rate is set by the SETP
command. The CNC is set up for Asynchronous Communication only.
The CNC control expects and transmits seven (7) data bits and one (1) stop bit.
For ASCII data, even parity (E) is required, and for EIA-RS-244-B data, odd
parity (O) is required.
FADAL’s Parts Department has RS232C cables and NULL modem cables
available, properly configured for communication with the VMC.
Cable Configuration
Table 1: Cable Configuration
PIN NUMBER
DESCRIPTION
SIGNAL SOURCE
25 PIN DIN CON-
NECTOR
DTE (VMC)
DCE
(MODEM)
1
Protective Ground (PG)
2
Transmitted Data (TD)
X
3
Received Data (RD)
X
4
Request To Send (RTS)
X
5
Clear To Send (CTS)
X
6
Date Set Ready (DSR)
X
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IBM-Compatible PC-
Simple DB25 Null
Modem
Note: Connect pin one to the shield only at the machine end.
IBM-Compatible PC-
DB9 to DB25 for DTE
Equipment-Null
Modem Not Included
7
Signal Ground (SG)
8
Received Line Signal Detector
(RLSD)
X
20
Data Terminal Ready (DTR)
X
Table 1: Cable Configuration
PIN NUMBER
DESCRIPTION
SIGNAL SOURCE
RS232 Pinouts for the IBM-compatible PC
Simple DB25 Null Modem
PC DB25
connector
Transmit
Receive
Signal Ground
Fadal DB25
connector
Transmit
Receive
Signal Ground
1
2
3
4
5
6
7
8
20
22
1
2
3
4
5
6
7
8
20
22
To Protective Ground
RS232 Pinouts for the IBM-compatible PC
DB9 (@PC) to DB25 (@VMC) for DTE Equipment
PC DB9 COM
connector
Fadal DB25
connector
Received
Line Signal Detector
Receive
Transmit
Data Terminal Ready
Signal Ground
Data Set Ready
Request to Send
Clear to Send
Ring Indicator
Note: Null Modem performs
crossover in this configuration
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
To Protective Ground
Transmit
Receive
Request to Send
Clear to Send
Data Set Ready
Signal Ground
Received Line Signal
Detector
Data Terminal Ready
Ring Indicator
20
22
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Note: Connect pin one to the shield only at the machine end.
Macintosh II Mini-8
Connector
Note: Connect pin one to the shield only at the machine end.
Macintosh Plus DIN-
9 Connector
Note: Connect pin one to the shield only at the machine end.
RS232 Pinouts for the Macintosh II
MAC Mini8
connector
Transmit
Receive
Signal Ground
Fadal DB25
connector
Transmit
Receive
Signal Ground
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
To Protective Ground
Request to Send
Clear to Send
Data Set Ready
Received Line Signal
Detector
Data Terminal Ready
20
Need 10-12 volts from
#3 (red) and #8 (black);
‘Xon/Xoff’ and ‘Strip’
disabled
RS232 Pinouts for the Macintosh Plus
MAC DIN9
connector
Transmit
Receive
Signal Ground
Fadal DB25
connector
Transmit
Receive
Signal Ground
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
To Protective Ground
Request to Send
Clear to Send
Data Set Ready
Received Line Signal
Detector
Data Terminal Ready
20
Frame Ground
9
Clear to Send
+12 volts
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Macintosh Plus DIN-
8 Connector
Note: Connect pin one to the shield only at the machine end.
VMC
Communications
Procedures
VMC Control
Parameters
The first step to any communications is to prepare the VMC control. At the
ENTER NEXT COMMAND prompt, enter the command CD,# and press ENTER.
This sets the machine baud rate and readies the RS-232 port. Use the
appropriate command for the desired baud rate.
CD,1 = 110 baud
CD,2 = 150 baud
CD,3 = 300 baud
CD,4 = 600 baud
CD,5 = 1200 baud
CD,6 = 2400 baud
CD,7 = 4800 baud
CD,8 = 9600 baud
CD,9 = 19200 baud
CD,10 = 38400 baud
CD,11 = 57600 baud
CD,12 = 115200 baud
RS232 Pinouts for the Macintosh Plus
MAC DIN8
connector
Receive
Receive RS-422
Signal Ground
Fadal DB25
connector
Transmit
Receive
Signal Ground
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
To Protective Ground
Request to Send
Clear to Send
Data Set Ready
Received Line Signal
Detector
Data Terminal Ready
20
Data Set Ready
RS-422
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Receiving Data /
Programs at the VMC
EXAMPLE:
To Receive Data:
CD,6 ENTER This sets the baud rate at 2400 baud
The line feed and echo parameters may also be used with the CD command.
See Section Eight, Commands for detailed information on these parameters.
When a file is to be received at the VMC the TA,1 command is used. This
command is entered after the CD command.
EXAMPLE:
The program sent to the control should start and conclude with the “%” sign.
CD,6 ENTER
TA,1 ENTER The VMC is now ready to receive a program
After entering the TA command the control is ready to receive a file. The
program can now be sent to the control from the source device.
Sending Data /
Programs from the
VMC
When a program is to be transmitted from the VMC to a receiving device, the
PU command is used. Prior to using the PU command the receiving device
MUST be ready to receive. Check the device requirements for receiving a file.
When the device is ready to receive, enter the CD and PU commands at the
VMC.
EXAMPLE:
To Send Data:
CD,6 ENTER
PU,2 ENTER This transmits the program data only to the receiving device
The use of the PU command parameters may be required for different devices.
Data Options
0 = Currently active program and offsets
1 = Offsets only
2 = Currently active program only
3 = All programs in memory
Code Option
0 = ASCII (Standard)
1 = EIA
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TTY Option
0 = Computer (Standard)
1 = Leader, Program, Trailer (This option is used for tape punches)
After entering the PU command the program is transmitted to the receiving
device.
Device
Communications
Procedures
Computer
The procedures described in this section are for generic computer
communications.
The computer MUST be equipped with a serial port (RS-232 port). If a mouse
or pointing device is installed, insure that there is a serial port available for
communications. Identify whether the port is COM1 or COM2. This information
is required for the software being used.
The RS-232 cable MUST be configured for communications. The standard 25-
pin configuration in Table 2 above should be used. This pin configuration may
be achieved by using the FADAL Null Modem cable. Connect the cable(s) from
the VMC to the computer serial port.
The communications parameters must now be set at the computer software.
The software documentation will describe the procedure for setting these
parameters. To communicate with the FADAL VMC use the following parameter
settings:
1) Set the baud rate compatible with the machine (Normally 2400).
2) Even Parity
3) 7 Data Bits
4) 1 Stop Bit
5) XON/XOFF Handshaking In Effect (On)
Some software may have additional parameters. Use the following settings:
6) Strip Line Feeds (No)
7) Code Format (ASCII or EIA)
8) Strip Carriage Returns (No)
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9) Echo Keyboard To Screen (Yes)
10) Delay After End Of Line (0.0 seconds)
The VMC and computer are now ready for communications.
Receiving at the VMC:
1) Enter the appropriate CD command at the VMC control.
2) Enter the TA command desired to receive a program at the VMC.
3) Perform the software procedures to transmit the file to the VMC.
4) After receiving the file, press the MANUAL button to return to the command
mode.
Transmitting from the VMC:
1) Enter the appropriate CD command at the VMC control.
2) Prepare the computer to receive a file. See the software documentation for
these procedures.
3) Enter the desired PU command at the VMC control.
4) After receiving the file, press the Manual button to return to the command
mode.
Tape Punch /
Teletype
The procedures outlined in this section are designed for the DSI tape punch
model LRP300. Procedures for other tape punches or teletypes may vary with
model. Contact your device manufacturer for exact procedures.
This tape reader uses the RS-232 cable for data transfer. The cable MUST be
straight wired. This means that the wire connected to each pin must connect to
the corresponding pin at the opposite end of the cable. The Null Modem is NOT
used for the tape reader or teletype. The RS-232 cable should be attached to
the DSI tape punch at the bottom 25 pin port.
The DSI tape punch switch settings for communication are defined as follows:
OC/L RS-232
RS-232
HIGH/LOW
HIGH
FULL/HALF
FULL
LINE/LOCAL
LOCAL
OFF/REM CTL
OFF
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OFF/PRINT
PRINT
ON/PUNCH
PUNCH
RUN
Press to start
Prepare the machine for communications by entering the CD command. Use
the command CD,3 to set the baud rate at 300 baud. This is the baud rate that
the tape punch uses. The machine and the tape punch are now ready for
communications.
Receiving at the VMC:
1) Enter the CD,3 command at the VMC control.
2) Enter the TA command desired to receive a program at the VMC.
3) Load the paper tape into the tape reader or teletype.
4) Press the RUN button to begin the transmission.
5) After receiving the file, press the Manual button to return to the command
mode.
Transmitting from the VMC:
1) Enter the CD,3 command at the VMC control.
2) Press the RUN button on the tape reader to prepare the reader to receive
the file.
3) Enter the desired PU command at the VMC control.
4) After receiving the file, press the MANUAL button to return to the command
mode.
Communications
Troubleshooting
For communication problems several factors must be examined. Review the
environment, then check the file, the VMC, the cables, the computer, and finally
the computer’s communications software. Any one of these subsystems can
propagate a communication problem.
If, after following these procedures, communications cannot be successfully
carried out, please call FADAL’s its representative’s) Programming Support
department for assistance.
Environment
In areas where lightning strikes are common, communications can be
interrupted when or after lightning has struck a power line. The lightning may
affect the memory of the CNC control, which would then have to be zeroed from
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the DI mode. It is suggested to call a service person or see the maintenance
manual for this zeroing procedure.
Note: An RS-232 surge suppressor adds protection in this kind of
environment.
File
1) Has the file ever successfully been transmitted to the VMC before? If the file
has been transmitted before, has it recently been edited and has
something been introduced into the file? Use an editor or word processor to
show hidden characters. If hidden characters are present in the file, remove
them.
2) If the file has not been successfully transmitted, use an editor or word
processor to show hidden characters. If hidden characters are present in
the file, remove them.
a. The only accepted characters allowed before the initial percent sign are
DNC, DNCX, or TA,1. In addition, no O words are allowed in DNC mode.
EXAMPLE:
DNC
%
b. A two-second dwell is required between the DNC command and the first
percent symbol (%). If the software being used to transmit the program
cannot support this dwell time, remove the DNC, DNCX, or TA,1 com-
mand from the file and type the command at the VMC before starting
file transmission.
3) When a file is posted for a paper tape, or when a paper tape is read and
placed on a disk, it may have leader characters before the initial percent
sign — they need to be removed.
4) If some of the file can be transmitted, but some of it cannot, check for
syntax errors.
a. Examine the area in the file for syntax errors and repair them. For exam-
ple, double motion words or missing words are syntax errors.
EXAMPLE:
X1.23 X4.5 Double motion words
-Y2.3 Incorrect placement of - (minus)
.534 No word at all
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Note: Use the TA,1,1 command for program transmission so that the control
will halt transmission and display the line where the syntax error occurs.
5) If a word processor or editor is used to write the program, it must be saved
in a text only format. Some processors will add formatting characters to the
file which will disallow communications.
VMC
1) Check to see if the grounding wires are properly attached.
a. The only proper and acceptable primary ground is a single continuous
copper wire attached from the ground bus in the junction box of the
VMC to the main power box of the building. A green sticker in the junc-
tion box further expounds the grounding requirement. Any other meth-
ods of grounding, such as grounding to the conduit, or to a ground rod,
are not acceptable and will lead to communication problems. See the
Maintenance Manual for grounding procedures.
b. Check to see if the screws attaching the ground wire to the VMC are
tight at both ends.
c. The ground wire of the RS-232 DB25 plug on the inside of the CNC con-
trol cabinet must be attached from the RS-232 port to the inside of the
CNC control cabinet. This wire is attached to pin #1 of the DB25 plug,
and is used to shield the cable at the VMC end ONLY (see Table 2 for
proper pin configuration).
Note: If the paint has not been removed from this area, scrape the paint away
and re-attach the wire.
2) Check the cable from the RS-232 port on the inside of the CNC control
cabinet to the 1030 board.
a. Sometimes this cable will work itself out of the plug. Press the plug into
the board to confirm a good connection.
b. Examine the cable for cuts or kinks and replace it if there is evidence of
damage.
3) For VMCs with a phone modem, make sure that the DB25 plug on the
inside of the CNC control cabinet is NOT plugged into the back of the
modem — if it is, it will interrupt normal communications through the RS-
232 port.
4) Use the test plug to test the 1030 board. The test plug is stored in the
bottom of the CNC control cabinet when the VMC is shipped. It is a DB25
plug with no wires coming from it. On the inside of the plug, pins 2 and 3
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are crossed to complete the communications path. Plug the test plug into
the RS-232 port on the outside of the back of the CNC control cabinet.
Use the diagnostics mode to complete the test.
a. Move to the cold start position.
b. From the command mode type DI then press ENTER.
c. Type G0 3000 and press ENTER to enter the test menu.
d. Press 4 to select the RS-232 (1030) test.
e. Select a baud rate (usually the baud rate used in normal communica-
tions).
f. Observe the screen.
• Numbers next to the word TESTING should be changing constantly.
This is good, and the 1030 board has passed the test.
•
The numbers at the end of the other sentences should all be zero. Any
numbers appearing at the end of these sentences indicates that the
1030 board is faulty (assuming the cable was checked in step (2)
above).
Note: It has been our experience that the 1030 is rarely faulty.
•
If the diagnostics test passes, then it is safe to conclude that the VMC is
not at fault for a communication problem.
g. Press the MANUAL button to end the communication test.
h. Power off the VMC, wait 10 seconds, then power on again.
5) Has the proper baud rate been selected at the VMC?
a. The CD,# command is used to select a baud rate. The MU command
has a list of each baud rate in the menu, or see Section Eight, Com-
mands for the same list.
b. The SETP command, for the VMC parameters, can be used to select a
baud rate as default. The CD,# command will temporarily override the
selection in the SETP parameter page.
Cables
1) Verify that all connections between the communications cable and both the
VMC and the computer are firmly seated, including surge suppressors,
gender changers, and couplers. Pick up the cables and physically confirm
that each connection is properly together.
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•
Loose cable connections are one of the most common causes of com-
munication problems.
2) If a switch box is used, determine if the switch is in the proper position.
a. Examine the cable connections to see if they are in the correct ports.
b. Turn the switch handle back and forth a few times. Sometimes the con-
tacts are corroded and turning the handle will temporarily correct the
problem.
•
If turning the handle corrects the problem, it is suggested to clean the
contacts or replace the switch box with a new one.
3) If the cable is coiled because the cable is too long, it is suggested to get a
shorter cable. The coiling may cause intermittent problems.Also, the
shorter the cable, the less chance a parity error will occur.
4) Check to see if the cable is draped over fluorescent lights or wrapped
around or connected on the high-voltage line for the power to the VMC or
other machines. This can cause RF noise and inductive voltages on the
cable, and communications will be interrupted from time to time.
a. Welding machines and EDM machines close to the VMC or the cable will
also cause communication problems. These machines also cause RF
noise which interrupts communications.
5) Open the DB25 plugs to see if the solder on the pins has been applied
properly. Cold solder joints for these wires will need to be soldered again.
6) Check to see if the wires are connected to the proper pins. See earlier in
this section for the proper pinout.
• Confirm that, with shielded cable, pin one is connected to the shield at
the VMC side only. Pin one cannot be connected at the computer side.
7) If straight cable is used a null modem is required. A null modem cable can
be purchased from the FADAL Parts Department (part # WIR-0150), or from
any computer store. A null modem is a short portion of cable or ribbon
cable that has pins 2 and 3 crossed. The crossover and the proper jumpers
on each end can be found earlier in this section. If a null modem is used
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that was supplied from FADAL, the switch must be in the outward position
away from the cable.
8) Use the mirror plug test as described in step 4 of the VMC section above to
test each section of cable from the VMC to the computer, replacing any
section that fails.
9) What is the length of the cable?
a. The longer the cable the slower the baud rate must be.
b. The faster baud rates may work for the longer cables, but the chance of
losing information increases the faster the baud rate.
c. Try using a slower baud rate, and if this works better, this may be the
best solution. However, this may also indicate an IO port at the com-
puter with low voltage. See the Computer and Computer IO Port sec-
tion on the next page.
Computer and
Computer IO Port
1) Is the cable plugged into the proper port in the back of the computer?
a. Some ports are marked COM or SER — these are the proper ports.
b.
If the ports are unmarked, a COM or serial port will be the male gender
port (the port with the exposed pins — the female gender port will have
sockets).
Note: A gender changer plug may be needed if the gender on the cable will
not plug into the proper COM or serial port.
2) Is the port active?
a.
Is the cable on the inside of the computer cover attached to the port?
b. Check the voltage across pins 2 and 7 while transmitting a file (use a
file large enough to allow time to check the voltage while the transmis-
sion is in progress). With the positive lead on pin 2 and the negative on
pin 7, the voltage should range between 10 and 12 volts. Any voltage
below 10 volts could result in interrupted communications.
Note: A FLUKE meter (or equivalent) used to measure voltage must be set to
AC to obtain a reading.
3) When the computer was set up, did any interrupts interfere with the
communications port?
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Note: A qualified computer setup person will be able to confirm that the port is
free of other interrupts.
4) If an IBM-compatible computer has a serial mouse, is the mouse plugged
into the proper port?
a. Usually the serial mouse is used in COM1 or serial port one.
• Move the mouse to COM1 and the VMC cable into COM2 and try to
communicate again.
•
If the mouse is not to be used during the DNC process, remove the
mouse software
commands
from
the CONFIG.SYS and/or
AUTOEXEC.BAT file(s), and then reboot the computer. (CAUTION: Only
a person familiar with altering these files should perform this operation,
as these files are necessary for startup of an IBM-compatible computer.
Refer to the DOS manual for any questions regarding these files and
how to properly modify them.)
5) Some screen saver software can interrupt communication, change the
baud rate, or transmit an odd hidden character, when the screen saver
starts to display. Remove or disable the screen saver software and try to
communicate again.
6) The quality of the IO board must be considered. Multipurpose IO boards are
usually not recommended. High quality boards dedicated to only IO
functions are recommended. DigiBoard and Quad Tech are examples of
companies which produce high quality IO boards. These boards are
specific to the operating system used by the computer — one board is
used for DOS, another for Windows, and another for micro channel (IBM
PS/2). These boards usually test 12 volts across pins 2 and 7 at the
computer, for the best quality transmission.
Note: A FLUKE meter (or equivalent) used to measure voltage must be set to
AC to obtain a reading.
7) If a network board is installed in the computer, the computer technician
who installed the board must check for conflicting interrupts and IO
addresses.
8) The FADAL Assist software has in its utility menu an RS-232 tester. Use the
mirror plug in the port and follow the instructions on the screen for test
number one.
Software
1) Check the communication parameters in the software.
a. TA, DNC, and PU (using Xon/Xoff)
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• Baud rate - This is variable and it must match the baud rate set at the
VMC with the SETP command or with the CD,# command.
• Parity - E (Even)
• Data Bits - 7 (Seven)
• Stop Bits - 1 (One)
•
EOB (End Of Block) - CR,LF (ASCII 13,10)
• Starting and ending character - % (ASCII 37)
•
Xon/Xoff (Software handshaking) disabled for TA
• Enabled for DNC and PU
• Hardware handshaking - disabled
b. DNCX (using XMODEM)
• Baud rate - This is variable and it must match the baud rate set at the
VMC with the SETP command or with the CD,# command.
• Parity - N (None)
• Data Bits - 8 (Eight)
• Stop Bits - 1 (One)
•
EOB (End Of Block) - CR,LF (ASCII 13,10)
• Starting and ending character - % (ASCII 37)
• Packet Data Bytes - 128
• Hardware handshaking - disabled
•
For more information, see ‘How to Send a File Using XMODEM for
DNCX’.
2) Use DOS to send a file, bypassing the communications software in the
computer. If this works, the software is in doubt.
a. From the DOS prompt type the following two DOS commands:
Type MODE COM2:2400,E,7,1 MODE port:parity,data bits,stop bits
MODE
= DOS command (followed by a space)
port
= COM2
:
= : (the : is required DOS syntax)
baud
= 2400
,
= , (the , is required DOS syntax)
parity
= EVEN
,
= , (the , is required DOS syntax)
data bits = 7
,
= , (the , is required DOS syntax)
stop bits
= 1
Type TYPE C:\CNCDATA\PN1234.NC>COM2TYPE pathnamefilename>port
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TYPE
= DOS command (followed by a space)
pathname = C:\CNCDATA\ substitute the drive-and-directory(ies) where
the file being sent to the
VMC is stored
filename =
N1234.NC substitute the name of the file sent to
the VMC
>
=
> (the > is required DOS syntax to redirect the file to COM2
port
=
COM2
• Note: Before typing these two lines, the VMC should be in the TA,1
mode ready to receive the program at 2400 baud.
• Refer to the DOS manual for answers to additional questions about the
DOS commands used here.
3) Running DOS-based software from Windows may not work for
communications.
4) Introducing another computer into a situation where communications are
not happening may be useful only if the computer has been proven to work
in other situations. Otherwise the second computer may also have a
problem.
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Table 2: Fadal Software Error Codes
04 OUT OF DATA
52 BAD FILE NUMBER
05 ILLEGAL FUNCTION CALL
53 FILE NOT FOUND
06 OVERFLOW
54 BAD FILE MODE
07 OUT OF MEMORY
55 FILE ALREADY OPEN
11 DIVISION BY ZERO
57 DEVICE I/O ERROR
12 ILLEGAL DIRECT
58 FILE ALREADY EXISTS
13 TYPE MISMATCH
61 DISK FULL
14 OUT OF STRING SPACE
62 INPUT PAST END
15 STRING TOO LONG
63 BAD RECORD NUMBER
16 STRING FORMULA TOO COMPLEX
64 BAD FILE NAME
17 CAN’T CONTINUE
67 TOO MANY FILES
18 UNDEFINED USER FUNCTION
68 DEVICE UNAVAILABLE
19 NO RESUME
69 COMMUNICATION BUFFER OVERFLOW
21 UNPRINTABLE ERROR
70 DISK WRITE PROTECTED
22 MISSING OPERAND
71 DISK NOT READY
23 LINE BUFFER OVERFLOW
72 DISK MEDIA ERROR
24 DEVICE TIMEOUT
74 RENAME ACROSS DISKS
25 DEVICE FAULT
75 PATH/FILE ACCESS ERROR
27 OUT OF PAPER
76 PATH NOT FOUND
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Table 3: CNC Main Errors
150
“THE CNC NEEDS TO BE UPGRADED TO USE THIS PROGRAM”
151
”THIS VERSION OF CNCMAIN IS INCOMPATIBLE WITH YOUR CNC“
152
”CANNOT ESTABLISH LINK WITH CNC“
153
”INTERNAL ERROR: “
154
”CNC WILL NOT RESPOND“
155
”CANNOT RESPOND TO CNC“
156
”NO RESPONSE FROM CNC“
157
”INTERNAL ERROR: R“
158
”CNC DOES NOT RESPOND“
159
”OPERATION ABORTED“
160
”CNC REQUIRES A COLD START“
161
”NO SUCH STARTING BLOCK“
162
”SERIAL PORT NOT RESPONDING“
167
”STARTING BLOCK NOT FOUND“
170
”TOO MANY RETRIES ON A SINGLE PACKET“
180
”CANNOT FIND FILE“
181
”NOT AVAILABLE IN DESKTOP VERSION“
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Table 4: Syntax Errors
190 “ALPHA CHARACTER MUST SEPARATED BY NUMBERS”
191 ”DATA INPUT ERROR”
192 ”ILLEGAL CHARACTER”
193 ”ILLEGAL ENDING CHARACTER”
194 ”ILLEGAL STARTING CHARACTER”
195 ”CANNOT FIND NESTED FILE”
196
”FILES NESTED MORE THAN 3 DEEP”
251 ”THIS PROGRAM REQUIRES A MOUSE”
253 ”THIS PROGRAM REQUIRES A VGA COLOR MONITOR”
254 ”.SYS FILE IS MISSING”
255 ”INCORRECT VERSION OF .SYS FILE”
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