Service Maincon / Software - Troubleshooting Guide - NGC
Last updated: 02/23/2021

Maincon / Software - Troubleshooting Guide - NGC

Maincon / Software - Troubleshooting Guide - NGC

Introduction

Use this document to troubleshoot the Maincon PCB and software update problems on a machine with the Next Generation Control. If you can not find the scenario that matches your situation, please submit an error log ([SHIFT] + [F3]) to [email protected]

 Note: If necessary the error log command ([SHIFT] + [F3]) can be initiated while the program is running.

MainCon PCB

The Next Generation Control Maincon PCB includes the units for Video, Main, and Motion controller. It accommodates 16 motion control channels. No need to add extra MOCON for the applications that require more channels. This board communicates with the I/O PCB via serial communication through a single RJ45 cable using the RS422 system. The Next Generation Control includes ports for linear scale encoders. Communication with the front panel is done via RJ45 cable and includes the video signals for the LCD display.

Maincon Function Reference

1 - 16 Encoder Input

9A - 13A Scale Encoder Input

1-16 Amplifier Command

J2 Wifi Antenna

J3 Power Input from PSUP

J4 HDMI Output

J7 Ethernet / Dual USB, J8 Dual USB

  1. RJ45 cable Ethernet input
  2. USB cable to going to SKIBF PCB at J23
  3. Not used
  4. Not used
  5. Not used

J9 RJ45 cable to SKIBF PCB J28

J12 WIFI module power.

J13 Not Used

J14 RJ45 cable to I/O PCB J4

J16 Voltage Monitor Input from the Drive

BT1 System Battery

NGC Boot Troubleshooting

The illustration shows the NGC control boot sequence.  If the Boot sequence stops at:

Stage 1

  • Test the +5V / +12VDC voltage levels at J3. Power off / on a few times and check that voltages stay consistent. If the voltage levels are not consistent, the low volt power supply could be at fault.
     Caution: When testing for voltage be careful not to short out the red and black leads. This can cause damage to the Maincon PCB or the low volt power supply.
  • Check for loose connections at the Wi-Fi module PCB connector and also at J12.
  • Check the RJ-45 cable and connector from the Maincon PCB to the SKBIF PCB.
  • Check the Low Volt power supply to SKBIF PCB, and connections to the LCD.  Refer to the LCD and SKBIF Troubleshooting Guide.
  • Recover the software with Software Update Recovery - NGC procedure.

Stage 2

  • Check all the connections at the Maincon PCB.  Check for loose connections at the Wifi module.
  • Recover the software with Software Update Recovery - NGC procedure.

Stage 3 - 8

  • Check processor / software compatibility chart below.
  • Reload the software using the Clean Install method (Option 5).

Note: If the problem is intermittent, generate an error report and e-mail the report to the service department. 

Stage 9 

  • Alarm 9972 FPGA CONFIGURATION FAULT at boot up.  Check the software release notes for updates. 
  • Reload the software using the Clean Install method (Option 5).

Hardware and software Version Compatibility Table

 Note: Do not upgrade to the current software from software version 100.16.000.1020 or lower. You need to upgrade to 100.16.000.1021 first then you can upgrade to the current software version.

Hardware Compatible Software Version Hardware PN# TP#
NGC Main PCB      
NGC maincon PCB with Q7_4GB eMMC module. 100.16.000.1011 to current (see note*) 32-4250A, 32-4250B, 32-4251B, 32-4252F, 32-4253F N/A
NGC maincon PCB with Q7_8GB eMMC module. 100.17.000.1018 and higher 32-4250C, 32-4250D, 32-4251C, 32-4252A, 32-4253A 20433
NGC maincon PCB with Q7_16GB eMMC module. 100.17.000.2034 and higher 32-4252B, 32-4253B 20566
Y/D Contactor      
Y/D contactor with feedback cables. 100.17.000.2034 and higher 32-5280A, 32-5281A 20007

Symptom Table

Symptom Possible Cause Corrective Action

The Time/Date or Activation will reset intermittently.

 The system battery is defective. Measure the system battery voltage, if the voltage is below 3.0 VDC replace the battery. Refer to Next Generation Control - Main Control PCB - Battery Replacement
The machine display will not turn on. A loose cable connection to the WIFI module PCB is causing the processor to hang.
  1. Power Off the machine.
  2. Disconnect the WIFI module connector at J12.
  3. Power On the machine. If the machine boots correctly, reseat the WIFI module connector at J12 and also on the WIFI module PCB [1].
The cable from the SKBIF to the Maincon PCB is defective. Refer to the Next Generation Control - SKBIF / LCD Monitor - Troubleshooting Guide for more troubleshooting information.
The control won't boot up or hangs at the Haas logo after a software update. The software version is not compatible with the processor installed. Check the processor part number and make sure that the correct software version was installed. See the Hardware and software Version Compatibility Table.
The software did not load correctly. Use a SanDisk Extreme USB 3.0 USB device to load the software. Reload the software using option 5) Perform Clean Software Install. Refer to: Next Generation Control - Software Update - Clean Installation.
The machine will not boot to the software updater screen when powering on and holding the U button. The machine lost power during a software update. Do not replace processor try to recover the software with the Software Update Recovery - NGC procedure.
The software files are corrupted.
The USB deviced failed during a software update.
The screen on the control flickers or goes blank when the servos are on. The cable from the SKBIF to the Maincon PCB is defective. Test the RJ-45 cable that connects to J28 on the SKBIF PCB and J9 on the Maincon PCB using a network cable tester. Refer to Network Cable Tester Tool procedure.
The connector on the SKBIF PCB has a broken solder joint or is not soldered correctly. Check the solder on the J28 header connector on the SKBIF PCB. Make sure that it is soldered correctly. Replace the SKBIF PCB if the connector is not soldered correctly.
The connector on the Maincon PCB has a broken solder joint or is not soldered correctly. Check the solder on the J9 header connector on the Maincon PCB. Make sure that it is soldered correctly. Replace the Maincon PCB if the connector is not soldered correctly.
Machines with software version prior to 100.17.000.2034. The control freezes, blank monitor, black screen, keypad not working, won't boot sometimes, random shutdowns, or software alarms. The parameters for the Q7 module on the Maincon PCB are outdated. The updated parameters have been incorporated into the software version 100.17.000.2034 (TP 21894). Update the software to the latest version. If the symptoms continue after updating the software, download the error log with [SHIFT] + [F3] and e-mail it to Haas Service Department.

Alarm 9100.021 NON RESETTABLE SOFTWARE ERROR

Alarm 9101.011 RESETTABLE SOFTWARE ERROR

 The software encounter an error. Download the error log with [SHIFT] + [F3] and e-mail it to Haas Service Department.
Alarm 9972 FPGA CONFIGURATION FAULT. The FPGA software did not get loaded correctly during the software update. Use a SanDisk Extreme USB 3.0 USB device to load the software. Reload the software using option 5) Perform Clean Software Install. Refer to: Next Generation Control - Software Update - Clean Installation.
Alarm 9933 - SOFTWARE VERSION MISMATCH The configuration files loaded to the control do not match the software version on the machine. Make sure the configuration file that is being loaded matches the software version on the machine.
  1. Download the configuration file from the portal
  2. Add the .zip extension and unzip the files.
  3. open the _cv.xml file in notepad
  4. search for keyword: Software Version make sure the software version matches the software version on the machine.
If the configuration file is correct:
Alarm 9934 - INTERNAL VARIABLE NOT INITIALIZED The configuration files loaded on the control do not have all settings that the new software has. Make sure you load the latest configuration file for the software version you have on the control.
The Z Axis does not jog and can not do a tool change after a software update. Option 5 Clean Software Install was selected for software update and theserial_number.fs file in the configuration folder is missing. Make sure the Factory Settings File box is checked when you download the configuration files. Make sure theserial_number.fs file is in the configuration folder.
The software was updated to the latest version from a machine that had software version 100.16.000.1020 or lower. Load software 100.16.000.1021 first then you can upgrade to the current software version. This version is located on the portal.

Alarm 9915 - IO BOARD CONFIGURATION MISMATCH

Alarm 9100.006 - NON RESETTABLE SOFTWARE ERROR

 The new configuration files were not updated before the software update.
  1. Press [POWER OFF].
  2. Put the USB memory device into the control.

    Note: The USB memory device must contain your Haas Control Key and the correct configuration files.

  3. Press [POWER ON].
  4. Press [DIAGNOSTIC].
  5. Use the arrow keys to go to I/O Config [2] in the Diagnostics tab [1].
  6. Press [F3] to Update Config Table [4].
  7. Press [RESET] to continue. If the alarm does not clear, cycle the machine power.

The Main Crc and the Factory Crc [3] are now the same.

[ERROR] appears during a software update or platform version update.

 The USB is not being read.
  1. Press [POWER OFF].
  2. Do the software update again with a different USB memory device.
The software binary is corrupted. Re-download the software from the portal and try the update with the new files.
Machines with 100.17.000.2040 of later, during a software update you get the following USB error: "The system check detected the USB connector is inserted into the wrong port on the skbif or main board......" The USB cable on the Maincon or SKIBF PCB is connected to the wrong location. Make sure the USB cable going to the SKIBF PCB is connected to the correct location, #2, on the Maincon PCB (See above diagram).
Alarm 120 LOW AIR PRESSURE OR FLOW and inputs are not being read after software update to 100.20.000.1110 or higher. The I/O configuration file did not got loaded correctly.   Reload the software using option 5) Perform Clean Software Install. Refer to: Next Generation Control - Software Update - Clean Installation.

PCB Component Inspection

Intermittent symptoms or alarms can be caused by component failure. Below is a list of possible failures:

  1. Missing solder on all or some components pins
  2. Poor solder
  3. Solder bridges
  4. Wrong component installation (orientation)
  5. Missing components

     Note: Some PCB's have unused circuits and are missing components intentionally, look for broken off components.

  6. Broken components
  7. Broken pins on IC's
  8. Bent pins on the connectors

Use a magnifying glass to inspect the circuit components on the front and back of the Maincon PCB. Below are the circuit component zones to inspect:

  1. Inspect for bent pins inside the connectors, also look for loose header connectors.
  2. Inspect for a loose battery, broken battery tabs, repair if needed.

     Note: Do not replace the Maincon PCB. Refer to Next Generation Control - Main Control PCB - Battery Replacement for repair instructions.

  3. Inspect for bent or missing pins inside the connectors, also look for loose header connectors.
  4. Inspect the E-net module for loose connections or broken wires.
  5. Inspect all solder joints and surface mount components on the back of the Maincon PCB.

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