GE Fanuc 0-15-16-18-21 All Version Backup Manual

Automation Inc. ______________________________________________________________________________________Fanuc CNC Backup I nstruction Manual1 Table of ContentsTable of Contents (1)Procomm Plus® version 4.8 Configuration (3)Serial Cable Connection (6)Memory Card Usage (8)What Data Can be Archived (9)CNC Parameter settings for RS-232 communications (11)CNC Parameters Related to Memory Card Communications (13)How to Backup and Restore ALL Data in your CNC (14)Series 0 models A/B/C/D (14)Using the RS-232 interface (14)Series 16/18/21 models A/B/C, Powermate models D/H (16)Using the RS-232 interface (16)Series 15 models A/B (20)Using the memory card (20)Using the RS-232 interface (26)Series 16i/18i/21i/0i models A/B, Powermate i models D/H (29)Using the memory card (29)Using the RS-232 interface (34)Series 15i model A (38)Using the memory card (38)Using the RS-232 interface (43)How to Backup and Restore Programs in your CNC (47)Series 0 models A/B/C/D (47)Using the RS-232 interface (47)Series 16/18/21 models A/B/C, Powermate models D/H (47)Using the RS-232 interface (48)Series 15 models A/B (49)Using the RS-232 interface (49)Series 16i/18i/21i/0i models A/B, Powermate i models D/H (50)Using the memory card (50)Using the RS-232 interface (54)Series 15i model A (55)Using the RS-232 interface (55)How to Backup and Restore CNC Parameters in your CNC (57)Series 0 models A/B/C/D (57)Using the RS-232 interface (57)Series 16/18/21 models A/B/C, Powermate models D/H (58)Using the RS-232 interface (58)Series 15 models A/B (59)Using the RS-232 interface (59)Series 16i/18i/21i/0i models A/B, Powermate i models D/H (60)Using the memory card (60)Using the RS-232 interface (63)Series 15i model A (64)2Using the RS-232 interface (64)How to Backup and Restore PMC Parameters in your CNC (66)Series 16/18/21 models A/B/C, Powermate models D/H (66)Using the RS-232 interface (66)Series 15 models A/B (67)Using the RS-232 interface (67)Series 16i/18i/21i/0i models A/B, Powermate i models D/H (68)Using the memory card (68)Using the RS-232 interface (70)Series 15i model A (72)Using the RS-232 interface (72)Open Systems Backup and Restore using the Basic Operation Package (BOP) (74)References (75)3 Procomm Plus® version 4.8 ConfigurationThe following setup information applies to ProComm Plus 2.0® for Windows 95/98 through version 4.8 for Windows 95/98/2000/XP.NOTE:It is possible that you may experience timeouts when uploading a program using drip feed to the CNC while using ProComm Plus Version 4.8. ProComm's default delay time is to wait 20 seconds after an XOFF command and then abort. Symantic has provided a solution to this on their web pages. For further explanation, please visit their Tech Support site at /techsupp/index.html, enter a search for that version of Procomm product and open the FAQ section for that product.1. After installing ProComm Plus®, launch the application by double clickingon the appropriate icon or selecting the appropriate item from the Startbutton. If you need any additional help on installing or launching theapplication, please refer to the ProComm documentation thataccompanied the software. This is the main screen of ProComm Plus®.Clicking the SETUP button will bring up the screens used to change thecommunications parameters.2. By clicking the SETUP button the following screen appears. Click on the“System" tab followed by the "Modem Connection" button. Next, select"direct connect – Com1" from the "Current Modem / Connection" dropdown box. To configure the Com1 port, click on the "Modem/ConnectionProperties…" button.43. After selecting the "Modem/Connection Properties…" button, youshould see the following screen. Set your PC to match the following:5 Click on "OK" to accept the settings and close the window4. Clicking on the "Data" tab of the Setup screen allows you to set the typeof transfer to be used. Click on the "Transfer Protocol" button. To communicate with the CNC, you should select ASCII from the "Current Transfer Protocol" drop down box. Set the remaining fields in this window to match those shown below.Click on "OK" to accept the settings and close the window6Serial Cable ConnectionThe GE Fanuc CNC controls have a minimum of one serial communication port available for communications. This port is designed to conform to the basic requirements of the EIA232C standard. Connection to an EIA232 or EIA574 compliant device can be accomplished using a null modem cable. Communication Cable DiagramsEIA232C Null Modem CableThis cable, utilizing a DB25P connector to a DB25S connector, uses Control Codes also known as Software Handshaking. Controls and PG systems use serial inter-face.NOTE:Pin #25 has 24 volts power supply on it. Do not use for normal interface connection or damage to the control may occur.EIA232C to EIA574 Null Modem CableThis cable can be used for interfacing between IBM-compatible computers and GE Fanuc controls. This cable uses a DB25P connector to a DB9S connector. This is the most commonly used cable for communications and is available from GE Fanuc or easily fabricated.7DB25P (male)RD SD SG RS CS CD ER DR RD SG RS CS DR CD ER SDFG: Frame ground SD: Send data RD:Receive data RS: Request to send CS: Clear to sendDR: Data set ready SG: Signal ground ER: Equipment readyCD: Received line signaldetector8Memory Card UsageThree types of memory cards can be used with our CNC and Power Matecontrols:1. ATA Flash Rom2. SRAM (Static Ram Access Memory), which are battery-backed.3. FlashROM (called FROM for the rest of this document), which do notrequire battery backup.Which type of memory card do you need? The Pros and Cons of each type ofcard are given below. We recommend SRAM or ATA Flash. The SRAM workswith a larger variety of controls, but requires a small battery on the card to retainits memory and should not be used as a permanent storage device. ATA Flashis lower cost and can be used for permanent storage of backup files, but is newertechnology and therefore works with a smaller number of controls.Memory Card Type ATA Flash SRAM FROMWorks with i series controls Yes Yes Yes Works with 15/16/18/21-B and 20/21-A controls No Yes YesWorks with PowerMate-C/D/E/F/H/I controls No Yes YesCan read/write from a PC Yes Yes NoFast Write Time Yes Yes NoPlug and Play for WIN95 and newer Yes No NoLow Cost Yes No YesRequires battery to retain backup data No Yes NoFiles can be deleted individually Yes Yes NoCan be formatted on PC Yes Yes NoRequires special drivers No No YesGE Fanuc Part Numbers 44A725977-G09 (8MB) 44A725977-G01 (2MB) 44A725977-G02 (4MB)44A725977-G10 (16MB)44A725977-G03 (4MB)What Data Can be ArchivedThe system software that operates GE Fanuc CNC controls is stored in EPROM. They are essentially fixed and unchangeable. The CNC is shipped from GE Fanuc ready for the machine builder to customize for his application. The files needed for final operation are contained in non-volatile RAM, or battery backed-up RAM. The data stored here can be lost for a variety of reasons and therefore must be saved externally on permanent media. It is recommended that all user data be kept both on a computer diskette or CD-ROM as well as on paper to ensure that it will be available in time of need.User FilesLong term archival:1. CNC Parameters (including servo parameters)2. Pitch Error Compensation (if used)3. PMC Parameters (or Diagnostic Data on FS-0 Controls)This data seldom changes after installation of the machine tool. However, the archive must be updated whenever changes are madeData that changes regularly.1. Tool Offsets2. Work Offsets3. Dynamic Tool Offsets4. Macro Variables5. Tool Form Data6. CAP Tool Data7. CNC Part ProgramsThis data should be backed up any time maintenance is performed that might cause a memory loss.Data normally stored in EPROM but may be stored in RAM format:1. PMC ladder program2. Macro executor programsFile NamingWhen user data is saved to a diskette, it should be remembered that in an average plant there may possibly be multiple machines and controls of the same model. This means that there will be multiple versions of this data. There should be a complete set for each machine on which a GE Fanuc control is applied. It is important to realize that even identical machines may have different parameter data based on any number of factors. The existence of so much similar data can easily cause problems if not addressed from the beginning, so some type ofsystem for naming and archiving files must be created. For example, when backing up the data, you will be asked what to name the resulting data file on disk. GE Fanuc recommends that you use a unique name such as the machine serial number, brass tag or asset number, combined with an extension that helps label the type of data being backed up. By using the first eight (8) characters to identify the machine and the extension to identify the file type, much confusion can be avoided. For example, the filename C could be used to name the CNC parameter file for machine BT156679.CNC Parameter settings for RS-232 communicationsThe parameter tables on the following page can be used as a reference when setting up the various models of CNC control for RS-232 communications. These parameters tell the control which port to use and the device type (in this case, RS-232). These parameters also determine that the number of data bits will be “8”, the number of stop bits “2”, that “EVEN” parity will be used as well as a baud rate of 4800bps set. These settings coincide with the ProComm configuration explained earlier in this manual.Additionally, these parameters also unlock the custom macro protection, allowing the download of the macro programs. When setting CNC parameters ensure that the Parameter Write Enable (PWE) setting is set to “1” on the control settings screen.PWEPWE Setting from series 16i-MA controlControl Series 10/11/12/15A/15B/15i Parameters Port 1 Port 2 P 0000 ****1010****1010 P 0020 12 P 0021 12 P 0011 ******00******00 P 2201 ******00******00 P 5001 1P 5002 2 P 5110 8P 5111 2P 5112 10P 5120 8 P 5121 2 P 5122 10 Control Series 0A/0B/0C/0DParameter Port 1 Port 2 P 0000 1******1P 0010 ***0*******0****P 0038 01******P 0050 1******1P 0250 10P 0251 10P 0552 10P 0553 10TVON 00ISO 0,12I/O 11PWE 11TAPEF 00Control Series 16/18/20/21-ABCi / 0iParameter Port 1 Port 2P 0000 ******10******10P 0020 0,12P 0101 1***0**1P 0102 3P 0103 10P 0111 1***0**1P 0112 3P 0113 10P 3202 ***0***0***0***0CNC Parameters Related to Memory Card Communications1. Select the MDI mode on the operator panel for the CNC.2. Go to the Offset/Setting screen.3. Set I/O channel =4.or1. Select the MDI mode on the operator panel for the CNC.2. Place the CNC into an Emergency Stop condition.3. Set your control so that Parameter Write is enabled.4. For series 18i set parameter 20 = 4, series 15i set 20=4.These settings will let you upload and download files to the cards the same as you would to a PC and there is also an additional menu called all IO with additional I/O functionality.IO Channel SettingIO Channel Setting from series 16i-MA controlHow to Backup and Restore ALL Data in your CNCOne of the most common procedures on CNC controls during maintenance is to backup all of the data possible before working on a CNC system. In this manner, a maintenance person can easily restore the control to the original state should a problem be encountered during the maintenance activity.Series 0 models A/B/C/DThis series of controls is restricted to using the RS-232 interface for all data backup and restore operations.Using the RS-232 interfaceTo Transfer Programs from CNC to PCFrom the CNC Side, do the following:1. Select EDIT mode.2. Select the PROGRAM screen.3. Depress I/O key.4. Prepare the PC to receive file (See appropriate section on ProComm forreceiving a file on the PC).5. To output an individual program, enter the Letter O and the part programnumber OR to output all programs enter –9999.To Transfer Program from PC to CNCFrom the CNC side, do the following:1. Select EDIT mode.2. Select the PROGRAM screen.3. Depress I/O softkey.4. Depress READ softkey.5. Send file from PC (See appropriate section on ProComm for sending fromPC).To Transfer Parameters from CNC to PCFrom the CNC side, do the following:1. Select EDIT mode.2. Select the PARAMETER menu.3. Prepare PC to receive the file (See appropriate section on ProCommfor receiving a file on the PC).4. Hold down EOB key and simultaneously depress OUTPUT STARTkey.NOTE:Failure to press the EOB key and OUTPUT START will result in an incomplete parameter file being downloaded.Transfer Parameters from PC to CNCFrom the CNC side, do the following:1. Set Parameter Write Enable (PWE) to 1.2. Select EDIT mode.3. Select the PARAMETER menu.4. Depress INPUT key.5. Send the parameter file from the PC (See appropriate section onProComm for sending from PC).6. When the transfer is complete, turn CNC OFF and back ON to use thenew parameter set. Also verify that PWE is set to 0.NOTE:To upload and download PMC parameters (Diagnostics) and offsets, the procedures are the same as for the system parameters. The only difference is that you must be on the CNC Diagnostic Page for transferring PMC parameters and the Offset Page for transferring offsets.Series 16/18/21 models A/B/C, Powermate models D/HThe primary method for archiving data from this series of control is through the RS-232 port. Newer models B/C controls may have PCMCIA memory card slots located in the control rack and are accessible through the boot mode. For instructions on using the boot mode backup procedures for the model A/B controls, see the section for 16i/18i/21i/0i controls.Using the RS-232 interfaceFirst set the CNC parameters as per the settings in the section labeled “CNC Parameter Settings for RS-232 Communications”Punching CNC Parameters (CNC --> PC)Connect the cable to the computer and the serial port on the CNC.Set up the computer in accordance with "Procomm Plus® Version 4.8configuration."Set up the CNC for communications as per “CNC Parameter Settingfor RS-232 Communication.”Perform the following steps on the PC and CNC as follows:PC Launch Procomm Plus 4.8PC Select File Receive from the toolbarPC Designate a name and directory for the saved dataCNC Select EDIT mode.CNC Press SYSTEM key.CNC Hit softkeys [PARAM], [OPRT], [+], [PUNCH],[EXEC].(You will see the parameters scroll up on the PC screen.)(The CNC will flash OUTPUT on the lower section of the CRT.)Reading CNC Parameters (CNC <-- PC)Connect the cable to the computer and the serial port on the CNC.Set up the computer in accordance with "Procomm Plus® Version 4.8configuration."Set up the CNC for communications as per “CNC Parameter Setting forRS-232 Communication.”Perform the following steps on the PC and CNC as follows:PC Launch Procomm Plus 4.8CNC Select MDI mode and press ESTOPCNC Set PWE to 1.CNC Press SYSTEM key.CNC Hit softkeys [PARAM], [OPRT], [+], [READ], [EXEC].PC Select File Send from the toolbarPC Designate the name and directory for the file to send(You will see the parameters scroll up on the PC screen.)(The CNC will flash INPUT on the lower section of the CRT.) CNC Power the CNC off then on to have the new parameters takeeffect.Punching CNC Part Programs (CNC --> PC)Connect the cable to the computer and the serial port on the CNC.Set up the computer in accordance with "Procomm Plus® Version 4.8configuration."Set up the CNC for communications as per “CNC Parameter Settingfor RS-232 Communication.”Perform the following steps on the PC and CNC as followPC Launch Procomm Plus 4.8PC Select File Receive from the toolbarPC Designate a name and directory for the saved dataCNC Select EDIT mode.CNC Press PROG keyCNC To output current program hit softkeys [PRGRM], [OPRT], [+],[PUNCH],[EXEC]CNC To output all programs input O-9999 and hit [+],[PUNCH], [EXEC].(You will see the program scroll up on the PC screen.)( The CNC will flash OUTPUT on the lower section of theCRT.)Reading CNC Part Programs (CNC <-- PC)Connect the cable to the computer and the serial port on the CNC.Set up the computer in accordance with "Procomm Plus® Version 4.8configuration."Set up the CNC for communications as per “CNC Parameter Settingfor RS-232 Communication.”Perform the following steps on the PC and CNC as follows:PC Launch Procomm Plus 4.8CNC Select EDIT mode and turn program protect key off.CNC Press PROGRAM key.CNC Hit softkeys [PRGRM],[OPRT], [+], [READ], [EXEC].PC Select File Send from the toolbarPC Designate the name and directory for the file to send(You will see the parameters scroll up on the PC screen.)(The CNC will flash INPUT on the lower section of the CRT.) Punching PMC Data (CNC --> PC)Connect the cable to the computer and the serial port on the CNC.Set up the computer in accordance with "Procomm Plus® Version 4.8configuration."Perform the following steps on the PC and CNC as follows:PC Launch Procomm Plus 4.8PC Select File Receive from the toolbarPC Designate a name and directory for the saved dataCNC Select EDIT mode.CNC Go to the PMC side and select I/O.CNC Select Channel 1 for Port 1 and Channel 2 for Port 2.CNC Set Device to OTHERSCNC Set Data kind to type desired --- ALL/LADDER/PARAM. SetFunction to WRITE.CNC Press the SPEED softkey.CNC Select 4800 Baud (depending on computer setup).CNC Select Parity 0, Stop bits 1, Write code ASCII.CNC Press < and EXEC softkeys to initiate download.(The CNC screen will flash executing and count up untilcomplete.)Reading PMC Data (CNC <-- PC)Connect the cable to the computer and the serial port on the CNC.Set up the computer in accordance with "Procomm Plus® Version 4.8configuration."PC Launch Procomm Plus 4.8CNC Select MDI mode and press ESTOPCNC Set PWE to 1.CNC Go to the PMC side and select I/O.CNC Select Channel 1 for Port 1 and Channel 2 for Port 2CNC Set Device to OTHERS.CNC Set Function to READ.CNC Press the SPEED softkeyCNC Select 4800 Baud.CNC Select Parity 0, Stop bits 1.CNC Press < and EXEC softkeys. (Executing should flash)PC Select File Send from the toolbarPC Designate the name and directory for the file to send (You will see the parameters scroll up on the PC screen.)(The CNC will flash INPUT on the lower section of the CRT.)Series 15 models A/BThe series 15 model A control is restricted to using the RS-232 interface whereas the series 15 model B control additionally offers a PCMCIA memory card slot in the control rack. For more information refer to GE Fanuc Manual GFZ-62075 Series 15/150 Model-B Maintenance Manual.Using the memory card(Not available on series 15 model a)The table below lists the functions and corresponding memory card types that can be used. Cards must be of TYPE 1 or 2 as defined in the Personal Computer Memory Card International Association (PCMCIA) standard, version 2.0 or later, or the Japan Electronic Industry Development Association (JEIDA) standard, version 4.1 or later. The format conforms to the DOS FAT file system. The memory card has a maximum storage capacity of 32M bytes.Accessing the Boot SystemInsert the SRAM Memory card into the PCMCIA slot in the control rack.Turn the power on while holding down the page up/down keysNote: If you are using a 9” small MDI unit, turn the power on while holding down cursor keys up and down keys instead of the page up/down keys.SYSTEM DATA SAVEThe SYSTEM DATA SAVE screen enables the saving of user files, such as PMC ladder files. System files, such as executive software cannot be saved. To save SYSTEM DATA use the following procedure.Press a cursor up/down key to choose the desired function.Position the cursor to a desired function, then press the INPUT/INSERT key.The ROM files in flash memory are listed together with the number of management units (128KB management units) in each file.Use the cursor keys to position the cursor to the file to be saved to the memory card. Then, press the INPUT/INSERT key.The INPUT FILE NAME (CAN: RESET) message appears in the message field. Enter the name of the desired file on the memory card, then press the INPUT/INSERT key.To abandon saving, press the RESET key. To end the processing, position the cursor to END, then press the INPUT/INSERT key. The main menu appears again.SRAM DATA BACKUPTo save a complete image of the data stored in SRAM memory, select FILE DATA BACKUP from the System Monitor screen (selection 4).From the File Data Backup screen, select STORE FILE. To execute batch restoration, select LOAD FILE. To terminate the processing, select END. To select the processing, press a cursor key to position the cursor, then press the INPUT/INSERT key.When the batch saving or restoration of a file is selected, the size of the system’s backup RAM is displayed on the screen. To execute the selected processing, press the INPUT/INSERT key. To cancel the processing, press the CAN key. (See the detailed description given below.)NOTEThe backup data is saved to file FILEx.BAK, where x is a value of 1 to 4. The original data can be saved in up to four files. If a single memory card cannot hold all the original data, the data can be saved using up to four memory cards. Existing FILEx.BAK files on a memory card may be overwritten if a file of thesame name is stored. The names of the files already on the memory card can be listed in the FILE DIRECTORY field of the SYSTEM DATA LOADING screen.To execute the batch saving of backup data, perform the following steps:1. Select the STORE FILE function on the initial screen.2. When the SET IC CARD NO.1 & HIT INPUT KEY message appears inthe message field, mount the first memory card. Then, press theINPUT/INSERT key. To cancel the processing, press the RESET key.The initial screen appears again.3. While data is being saved, the STORE TO IC–CARD message blinks.Once saving has been completed, the STORE FILE COMPLETE andHIT INPUT KEY messages appear in the message field. When theINPUT/INSERT key is pressed, the initial screen appears again. If thefirst memory card cannot hold all the data to be saved, the SETIC/CARD NO.2 & HIT INPUT KEY message appears in the messagefield. Mount the second memory card without turning the power off,then press the INPUT/INSERT KEY.4. The backup data can be saved using up to four memory cards byperforming step (3) repeatedly. If four memory cards cannot hold allthe data, the FILE DATA SIZE ERROR and HIT INPUT KEYmessages appear in the message field. When the INPUT INSERT keyis pressed, the initial screen appears again.NOTEOnce batch saving starts, requests to replace the memory card are repeated until all the backup data has been normally saved (using up to four memory cards). To stop the processing, press the RESET key while the SET IC CARD NO.x & HIT INPUT KEY message is displayed.Data is stored on the memory cards under the following file names:First memory card: FILE1.BAKSecond memory card: FILE2.BAKThird memory card: FILE3.BAKFourth memory card: FILE4.BAKNote that a file on a memory card can be overwritten. If the specified name of a file to be saved duplicates that of a file already on the card, the old data will be overwritten.To execute the batch restoration of backup data, perform the following steps:1. On the initial screen, select the LOAD FILE function.2. The SET FILE1.BAK & HIT INPUT KEY message appears in themessage field. Mount the first memory card containing FILE1.BAK,then press the INPUT/INSERT key. To cancel the processing, pressthe RESET key. The initial screen appears again.3. While data is being restored, the LOADING FROM IC–CARD messageblinks. Once data restoration has been completed, the LOAD FILECOMPLETE and HIT INPUT KEY messages appear in the messagefield. When the INPUT/INSERT key is pressed, the initial screenappears again.4. Backup data stored using up to four memory cards can be restored byperforming step (3) repeatedly. If all the required data cannot berestored from all of the four memory cards, the FILE DATA SIZEERROR and HIT INPUT KEY messages appear in the message field.When the INPUT/INSERT key is pressed, the initial screen appearsagain.NOTE:The function for saving or restoring a file in batch mode of the boot system assumes that the backup RAM (file SRAM) used for saving and that used for restoration are of the same size. So, this function should be used in the following cases:1. To restore a file when file all clear must be executed (the file SRAMmodule is not replaced)2. To restore a file when the file SRAM module must be replaced andwhen the size of the new backup RAM is the same.If this function is used for any other purpose, such as restoring SRAM into a module of a different size after an upgrade, file restoration may not be performed correctly. In the case of a memory upgrade, use the RS-232 option to backup and restore the control. Similarly, if an error (a RAM parity error, for example) is found in the contents of the backup RAM during batch saving, file restoration may not be performed correctly and the RS-232 method must be used.Using the RS-232 interfacePUNCHING CNC PARAMETERS (CNC --> PC)Connect the cable to the computer and the serial port on the CNCSet up the computer in accordance with "Procomm Plus® Version 4.8configuration."Set up the CNC for communications as per “CNC Parameter Settingfor RS-232 Communication.”Perform the following steps on the PC and CNC as follows:PC Launch Procomm Plus 4.8PC Select File Receive from the toolbarPC Designate a name and directory for the saved dataCNC Go into EDIT mode.CNC Press the <, SERVICE, CHAPTER, PARAMETER, >, PUNCH,ALL keys.( The CNC will flash PNCH on the lower portion of the CRT. )( The PC will display the text and count lines until finished.) READING CNC PARAMETERS (PC --> CNC)Connect the cable to the computer and the serial port on the CNC.Set up the computer in accordance with "Procomm Plus® Version 4.8configuration."Set up the CNC for communications as per “CNC Parameter Settingfor RS-232 Communication.”Perform the following steps on the PC and CNC as follows:PC Launch Procomm Plus 4.8CNC Go into EDIT mode.CNC Press ESTOP.CNC Press the <, SERVICE, CHAPTER, PARAMETER, >, READ,ALL keys.PC Select File Send from the toolbarPC Designate the name and directory for the file to send(You will see the parameters scroll up on the PC screen.)(The CNC will flash INPUT on the lower section of the CRT.) CNC Power the CNC off and then on to have the new parameterstake effect.。