Shoda NC516U-1634

Fanuc 150-M Controller Error / Failure

11/28/2017 – Rev A

Fanuc Maintenance Manual Used for Reference:

GFZ-62075E/04 - May 1998

Erik Lassen
Monolith erik@monolith.aero
Cell: 805-815-9780
Aeroworks Office: 661-750-7999
L.L.C. 101 Commercial Way
Unit I
Tehachapi, CA 93561
Pic 1
Error Message –
We shut machine down on
Thursday Evening 11/16
after a successful day of
running

Machine powered on Friday

11/17 morning to this
Message:
Pic 2
Current Machine Setup
Pic 3
Machine Data Plate
Pic 4
Control Box Exterior
Pic 5
Control Label
Pic 6
Control Box Interior
Pic 7
Main Fanuc Hub
Showing Error Lights
and Status Window
(11/17/2017)
Pic 8
Part and Serial Number
for Main-C Board
Pic 9
Operator Console
Pic 10
Close up of Faunc half
Of the Operator Console
Pics 11 - 15
Prior to Failure on
11/17/2017 – The
Boot up Sequence
looked like this –
(Pics Taken in Aug of
2016)
Pic 16 -
We ordered a New Main-C
Card and Daughter Cards off
of EBAY – Arrived
11/27/2017

Installed on 11/28/2017 –

The new board is a slightly

different (assuming older)
model.

Original Board # is:

A16B-3200-0060/09D

New Board # is:

A16B-3200-0060/07C

It is also missing the CRTC

daughter board when it is
delivered. I installed the
original Main-C board CRTC
Daughter board and
attempted to boot
Pic 17 –
First Boot with replacement
Main C board Looked like this
Pic:

I Assume We are good!

I (maybe foolishly) restart the

controller so I can insert the
PCMCIA SRAM card, in an
attempt to make a backup of
the Boot System Files not
knowing if I can insert the card
while the controller is hot
Pic 18 - 21
The next Boot Process Looks like
this:

- After installing the SRAM card

and powering on I get the
following boot sequence.

- After getting to the RAM Parity

Error (pic 4), the controller won’t
respond, and no further input,
button pushes etc. will wake the
machine up.

- I shut down, remove the SRAM

card and repower on
Pic 22
After removing PCMCIA
SRAM card, the reboot
yields this familiar screen
:o(

I reinstalled the original

main-C card and
attempted to reboot, but
no success, but get the
same result.

I try new Main C Card

with original daughter
cards, and Original Main
C, with new replacement
daughter cards and have
no success.

CRTC Daughter card is the

only thing that is the
same on both Main C
boards
Still Stuck – Current LED Status and Error Lights – and No Boot
Pics 23 & 24
- PSU Card - status light (PIL) is green and good, no error

- HSSB sub card: Mounted in slot on PSU BI - I can’t find

information in the Maintenance manual to understand that
sub card’s errors
PN # A20B-8001-0290/2A700238

- PMC-NA Card Status Lights indicate:

“Initial state. PMC initialization is in progress.”
- PMC-NA Card Error lights indicate:
“A RAM (RAM on the PMC engine module or PMC DRAM
module) parity error occurred in the PMC.”

- Main-C is Status lights indicate:

“Initial state immediately after power–on”
- Main-C Card - Error Lights indicate:
“An ABC alarm (fault in the peripheral bus,FANUC bus)
occurred.”

- ADAX Card Error lights indicate:

“ SYSEMG (NMI occred on some modules of F–BUS.)”
Pics 25 & 26

I pulled all Cards and removed and cleaned

all terminals with CRC QD Contact cleaner

Inspected the back plane card looking for

any obvious issues – Everything looked
good and clean

Cleaned the female and male side of all

connectors on all cards, sockets and plugs

Double check that all Daughter Cards on

the Main C card are seated
Pic 27

In order to minimize potentially

conflicting items on the FBUS, I
attempted to boot without the
ADAX and PMC- NA Cards installed,
as well as all the Servo and
interconnecting cables unplugged

I attempted booting with both the

original and replacement Main-C
cards with the same result
Pic 28

Only things left that I can think of

testing is to buy and swap

- Power supply card - PSU

- CRTC Daughter card on Main C

- Fanuc MDI (Operator Console,

screen and Keyboard)

- Fanuc Backplane Card

- Cable that Plugs into JA1 CRT to

the Fanuc MDI (Operator
Console)

I’m open to any other ideas to test

and try!