HW Diagnostics

3 Diagnostics

3.1 LED

3.1.1 LEDs card power supply unit

Figure 3.1 -LEDs card power supply unit

• LED 1: CNC on signal led (RUN) (green led)

• LED 2: CNC off signal led (STOP) (red led)
• LED 3: Internal power supply signal led +5V (green led)
• LED 4: Internal power supply signal led +12V (green led)
• LED 5: Internal power supply signal led -12V (green led)
• LED 6: Internal power supply signal led +Ve (green led)
• LED 7: System state signal led (SYSTEM MONITOR)

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Diagnostics HW

LEDs power supply The 4 LEDs (LED 3, 4, 5 and 6) indicate the state of the voltages generated by the
power supply unit card and used by the equipment. The following conditions may arise.
• All of the LEDs are on: the card is working properly.
• All the LEDs are off: the card is not supplied with power correctly. The causes can
be:
− no power supply voltage 24V AC/DC;
− one or both of the fuses F = 6.3A T to the side of the power supply sockets are
blown;
− there is a fault in the equipment; please contact Esa/Gv Technical Assistance.
• LED 6 (+Ve) is off but all the others are on: the card is not working properly. The
causes can be:
− one of the sensors connected to the CNC (encoder, lines optics, etc.) causes a
short circuit on the encoder power supply; turn the power of the CNC off,
disconnect all the connectors of the encoder and turn the power of the CNC on;
if LED 6 lights, one of the sensors is faulty or the wiring is wrong, repeat the
operation connecting each encoder separately and then check the wiring and
the sensors. If LED 6 does not light, the card is faulty.
− the power supply unit card is faulty, replacing the card requires in-depth
knowledge of the CNC, therefore we recommend replacing the part;
− there is a fault in the equipment, please contact Esa/Gv Technical Assistance.
• Any other configuration different from the above but with at least one led off: the
card is not working properly. The causes of this can be:
− A card inside the equipment is faulty and trips the power supply voltage cutout.
In this case finding the fault requires in-depth knowledge of the CNC, therefore
we recommend replacing the part;
− the card power supply unit is faulty, replacing the card requires in-depth
knowledge of the CNC, therefore we recommend replacing the part;
− there is a fault in the equipment, please contact Esa/Gv Technical Assistance.

RUN/STOP LEDs LED 1 and LED 2 indicate the operational state of the machine, when it is powered
correctly. The following conditions may arise.
• LED 1 (RUN) is on and LED 2 (STOP) is off: the card is working properly.
• LED 1 (RUN) is on and LED 2 (STOP) is also on: impossible state, the card is not
working properly. In this case finding the fault requires in-depth knowledge of the
CNC, therefore we recommend replacing the part;
• LED 1 (RUN) is off and LED 2 (STOP) is on: the CNC is not working, the card is
not working properly. In this case finding the fault requires in-depth knowledge of
the CNC, therefore we recommend replacing the part.

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HW Diagnostics

System Monitor The 7-segment display LED 7, indicates the state of the system. The following
display conditions may arise.

• The display is on and displays 8:

− If the operating system version is earlier than version 3.5 (firmware version
3.5) the display is not managed and therefore the card can work properly;
− If the operating system is version 3.5 or later, the display is managed and
below you will find the list and description of the messages.
• The display is off: the causes can be:
− the display is not working properly but the CNC is, in this case, if necessary
replace the CNC;
− there is a fault in the equipment, please contact Esa/Gv Technical Service.

System Monitor Below you will find the list of the LED 7 messages. There are other types of messages
display diagnostics that appear on the display called “exceptions”, these exceptions are described in the
software manual of the operating system.
• 0 - OK.
− CNC working.
• 1 - Reserved.
• 2 - Reserved.
• 3 - Kvara install CNC.
− The ISO or the SLAVE or the PLC have not been installed. After executing the
application, if the display shows 3, this means that the PLC has not started or
has not been loaded or I/O are missing or are wrong. The I/O configuration
file, IOREDIR, on the disk H of the CNC may also be wrong, recover and
install the application correctly with autosetup.
• 4 - Kvara application.
− After executing STARTCN the display indicates 4 if the file KVARA.GZ is on
disk H of the CNC.
• 5 - Kvara loader.
− When the CNC is turned on, the display indicates 5 if both BIOSEXT and
LOADER are in the FLASH memory of the CNC, while waiting for the
execution of STARTCN.
• 6 - Kvara biosext.
− When the CNC is turned on the display indicates 6 if only BIOSEXT is in the
FLASH memory of the CNC; you will have to recover LOADER and run
autosetup.

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Diagnostics HW

• 7 - Power Fail.
− Drop in of the power supply voltage for a time below the system RESET; this
means that the power supply is unstable. In this case, turn the CNC off and
check the power supply before turning the equipment on again.
• 8 - Power ON.
− This appears when the CNC is turned on, but must disappear and leave 0 on
the screen when the CNC is running, 8 will be displayed when the CNC is not
operating.
• 9 - User interface DLL not present.
− The file GUIAPP.DLL in KVARA6 A and B is missing, recover the file.
• A - Diagnostic menu.
− After executing STARTCN the display indicates A if the file KVARA.GZ is
missing on disk H of the CNC or PERMISSION=LOADER is present in the
file KVARA.INI of the PC, run autosetup.
− Autosetup in progress.
− Recovery in progress.
− Loader, problems with decompressing KVARA.GZ or check the memory or
that the applications are loaded.
• B - CPU NC battery fail.
− CMOS SETUP backup battery flat, contact Esa/Gv Technical Assistance to
replace the NC card.
• C - Shut Down.
− You can turn the CNC off without loosing any machine data.
• D - Reserved.
− Debug.
• E - Reserved.
− Not used
• F - MFB reset.
− CNC in reset mode, CNC reset command has been sent, wait for the CNC to
reset.
− Loader has problems when opening File System disks.

System Monitor In operating systems that manage the System Monitor display, once the CNC is
display start-up supplied with power, the following messages will appear in sequence (after a few
sequence seconds).

• Power ON.
− Messages: 8 à 5 à 4 à 3 à 0.

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HW Diagnostics

System Monitor
display orientation

Figure 3.1 - System Monitor display orientation

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