Good hardware designs, components and manufacturing relieve the need for service. However when a problem does occur, being able to quickly and accurately diagnose the problem is the key to success. Nothing is more important than providing the service technician with as many useful tools they require to correctly service a problem.
Software Features
Remote Customer Support
With our Remote Support it’s just like our service team is standing right in front of your machine. From our office to your floor, we can do everything just as if we are there.
Service Windows
Displays axis information directly from the motion control board and allows commands to be sent directly to the motion control board. Used for factory direct diagnostics features for low level trouble shooting. This window can be activated anytime while the Control is on.
The IO LED window displays all digital inputs and outputs. Now the serviceman can toggle the outputs manually to operate a specific relay and check signal inputs. This window can be activated anytime while the Control is on.
Displays many of the internal activities such as axis encoder data, auxiliary encoder data and analog output voltages, commanded velocity, actual velocity and actual output pot voltages. This data is another tool that greatly helps the serviceman quickly determine what is or is not working.
Advance Diagnostic Trace

To aid in diagnosing the control logic we’ve added background logic trace recording. This feature can be easily turned on/off with the touch of a service button or an M code can be added to the program. This is a very detailed capture of all control logic that is stored in a simple text file that can then be analyzed allowing exact determination of a problem without the intervention of the user.

Message Log

A running record is stored with date, time and error/fault messages. Now we record and you can review all messages dating back to when the machine was installed. The log is designed so the operator can email it for service review before a service call is made.

Parameter Settings

The SETP command is used for easy parameter modifications such as ramp setting, rapid speed, ball screw pitch and encoder feedback count. Now we provide complete access to many machine specific adjustments giving you more flexibility. The parameters are stored in an editable text file that can be saved on a flash drive for backup or easily moved to other machines.

Simplified Servo Tuning

We have greatly simplified the amplifier tuning and improved the accuracy at the same time. The new “AMPS” command automatically calculates the required signal pot value depending on rapid speed and ball screw ratio in SETP. During the adjustment, it actually tells you which way to rotate the Signal Pot and when to stop. Now adjusting the COMP, BAL and SIG pots are very easy and fast.

Ball Screw Pitch Error Compensation

The Control greatly simplifies the screw compensation as the compensation values are easily entered and adjusted. Instead of one inch increments, they can be at any distance apart. The axis compensation data is stored in one simple text file that can be saved to a flash drive and/or printed out for future use.

Tool Changer Diagnose

Turning on the TC Diagnose feature causes the tool changer to go into a Single Step mode which waits after each action during the tool change. Pressing the start key triggers the spindle to orient and wait. Pressing Start again and the TC slide will come in and wait, press One final press and the tool draw-bar comes down. A terrific tool when servicing the tool changer!

 New Tool Changer Commands


TC 1 Orient, TC In, Z Head Up And Wait
TC 2 Orient, TC Moves Back
TC 3 Orient, Z Head Up First, TC In And Wait
TC 4 Retract TC using TCSLD Override
TC 5 Set Tool And Turret Number
TC IN Jogs the Tool Changer to the Spindle
TC BK Jogs To Tool Changer to Park Position
Other Service Tools
Service Lockout Prevent service modification with password protection
Power On Service Reminders Generate scheduled maintenance prompts
System Restart “Hot Restart” or “Revert to Power On”
Following Error Display Correction ON/OFF
One Touch Spindle Functions Orient/Unlock, Spindle Forward, Spindle Reverse
One Touch Backlash Adjust in Command Mode or while in JOG (faster)
Servo Command Easy tuning of the servos parameters for best performance
RAMP Command Turn ON/OFF / adjust automatic ramping. No more “banging” during contouring
Hardware Features
The Card Cage
A proven design. And only three cards.

One of the successes of the Legacy’s ease of service is the original card cage design because it simplifies diagnosis and board replacement. Now we have taken it to a higher level of both performance and reliability. For  example, with the Legacy CNC, there were eleven cards in the card cage. The reliability benefit is two fold:

  1. Reducing the board-count greatly simplifies the system architecture.
  2. Few components means fewer mechanical bus edge-connectors, significantly improving reliability.
Completely Isolated

The Control is isolated from the machine power and earth ground, eliminating grounding issues that can affect CNC components. Power problems plague many machine shops and are usually caused by unknown and difficult-to-detect electrical problems such as ground loops, or random noise Sometimes, voltage spikes pass through the CNC board causes premature failure and create dependability issues.

Due to lack of truly understanding power & ground, many other control builders are still using grounding rods at the machine to cover up a design flaw when commonly, the control is actually being affected by other devices in the building, causing various problems in their building system. We have worked very closely with Baldor Electric to develop our isolated power system. Baldor doesn’t just make motors, they are also some of the top engineers in High Power Generation Systems.

With our new isolated power design, you’ll never need to install a grounding rod because of “unknown” grounding problems, no matter where the machine is going to be installed.

Isolated Control Power and Ground
Windows Embedded System
Most Stable Version of Windows

The Windows system is not your familiar PC edition of Windows. Our Control runs an Embedded Standard edition of Windows customized for the NXGEN system. With less features then Profession or Home edition, Embedded is the most stable version of Windows available. You’ll never need to reinstall any software or register licenses over the phone.

The modular design of Embedded means that the OS is serviced just like other machine components. In the event of a failure, the serviceman simply removes the SSD card and replace it with another one, similar to the Legacy program module. Backup files are then copied to the new SSD card, and machine uptime is maintained.

Multi Check Safety System (MCSS)
Your Control is operating safely

The Control has safety arbitration hardware that is independent from the CNC system hardware, software and the Windows Operating System. Historically, Windows based controllers have been subject to the instability of previous operating system software. With Windows 7, the operating system has been greatly improved. We have taken steps to also help ensure the system will not be subject to illogical or system lockups relating to the problems of the past.

The critical control signal outputs must first pass through the arbitration board to verify logical states before allowing the signal to proceed.
While the spindle is rotating, the Tool In/Out, the Orientation Arm and the Tool Changer signals are all locked out by the MCSS, regardless of the control signal output. For example, before the Tool Changer can operate, the spindle must not be rotating AND the spindle must be orientated. Also, the tool changer will stop if any of these states change while the tool changer is in action.

Enhanced Spindle Chiller Control
You have more control over the operation of the chiller.

In the parameter setting (SETP) you can set the ON and OFF temperature values. We added a third parameter that specifies the maximum spindle temperature before ESTOP. There is a new command (CHIL) that displays the current temperature sensor voltage and settings, plus it allows you to manually cycle the chiller system.
With the Legacy, the machine kept running regardless of the spindle temperature which could allow a spindle failure if any of the chiller components fail. We’ve seen spindles replaced without knowing that one of the chiller components has failed (pump/coolant/chiller) and after replacing, the new spindle also fails. The new chiller control system now helps to avoid spindle temperature failures all together by shutting down before the spindle failure.