Wohlenberg Cut-tec 92 - problem with mainboard.

[QBAelectric]

Hello everyone,

I have a problem with Wohlenberg 92 or rather the Cut-tec 92 PC itself. The computer does not output 5 which controls the activation of the saddle contactor. The problem occurred more and more often until it failed completely. All functions work properly, the saddle cannot be moved either in manual mode or after entering the dimension and pressing start. I traced the entire board from the connector to the IDE tape, I traced the second board from the IDE tape connecting the boards to the FDC37C651 IC. The problem seems to me to be something on the input side because the operation of the saddle forces the operation of as many as 3 outputs: the output to the saddle contactor, the output to the saddle speed contactor and the brake, in my case it does not control any of them. I hope I am describing it in a way that makes sense. Which of the inputs on the X2 Cuttec can block the saddle from reaching? I have already simulated most of them and there are no changes, but maybe I have missed something. The machine reacted to shocks, often after a cutting cycle it stopped moving, but also to knocking on the Cuttec motherboards. Please provide information on which controller the program is executed in and which signals from the machine enter and leave.

Please also provide the login and password for service settings such as PLC I/O preview, after entering without a login the computer freezes completely and you have to restart.

 

[ESPofKC.com]

Hello everyone,

I have a problem with Wohlenberg 92 or rather the Cut-tec 92 PC itself. The computer does not output 5 which controls the activation of the saddle contactor. The problem occurred more and more often until it failed completely. All functions work properly, the saddle cannot be moved either in manual mode or after entering the dimension and pressing start. I traced the entire board from the connector to the IDE tape, I traced the second board from the IDE tape connecting the boards to the FDC37C651 IC. The problem seems to me to be something on the input side because the operation of the saddle forces the operation of as many as 3 outputs: the output to the saddle contactor, the output to the saddle speed contactor and the brake, in my case it does not control any of them. I hope I am describing it in a way that makes sense. Which of the inputs on the X2 Cuttec can block the saddle from reaching? I have already simulated most of them and there are no changes, but maybe I have missed something. The machine reacted to shocks, often after a cutting cycle it stopped moving, but also to knocking on the Cuttec motherboards. Please provide information on which controller the program is executed in and which signals from the machine enter and leave.

Please also provide the login and password for service settings such as PLC I/O preview, after entering without a login the computer freezes completely and you have to restart.

From the cutting screen (manual or automatic) hold CTRL and press F6. This brings up your I/O screen. What errors are you getting after attempting a move? Front/rear limit switches as well as cam switches will prevent backgauge movement.

Please explain the errors you are getting beside backgauge not moving. There should be something displaying on screen. Is the brake releasing? pressing F1 in a cutting screen?

 

[QBAelectric]

After entering the PLC I/O menu via CTRL + F6 the computer freezes, you can't do anything then and you have to restart it, exactly the same way as I entered from the menu level.

It doesn't display any errors. Right now I'm running it on the table, simulating inputs on X2. The limit switches for the beginning and end of the beam are already behind the computer output. (as in the diagram), I no longer get +24V from X3/5. I simulated the limit switches on the cams, I have +24V on the input X2/15 and X2/27

The brake releases after switching on F2 in the cutting menu.

It's obvious that something is blocking the backward movement.

 

[ESPofKC.com]

After entering the PLC I/O menu via CTRL + F6 the computer freezes, you can't do anything then and you have to restart it, exactly the same way as I entered from the menu level.

It doesn't display any errors. Right now I'm running it on the table, simulating inputs on X2. The limit switches for the beginning and end of the beam are already behind the computer output. (as in the diagram), I no longer get +24V from X3/5. I simulated the limit switches on the cams, I have +24V on the input X2/15 and X2/27

The brake releases after switching on F2 in the cutting menu.

It's obvious that something is blocking the backward movement.

The rear limit switch is the only thing I can think of that would prevent backwards movement. Computer freezing isnt good. Have you tried replacing the RAM?
The login and password is different depending on the version of software. Pre 96 was a 3 line input and post 96 was only 2.
097532 159370 461956
735816 251503
Some very old versions used 9473 8591
Careful what you do in there as it can make you liable for malfunctions and possible lawsuit.

 

[QBAelectric]

Thank you for the passwords, I will check them.

The limit switches (S28, S29) will not have an effect because they are on the PLC output and I no longer have voltage there.

The computer reacts to incorrect Input signals because it displays alarms, then when it is supposed to go backwards there are no errors, it simply does not control the approach outputs when it should.

I am trying to figure out what the fault on the main board may be but I have no more ideas.

 

[CHOCK]

Dear Sir:

I believe, that you can NOT read the schematic, since you are saying the computer NO output + 5Vdc

I strongly suggest the 1) to the regulated power supply BL # 5 in the schematic, and Measure the input of Main Transformer 400 Vca, Previously see if the thermal device Q 52 is ON, it is OPEN, RESET, so there must be 400 Vca in the Primary of Main Transformer,

2) Measure the Output of regulate power Supply : + 24 Vdc in TOLERANCE : 0.7% UP OR DOWN. if Not O.K you must review , repair or replace it. Of course Reset the circuit breaker: F50, and test the Fuses: f51- f54 FOR TO SEE IF THERE OPEN OR BLOWN !!!! repair or replace it.

3) The Backgauge work with the REQUENCY INVERTER ( THIS CONTROL THE BACKGAUGE MOTOR) . Measure the input of F , Converter lines: L1+ L2+L3 for 400 Vca. previously you must sure to RESET THE Thermal device Q23 , AND see if the contacts K26 from the contactor K26 IS PULL IN , when you press the push button for the backgause.. Previously measure the output of Frequency converter : U+ V+ W in order to see if active the backgauge motor.

Let me know, Good luck.

 

[ESPofKC.com]

Dear Sir:

I believe, that you can NOT read the schematic, since you are saying the computer NO output + 5Vdc

I strongly suggest the 1) to the regulated power supply BL # 5 in the schematic, and Measure the input of Main Transformer 400 Vca, Previously see if the thermal device Q 52 is ON, it is OPEN, RESET, so there must be 400 Vca in the Primary of Main Transformer,

2) Measure the Output of regulate power Supply : + 24 Vdc in TOLERANCE : 0.7% UP OR DOWN. if Not O.K you must review , repair or replace it. Of course Reset the circuit breaker: F50, and test the Fuses: f51- f54 FOR TO SEE IF THERE OPEN OR BLOWN !!!! repair or replace it.

3) The Backgauge work with the REQUENCY INVERTER ( THIS CONTROL THE BACKGAUGE MOTOR) . Measure the input of F , Converter lines: L1+ L2+L3 for 400 Vca. previously you must sure to RESET THE Thermal device Q23 , AND see if the contacts K26 from the contactor K26 IS PULL IN , when you press the push button for the backgause.. Previously measure the output of Frequency converter : U+ V+ W in order to see if active the backgauge motor.

Let me know, Good luck.

The power supplies werent regulated in those models. They had capacitor modifications years later to help. I would install aftermarket power supplies that were regulated to prevent issues in the ones I serviced.
Im honestly not sure what they are having problems with, and yes the picture they show of the schematics is not what is represented in what they say in their post.
Im not one to argue as they are further that I think they need to be. I have 30 years experience on the Cuttecs.

 

[QBAelectric]

CHOCK

I don't really understand what you're writing about, I didn't write anywhere that the computer doesn't have a 5VDC output, only that it doesn't have a 24VDC output on X3/5.

I can read electrical diagrams.

Why should I check the power supply if I don't have any problems with it, besides, I have a PC connected on a table with a stabilized power supply.

This machine doesn't have an inverter and the speed is regulated by contactors.


ESPofKC.com

Thank you for the passwords, mine are 3-line, they work but I can't start the most important PLC I/O, maybe something in the software or in the flash card itself.

Do you also repair motherboards and could you describe the signal route for me when it comes to PLC operation? What IC elements are responsible for the PLC? As I mentioned earlier, the computer reacted to slight shocks. I'm an electronics engineer, I re-soldered the most important elements but unfortunately still no change.

 

[CHOCK]

ok, proceed with your 30 years of experience.

Good luck.

 

[ESPofKC.com]

CHOCK

I don't really understand what you're writing about, I didn't write anywhere that the computer doesn't have a 5VDC output, only that it doesn't have a 24VDC output on X3/5.

I can read electrical diagrams.

Why should I check the power supply if I don't have any problems with it, besides, I have a PC connected on a table with a stabilized power supply.

This machine doesn't have an inverter and the speed is regulated by contactors.


ESPofKC.com

Thank you for the passwords, mine are 3-line, they work but I can't start the most important PLC I/O, maybe something in the software or in the flash card itself.

Do you also repair motherboards and could you describe the signal route for me when it comes to PLC operation? What IC elements are responsible for the PLC? As I mentioned earlier, the computer reacted to slight shocks. I'm an electronics engineer, I re-soldered the most important elements but unfortunately still no change.

No inverter for the backgauge? Ive never seen a Cuttec that didnt have one. Could you send a pic of the control cabinet? Id love to see it.
You mentioned you think its an input. Do you mean you think the computer is missing a signal from the machine?
I suggested replacing the RAM. Did you try that? Should be easy and cheap to try.

 

[QBAelectric]

We have a 92 and a 115 and both do not have an inverter.

 

[QBAelectric]

I will try to buy RAM and swap it.

I mean it looks like the problem is on the main board from the Input side because it does not control 3 outputs responsible for switching the motor on backwards. I do not know which IC is responsible for the PLC logic, what is the block diagram of the main board.

 

[ESPofKC.com]

I will try to buy RAM and swap it.

I mean it looks like the problem is on the main board from the Input side because it does not control 3 outputs responsible for switching the motor on backwards. I do not know which IC is responsible for the PLC logic, what is the block diagram of the main board.

Using the control+F6 you should be able to see those inputs. Since it crashes your computer that makes it difficult. Have you tried swapping computers? The parameters would need changed before operation but you could check the inputs that way. You will need to log all the parameters under the password protection screens.

 

[QBAelectric]

Computers are different, different generations.

The biggest problem is that right after entering the PLC I/O the computer freezes, the clock stops counting, only this menu, all others work. I don't have such RAM to swap, although I doubt it would be a problem.

 

[Paul Bradley]

Hi are you sure that the keyboard is not faulty I have had several cases where the backgauge forward reverse buttons dont work this part of the keyboard is separate from the QWERTY section