Micromill 2000 RS-232 error

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Customer writes in:
Micromill 2000
S/N u00522/13
VR Milling v2.30
Windows XP sp2

Problem:
When connecting to the machine the "RS-232 Error" window pops up stating, "A problem has occured! Make sure the machine is switched on and the RS-232 cable is connected correctly"
The machine is ON and the cable is connected.
Replaced the cable with a known working cable.
Reloaded the software.
Removed all the software that might cause a communication error.
Connected the machine to a computer with known working software.
Checked the fuses, all 4 of them are OK.

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Attached is a link to the Denford Forum that covers the RS-232 error. This covers the usual problems that create the error you are getting.

viewtopic.php?t=544&highlight=rs232+error

Correct machine selected?

Using the RS-232 cable that came with the machine (LINDY molded into the connector)?

Power to the control card in the machine?

I have already read this and completed these checks before contacting you. Any other suggestions?

[boots]

Here is list to check and give me the answers.

When was the last time the mill was working properly?

There should be a “Dispatch Date” on the black data plate on the side of the machine. What is the date?

Is the computer part of a network? Or is it a stand alone, dedicated computer?

Has anything changed since? New computer, new operating system, the machine or computer moved, programs added to the computer, security, etc.
In the upper left corner of the computer screen, what machine is named after “Virtual Reality CNC Milling - ???”

Remove the back panel of the machine.
With the power ON, What color is the 7-segment LED Display on the control card? Upper left corner above the RS-232 cable connection.
What is on the display? A “2”, a “-“, an “8”, etc. there are 19 different symbols.
Is there a “.” (dot) on the display?
Is it flashing?

Replace the fuse on the control card. It’s on the lower right corner of the card, between 2 “black boxes” (Rectifiers). It is a 6.3 amp fuse, Radio Shack P/N 270-1068.

You said you have a working cable. Is it the “LINDY” RS-232 cable that came with the machine?
We have had problems with other cables (ie Radio Shack).

If you’re good with a soldering iron, you can build a 9-to-9 pin test cable.
The link has a color diagram viewtopic.php?t=544&highlight=rs232+

Have you tried re-installing the VR Milling software? A file maybe corrupted. Use “Add/Remove Programs” in the computers Control Panel to delete VR Milling.
Go to the Denford website and download VR Milling v2.31
https://www.website.denford.ltd.uk/suppo ... -downloads

After the file is downloaded, you will need to use “Extract All” before installing. Open the new folder and select “start.exe” to install the software.
You will need your Registration Disk when installing the software.

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When was the last time the mill was working properly? Last reimage and installation of software

There should be a “Dispatch Date” on the black data plate on the side of the machine. What is the date? January 2005

Is the computer part of a network? Or is it a stand alone, dedicated computer? Dedicated

Has anything changed since? New computer, new operating system, the machine or computer moved, programs added to the computer, security, etc. The computer was reimaged. This image has worked with other mills without this communication error.

In the upper left corner of the computer screen, what machine is listed after “Virtual Reality CNC Milling - ???” ? See attached Machine Type.jpg. Micromill 2000

Remove the back panel of the machine.
With the power ON, What color is the 7-segment LED Display on the control card? Green Upper left corner above the RS-232 cable connection.
What is on the display? A “2”, a “-“, an “8”, etc. there are 19 different symbols. 2
Is there a “.” (dot) on the display? no dot
Is it flashing? no

Replace the fuse on the control card. It’s on the lower right corner of the card, between 2 “black boxes” (Rectifiers). It is a 6.3 amp fuse, Radio Shack P/N 270-1068. Checked fuse OK did not replace

You said you have a working cable. Is it the “LINDY” RS-232 cable that came with the machine? Yes
We have had problems with other cables (ie Radio Shack).
If you’re good with a soldering iron, you can build a 9-to-9 pin test cable. Attached are instructions.
The link has a color diagram viewtopic.php?t=544&highlight=rs232+

Have you tried re-installing the VR Milling software? A file maybe corrupted. Use “Add/Remove Programs” in the computers Control Panel to delete VR Milling.
Go to the Denford website and download VR Milling v2.31Done that

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You have the wrong machine selected.

In VR Milling,
Click on the SETUP tab
Select “Setup Machine Parameters”
Password denny (lower case sensitive)
Click OK
Scroll through the machines and RIGHT click on MICROMILL 2000 NS
Select “Set As Active Machine”
Click OK to close the window

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There is no NS sticker next to the micromill 2000 on the tag. I already thought this might be the problem, and changed the machine parameters with the same result. Are you sure it is a NS machine?

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Yes, the green LED Display is on the newer NextStep and NextMove control cards.
The older cards (SmartStep & DenStep) have a Red LED Display.
The "2" on the LED Display is a good sign, the card is ready and waiting for a signal from the computer.

You said you have other mills that are working. Have you tried switching computers and cables with these mills?

We have had problems with other schools that re-imaged (ghosted) their software on to new computers.

Install a brand new 6.3 amp fuse on the control card. The element in the fuse may have fractured and is not allowing enough current to flow.

You may need to build the 9 to 9 pin test cable. It could be the cable. the socket/pins on the cabinet, or the internal cable.

Try a different computer, possible comm port problem.

You may need to schedule a service call with a tech.

[Martin]

According to the record sheet the machine is fitted with a NextStep non USB card.

It may be worth downloading the latest "Denford Machine Firmware EasyUpgrader " from the Denford website & try to connect to the card.

Also make sure that the Green LED on the card is lit.

If the problem persists you could try running WorkBench that is on the VRMilling cd supplied.