1996 Cincinnati Milacron Falcon 200 CNC lathe machine – repair and refurbishment step 1


This time I got a very interesting client with interesting request. Client imported 1996 Cincinnati falcon 200 CNC Lathe machine. Comparatively to the new Chinese lathe machines this one is a solid beast even though it’s uses 1996 technology. Its 15 years old but still good as new.

However the machine is not working because of few faults. But all of the faults are electronic and software related faults. Below are the identified faults.

1) Acramatic 2100 Control System Real time processor board is dead
Main system is booting up properly but the real time processor board is not booting up at all. It may be because of on-board power section fault. Used boards are available but for shitty price. So not worth to buy a used board.
So I have to throw away the whole Acramatic 2100 Computer System and install a new industrial PC with a MACH4 or china GSK system, by the way which I hate to use. (Its feel like a command line PC no GUI at all. And this is almost 2016 right ?)

2) Cincinnati Milacron PSR 4/5 Power Supply Module – No power.
This must be repairable. If the proprietary controller chips are good other discrete components can be fixed. However if the power supply is completely dead I may have to remove the whole system and use new servo and spindle drivers. Will cost more but it will be an investment for the future.

3) Cincinnati Timer Relays – Dead but totally compatible with other models.

4) OAC24A (Solid State Relays) – Few of them are missing and some are not working properly. This model is kind of obsolete but still available to buy. So won’t be much of an issue.

Above are the known faults and I’ll update the project report as it develop.

Above is the DEAD PC.

k14163

And this is the CNC system

About pasanlaksiri

I am K.G. Pasan Laksiri Karunanayake and founder of OptoElectronics.lk. Since 2011 I have specialized in designing custom electronics for industrial applications. Over the years I have engineered a broad range of custom industrial products. When I work with a client I place a very high value on integrity, honesty and clear communication. With years of field experience I have learned that all business relationships are personal relationships. The more I know about the client and his project, the more I can contribute to a successful end product. After I learn about the client requirement I always give them the better understanding and clear picture about, how the end product will function in real world. In addition to the client requirement, I also offer lots of options, features and improvements. And I always very concern about the end product quality.
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