Section 07, Troubleshooting, 10 LCD Plus

Section 7:
Troubleshooting
This information is subject to the controls of the Export Administration Regulations [EAR].
This information shall not be provided to non-U.S. persons or transferred by any means to
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Section 7: Troubleshooting BK8053-000006 Rev A
Revision History
Rev ECO Author Date Description of Change
A -- CAD 01/15/2014 Released
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
Page 7-2
BK8053-000006 Rev A Section 7: Troubleshooting
Table of Contents
7.0 Troubleshooting......................................................................... 7-4
7.1 Corner, Edge and Hole Quality ..................................................................... 7-4
7.1.1 Corner Parameters .............................................................................. 7-4
7.1.2 Rough Edges ....................................................................................... 7-5
7.1.3 Small Holes ......................................................................................... 7-5
7.2 Feedrate Potentiometer ................................................................................ 7-6
7.2.1 Maximum Feedrate Not Displayed ...................................................... 7-6
7.2.2 Minimum Feedrate Not Displayed ....................................................... 7-6
7.3 Backlash Compensation ............................................................................... 7-7
7.3.1 Measure the Backlash ......................................................................... 7-7
7.3.2 Change Backlash Parameters ............................................................. 7-8
7.3.3 Example ............................................................................................... 7-8
7.4 Motion Troubleshooting ................................................................................ 7-9
7.4.1 Encoder Troubleshooting .................................................................... 7-9
7.4.2 Confirm Accurate Values for TicksPerMeter ..................................... 7-10
7.4.3 Special Considerations When Using the XX-Axis: ............................ 7-10
7.5 Motor / Drive Troubleshooting ..................................................................... 7-11
7.6 E-Stop Troubleshooting .............................................................................. 7-12
7.6.1 Phantom II (AC, DC or External Drives) ............................................ 7-12
7.6.2 PhantomST II (AC or External Drives) .............................................. 7-13
7.7 Startup and Motion Configuration Handling ................................................ 7-14
7.7.1 ConfigTable.ini ................................................................................... 7-14
7.7.2 BurnyLoadParams.ini ........................................................................ 7-14
7.7.3 HMI.ini................................................................................................ 7-14
7.7.4 Startup Sequence of Operation ......................................................... 7-15
7.8 Error Messages and Warnings ................................................................... 7-16
7.8.1 Startup Error: 1 (Can’t load initialization table file) ............................ 7-16
7.8.2 Startup Error: 3 (Cannot load Motion Configuration file) ................... 7-16
7.8.3 Startup Error: 4 (Cannot load General Setup file) ............................. 7-16
7.8.4 Configuration File Update Error ......................................................... 7-17
7.8.5 Cannot preload default motion configuration..................................... 7-17
7.8.6 Critical motion param set to default. Motion Denied ......................... 7-18
7.8.7 Errors occurred while saving the data (Error Trapping) .................... 7-19
7.8.8 Software Limit Warning (SW Limit) ................................................... 7-19
7.8.9 Consumable Statistics Warnings (Oxy Starts or Plasma Starts)....... 7-20
7.9 Fixing Corrupt Files and Software ............................................................... 7-21
7.9.1 Overview ............................................................................................ 7-21
7.9.2 Available Tools .................................................................................. 7-22
7.9.3 Configuration Backup ........................................................................ 7-23
7.9.4 System Backup.................................................................................. 7-24
7.9.5 User Image ........................................................................................ 7-25
7.9.6 Factory Image .................................................................................... 7-28
Page 7-3
7.0 Troubleshooting
7.1 Corner, Edge and Hole Quality

7.1.1 Corner Parameters
When a part is run, the change in direction that occurs from one line segment to another is
checked. If the change in direction is less than the MinCornerAngle, no slowdown will
occur at the intersection of the two segments (see Example 1). If the change of direction is
greater than the MaxCornerAngle, the torch will decelerate to a stop then accelerate in the
new direction based on the setting of the MaxAcel parameter (see Example 2).
When the angle of the change in direction, from one line segment to the next, falls between
MinCornerAngle and MaxCornerAngle, the two line segments will be connected with an arc
if the CorneringSpeed is not set to 0 (see Example 3). Setting CorneringSpeed to 0 allows
for stopping in the corners and no arc is created. When set above 0, an arc is created in
order to go through the corner without dropping below the CorneringSpeed. If the
CorneringSpeed is increased, the size of the arc will increase in order to keep the velocity
from falling below the CorneringSpeed. The GoalPointTolerance parameter sets the
maximum radius of the arc that is created. If GoalPointTolerance is set high, a larger arc
can be created and a smoother transition will occur. If GoalPointTolerance is set low, the
radius of the arc is limited and the velocity through the corner will be allowed to fall below
the CorneringSpeed setting.
The following examples are used to visualize these settings.
4° change
in direction
60° change
in direction
98° change
in direction
GoalPointTolerance = Higher Value

GoalPointTolerance = Lower Value
Direction Direction Direction

of Motion of Motion of Motion
Example 1: Example 2: Example 3:

If MinCornerAngle = 5, If MaxCornerAngle = 90, If the change of direction falls between
then there is no slowdown then motion stops in the MinCornerAngle and MaxCornerAngle
in the corner. corner before continuing. (and CorneringSpeed is greater than
zero) an arc is added for a smooth
transition. GoalPointTolerance is used
to determine the radius of the arc.
Page 7-4
7.1.2 Rough Edges

Some CAD systems output part programs with arcs that consist of many small line
segments. Part programs that were created through tracing or scanning usually have the
same segmented arcs. To get these segmented arc parts to run smooth without slowing
down at every segment junction, start by experimenting with the setting of the
MinCornerAngle parameter. The default setting of 11 will cause most junctions to run
without slowing down but if the system is fairly responsive, some roughness may be
observed due to the abrupt direction change between segments. A setting of 5 may be
good to allow only the slightest direction changes to run without slowing down and the
abrupt direction change will be less noticeable. The other junctions, more than 5 degrees,
will be smoothed by the arc that is created to join them. If CorneringSpeed and
GoalPointTolerance are set fairly high, the connecting arcs will have a larger radius and the
junctions will run faster and smoother. If the values are set too high, the amount of
rounding in the corners that occurs may be unacceptable.
If the MaxCornerAngle parameter is set fairly low, any direction changes sharper than the
setting will only occur after the torch comes to a stop. The default value of 22 is usually
acceptable for the slower speeds of Oxy/Fuel cutting. If some rounding in the corners is
acceptable, it may be better to set the value higher to keep the torch moving in the corners.
A value of 90 or 100 is usually a good value for plasma cutting to accomplish this.
7.1.3 Small Holes

ArcAcelDerate is used to make smaller holes cut slower. Even if the machine
characteristics will allow a small radius hole to cut at a fairly fast speed, this is often
undesirable when cutting thicker material. This parameter actually modifies the MaxAcel
response based on the radius of the holes. A value of 100 will produce no additional
slowdown based on radius. Experiment with a value of 50 and go up or down from there to
achieve the desired response.
Page 7-5
7.2 Feedrate Potentiometer

7.2.1 Maximum Feedrate Not Displayed
Situation: The known maximum feedrate of the cutting machine is 500 Inch./Min, but when
the feedrate potentiometer (POT) is turned to the maximum clockwise position the
displayed value in the Feedrate Window is something different, like 499.95 Inch./Min.
Resolution: Calibrate the feedrate potentiometer for maximum range.
To do this, turn the feedrate POT to its maximum clockwise position and then press the
Status Window at the bottom of the screen. The value inside the Override box should
match the value displayed on: Home>Utilities>System Setup>Motion Configuration>
IO Configuration ⇒ SpdPotMaxPer. If they don’t match, first make sure the POT is
turned completely clockwise. If they still don’t match, continue below.
With the POT still set to the maximum clockwise position, go to: Home>Utilities>Dictionary
Viewer and select: IOCMC || WorldOut || w_ADC1 (or w_ADC0 for an external feedrate
pot). Note the value displayed.
Press Home>Utilities>System Setup>Motion Configuration. Enter the value noted above
for IO Configuration ⇒ SpdPotMax. Press Send and then Save to File to complete the
procedure.
7.2.2 Minimum Feedrate Not Displayed

Situation: The feedrate potentiometer (POT) is turned to the minimum counterclockwise
position, but the displayed value in the Feedrate Window is not zero (0.000).
Resolution: Calibrate the feedrate potentiometer for minimum range.
To do this, turn the feedrate POT to its minimum counterclockwise position. Go to:
Home>Utilities>Dictionary Viewer and select: IOCMC || WorldOut || w_ADC1 (or w_ADC0
for an external feedrate pot). Note the value displayed.
Press Home>Utilities>System Setup>Motion Configuration. Enter the value noted above
for IO Configuration ⇒ SpdPotMin. Press Send and then Save to File to complete the
procedure.
Page 7-6
7.3 Backlash Compensation

Backlash is defined as the lost motion that occurs in gearboxes and belt drive systems
when changing direction. It occurs on systems where the encoder is mounted on the end
of the motor.
The CNC controls and maintains the exact position of the motor based on encoder
feedback, but the position of the drive pinion will not be exact due to backlash. If there is
any looseness in the gear train, the machine may not move the proper distance and, thus,
reduce the accuracy of the machine.
The backlash compensation procedure teaches the CNC how much lost motion is present
in the gear train. A small adjustment is made to compensate for this lost motion every time
a motor reverses direction.
7.3.1 Measure the Backlash

1) Confirm that all mechanical components of the drive train are mounted securely.
2) Load the test program SquareX.CNC (located on D:\Burny\CNC) then select it to run
from the RUN menu.
3) On the Job Setup Screen (Run02), press the Row/Column button and change the
Scale Factor to 0.025. This will cause the part to be a 0.10” square instead of the
normal 4” square. This part has no lead ins/outs and it finishes where it started.
4) Change the Cut Mode to Single Step Test Run and the Test Feedrate to 1 in/min.
5) Press OK to run the part.
6) Press the GO membrane button again and again to run the part one line at a time.
Observe the motion and determine the best place to mount the dial indicator to
measure the actual travel distance of the first axis being tested.
7) Mount the dial indicator and zero the dial.
8) On the Status Screen (Status01), select the REL button then zero each display by
pressing the X and Y buttons.
9) Press the GO membrane button again and again to run the part one line at a time.
After each move, compare the dial indicator value to the value shown for the axis being
tested on the Status Screen. The display will indicate that the machine should have
moved to either 0.1” or back to 0”. The dial indicator will usually show that the axis
stopped several thousandths short of those positions.
This shortfall is the backlash, or lost motion for that particular axis.
10) Make a note of the amount of backlash measured for the axis being tested.
11) Repeat this procedure for the remaining axes.
Page 7-7
7.3.2 Change Backlash Parameters

1) Login as an Administrator.
2) Press Home>Utilities>System Setup>Motion Configuration.
3) Enter the backlash value measured for the appropriate parameter. Because the unit is
meters, make sure to multiply by 0.0254 if the backlash was measured in inches.
• AxisX ⇒ Backlash ( units = meters )
• AxisY ⇒ Backlash ( units = meters )
• AxisXX ⇒ Backlash ( units = meters)
4) Press Send, and then measure the backlash again using the steps above.
5) Press Save to File and select BurnyLoadParams.ini to complete the procedure.
7.3.3 Example
After a line of the test program is run, the Status Window indicates that the machine moved
from 0.000 to 0.100 in the X-Axis, but the dial indicator only shows 0.085” of movement.
This means there was 0.015” of lost motion due to the backlash. Set the AxisX ⇒
Backlash parameter to 0.000381 meters (0.015 X 0.0254).
Page 7-8
7.4 Motion Troubleshooting

1) Disengage the pinions from the rack.
2) Change FollowingErrorLim and Stop Following Error to 100 on both axes.
3) If rack mounted encoders are used, skip to step 5. Otherwise, continue to step 4.
4) Jog again and observe Amp Output on the check screen.
• A 10V reference with the motor not turning indicates a motor, drive or cable
problem. See these specific troubleshooting items listed below.
• A 10V reference with the motor running fast may indicate a problem with encoder
feedback. See these specific troubleshooting items listed below.
• A 10V reference near or at full speed indicates a speed scaling problem.
Confirm that the drives run at full speed with no more than 9.5V.
• An oscillating motor may indicate a motor tachometer problem.
5) Temporarily put both axis in “Partial OpenLoop” by setting the following parameters:
• DefaultAff ..................... 0
• DefaultDGain ............... 0
• DefaultIGain ................. 0
• DefaultPGain ............... 0
• DefaultVff .................... Do not change
• FollowingErrorLim ........ 100 (already done in step 2)
• Stop Following Error .... 100 (already done in step 2)
6) Jog in all directions and check for drive drift, correct rotation and proper speeds.
7.4.1 Encoder Troubleshooting

• Check the Status Window to see if the X-Axis and Y-Axis positions change. To
check if the XX-Axis position is changing, use the I/O Status screen to observe
the XX encoder pulses or Dictionary Viewer.
• Check if the encoder is turning. Check for loose set screws, belts etc. Check for
a faulty encoder cable. Confirm proper setting of back panel encoder DIP
switches.
• Use an oscilloscope or meter to check for proper encoder signals
Page 7-9
7.4.2 Confirm Accurate Values for TicksPerMeter

Because the TicksPerMeter parameters were determined while still in the Open Loop
mode, a small amount of servo drive drift may have resulted in slightly inaccurate values.
Perform the following steps to confirm that the TicksPerMeter values are accurate:
1) Mark the rail with a fine line using a method that can be easily repeated accurately
after the axis is moved.
2) Press the Status Window to display the Status01 screen. Change the display to “Rel”
(relative) and reset the X and Y coordinates to zero by pressing both the X and Y
buttons at the top of the screen.
3) Press the GOTO membrane button. Select Increment Jog and enter a distance to
move for the axis being tested. Enter a distance that is as large as practical to ensure
accurate results. Take into consideration the length of the rails and the means to
measure it accurately.
4) Press a jog direction key to move the selected distance in the selected direction, then
make a second mark when the machine stops.
5) Press Cancel to prevent a second Increment Jog, then move the machine out of the
way so a measurement can be made.
6) Measure between the two marks and record the actual distance traveled.
7) Use the following equation to calculate the new TicksPerMeter value:
Displayed Distance
New TicksPerMeter = x Current TicksPerMeter
Measured Distance
8) Enter the New TicksPerMeter value into parameter table and then press Send.
9) Repeat the above steps to confirm the new TicksPerMeter value or to test the other
axis and slave axis, if used.
7.4.3 Special Considerations When Using the XX-Axis:

The TicksPerMeter value for the X-Axis is automatically used for the XX-Axis. You can
test for proper operation of the XX encoder by doing the following:
1) Confirm that the X-Axis TicksPerMeter value is accurate using the steps above.
2) Disengage the Master X side pinion to ensure that only the XX motor will move the
machine during the test.
3) To avoid abrupt, fast movements while only one pinion is engaged, temporarily reduce
JogAcel and MaxAcel to 0.1 or 0.05. You can also temporarily set MaxVel and
MaxJogVel to a lower value for slower movements during this testing. (0.1 for about
236 IPM)
4) Follow steps 1 through 6 above making the marks and measurements on the XX rail. If
the Measured Distance does not equal the Displayed Distance, there may be a
problem with the XX side encoder or mechanical drive components. Check that all
related components and set screws are tight.
5) Re-engage the Master X side pinion and restore the Acel and Velocity parameters to
their original values.
Page 7-10
7.5 Motor / Drive Troubleshooting

• Check for any fault indicators on drive. Refer to the appropriate drive manual for
troubleshooting.
• Check all motor cables for shorts, cuts, or other damage.
• Check continuity of all motor cable and confirm no shorts to earth ground.
• Check DC motor armature / tach brushes.
Page 7-11
7.6 E-Stop Troubleshooting

7.6.1 Phantom II (AC, DC or External Drives)
1) If the green Reset light comes on when the Reset button is pressed, (even if it does not
stay on), the 24V E-Stop circuit is good and the Burny motion controller status is OK. If
the Reset light does not stay on, make sure the ribbon cable from RECP1 on the Front
Panel card to RECP2 on the Relay Card is connected properly. Re-seat the cable to
be sure.
2) Observe the initial screen displayed after boot-up and confirm the following:
• Controller Mode - "CMC IO card present, full control"
• Status - "Initialization done" If the message is "Critical motion param set to
default. Motion denied", check the parameter tables for new parameters. They
will be highlighted orange. These new parameters must be acknowledged before
the control will reset.
3) Press and release the E-Stop button. If the control was powered up with the button
already released, it must be cycled before a Reset will work.
4) Confirm that the "OK ToRun Type" parameter is set to 1.
5) Observe GPI 1A 30 on the ALL GP I/O screen to confirm that the Reset key is
functioning properly.
6) Check for 24 VDC at the E-Stop button terminals. If 24 VDC is not present, check the
following:
• If an external E-Stop button is not used, a jumper must be installed across pins
25 & 26 of 10 RECP.
• Check the E-Stop circuit fuse - F9 on the Relay Card
• Check the 24 VDC ISO power supply for good 24V
7) If the E-Stop resets, but the "External Stop" message does not clear, check the
following:
• Check for any drive fault LEDs and investigate any drive faults
• The AC servo drives MUST have the correct parameter file loaded.
• If using the internal AC servo drives, confirm that the encoders are connected
properly.
8) If an XX-Axis motor is not present or is not to be controlled by the CNC, check the
XX-Axis encoder input on the CNC back panel. A jumper should be installed between
pins 7 and 11. Refer to Section 3: Installation and Section 4.6.1.
NOTE:
The Crash Sensor input and the Travel limits must be satisfied for proper operation but they
are NOT required to successfully reset the E-Stop.
Page 7-12
7.6.2 PhantomST II (AC or External Drives)

1) If the green Reset light comes on when the Reset button is pressed, (even if it does not
stay on), the 24V E-Stop circuit is good and the Burny motion controller status is OK.
2) Observe the initial screen displayed after boot-up and confirm the following:
• Controller Mode - "CMC IO card present, full control"
• Status - "Initialization done" If the message is "Critical motion param set to
default. Motion denied", check the parameter tables for new parameters. They
will be highlighted orange. These new parameters must be acknowledged before
the control will reset.
3) Press and release the E-Stop button. If the control was powered up with the button
already released, it must be cycled before a Reset will work.
4) Confirm that the "OK ToRun Type" parameter is set to 1.
5) Observe GPI 1A 30 on the ALL GP I/O screen to confirm that the Reset key is
functioning properly.
6) Check for 24 VDC at the E-Stop button terminals. If 24 VDC is not present, check the
following:
• If an external E-Stop button is not used, a jumper must be installed across pins
25 & 26 of 10 RECP.
• Check the E-Stop circuit fuse - FU2 on the Back Panel Card
• Check the 24 VDC ISO power supply for good 24V
7) If the E-Stop resets, but the "External Stop" message does not clear, check the
following:
• Check for any drive fault LEDs and investigate any drive faults.
• The AC servo drives MUST have the correct parameter file loaded.
• If using the internal AC servo drives, confirm that the encoders are connected
properly.
8) If an XX-Axis motor is not present or is not to be controlled by the CNC, check the
XX-Axis encoder input on the CNC back panel. A jumper should be installed between
pins 7 and 11. Refer to Section 3: Installation and Section 4.6.1.
NOTE:
The Crash Sensor input and the Travel limits must be satisfied for proper operation but they
are NOT required to successfully reset the E-Stop.
Page 7-13
7.7 Startup and Motion Configuration Handling

The Motion Configuration and the Human Machine Interface (HMI) settings are maintained
in specific files that are critical to the startup of the Burny Software. These files contain
information that is vital for the operation of the motion as well as default information for the
operator's convenience. The list below shows these filenames and directory locations.
• ConfigTable.ini ............. D:\Burny\SystemIni\
• HMI.ini.......................... D:\Burny\SystemIni\
• BurnyLoadParams.ini .. D:\Burny\Ini\
See Section 7.8 for possible error messages when there are problems with these files.
7.7.1 ConfigTable.ini
This file contains the actual filenames of the HMI settings file and the Motion Configuration
file. The names are typically HMI.ini and BurnyLoadParams.ini. The following is the typical
contents of the ConfigTable.ini file.
[ConfigFiles]
cmcc=d:/burny/Ini/BurnyLoadParams.ini
general=d:/burny/SystemIni/Hmi.ini
7.7.2 BurnyLoadParams.ini
This file contains all of the information that is displayed in the Motion Configuration (Util10)
screen. This information includes the Homing parameters, Axis tuning parameters, motor
setup, Tool offsets and more.
7.7.3 HMI.ini
This file contains information relating to frequent interaction with the Burny Software. The
following describes the information maintained in the HMI.ini file.
• Default part programming language, i.e. Word Address, ESSI, Aux Code.
• English/Metric units
• Left/Right plate side
• Language, i.e. English, Spanish, etc.
• Default cut process, Plasma or OXY/Fuel
• Default process feedrates.
• Default program format.
• RS-232 settings
• Network settings, including subdirectories
• FTP settings, including subdirectories
Page 7-14
7.7.4 Startup Sequence of Operation
Start
Display MESSAGE
BOX.
"Can't load
ConfigTable.ini
Read configuration file
Create
ConfigTable.ini ERROR Default Settings have
ConfigTable.ini File
been established
Cycle power on the CNC
Startup Error: 1"
Display MESSAGE
BOX
"Configuration File
Update Update Error
BurnyLoadParams.ini BurnyLoadParams.ini
from Default.ini ERROR may be corrupt
Check the Motion
Parameters for
completeness and
accuracy"
STOP Burny
Establish "Can't Run" This sets "Default's Used" Software
status and "Critical Defaults Used"
status'
Display MESSAGE
BOX
Read and Load "Cannot load Motion
ERROR
BurnyLoadParams.ini Configuration file
Startup Error: 3"
Display MESSAGE BOX

Read and Load "Cannot load General
HMI.ini ERROR Setup file
Startup Error: 4"
Burny Software
Initializes
Display in Burny
Is "Default's Yes Splash screen STATUS
Area
Used" set "Default motion
TRUE? parameters applied.
Check values"
No
Display in Burny
Splash screen STATUS
Is "Critical
Default's Used"
Yes Area
"Critical motion param set
set TRUE?
to default. Motion denied"
IN RED LETTERS
No
Done
Page 7-15
7.8 Error Messages and Warnings

7.8.1 Startup Error: 1 (Can’t load initialization table file)
Error Message: Description:
During startup, the ConfigTable.ini is accessed to
get two filenames. One file contains the Human
Machine Interface data and the other file contains
the Motion Configuration data. If the
ConfigTable.ini is missing, a new one is
automatically created with the following defaults:
Human Machine Interface file is named HMI.ini
Motion Configuration file is named
BurnyLoadParams.ini
Press the OK button then cycle power to the CNC.
7.8.2 Startup Error: 3 (Cannot load Motion Configuration file)

During startup, Burny software reads and
processes the motion configuration data and the
“Automatic Update” feature is utilized. This
feature allows a previously saved motion
configuration, i.e. from previous Burny Software
version, to be updated to current requirements,
automatically.
Contact Technical Support.
7.8.3 Startup Error: 4 (Cannot load General Setup file)

Copy a previously saved HMI.ini file in the
d:\burny\SystemIni directory using Windows
Explorer. Cycle power to the CNC.
Page 7-16
7.8.4 Configuration File Update Error

There is a problem with the Motion Configuration
file. When this message box appears, default
settings are used for the motion parameters that
could not be recovered. The Burny Software
continues starting, however, it is advisable to
review the motion configuration parameters for
accuracy. Alternately, a previously saved Motion
Configuration file can be loaded.
7.8.5 Cannot preload default motion configuration.

When this message box appears, the default
Motion Configuration files are not found. The
Burny Software startup will abort. Replace the
default files from a System Backup or other
method.
Page 7-17
7.8.6 Critical motion param set to default. Motion Denied

At least one critical motion
parameter has been set to its default
value.
When this error occurs, the motors

cannot be enabled until each of the
indicated parameters in the Motion
Configuration tables have been
reviewed and edited.
Critical motion param set to

After these parameters are edited,
default. Motion denied
motion will be enabled.
ERROR – Controller not running
Editing Parameters after a Critical Motion Param Error
The parameter table and the

parameter itself change to
orange to indicate that value
needs to be reviewed.
Parameter tables containing parameters set to their default values are highlighted in
Orange. The reset parameters themselves are also highlighted in orange.
To view and edit parameters:
1) Use the Up and Down arrow buttons to highlight an orange colored parameter and then
press the Edit button.
2) Enter the correct value and press the OK button. Note that the default value may be
the correct setting. Simply press the OK button on the edit screen to continue.
3) When all orange parameters have been edited press the Send button. The parameters
are sent to the motion controller and are set to a no-warning state. The motion
controller will be enabled and motion will be allowed.
4) Press the Save to file button to save all motion configuration parameters to a file.
Page 7-18
7.8.7 Errors occurred while saving the data (Error Trapping)

Error Message: Description
When saving motion configuration
data to a file, error trapping is
performed during the save operation.
If errors occur, the error trapping
Errors occurred while saving the data
feature keeps track of the first and
First error = 5 on line: 1 last error. If one error occurs, the
UtilsError01 screen is displayed as
shown. If multiple errors are
encountered, the first and last errors
are displayed. If no errors are
encountered, this message is never
displayed.
Reload the Motion Configuration file

(BurnyLoadParams.ini) from the
initial software installation.
7.8.8 Software Limit Warning (SW Limit)

When the SW Limit Warning is active, this feature displays warnings if the part is too large
to fit within the specified Software Limits (See Section 4.0 for more information).
If a Software Limit is exceeded then a yellow bar is displayed around the perimeter of the
Thumbnail Window on the Run03 screen. The location of the yellow bar identifies the
direction(s) in which the software limit is exceeded. In addition, a notification is added to
the offending axis (or axes) in the Status Window that reads “SW Limit” and the Status Line
changes to yellow.
This part exceeds the

software limits in the
+X and -X directions.
Check the overall size of the part and any scaling that may have been applied on the
Run02 screen.
Page 7-19
7.8.9 Consumable Statistics Warnings (Oxy Starts or Plasma Starts)

When the Maximum Number of Plasma or Oxy Starts is exceeded, the following warning
message is displayed at startup. See the Consumable Statistics screen to change the
maximum value or to reset the values.
Page 7-20
7.9 Fixing Corrupt Files and Software

7.9.1 Overview
While robust and reliable, the files and software on the CNC hard drive can become corrupt
due to improper shutdowns, malicious users, and viruses. Numerous problems may follow,
including: erratic motion, software that won’t start and missing files just to name a few.
Fortunately, the CNC hard drive and Burny Software already contain all the necessary tools
to recover from these situations.
Mechanical failure of the CNC hard drive is the one exception. This requires the faulty
drive to be replaced with a pre-programmed hard drive. Contact Technical Support for
more information.
Each tool relies upon backup files captured at an earlier point in time, hopefully before the
problem began. The Burny Software version and any third-party software versions used at
the time the backup was created may affect how the recovered software operates and what
subsequent steps are required. Further, it may be necessary to contact the OEM or
System Integrator to obtain “clean backups” if the available backups don’t fix the problem.
Backups are not available by contacting the factory.
Since it is impractical to describe how to recover from every situation, the remainder of this
section focuses on the available tools and how to use them. Sometimes a combination of
tools is required to fix a serious corruption and restore the software to the desired point.
WARNING!
Unexpected Cutting Machine Movement Can Injure.
• Initiating machine motion after restoring
a backup without reviewing machine
and motion parameters may result in
personal injury or property damage.
• Before initiating machine motion, be
sure all personnel are clear of the
machine and be prepared to activate
the machine's E-Stop mechanism.
Page 7-21
7.9.2 Available Tools

The tools shown below are in the sequence they should be attempted.
1) The most basic tool is the “Configuration Backup.” This is simply a copy of the
BurnyLoadParams.ini file, which contains all the “as tuned” settings necessary for
smooth and accurate machine motion. Restoring a Configuration Backup is the first
thing to try when the message “Critical motion param set to default” occurs at startup.
A Configuration Backup should have been created just after the Motion Setup and
Drive Tuning procedure was completed. Additional Configuration Backups should be
created each time changes are made to the parameters in the motion configuration
tables (Util10 screen). Store all Configuration Backups in a safe location, like a PC
hard drive and/or network server in case the CNC hard drive has a mechanical failure.
2) The “System Backup” tool contains all Burny Software configuration files in a single
.zip file. Restore a System Backup if a Configuration Backup does not fix the problem.
A System Backup should have been created just after the Motion Setup and Drive
Tuning procedure was completed. Additional System Backups should be created after
changes are made to Burny Software settings. Examples include: network connection
changes, adding/deleting user accounts, changing OCX options or tweaking motion
configuration parameters, etc.
The System Backup can also be used to duplicate Burny Software configurations
across multiple CNCs (same model and software version) or to configure a pre-
programmed replacement hard drive. Store all System Backup files in a safe location,
like a PC hard drive and/or network server in case the CNC hard drive has a
mechanical failure.
3) The “User Image” tool contains compressed versions of all files on the C: and D: hard
drive partitions. Restore a User Image if the Configuration Backup and/or System
Backup do not fix the problem. This can be done conveniently through the Burny
Software (Home > Drive Snapshot) or by using the Drive Snapshot™ USB stick (part
number MO-15057), which is mounted to the motherboard chassis inside the CNC
cabinet.
A User Image should have been created just after the Motion Setup and Drive Tuning
procedure was completed. Additional User Images should be created after changes
are made to Burny Software or the CNC hard drive. Examples include: installing a
newer version of Burny Software, accumulating a large number of part programs or
after installing third-party software.
4) The most extreme tool restores the “Factory Image.” Each CNC hard drive that
leaves the factory contains compressed versions of all files on the C: and D: partitions.
Only restore a Factory Image if all other tools fail to fix the problem since all settings
will be at factory default and will not be correct for the installed machine. Any Burny
Software updates previously installed will be lost. Do not attempt machine motion until
known good motion parameters are restored from a Configuration Backup or a System
Backup.
The following pages contain step by step instructions to restore existing backups and
creating new backups to use in the future.
Page 7-22
7.9.3 Configuration Backup
Restoring a Configuration Backup

IMPORTANT! Make sure the correct Configuration Backup is used because old
settings or settings from a different cutting machine may cause unsafe operation!
1) Finish running any part programs, save all work, and then log in as Administrator.
2) Press E-Stop to prevent motion until the parameter file is correctly loaded.
3) If the desired Configuration Backup is already located in: D:\Burny\INI\, skip to Step 5.
Otherwise, press: Home > Load.
4) Select the appropriate location of the Configuration Backup (network, USB, etc.).
Press Options. Select Configuration (Password Required) as the File Type.
Confirm the appropriate File Path in Connection Settings. Press OK.
5) Select the configuration file to be loaded and press OK. Press OK again when the
Load operation is done.
6) Press Home > Utilities > System Setup > Motion Configuration.
7) Press the Load from File button. Choose the Configuration Backup that was loaded
earlier and then press OK.
8) Press the Send button and then press the Save to File button.
9) Select “BurnyLoadParams.ini” from the File List and then press OK.
10) Review all machine and motion parameters before operating the CNC.
11) End of procedure.
Creating a Configuration Backup

2) Press Home > Utilities > System Setup > Motion Configuration.
3) Press the Save to File button. Press the Filename button and enter a new file name.
It is good practice to include the date, machine name, CNC unit number or similar
identification information. Press OK when finished.
4) Press OK again to save the new Configuration Backup.
5) Press Home > Store.
6) Select the desired location to store the Configuration Backup (network, USB, etc.).
Press Options. Select Configuration (Password Required) as the File Type.
Confirm the appropriate File Path in Connection Settings. Press OK.
7) Select the Configuration file to be stored and press OK.
8) Press OK when the Store operation is done.
Page 7-23
7.9.4 System Backup
Restoring a System Backup

This process automatically replaces all Burny Software configuration files on the C: and D:
hard drive partitions with the files contained in the System Backup, which is a .zip file.
IMPORTANT! Make sure the correct System Backup is used because old settings or
settings from a different cutting machine may cause unsafe operation!
2) Press Home > Load.
3) Select the appropriate location of the System Backup (network, USB, etc.). Press
Options. Select System Backup (Password Required) as the File Type. Confirm
the appropriate File Path in Connection Settings. Press OK.
4) Select the System Backup file to be loaded and press OK. Press OK again when the
Load operation is done.
5) A warning message about re-starting will appear. When OK is pressed, the Burny
Software will shutdown automatically. Cycle power to the CNC.
6) When the Burny Software starts up, review all machine and motion parameters before
operating the CNC.
Creating a System Backup

The System Backup automatically creates a .zip file containing all critical Burny Software
configuration files from both the C: and D: hard drive partitions.
2) Press Home > Store.
3) Select the appropriate location to store the file. This should be a safe location, like a
USB drive (then transferred to a PC hard drive) or network server in case the CNC
hard drive has a mechanical failure.
4) The name of the System Backup file to be stored will appear greyed out in the
Filename box. It automatically contains the controller unit number and the date it was
saved. Example: The file created on unit #10365 saved on January 8, 2014 would be
BURNY010365_20140108.zip.
5) Press Options. Select System Backup (Password Required) as the File Type.
Confirm or change the File Path in Connection Settings to be the root folder of
whatever location was selected. Do not use sub-folders. Press OK.
6) Press OK to save the System Backup. Press OK again when the process is done.
Page 7-24
7.9.5 User Image
Restoring a User Image (using Burny Software)

This method can only be used if the Burny Software is accessible. See the next section if
the Burny Software is inaccessible.
IMPORTANT! Make sure the correct User Image files are used because old settings
or settings from a different cutting machine may cause unsafe operation!
2) Temporarily connect a USB keyboard and USB mouse to the front panel of the CNC.
3) Use Windows Explorer to navigate to E:\User\ and then decide which User Image files
are to be used as the restore point.
4) Create a copy of the desired User Image files in the E:\User\ folder and then rename
the copied files to match the default file names. Example:
Copy of TableTuned2014-JAN-15-C-Drive.hsh rename as C-User.hsh
Copy of TableTuned2014-JAN-15-C-Drive.sna rename as C-User.sna
Copy of TableTuned2014-JAN-15-D-Drive.hsh rename as D-User.hsh
Copy of TableTuned2014-JAN-15-D-Drive.sna rename as D-User.sna
If additional .sna files (named .sn1, .sn2, .sn3, etc.) were also created, rename them as
well because they are critical to restoring a User Image.
5) In the Burny Software, press: Home > Drive Snapshot.
6) Press the Restore C: or Restore D: icon. If necessary, return to this procedure to
restore the other partition.
7) A pop-up window displays a 30 second countdown clock.
a. If restoring the drive partition is no longer desired, press the Cancel Restore icon
before the timer expires.
b. If restoring the drive partition is still desired, allow the countdown clock to expire.
The Burny Software will restart automatically.
9) Remove the keyboard and mouse.
Page 7-25
Restoring a User Image (without Burny Software)

This method can be used if the Burny Software is inaccessible.
IMPORTANT! Make sure the correct User Image files are used because old settings
or settings from a different cutting machine may cause unsafe operation!
2) Use Windows Explorer to navigate to E:\User\ and then decide which User Image files
are to be used as the restore point.
3) Create a copy of the desired User Image files in the E:\User\ folder and then rename
the copied files to match the default file names. Example:
Copy of TableTuned-2014-JAN-15-C-Drive.hsh rename as C-User.hsh
Copy of TableTuned-2014-JAN-15-C-Drive.sna rename as C-User.sna
Copy of TableTuned-2014-JAN-15-D-Drive.hsh rename as D-User.hsh
Copy of TableTuned-2014-JAN-15-D-Drive.sna rename as D-User.sna
If additional .sna files (named .sn1, .sn2, .sn3, etc.) were also created, rename them as
well because they are critical to restoring a User Image.
4) Locate the Drive Snapshot™ USB Drive (item # MO-15057). This item is shipped from
the factory mounted to the motherboard chassis, which is inside the CNC cabinet.
5) With the power off to the CNC, insert the Drive Snapshot USB Drive into an available
USB port on the front panel of the CNC.
6) Apply power to the CNC and wait for the following screen to appear:
7) Enter 2 to restore the User Image.

8) Wait for the restore process to complete; A:\>_ will be displayed.
9) Remove the USB drive and press Ctrl+Alt+Delete to reboot the CNC.
Page 7-26
Creating a User Image

It is a good idea to create a User Image whenever important changes are made to the
Burny Software.
3) Press: Home > Drive Snapshot.
4) Press the Backup System icon to automatically back up the C: and D: partitions.
5) The backup process is complete when all four of the files below have been created on
the E: partition. If desired, use Windows Explorer to watch as the files are created.
E:\User\C-User.hsh
E:\User\C-User.sna
E:\User\D-User.hsh
E:\User\D-User.sna
Important! The files shown above are automatically overwritten each time a User Image
is created. This means any previous restore points will be lost unless the file names
are changed.
NOTE: If the storage space required for a User Image is greater than 1500 MB, the
.sna file is automatically split into additional files. Each additional file is named: .sn1,
.sn2, .sn3, etc. These files are critical to restoring a User Image.
6) Use Windows Explorer to rename each of the files so they can be easily recognized as
to what configurations they contain. This also prevents subsequent User Images from
overwriting existing restore points. Example of renamed files:
E:\User\TableTuned-2014-JAN-15-C-Drive.hsh
E:\User\TableTuned-2014-JAN-15-C-Drive.sna
E:\User\TableTuned-2014-JAN-15-D-Drive.hsh
E:\User\TableTuned-2014-JAN-15-D-Drive.sna
If additional .sna files were automatically created (named .sn1, .sn2, .sn3, etc.), make
sure those files are renamed as well. Example:
E:\User\TableTuned-2014-JAN-15-C-Drive.sn1
E:\User\TableTuned-2014-JAN-15-C-Drive.sn2
Page 7-27
7.9.6 Factory Image

The Factory Image should only be used if all other tools don’t resolve the issue. The
Factory Image is stored on the E: partition in the following files:
E:\Factory\C-Factory.hsh
E:\Factory\C-Factory.sna
E:\Factory\D-Factory.hsh
E:\Factory\D-Factory.sna
IMPORTANT! The Factory Image does not contain changes made during the Motion
Setup and Drive Tuning procedure, which are critical for safe operation of the cutting
machine!
Follow these steps to restore the CNC to factory defaults:
1) Finish running any part programs, save all work, and then shut down the Burny
Software.
2) Locate the Drive Snapshot™ USB Drive (item # MO-15057). This item is shipped from
the factory mounted to the motherboard chassis, which is inside the CNC cabinet.
4) With the power off to the CNC, insert the Drive Snapshot USB stick into an available
USB port on the front panel of the CNC.
5) Apply power to the CNC and wait for the following screen to appear:
6) Enter 1 to restore the Factory Image.

7) Wait for the restore process to complete; A:\>_ will be displayed.
8) Remove the USB drive and press Ctrl+Alt+Delete to reboot the CNC.
10) If a System Backup file is not available, complete the Motion Setup and Drive Tuning
procedure before operating the CNC. If a System Backup file already exists, perform
the Restore a System Backup procedure.
Page 7-28

Section 07, Troubleshooting, 10 LCD Plus

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Section 7:

7.1 Corner, Edge and Hole Quality

GoalPointTolerance = Higher Value

Direction Direction Direction

Example 1: Example 2: Example 3:

7.1.2 Rough Edges

7.1.3 Small Holes

7.2 Feedrate Potentiometer

7.2.2 Minimum Feedrate Not Displayed

7.3 Backlash Compensation

7.3.1 Measure the Backlash

7.3.2 Change Backlash Parameters

7.4 Motion Troubleshooting

7.4.1 Encoder Troubleshooting

7.4.2 Confirm Accurate Values for TicksPerMeter

7.4.3 Special Considerations When Using the XX-Axis:

7.5 Motor / Drive Troubleshooting

7.6 E-Stop Troubleshooting

7.6.2 PhantomST II (AC or External Drives)

7.7 Startup and Motion Configuration Handling

7.7.4 Startup Sequence of Operation

Display MESSAGE BOX

7.8 Error Messages and Warnings

7.8.2 Startup Error: 3 (Cannot load Motion Configuration file)

7.8.3 Startup Error: 4 (Cannot load General Setup file)

7.8.4 Configuration File Update Error

7.8.5 Cannot preload default motion configuration.

7.8.6 Critical motion param set to default. Motion Denied

When this error occurs, the motors

Critical motion param set to

ERROR – Controller not running

Editing Parameters after a Critical Motion Param Error

The parameter table and the

7.8.7 Errors occurred while saving the data (Error Trapping)

Reload the Motion Configuration file

7.8.8 Software Limit Warning (SW Limit)

This part exceeds the

7.8.9 Consumable Statistics Warnings (Oxy Starts or Plasma Starts)

7.9 Fixing Corrupt Files and Software

7.9.2 Available Tools

7.9.3 Configuration Backup

Restoring a Configuration Backup

Creating a Configuration Backup

7.9.4 System Backup

Restoring a System Backup

Creating a System Backup

7.9.5 User Image

Restoring a User Image (using Burny Software)

Restoring a User Image (without Burny Software)

7) Enter 2 to restore the User Image.

Creating a User Image

7.9.6 Factory Image

6) Enter 1 to restore the Factory Image.

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