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Current case
Customer issue
Ryan, We have not investigated the UPS connection yet. I have it on my todo list for tomorrow. Background for why this email chain was started: 1. Twice the OS Boot drive became corrupted within a few weeks of each other. 2. Second time around during review, files were identified that became corrupted. Today we removed the files that we noticed were getting corrupted. When we went to perform an inspection, the operator running the machine let me know that we had the same issue from 2023-2024 with the Inspection Programs not opening on the first try. I worked with you last time this was happening. What we found back then was the Log folder was 17 GB and the software could not write to the files in the allotted amount of time, would silently fail, and return to the program selection menu. The log folder was recreated and everything worked fine since until today. Today is the first time this has been seen happening again since late 2024. I remade the Log folder twice today and still the issue is persisting. I have remade the Log folder at the start of every year to keep it clear (those resulting folders are all about 2.5 GB which is nowhere close to what we had when it errored our previously). We also notice that the Brightness box during a program inspection in the bottom right does not show as green with a number. It has dashes and ALARM next to it. What we expect to see: [email] What we are seeing: [email] Have you had any reports of this from anyone else over the last two years? Is there a fix other than recreating the log folder? Thank you, Nolan Cassoday Manufacturing Engineer BAE Systems Electronic Systems, Controls & Avionics Solutions T: [phone] | E: [email] 4250 Airport Expressway, Fort Wayne, Indiana 46809 United States From: [email] Sent: Tuesday, June 2, 2026 11:39 AM To: Cassoday, Nolan E (US) ; Bowers, Samuel L (US) Cc: [email] Subject: Re: BAE Systems - Fort Wayne - Omron AXI External Email Alert This email has been sent from an account outside of the BAE Systems network. Please treat the email with caution, especially if you are requested to click on a link, decrypt/open an attachment, or enable macros. For further information on how to spot phishing, access "Cybersecurity OneSpace Page" and report phishing by clicking the button "Report Phishing" on the Outlook toolbar. I'll take a look at UPS manual shortly and see if there is a setting on that side of things. Normally on the 750s the UPS shuts down pc a short time after windows shuts down PC, then the electrical panel about 80sec. later. Get Outlook for iOS ________________________________ From: Cassoday, Nolan E (US) > Sent: Tuesday, June 2, 2026 11:33:44 AM To: Ryan Morrow / OEI >; Bowers, Samuel L (US) > Cc: AOISupport-US-A > Subject: RE: BAE Systems - Fort Wayne - Omron AXI The UPS battery should be good. It was just replaced. We also replaced the CMOS battery within the last month. For the entire time I have been here the machine has cut power before the PC can finish shutting down. From: [email] > Sent: Tuesday, June 2, 2026 11:27 AM To: Bowers, Samuel L (US) > Cc: Cassoday, Nolan E (US) >; [email] Subject: RE: BAE Systems - Fort Wayne - Omron AXI External Email Alert This email has been sent from an account outside of the BAE Systems network. Please treat the email with caution, especially if you are requested to click on a link, decrypt/open an attachment, or enable macros. For further information on how to spot phishing, access "Cybersecurity OneSpace Page" and report phishing by clicking the button "Report Phishing" on the Outlook toolbar. There is not, that I'm aware of. It sounds like the lead acid battery inside the UPS is dead. Can you please check what the UPS LED message (Code) reads. From: Bowers, Samuel L (US) > Sent: Tuesday, June 2, 2026 10:22 AM To: Ryan Morrow / OEI > Cc: Cassoday, Nolan E (US) > Subject: BAE Systems - Fort Wayne - Omron AXI Hi Ryan, We currently have an issue with our Omron AXI machine. When initiating a shutdown from within the AXI software, the AXI machine is cutting power to the PC before the OS can fully shutdown. Is there a way to adjust the timing to allow the OS to gracefully shutdown before the AXI machine cuts power to the PC? Thank You! Sam Bowers SPV II - IT Factory Support Enterprise Shared Services IT, BAE Systems, Inc. M: [phone] | E: [email] BAE Systems, 4250 Airport Expressway, Fort Wayne, Indiana 46809 www.baesystems.com Connect with BAE Systems: [email] [email] [email] [email] [email] [email] WARNING! This is an email from an external party. Do not click on any link or open any attachment if you cannot ascertain that it is safe. WARNING! This is an email from an external party. Do not click on any link or open any attachment if you cannot ascertain that it is safe.
Conversation
Engineer and customer thread
5 messages
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CustomerCustomer reply | Jun 5, 2026 at 8:50 AM
Ryan and Omron Team, I believe I sorted out the Brightness showing ALARM. That looks to be from remaking the Log folder and not having data saved. Forcing a calibration filled in a Brightness value for that box after remaking the Log folder. Looking at the manual for the UPS, what I see is there is software that needs installed on the computer for the communication with the UPS to work and I am not sure if we even have that software installed. Can you confirm if there is additional software that is needed for the communication between the UPS and PC to work? Also what cable is the UPS cable for the UPS and PC to communicate? How is the UPS supposed to communicate with the PC (RS232, USB, etc.)? The inspection programs not opening on the first try does continue to happen. Thank you, Nolan Cassoday Manufacturing Engineer BAE Systems Electronic Systems, Controls & Avionics Solutions T: [phone] | E: [email] 4250 Airport Expressway, Fort Wayne, Indiana 46809 United States
Omron Application EngineerOmron reply | Jun 9, 2026 at 5:41 PM
Hello Nolan, No software need to be installed, you only need to confirm some of the dip switch are as the attached procedure. The way UPS and PC communicate is by RS-232, when battery level reaches 60 %, it will send a signal to the PC to power off. Francisco Villalpando Engineering Supervisor Direct: +[phone] [email]
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CustomerCustomer reply | Jun 12, 2026 at 2:24 PM
Francisco, Ryan, I believe we are explaining the issue poorly on our end. For example, if I select “System Shutdown” from the main menu, the PC and the machine will shutdown. [email] UPS goes from “On” to “--" (which I assume means off) from that process. [email] However, the PC had not finished shutting down when the UPS switches to off. On next boot, we get a screen like the one below because Windows did not shut down successfully. The PC takes too long to shut down before the UPS is turning off. (image is from google images. It was the only one I could fine that said “Windows did not shut down successfully. Sorry for the “2 min fix” bubble in the image) [Windows Error Recovery | Blue screen starting windows | Start Windows Normally] Thank you, Nolan Cassoday Manufacturing Engineer BAE Systems Electronic Systems, Controls & Avionics Solutions T: [phone] | E: [email] 4250 Airport Expressway, Fort Wayne, Indiana 46809 United States
Omron Application EngineerOmron reply | Jun 30, 2026 at 12:57 PM
Hello Nolan, it seems this ticket is duplicated, I replaied to the other one yesterday, I'll mark this as resolved and keep wotking on the other one Hello Samuel, Nolan Please refer to attached manual, page 78. You will need to power off machine and take out a control board inside the UPS to change dip switch configuration, according to the manual you can add a delay before shut down UPS power, lets try with 60 seconds so your Switch configuration must be 1=OFF, 2= ON, 3 =ON Francisco Villalpando Engineering Supervisor Direct: +[phone] [email]
