FANUC CRT to LCD Upgrade — Practical Installation Case —Kongto Technology Case Study
Keywords: FANUC CRT to LCD retrofit, LCD conversion, CNC display upgrade, industrial display
Target Audience: CNC engineers, factory equipment managers, industrial automation integrators
1. Project Background
A precision machining factory in Shenzhen operates 15 FANUC 0i-MC CNC milling machines, all equipped with original 9-inch CRT displays manufactured between 2003-2008. After 15+ years of continuous operation, these CRT displays exhibited the following issues:
- Screen flickering and brightness degradation (over 60% reduction from original)
- Intermittent display failures causing unplanned production stoppages
- Color distortion affecting operator ability to read tool position data
- High-voltage circuit failures requiring increasingly frequent repairs (average 3 service calls per machine per year)
Annual maintenance costs per machine: approximately CNY 3,600 (parts + labor + production loss from downtime).
2. Solution Design
Kongto Technology proposed a comprehensive CRT-to-LCD retrofit solution:
| Component | Specification | Quantity |
|---|---|---|
| FANUC A61L-0001-0093 LCD Display | 9-inch TFT-LCD, 800x600, 350 cd/m² | 15 units |
| Signal Adapter Cable | HONDA 20-pin to VGA | 15 units |
| Mounting Kit | Stainless steel brackets + screws | 15 sets |
| Anti-Glare Filter | 9-inch optical grade | 15 units |
Total project cost: CNY 52,500 (CNY 3,500/unit including installation)
Expected annual savings: CNY 54,000 (CNY 3,600/machine/year in reduced maintenance + downtime)
ROI period: Less than 12 months
3. Installation Process
A team of 2 technicians completed all 15 machines in 3 days (approximately 4-6 hours per machine):
Day 1: Machines 1-5
- Power off and verify complete discharge of CRT high-voltage circuit (wait 30 minutes after power-off)
- Remove original CRT display from mounting bracket (4 screws + HONDA 20-pin + 24V power)
- Install LCD display using original mounting holes, connect HONDA 20-pin adapter cable
- Power on and calibrate display settings in FANUC system parameters
- Run 2-hour burn-in test to verify stability
Day 2: Machines 6-10
Installation proceeded faster after the team optimized the workflow. Average time per machine reduced to 3.5 hours.
Day 3: Machines 11-15 + Final Testing
All 15 machines completed. Comprehensive system testing performed across all machines simultaneously.
4. Results & Benefits
| Metric | Before (CRT) | After (LCD) | Improvement |
|---|---|---|---|
| Display Brightness | ~120 cd/m² (degraded) | 350+ cd/m² | +192% |
| Annual Failure Rate | 3 incidents/machine/year | 0 incidents (first 6 months) | -100% |
| Power Consumption (per display) | 30W | 8W | -73% |
| Annual Maintenance Cost (total) | CNY 54,000 | CNY 0 (under warranty) | -100% |
| Operator Satisfaction | Frequent complaints about eye strain | No complaints reported | Significantly improved |
5. Customer Feedback
"The LCD upgrade has transformed our shop floor. Operators report significantly less eye fatigue during long shifts, and we haven't had a single display-related downtime incident since installation. The investment paid for itself within the first year through eliminated repair costs alone."
—Factory Equipment Manager
6. Conclusion
This case study demonstrates that FANUC CRT-to-LCD retrofit delivers:
- Immediate elimination of display-related production stoppages
- 73% reduction in display power consumption
- Complete ROI within 12 months
- Significantly improved operator working conditions
For similar retrofit projects, contact Kongto Technology at [email protected] for a free on-site assessment and customized solution.