How to Retrofit FANUC CRT to LCD — 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 szkongto01@foxmail.com for a free on-site assessment and customized solution.