The control starts up in Incremental jog mode. In order to jog the axes in continuous movement, you need to press the INCR/CONT key to switch from incremental to continuous jog mode.
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The control starts up in Incremental jog mode. In order to jog the axes in continuous movement, you need to press the INCR/CONT key to switch from incremental to continuous jog mode. |
Sometimes in the initial homing attempt after power-up, the control will report "327 Fault: job cancelled" and cancel homing. If this happens, press and release Emergency Stop; jog each axis back and forth a half inch or so; and start the homing sequence again.
If desired, press the Aux3 key, then CYCLE START, to move the
machine back near the home position. This will save homing
time when the machine is restarted.
The work light will come on automatically when the machine is powered up.
You can turn the light off and on by pressing the Aux1 key on the jog panel.
You can insert and remove tools by hand when needed, using the tool clamp and unclamp pushbuttons to the right of the work area doors.
The machine has spiral chip augers on either side of the table, which drive chips out the back of the enclosure. It has a flat chip conveyer/elevator in the back which collects chips from the spiral augers and transfers them to a bin.
You can start and stop the internal chip augers using Aux keys on the jog panel.
You can start and stop the flat conveyer/elevator using the operator panel on the side of the elevator.
You can start and stop both systems in a CNC program using the listed M functions.
 or M64 |
Start internal chip augers running forward |
 or M65 |
Stop internal chip augers |
 |
Momentarily jog internal chip augers in reverse |
| FORWARD or M66 |
Start the external chip conveyer running forward |
| STOP or M67 |
Stop the external chip conveyer |
| REVERSE | Momentarily jog the external chip conveyer in reverse |
| M68 | Start both systems running forward |
| M69 | Stop both systems |
The chip augers and conveyer will automatically stop in case of emergency
stop or any fault condition. You will have to restart them when
you resume operation after clearing the fault.
The machine has a dual-winding spindle motor, with winding-selection contactors controlled through the spindle drive. Operation from 0 to 7000 RPM is possible with either winding, but you will have more torque at low speeds on the low winding, and more efficient operation at high speeds on the high winding.
The control will automatically select the most appropriate winding, based on the programmed spindle speed ("S" code), when you start the spindle with M3 or M4. In most cases, then, you will not need to take any extra steps to manage the spindle range.
| M3 S__ | Select appropriate winding and start spindle forward |
| M4 S__ | Select appropriate winding and start spindle in reverse |
| M5 | Stop the spindle |
The control will also automatically switch the spindle to the low-speed winding when it orients the spindle for a tool change.
For manual spindle operation, you can switch windings using the M41 and M42 codes, either in a program or at the MDI prompt.
| M41 | Select low-speed winding (approx. 0 to 3500 RPM) |
| M42 | Select high-speed winding (approx. 2000 to 7000 RPM) |
| M49 | Select best winding based on S code |
The B axis can index to positions in 1° increments. It must be unlocked before indexing, and locked back down when the move is complete.
You can unlock and lock the indexer using the M11 and M10 codes, either in a program or at the MDI prompt.
| M11 | Unlock the indexer |
| M10 | Lock the indexer |
The B axis indexer has a couple idiosyncrasies:
A CNC macro, "index.cnc", is provided for convenience. It unlocks the indexer, moves, and locks. It also detects failure to lock down and retries multiple times in positions surrounding the target position; and it automatically uses a lower speed for the first index after power up.
Program example:
G91 G28 Z0 G90 M11 G0 B0 ; (using explicit M functions) M10 M98 P1234 ; cut parts on first face of tombstone G91 G28 Z0 G90 G65 "index.cnc" B90 ; (using the macro) M98 P1234 ; cut parts on second face of tombstone ...
Machine zero and part zero on the B axis must be set with the pallet aligned to the pallet changer.
The control does not automatically recognize that 0° and 360° are interchangeable locations, nor does it automatically choose the shortest path. For most efficient operation, you can program a series of moves which bring the indexer all the way around, then reset machine home so that the 360° position it has arrived at becomes the new 0° position. For example, the program above might continue like this:
G65 "index.cnc" B270 M98 P1234 ; cut parts on fourth face of tombstone G91 G28 Z0 G90 G65 "index.cnc" B360 ; index the rest of the way around M26/B ; reset B axis machine zero here
To perform an automatic tool change use the M6 code, either in a program or at the MDI prompt.
E.g.
M6 T9
will put away whatever tool is in the spindle and will load tool #9.
You can also change tools using the F7/ATC option on the Setup, Offset Library, and Tool Library screens. On those screens, press F7/ATC; enter the tool number you wish to load; and press CYCLE START.
There are 200 tool entries available in the control's Tool and Offset Libraries. There are 40 useable stations ("bins") available in the machine's tool magazine. You can assign magazine bin numbers, from 1 to 40, to any tools in the Tool Library (F1/Setup, F2/Tool, F2/Tools).
For example, if you specify that tool 52 is in magazine bin 12, then when your program calls for T52, the machine will load the tool from bin 12.
You can assign more than one tool to a magazine bin.
You cannot change the bin assignment for the tool that is presently in the spindle. If this is necessary, put it away first by using M6 with a different tool number. Once the tool is back in the magazine you can change its bin assignment (and move it by hand). If you wish, you can manually remove the tool from the spindle before telling the control to put it away in the magazine and load a new tool. This will leave the magazine bin empty.
As the machine runs and changes tools, it will always put away the old tool in whatever magazine bin the new tool came out of. The control will automatically change the tool's bin assignment to reflect its new location.
When you call for a tool change, the control will retrieve the tool from whatever bin it is currently in.
In a program, you can pre-stage tools using the M107 code. This allows the tool changer to rotate to the next tool in the job and stage it in a ready position above the spindle while the preceding tool is still cutting. E.g.
M107 T21
will retrieve tool #21 while the current tool is working.
You can also save a little time by inserting an M17 code at the end of a tool's final cut, just before the tool change. M17 will shut off the spindle and coolant, then start the spindle orientation process.
For example, using both M17 and M107:
M6 T1 M107 T2 M3 S2000 G0 X-1 Y0 Z.1 G43 H1 G1 ... ... M17 M6 T2 M107 T3 M3 S1400 G0 X0 Y-1 Z.1 G43 H2 G81 ... ... ... G80 M17 M6 T3 M3 S2500 G0 X0 Y0 Z.1 G43 H3 ... G49 M25
Intercon will do these things automatically when it posts programs on the control. The above hints are useful when you are hand-writing G code programs or configuring offline CAD/CAM software.
When no tool change or other automatic cycle is in progress, you can
manually jog the tool magazine forward and back using the operator
panel next to the magazine access door on the back of the machine.
This is a convenient way to load and unload tools in the magazine.
Manual magazine rotation is only permitted when no program cycle is running and no fault condition is present (e.g. the control is not in E-stop).
The indicator LED in the MN position will light when manual magazine rotation
is enabled. If you turn the selector to MN, but the LED does not light and
the buttons do not work, check to see if a program cycle is active or if
there is a fault condition.
The pallet changer will exchange the pallet in the machining work area with the pallet in the setup area at the front of the machine.
To prepare a pallet in the setup area:
Once the pallet exchange starts, it cannot be interrupted except by Emergency Stop.
In your part program, use M60 to initiate a pallet exchange.
If the control reaches an M60 code before the setup pallet is ready, it will wait, as necessary, until you have closed the doors and pressed the green SETUP button.
When the pallet change is complete, the SETUP light will go out and the setup doors will be unlocked. You can then open the doors and start removing the finished parts.
In rare cases it may be necessary to operate the pallet changer and tool changer components manually. You can do this with the Aux keys on the jog panel, but only in "APC Maintenance Mode" and "ATC Maintenance Mode" respectively. To activate APC Maintenance Mode, press and hold the Aux13 key on the jog panel for one second. To activate ATC Maintenance Mode, press and hold the Aux14 key on the jog panel for one second. The associated Aux key light will come on, indicating that one or the other Maintenance Mode is active. To cancel Maintenance Mode, press the Aux key and hold for one second again.
Aux13 and Aux14 are the blank blue keys to the right of the Coolant control keys.
Aux10, Aux11 and Aux12 are the blank gray keys below Aux7, Aux8 and Aux9.
You must cancel Maintenance Mode before you can run normal program cycles.
There are no safety interlocks in Maintenance Mode. You must be careful, among other things, to:
To put the Y and Z axes at the G28 position, press F3 for the MDI prompt and enter:
G91 G28 Y0 Z0
In ATC Maintenance Mode, the Aux keys on the jog panel have the following functions:
|
Open Top Shutter |
 |
Close Top Shutter |
|
Orient Spindle |
 |
Overarm to Spindle |
 |
Overarm to Magazine |
 |
Pot Up |
|
Toggle drawbar charge tank relief valve |
|
Unlock Pot from Magazine |
|
Pot Down |
| Aux10 | (none) | Aux11 | Arm Reverse | Aux12 | Arm Forward |
| Aux13 | APC Maintenance |
Aux14 | ATC Maintenance |
If you have any doubt about whether the tool changer is in a known state (for example, if a fault occurred during a tool change), you should use the above Maintenance Mode controls to establish the following conditions:
Then use the F3/MDI prompt to enter:
M18
and press CYCLE START. This will home the magazine to tool 1, and reset the tool changer to the above conditions. The "tool in spindle" display on the CNC screen may be incorrect until the next tool change.
There are no safety interlocks in Maintenance Mode. You must be careful, among other things, to:
To put the X and B axes at the G28 position, press F3 for the MDI prompt and enter:
M11 G91 G28 X0 B0 M10
In APC Maintenance Mode, the Aux keys on the jog panel have the following functions:
|
APC relief valves on/off |
|
B axis unclamp on/off |
|
Coupling air blow on/off |
|
(none) | |
(none) | |
(none) |
|
(none) | |
APC Motor Reverse |
|
APC Motor Forward |
| Aux10 | (none) | Aux11 | (none) | Aux12 | (none) |
| Aux13 | APC Maintenance |
Aux14 | ATC Maintenance |
In addition to Aux8 and Aux9 above, the foot switch and the green SETUP pushbutton will operate the pallet changer motor forward and reverse, instead of performing their usual functions. This is very useful for troubleshooting, as it allows you to drive the pallet changer from in front of the machine.
DANGER You must be sure to cancel APC Maintenance Mode immediately when you are done using it. Failure to do so can cause unexpected motion of the pallet changer next time someone presses the foot switch or SETUP button.
In APC Maintenance Mode, the Aux8 and Aux9 LEDs, and also the light in the SETUP pushbutton will illuminate when the pallet changer is at its home position.
If for some reason the pallet changer did not fully return to its home position, you can use APC Maintenance Mode to drive the APC motor forward or reverse until the lights come on, then cancel APC Maintenance Mode to return to normal operation.
The following items should be done on a weekly basis:
Most servo drive parameters are set to factory defaults.
The following parameters are set to values other than factory defaults:
| Parameter | Value | Meaning |
| Pn000 | 0020 | Torque control mode |
| Pn001 | 0020 | Active decel to stop on overtravel |
| Pn10B | 0004 | Disable mode switching |
| Pn110 | 0012 | Disable online auto-tuning |
| Pn201 | 2048 | Encoder output cycles/revolution |
| Pn400 | X, Z: 100 Y, B: 50 |
Percent input for rated torque output |
| Pn407 | 1500 | Maximum RPM during torque control |
| Pn50E | 0211 | Remove /S-RDY from output SO3 (Y only) |
| Pn50F | 0300 | Put /BK (brake release) on output SO3 (Y only) |
See the Yaskawa Sigma II Series User's Manual for detailed information on these and other servo drive parameters.
The PLC program can generate various fault messages, in addition to those listed in the Centroid operator's manual.
You can use the PLC Diagnostic display on the console to view some of the Centroid PLC input and memory locations mentioned with these fault conditions. At the control's main screen, press Alt-I to activate the PLC Diagnostic display. Press Alt-I again to dismiss it.
The Diagnostic display shows four rows of red and green dots: the first row shows PLC inputs 1 through 80; the second row PLC outputs 1 through 80; the third row PLC memory bits 1 through 80; and the fourth row PLC program stages 1 through 80.
You can use the arrow keys to move a highlight box over any of these locations. The name of the highlighted location will be displayed at the bottom left.
Below the four rows of bit status information are twelve numeric ("word") variable values, labeled W1 through W10. Some of these variables also hold useful status information, described with the fault conditions to follow.
Most fault conditions must be cleared by pressing the Emergency Stop button. For this purpose, only the Emergency Stop button on the console will serve. The Emergency Stop buttons at the Setup station and the ATC Magazine panel will stop the machine in an emergency, but will not reset faults.
The MPU11 motion controller detected loss of fiber optic communication from the GPIO4D interface unit.
Check the optical fibers. Verify that they have not been bent, kinked, or pulled loose from their sockets. Verify that they are both plugged into the correct sockets (1 to 1 and 3 to 3, on both boards).
The GPIO4D interface unit reported back to the MPU11 motion controller a loss of fiber optic communication from the MPU11. This indicates that Fiber 3 is functioning normally, but Fiber 1 may have problems.
Check the optical fibers. Verify that they have not been bent, kinked, or pulled loose from their sockets. Verify that they are both plugged into the correct sockets (1 to 1 and 3 to 3, on both boards).
One or more of the Yaskawa servo drives is reporting a fault condition.
Check the LED displays on the axis drives themselves for a fault code.
Press and release Emergency Stop to clear the fault.
The Fanuc spindle drive unit is reporting a fault condition.
Check the LED display on the spindle drive itself for a fault code.
Press and release Emergency Stop to clear the fault.
You attempted to start the spindle running, or orient the spindle, with the DP-4 touch probe plugged in.
Remove the probe from the spindle and unplug the cord from the probe.
Press and release Emergency Stop to clear the fault.
The way lube tank is low on oil.
Refill, then press and release Emergency Stop to clear the fault.
During a jogging move the DP4 probe was tripped. The machine stops in order to prevent damage to the probe.
You exited the CNCM control software without first pressing Emergency Stop.
Press and release Emergency Stop to clear the fault.
You attempted to run an automatic cycle, or to start the spindle, but pressure switch PS3 was not closed to indicate adequate system air pressure.
Verify that air is connected, the shutoff is open, and the regulator is showing approximately 5 kg/cm2 (70 PSI).
Press and release Emergency Stop to clear the fault.
References:
PLC INP48: indicates PS3 state: Green = 1 = closed = pressure up; Red = 0 = low/no pressure Schematic: Line ??
The main coolant pump has tripped the overload on its starter (MS3).
Investigate possible causes for the overloaded motor.
Press the blue reset button on the overload unit, then press and release Emergency Stop to clear the fault.
References:
PLC INP33: indicates OL3 state: Green = 1 = tripped; Red = 0 = okay Schematic: Line ??
One of the spiral chip auger motors has tripped the overload on its starter (MS8A). Both motors are powered by one set of reversing contactors (MS8AF and MS8AR), but then run through separate overloads (OL8A and OL8B).
Investigate possible causes for the overloaded motor.
Press the red reset button on each overload unit, then press and release Emergency Stop to clear the fault.
References:
PLC INP35: indicates OL8 state: Green = 1 = tripped; Red = 0 = okay Schematic: Line ??
The external chip conveyer/elevator has tripped the overload on its starter (MS8C).
Investigate possible causes for the overloaded motor. Press the red reset button on the overload unit, then press and release Emergency Stop to clear the fault.
References:
PLC INP36: indicates OL8C state: Green = 1 = tripped; Red = 0 = okay Schematic: Line ??
The ATC magazine drive motor has tripped the overload on its starter (MS4F/MS4R).
Investigate possible causes for the overloaded motor. Press the red reset button on the overload unit, then press and release Emergency Stop to clear the fault.
References:
PLC INP37: indicates OL4 state: Green = 1 = tripped; Red = 0 = okay Schematic: Line ??
The ATC transfer arm motor has tripped the overload on its starter (MS5).
Investigate possible causes for the overloaded motor. Press the red reset button on the overload unit, then press and release Emergency Stop to clear the fault.
References:
PLC INP38: indicates OL5 state: Green = 1 = tripped; Red = 0 = okay Schematic: Line ??
The Y axis brake-release coil has tripped the circuit breaker (CB7) which feeds its power supply.
References:
PLC INP40: indicates CB7 state: Green = 1 = okay; Red = 0 = tripped Schematic: Line ??
The APC (pallet changer) motor has triggered an overload or fault in its variable-frequency drive unit. This is the SquareD Altivar 28 inverter mounted inside the bottom of the left cabinet door.
Check the inverter for a fault code display, then investigate possible causes for the overload or fault.
Press and release Emergency Stop to reset the inverter and clear the fault.
References:
PLC INP42: indicates APC Inverter state: Green = 1 = okay; Red = 0 = fault Schematic: Line ??
During a CNC job, with no tool change in progress, the PLC detected the tool changer arm out of its home (horizontal) position: the arm-home sensor LS72 was open, when it should have been closed.
Press Emergency Stop to clear the fault. Turn the arm motor manually or use ATC Maintenance Mode to return the arm to its home position. The arm motor is located directly above the work area doors.
References:
PLC INP69: indicates LS72 state: Green = 1 = closed = arm is home; Red = 0 = arm not home Schematic: Line ??
During a CNC job, with no pallet change in progress, the PLC detected the pallet changer out of its home position: the APC-home sensor LS249 was open, when it should have been closed.
Press Emergency Stop to clear the fault. Turn the APC motor manually or use APC Maintenance Mode to return the changer to its home position. The APC motor is located under the left side of the setup area.
References:
PLC INP54: indicates LS249 state: Green = 1 = closed = APC is home; Red = 0 = APC not home Schematic: Line ??
The way lube pump has tripped the overload on its starter (MS7).
Investigate possible causes for the overloaded motor. Press the red reset button on the overload unit, then press and release Emergency Stop to clear the fault.
References:
PLC INP34: indicates OL7 state: Green = 1 = tripped; Red = 0 = okay Schematic: Line ??
The way lube pump was activated, but pressure switch PS1 did not close to indicate that lube pressure had built up to the expected level. This may indicate leaks, open lines, or a malfunctioning pump.
The way lube pump was turned back off, but pressure switch PS1 did not open to indicate that lube pressure was bleeding back down. This may indicate clogged lines.
The oil-air lube pump for the spindle and ballscrews has tripped the overload on its starter (MS12).
Investigate possible causes for the overloaded motor. Press the red reset button on the overload unit, then press and release Emergency Stop to clear the fault.
References:
PLC INP39: indicates OL12 state: Green = 1 = tripped; Red = 0 = okay Schematic: Line ??
The oil-air lube pump was activated, but pressure switch PS5 did not close to indicate that lube pressure had built up to the expected level. This may indicate leaks, open lines, or a malfunctioning pump.
The oil-air lube pump was turned back off, but pressure switch PS5 did not open to indicate that lube pressure was bleeding back down. This may indicate clogged lines.
One of the PLCADD1616 expansion boards has failed to communicate properly with the GPIO4D board.
Check the gray PLC expansion cables that connect the offending PLCADD1616 board to the headers near the left edge of the GPIO4D board. Check for green 5V power and "PLC OK" LED indicators on the PLCADD1616 board.
The CNC software requested magazine rotation to an invalid tool position (not between 1 and 42).
This is probably due to an error in the Tool Library information. Look for invalid bin numbers in the tool library (most likely for the tool you just asked for when the error occurred).
If necessary, use the "ATC Init" feature on the Configuration screen to reset the tool library bin numbers.
During a tool putback, the tool changer detected a pot already in the magazine location where it is trying to put away the pot that is in the overarm. Either the magazine position has been lost, or an operator incorrectly placed a pot in the empty magazine position.
You attempted to start a normal program cycle with either ATC Maintenance Mode or APC Maintenance Mode active.
Check the Aux13 and Aux14 LEDs, to the right of the coolant buttons. Press and hold the related Aux key for one second to cancel Maintenance Mode.
Press and release Emergency Stop to clear the error.
The PLC program requested display of an error message, but provided an invalid message code. Notify your dealer.
The PLC program can also generate the following non-error messages, in addition to those listed in the Centroid operator's manual.
A previous PLC fiber communication fault (9023 or 9024) has been fixed and cleared.
You pressed a keyboard shortcut key for jogging the machine or starting a cycle, but those shortcuts have been disabled on this control.
A previous fault condition has been cleared by pressing Emergency Stop.
ATC magazine rotation was requested, but the magazine access door on the back of the machine is open. Close the door.
ATC magazine rotation was requested, but the magazine operation
selector on the operator panel on the back of the machine is in
the Manual ("MN") position. Switch the selector over to the
Auto ("AT") position.
