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.
The Machine Home position is fully X+ (turret up/back) and Z+ (carriage right).
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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. |
Turret positions are numbered 1 through 6. Tool offsets are numbered 1 through 99. Any offset number can be used with any turret position.
To be consistent with past procedures, I recommend measuring tool X and Z offsets relative to an "imaginary" reference tool. Part zero will be fixed (approximately at the lower left limit of machine travel), and X and Z offsets will be used to locate the part.
The procedure for this may be found at http://www.cncsnw.com/OLEL.htm, as "Method 2". However, instead of setting the part position to Z0 X4 at home, set the part position at home to the dimension specified on the job setup sheet.
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When no program cycle is active, you can index the turret to the next position using the TURRET INDEX key on the operator panel. |
In a program cycle, turret indexing is automatic, based on the first two digits of the four-digit tool number.
The machine has a hydraulically shifted two-speed headstock. Shifting is by automatic M functions and by Aux keys on the jog panel.
 | Neutral |
 | Low Range (0-240 RPM) |
 | High Range (240-740 RPM) |
IMPORTANT: You must use M41, M42, Aux5 or Aux6 to shift to one of the gear ranges before manually starting the spindle. Any fault, including Emergency Stop, will cancel the previous gear range and lock the headstock.
| M40 | Neutral |
| M41 | Low Range (0-240 RPM) |
| M42 | High Range (240-740 RPM) |
| M45 | Shift to best range based on S code |
In a program cycle, gear changing is generally automatic. Any time the program executes M3 (spindle CW) or M4 (spindle CCW) the control will execute an M45 to shift to the most appropriate gear range for the programmed RPM (low range at 240 RPM or less; high range above 240 RPM).
This will only work if the programmed spindle speed (S value) is an RPM, with constant surface speed mode canceled (G97 mode). Starting the spindle in constant surface speed mode (G96) will result in unpredictable gear shifting.
Your part programs should always start the spindle (usually just after a tool change) in G97 mode, with an RPM that is typical of the anticipated cutting speed. Once the first Rapid move towards the part is completed, you can switch to G96 mode if desired and specify a surface speed. For example:
G28 T0101 G97 M3 S190 ; start spindle at fixed RPM G0 X18 Z24.1 ; rapid until close to part G96 S250 ; switch to CSS mode and specify surface speed G1 F.01 X14 Z20 G0 X13.9 Z24.1 M5 G28 T0100
When using the conversational programming, insert a Rapid move (under F1/Line) at the beginning of the program and the beginning of each new tool. In that Rapid move, press F3 to access the "Modal" fields, then enter the new tool number; enter the desired spindle RPM; and toggle the spindle speed mode to RPM if necessary.
Use the Chuck/Unchuck selector switch to close and open the chuck.
Regardless of the position of the Chuck/Unchuck selector switch, the jaws will automatically move to the "Chuck" position when the spindle starts.
The machine can direct flood coolant to either the OD tool or the ID tool (if present) at the current station.
Use the "Flood" coolant controls (Flood key or M8) to apply OD coolant.
Use the "Mist" coolant controls (Mist key or M7) to apply ID coolant.
Use the Chip Conveyer buttons on the headstock panel, or the corresponding keys on the jog panel, to start and stop the chip conveyer.
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Start Conveyer Running Forward |
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Stop Conveyer |
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Jog Conveyer in Reverse |
In normal operation, the Auxiliary keys on the jog panel have the following functions:
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Work Light On/Off |
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Hydraulic On/Off |
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Index Turret One Position |
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Headstock Neutral |
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Headstock Low Gear |
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Headstock High Gear |
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Conveyer Jog Reverse |
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Conveyer Stop |
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Conveyer Start Forward |
| Aux10 | No function | Aux11 | No function | Aux12 | No function |
| Aux13 | Maintenance Mode On/Off |
Aux14 | Fault Reset |
In rare cases it may be necessary to operate the turret manually. You can do this with the Aux keys on the jog panel, but only in "Maintenance Mode". To activate Maintenance Mode, press and hold the Aux13 key on the jog panel for one second. The light in the Aux key will come on, indicating that 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:
In Maintenance Mode, the following Auxiliary keys on the jog panel have special functions:
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Unlock/Lock Turret (5SOL) | ||||
| Aux10 | Enable Turret Motor (11CR On/Off) |
Aux11 | Jog Turret Motor Low Speed (12CR) |
Aux12 | Jog Turret Motor High Speed (58CR) |
| Aux13 | Maintenance Mode On/Off |
Aux14 | Fault Reset |
Most servo drive parameters are set to factory defaults.
The following parameters are set to values other than factory defaults:
Parameter |
Value |
Meaning |
Pn000 |
0000 |
Velocity control mode |
Pn201 |
16384 |
Encoder output cycles/revolution |
Pn300 |
900 |
Reference Volts for rated velocity output, x100 |
See the Yaskawa Sigma II series user manual for detailed information on these and other servo drive parameters.
The PLC program can generate the following 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 the PLC input and memory locations mentioned with some of the following 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.
The hydraulic system has not yet been started. No machine operations are possible until the hydraulic system is started and Emergency Stop is released.
Press the HYDR ON key to start the hydraulic system, then release Emergency Stop.
One of the axis servo drives detected a fault. If possible, open the control cabinet and check the LED displays on the drives themselves for an alarm code.
References:
PLC INP17: indicates Z servo drive alarm state. Green = 1 = closed = okay, Red = 0 = open = fault PLC INP18: indicates X servo drive alarm state. Green = 1 = closed = okay, Red = 0 = open = fault Schematic: Lines 16, 22, 61, 63
The control was attempting to run the hydraulic pump, but control relay 21CR did not close within a reasonable time. This could be due to any of several causes:
References:
PLC INP15: indicates 21CR state. Green = 1 = closed = okay, Red = 0 = open = fault Schematic: Lines 49, 51, 52, 80
Starters 4M (hydraulic pump) and 7M (spindle cooling fan) were not both closed when expected. This is probably due to one of the following causes:
References:
PLC INP42: indicates 4M and 7M state. Green = 1 = both closed = okay, Red = 0 = either open = fault Schematic: Lines 25, 29, 46, 49, 86
The main spindle motor is overheating, and has opened its thermal sensor (1TH).
Check for excessive load, and verify that the spindle motor cooling fan is operating effectively.
Allow the motor time to cool. Press Emergency Stop to clear the fault.
References:
PLC INP12: indicates 1TH state. Green = 1 = closed = okay, Red = 0 = open = overheat Schematic: Line 78
The turret rotation motor is overheating, and has opened its thermal sensor (5TH).
Check for excessive load or drag.
Allow the motor time to cool. Press Emergency Stop to clear the fault.
References:
PLC INP13: indicates 5TH state. Green = 1 = closed = okay, Red = 0 = open = overheat Schematic: Line 79
The air pressure switch (6PS) is open, indicating insufficient air pressure to operate the way lube system.
Verify that air is connected and turned on, and that the regulator below the lube unit is set to at least 45PSI. Press Emergency Stop to clear the fault.
References:
PLC INP14: indicates 6PS state. Green = 1 = closed = okay, Red = 0 = open = low/no pressure Schematic: Line 79
One or both of the spindle lube flow switches (1FLS and 2FLS) has failed to close, indicating inadequate lube flow to the spindle and headstock.
References:
PLC INP41: indicates 1FLS/2FLS state. Green = 1 = both closed = okay, Red = 0 = either open = fault Schematic: Line 86
The coolant pump starter (6M) should be closed to run the pump, but is not.
This probably indicates that one or more of the thermal overload units on the starter has tripped due to pump overload.
Check for possible causes of the overload: plugged or jammed pump, phase loss, etc..
Press the white reset buttons on each of the three overloads.
Press Emergency Stop to clear the fault.
References:
PLC OUT3: indicates 6M request. Green = 1 = on/closed, Red = 0 = off/open PLC INP43: indicates 6M state. Green = 1 = closed, Red = 0 = open Schematic: Lines 27, 87, 99
One of the chip conveyer starters (8M/F and 8M/R) should be closed to run the conveyer, but is not.
This probably indicates that one or more of the thermal overload units on the starter has tripped due to conveyer motor overload.
Check for possible causes of the overload: jammed conveyer, phase loss, etc..
Press the white reset buttons on each of the three overloads.
Press Emergency Stop to clear the fault.
References:
PLC OUT4: indicates 8M/F request. Green = 1 = on/closed, Red = 0 = off/open PLC OUT5: indicates 8M/R request. Green = 1 = on/closed, Red = 0 = off/open PLC INP44: indicates 8M/F and 8M/R state. Green = 1 = either closed, Red = 0 = both open Schematic: Lines 31, 32, 87, 100, 101
The way lube system failed to complete its cycle, lubricating all points on the machine.
Check for blocked lines, open lines, and stuck shuttle valves.
The pattern of the turret position switches (7LS, 8LS and 9LS) does not correspond to any valid turret position. This may indicate a faulty switch, a wiring fault, or a PLC communication error.
Valid turret switch patterns are as follows:
| Tool | 7LS INP33 | 8LS INP34 | 9LS INP35 |
|---|---|---|---|
| 1 | X | - | - |
| 2 | X | X | - |
| 3 | X | X | X |
| 4 | - | X | X |
| 5 | - | - | X |
| 6 | - | - | - |
References:
PLC INP33: indicates 7LS state. Green = 1 = closed, Red = 0 = open PLC INP34: indicates 8LS state. Green = 1 = closed, Red = 0 = open PLC INP35: indicates 9LS state. Green = 1 = closed, Red = 0 = open PLC W38: records the invalid switch pattern as a binary value 0-7 Schematic: Lines 82, 83
The turret position, as indicated by switches 7LS, 8LS and 9LS, has changed without apparent cause. That is, no automatic tool change or manual turret index is taking place. This may indicate a faulty switch, a wiring fault, or a PLC communication error.
This fault may also appear if a tool change or turret index ends with the turret in the wrong position.
References:
PLC INP33: indicates 7LS state. Green = 1 = closed, Red = 0 = open PLC INP34: indicates 8LS state. Green = 1 = closed, Red = 0 = open PLC INP35: indicates 9LS state. Green = 1 = closed, Red = 0 = open PLC W38: records the incorrect tool number as a turret position 1-6 Schematic: Lines 82, 83
You attempted to start the spindle with the rolling guard open, or you opened the guard while the spindle was running.
You must close the guard in order to run the spindle.
References:
PLC INP17: indicates the door switch state. Green = 1 = guard closed, Red = 0 = guard open. Schematic: Line 80
You attempted to start an automatic program cycle, but Maintenance Mode is still selected.
Press the Aux13 key and hold for one second to cancel Maintenance Mode.
The part program requested a turret position other than T1 through T6.
Note that to cancel tool offsets at the end of a program, you must repeat the active turret position, changing only the offset portion to zero. For example "T0113" to "T0100" or "T0411" to "T0400". Programming "T000" will result in an invalid tool number error.
The turret clamp switch (10LS) did not open, or the turret unclamp switch (16LS) did not close within five seconds after the control powered the turret unlock solenoid (5SOL). If the turret visibly moved out, then this is probably a switch or switch position issue. If the turret did not move, it is probably a failure of 5SOL or the hydraulic lines that feed it.
The turret did not reach the desired station within ten seconds after starting rotation. This is probably because it is not rotating at all (failure to power the turret motor, or failure of the motor itself) or because a problem with the turret position switches is preventing the control from recognizing the target station when it comes around.
After reaching the desired station and changing to creep speed, switch 11LS did not indicate that the turret had reach the on-position detent within ten seconds. This is probably because the turret is not rotating at all (failure to power the turret motor at creep speed) or because the on-position switch (11LS) has failed.
The turret unclamp switch (16LS) did not open, or the turret clamp switch (10LS) did not close within five seconds after the control powered off the unlock solenoid (5SOL). This is probably a turret alignment issue: if the turret does not stop close enough to position, then it cannot lock down. If the turret does appear fully seated, then this error could be a switch or switch position issue.
The lube unit periodically reports a fault before completing its lube cycle. The system should be checked for clogged lines, clogged valves, and/or leaking lines. Because of this known problem, I made the lube system fault be only a warning on the control: a message will be displayed in the status message window, but operations will not be interrupted.
The spindle lube cooling flow switches (sail switches) on top of the headstock both read closed, even when the hydraulic pump is shut off. It is likely that these switches have been defeated at some time in the past. They should be restored to normal operation, to avoid the risk of spindle or headstock damage due to lube flow failure.
One of the hydraulic filter bypass switches is unplugged, presumably because it is closed (reporting a clogged filter). The switch should be plugged back in, and the filter or switch replaced as necessary to restore normal operation.
These codes usually only need to be entered once. They are stored on the control with the Machine Parameters. They should be kept on file in case the Parameters file is ever lost.
Serial Number: 100222 -- Key A (plain): 0329110322
The following are necessary to unlock software features:
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Option |
Parameter # |
Parameter Value |
2 |
Tapping cycles |
202 |
0.0000 |
3 |
Auto Tool Changer |
203 |
0.0000 |
25 |
Permanent Unlock |
298 |
0.0000 |
26 |
Intercon |
300 |
0.0000 |
