Cincinnati Milacron flat tape layer
with Centroid M400 Control

Startup

1. Switch on the main switch, on the electrical cabinet
2. Wait for console to boot and display "Home not set"
3. Release Emergency Stop
4. Press CYCLE START to find and set machine home

The Machine Home position is fully X- (bridge to left), Y- (carriage to front), Z+ (head up) and C to center (zero degrees).

Idle Periods

1. Press Emergency Stop to remove power from the servo drives, heaters, etc.
2. To resume normal operation, release Emergency Stop. If prompted, press Cycle Start to re-sync the paired X motors.

Shut Down

1. Press F10/Shutdown
2. Optionally, press F1/Park
to move the axes back near the machine home position. This will save time on the next startup and homing sequence.
3. Press Emergency Stop
4. Press F2/PowerOff
5. Wait for CNC console display to go fully blank (about 15 seconds).
6. Switch off the main switch, on the electrical cabinet

Tape Reel Controls

You can control the feed reel and takeup reel manually with jog panel keys, or automatically with program codes.

During setup and tape loading, you can control operation with these keys:

	Jog feed reel forward (leaving takeup reel free)
	Jog reels forward (from feed reel to takeup reel)
	Jog reels reverse (from takeup reel to feed reel)

In Auto mode, you can control operation with these codes:

In laydown mode, the reels apply constant tension to the tape, with a slight bias in the forward direction (towards the takeup reel).

Laydown mode should only be activated (M80) once the tape is in contact with the mold surface. Laydown mode should be cancelled (M81) before lifting off the mold surface.

The rollback operation (M82) is intended to bring the leading point of a diagonal cutoff back under the compactor (or roller), in preparation for starting the next course.

Prior to calling M82, the CNC program should set the desired rollback distance (in inches, as a positive value) in CNC variable #16.

Heater Controls

The chute heater system can be operated with automatic M functions, as follows:

C Axis Positions

The C axis is programmed in degrees of rotation. While laying tape, the CNC program must call out the correct angle on the C axis to keep the tape head aligned with the course.

• 0° is the X+ direction
• 90° is the Y+ direction
• ±180° is the X- direction
• -90° is the Y- direction

C axis travel is limited to ±190°. If the machine is laying tape at +135°, and the next course requires -135°, then the head must rotate the long way around (270° minus, instead of 90° plus).

Jog Panel Summary

In normal operation, the Auxiliary keys on the jog panel have the following functions:

	Jog feed reel forward		Jog tape reels forward		Jog tape reels backward
	No function		Force lube cycle *		No function
	Work lights on/off		Jog V axis minus (left)		Jog V axis plus (right)
Aux10	No function	Aux11	Jog B axis minus (CCW)	Aux12	Jog B axis plus (CW)
		Aux13	Special functions *	Aux14	Maintenance Mode On/Off

* To force a lube cycle, press the Aux5 key while holding the Aux13 key.

M Function Summary

M functions M93 and above are used internally in custom macro programs, but are generally not used directly in user machining programs.

See Chapter 13 of the Centroid M-Series Operator's Manual for descriptions of the higher-numbered M functions.

Machine Parameters Summary

The following parameters on the Centroid Machine Parameters table are used for features specific to this machine.

For all other Machine Parameter functions, see Chapter 14 of the Centroid M-Series Operator's Manual.

Faults, Errors and Warnings

The PLC program can generate several fault, error and warning 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 and error conditions. At the control's main screen, press Alt-I to activate the PLC Diagnostic display. Press Alt-I again to dismiss it.

Each page of 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 in the center of the screen below the red and green dots.

For example, in the illustration above the highlight box is on Output #42: The dot below the 2, to the right of the superscript 4, on the second line.

Below the four rows of bit status information are ten numeric ("word") variable values, labeled W1 through W10. Some of these variables also hold useful status information, described with the error and fault conditions to follow.

There are multiple pages of Diagnostic data. With the Alt-I diagnostic display showing, you can use the F12 and F11 keys to scroll right and left. For example, pressing F12 once will shift to the page showing inputs and outputs 81 through 160, and word variables W11 through W20.

Clearing Faults

Messages with 9000-series message numbers are Faults. After resolving the problem, you must press and release the Emergency Stop button to clear a Fault.

Messages with 8000-series message numbers are Errors. Errors will cancel the program cycle and stop the spindle and coolant, but they do not then need to be explicitly reset.

Messages with 5000-series and 2000-series message numbers are Warnings and Informational Messages. They do not cancel the cycle or require any action to reset.

"9001 !!! PLC EXECUTION FAULT !!!"

The control detected an internal error in processing the PLC logic program.

Report this error to your dealer, along with the values from W14 and W15. Also report what function the machine was performing when the fault occurred.

You must shut down and cycle the power to clear this fault.

References:

PLC W14: Copy of internal SV_PLC_FAULT_STATUS, indicating the type of problem
PLC W15: Copy of internal SV_PLC_FAULT_ADDRESS, indicating the location of the problem

"9031 Jog Panel Communication In Fault"

The control unit detected loss of communication from the operator panel in the Console.

Check for damage or disturbance to the cable between the console and the Oak control unit in the control cabinet.

Press and release Emergency Stop to clear the fault.

References:

Schematic: Lines 93, 106

"9032 Jog Panel Communication Out Fault"

The operator panel reported back to the control unit a loss of communication from the control unit. This indicates the return signal from the pendant is functioning normally, but the outgoing signal may have problems.

Check for damage or disturbance to the cable between the console and the Oak control unit in the control cabinet.

Press and release Emergency Stop to clear the fault.

References:

Schematic: Lines 93, 106

"9039 Software Ready Fault"

You exited the CNCM control software without first pressing Emergency Stop.

Always press Emergency Stop prior to exiting the control software.

Press and release Emergency Stop to clear the fault.

"9045 Safety Bumper Tripped: Press Emergency Stop to Clear"

One of the safety bumpers surrounding the head was bumped.

Verify that the bumpers are clear, then press and release Emergency Stop to clear the fault.

References:

PLC INP__: indicates monitoring relay (4CR) state.  Green = closed = okay, Red = open = tripped
Schematic: Lines __

"9046 Machine Emergency Stop Pressed"

One of the rope-pull emergency stops, on the supporting frame, was pressed.

Reset the auxiliary emergency stop switch, then press and release the console Emergency Stop button to clear the fault.

References:

PLC INP__: indicates safety relay (1SR) state.  Green = closed = okay, Red = open = tripped
PLC INP__: indicates console emergency (PB1) state.  Green = closed = okay, Red = open = tripped
Schematic: Lines 132, 147, 150

"9061 Mini PLC 1 Communication Fault"
"9062 Mini PLC 2 Communication Fault"
"9063 Mini PLC 3 Communication Fault"
"9064 Mini PLC 4 Communication Fault"

The control lost communication with one or more of the PLC I/O expansion boards.

Power down, open the cabinet, and check the connections at both ends of the gray cables which connects H8 - H11 on the Oak unit to H3 on the three PLCADD1616 boards, and to H2 on the ADD4AD4DA board.

Power up and check for green "PLC OK" LED indications on each of the expansion boards.

References:

PLC W36: bitmap of detected PLC expansion boards.  15 = four boards detected
Machine Parameter 900: bitmap of expected PLC expansion boards.  15 = four boards expected
Schematic: Lines 108, 155, 169, 180

"5100 BAD MESSAGE VALUE"

The PLC program requested display of a message on the screen, but the provided message code was not valid.

This indicates an error in the PLC program. Report the message to your dealer, along with the value in PLC variable W16.

References:

PLC W__: stores the invalid message code

"510n Unconfigured Mini PLC nn Found"

The PLC hardware detected the presence of an I/O expansion board, but the setting of Machine Parameter 900 did not tell it to expect that board in the system.

On this machine, there should be four I/O expansion boards installed, and Machine Parameter 900 should be set to 15.0.

References:

PLC W36: bitmap of detected PLC expansion boards.  15 = four boards detected
Machine Parameter 900: bitmap of expected PLC expansion boards.  15 = four boards expected

"2021 Axis Faults Cleared"

A previous servo drive fault condition has been resolved, and cleared with Emergency Stop.

"2024 PLC Faults Cleared"

A previous PLC fault condition has been resolved, and cleared with Emergency Stop.

"2035 KEYBOARD JOGGING DISABLED"

You inadvertently pressed a keyboard combination that is used for keyboard jogging controls, but keyboard jogging features have been disabled on this machine.

"2099 Message Cleared"

A previous fault condition has been cleared with Emergency Stop.

Wiring Schematics

Axis and Drive Numbering

The order of the axis drives; order of the axis definitions in the control configuration menus; and order of the axis jogging controls vary. Definitions are as follows: