Okuma MC-5VA
with Centroid M400 Control

Startup

  1. Press in the Emergency Stop button on the console
  2. Turn on the main power switch on the rear cabinet
  3. Wait approximately one minute for the control to start up
  4. Release the Emergency Stop button to start the hydraulic system
  5. Press CYCLE START to start the machine homing sequence

The Machine Home position is fully X- (table right), Y+ (saddle out) and Z+ (head up).

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.

Idle Periods

  1. Press in the Emergency Stop button on the console. This will remove motor power from the servo drives, inhibit spindle operation, and shut off the hydraulic system.
  2. To resume operation, release the Emergency Stop button.

Shutdown

  1. Press F10/Shutdown
  2. If desired, press F1/Park and CYCLE START, to move the machine back near the home position. This will save homing time when the machine is restarted.
  3. Press in the Emergency Stop button on the console
  4. Press F2/Poweroff
  5. Wait about 15 seconds for the screen to go dark
  6. Turn off the main power switch on the rear cabinet

Work Light

The work light will come on automatically when the machine is powered up.
You can turn the light off and on by pressing the Aux7 key on the jog panel.

Drawbar (Tool Clamp) Operation

Manual Tool Change Buttons You can manually change the tool in the spindle using the buttons on the front of the head.

With the spindle stopped and no program cycle in progress, press the Tool Change Cycle button to enable manual drawbar operation.

Hold the tool securely and press the Tool Unclamp button to open the drawbar. The drawbar will remain open.

Insert the new tool into the spindle and press the Tool Clamp button to close the drawbar.

Tool Changer (ATC) Operation

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 20 usable stations ("bins") available in the machine's tool magazine. You can assign bin numbers, from 1 to 20, to any tools in the Tool Library (F1/Setup, F2/Tool, F2/Tools).

For example, if you specify that tool 52 is in bin 12, then when your program calls for T52, the machine will load the tool from bin 12.

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 bin empty.

As the machine runs and changes tools, it will always put away the old tool in whatever 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 while the preceding tool is still cutting. E.g.

M107 T21

will rotate to 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.

Manual Magazine Operation

Magazine Operator Panel

You can rotate the tool magazine and manually load and unload tools using the operator panel on the left side of the machine.

Turn the Manual Int selector On to enable manual magazine operation.

Turn the outer ring (silver hood) of the Index Start button to the CW or CCW position, as needed.

Press the Index Start button to rotate the magazine. Keep the button held down to move multiple positions.

Optionally, turn the Constant Index selector On (right) to make the magazine rotate continuously after you press and release the start button.

In constant index mode, press Index Stop to stop at the next position.

You must turn the Manual Int selector back Off when you are done, to allow the machine to perform automatic tool changes.

Gear Shifters

The machine has a hydraulically shifted 3-speed transmission in the headstock.

Gear shifting is done with M functions, either in a CNC program or at the MDI prompt:

M43

High range(1251-5000 RPM)

M42

Mid range(401-1250 RPM)
M41 Low range(1-400 RPM)
M40 Neutral(spindle free)
M49 Shift to best range for programmed RPM

In automatic operation, the M3 and M4 codes call M49 at every spindle start, automatically shifting ranges as needed.

You only need to enter M41 - M43 for manual operations.

M41 - M43 require that spindle control be in Auto mode. For use in Manual mode, switch to Auto; run the gear shift M function; and switch back to Manual.

In manual operations, it is possible to run slower than the minimum for each range listed above. For example, the minimum possible speed in high range is about 60 RPM. Thus extra shifting can be avoided, as long as full torque is not required.

To run slower than the minimum shift speed for M42 or M43 in auto mode, first start the spindle at the minimum speed, then give a slower S code. For example:

M3 S401  ; start spindle in mid range
S200     ; slow down to a low-range speed, but remaining in mid range

Axis Way Lube System

The control will automatically operate the way lube pump periodically, when running automatic program cycles. The way lube system will not operate when the machine is idle, even if the hydraulic pump is running.

Machine Parameter 179 controls the interval between way lube cycles, and the operating time for a cycle. The hundreds place of the Parameter 179 value is the lube cycle interval in minutes. The tens and ones place is the run time in seconds. For example, a value of 3035 means to run the lube pumps for 35 seconds, every 30 minutes of program cycle time.

If the oil level in the way lube tank runs low, a Fault condition will result.

Jog Panel Summary

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

No function No function No function
No function No function No function
Work Light On/Off No function No function
(Aux10) No function (Aux11) No function (Aux12) Maintenance Mode On/Off
(Aux13) No function (Aux14) No Function

Aux keys with no default function shown above are available for custom PLC-controlled features, or for features assigned through Machine Parameters 188-199. See the Configuration chapter of the M-Series Operator's Manual.

M Function Summary

M0Stop (wait for Cycle Start)
M1Optional Stop (wait for Cycle Start)
M2Program Restart (with wait for Cycle Start)
M3Spindle CW / Forward
M4Spindle CCW / Reverse
M5Spindle Stop
M6Change Tools
M7Air-Blow Coolant
M8Flood Coolant
M9Coolant Off
M14*Swing Pot Down
M15*Swing Pot Up
M17Prepare for Tool Change
M18Send ATC-Reset Request to PLC
M19Orient Spindle
M20Start Spindle Orient, but do not Wait for Completion
M40Shift Spindle to Neutral
M41Shift to Low Gear
M42Shift to Mid Gear
M43Shift to High Gear
M49Shift Spindle to Best Range for Programmed RPM
M50Index Carousel Forward One Position
M51Index Carousel Reverse One Position

* These functions are used in error recovery and maintenance, and are only available when Maintenance Mode is on.

See the M-functions chapter of the Centroid M-Series Operator's Manual for descriptions of standard M functions.

M functions M91 and above are used internally in custom macro programs, but are generally not used directly in user machining programs.

Machine Parameters Summary

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

ParameterMeaningValueNotes
P6ATC installed1Enable automatic tool changing
P34Spindle encoder counts-4096Encoder counts per revolution, in forward run
P35Spindle axis6Use axis #6 for spindle settings
P36Rigid tapping1Enable rigid tapping
P57Load meters7Show PLC-controlled load meters for X, Y, and Z axes
P78Spindle speed1Show actual spindle speed from encoder (required for orient logic)
P143DRO display11Show load meters on DRO, plus distance-to-go display
P146Feedrate threshold3Activate Feed Hold if Feedrate Override is turned down below 3%
P160ATC type2Enhanced ATC, random access (swing-arm type)
P161ATC tools20Number of carousel positions
P178Output options4Use bipolar analog spindle speed/direction signal
P179Lube pump timing3035Minutes of cycle time and seconds of pump-active time
P720Tool carousel slow-time time100Time (ms) after leaving position preceding target,
before slowing the carousel to its low speed.
P721Tool carousel low-speed time1000Time (ms) to rotate at low speed, before extending lock pin.
P730Way lube pressure-up time30000Time (ms) to run lube pump before displaying warning,
if the way lube pressure switch has not closed.
P761Spindle motor RPM for gear-shift assist30Speed of spindle motor movement to help gears mesh during shift
P762Shift retry limit3Number of times to attempt gear shift before giving up
P773Analog zero32752Analog output value for zero RPM (midpoint of range)
P774Orient position-2532Spindle orient position for tool changes (from 0 to -4095 counts)
P775Orient window20Tolerance window, in encoder counts, for spindle to be considered in orient
P776Orient Kp4Proportional gain for spindle orient PID loop
P777Orient Ki0Integral gain for spindle orient PID loop
P778Orient Kd100Derivative gain for spindle orient PID loop
P779Orient approach speed0.5Speed during initial approach to orient position
P991 - P993Servo load meters scale (Volts)-2.5Analog volts from Yaskawa servo drives, for full-scale motor load

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

Maintenance Mode

The PLC program includes a "Maintenance Mode", which allows you to manipulate the tool changer components directly. This is primarily used in error recovery, but it can also be used to test or troubleshoot ATC components in isolation.

To switch Maintenance Mode on or off, press and hold the Aux12 key for one second. Aux12 is the blank gray key in the right-most column, immediately below the Aux9 or "Tool Index +" key. The LED in the Aux12 key will light up to indicate that Maintenance Mode is active.

You must cancel Maintenance Mode before you can again run normal program cycles.

In Maintenance Mode, the jog panel Aux keys have the following special functions:

Swing Pot Down/Up Orient Spindle or Cancel Orient Unclamp/Clamp Tools
Changer Arm Up Arm 60° CW (to park) Arm 60° CCW (to grip)
Changer Arm Down Arm 180° CW (exchange) Arm 180° CCW (exchange)
(Aux10) No function (Aux11) No function (Aux12) Maintenance Mode On/Off
(Aux13) No function (Aux14) No Function

For example, if a fault occurs with the pot down and the arm rotated 60° gripping both tools, you could:

  1. Press and hold Aux12 for one second to enable Maintenance Mode
  2. Press Aux5 to rotate the changer arm back to its parked position
  3. Press Aux1 to swing the tool pot up
  4. Press and hold Aux12 for one second to cancel Maintenance Mode

Be sure to cancel Maintenance Mode when you are done. You cannot run automatic program cycles with Maintenance Mode active.

The tool changer arm has four positions, shown at right.

Each position has a sensor which signals the PLC when the arm is in that position:
InputSensorNameArm Position
INP59LS17EAParked, A gripper to front
INP57LS16ESRotated 60°, A gripper to spindle
INP58LS15ERRotated 60°, B gripper to spindle
INP60LS14EBParked, B gripper to front

Errors and Faults

The PLC program can generate various fault and error messages, in addition to those listed in the Centroid operator's manual.

PLC Diagnostic Display

You can use the PLC Diagnostic display on the computer to view some of the Centroid PLC input and memory locations mentioned with the error fault conditions below. 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 center.

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 fault and error conditions which follow.

There are multiple pages of PLC Diagnostic information. You can page sideways using the F12 and F11 keys. For example, pressing F12 once will scroll to the page showing INP81 - INP160, W11-W20, etc..

In case of ATC Faults (errors or faults during the automatic tool change cycle) make particular note of W8, on the first page. W8 is a code showing the state of most of the important signals at the time the error occurred.

Clearing Faults

Most fault conditions must be cleared by pressing and releasing the Emergency Stop button.

Fault Messages

"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

"9022 PLC Communication In Fault (Fiber 3)"

There was an on-board communication error on the Oak control unit.

Contact your dealer.

"9023 PLC Communication Out Fault (Fiber 1)"

There was an on-board communication error on the Oak control unit.

Contact your dealer.

"9025 Axis1 Drive Fault Detected"
"9026 Axis2 Drive Fault Detected"
"9027 Axis3 Drive Fault Detected"

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.

References:

PLC MEM16: Axis #1 drive status.  Green = okay, Red = fault
PLC MEM17: Axis #2 drive status.  Green = okay, Red = fault
PLC MEM18: Axis #3 drive status.  Green = okay, Red = fault
Schematic: Lines 27, 31, 35

"9030 SPINDLE FAULT!"

The spindle drive unit is reporting a fault condition.

Check the LED indicators on the spindle drive itself for a fault code.

Press and release Emergency Stop to clear the fault.

References:

PLC INP6: Spindle drive status.  Green = okay, Red = fault
Schematic: Lines 10, 101

"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 81, 90

"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 81, 90

"9034 FAULT! REMOVE PROBE FROM SPINDLE!!!"

You attempted to start the spindle, but a touch probe is plugged into the probe receptacle.

Remove the probe from the spindle, and unplug it from the probe receptacle. Then try the spindle operation again.

References:

PLC INP771: Probe detect input.  Green = probe connected, Red = probe not connected
Schematic: Line 86

"9036 LUBE FAULT"

The float switch FS3 opened, indicating that the way lube tank is low on oil.

Check and refill the lube reservoir.

Press and release Emergency Stop to clear the fault.

References:

PLC INP29: FS3 status.  Green = level okay, Red = level low
Schematic: Line 116

"9039 Software Ready Fault"

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

Press and release Emergency Stop to clear the fault.

"9041 Hydraulic System Failure"

The control tried to start the hydraulic unit, but did not see the signal to show that the unit is running within a minimum amount of time.

Check the hydraulic unit behind the machine for error indications.

Press and release Emergency Stop to clear the fault.

References:

PLC INP23:  indicates hydraulic unit status: Green = 1 = running; Red = 0 = off
PLC OUT4:  output to turn on CR3, which turns on hydraulic unit
Schematic:  Lines 15, 16, 113, 155

"9042 Lube Motor Overload"

The way lube pump has tripped the overload on its starter (MS3).

Investigate possible causes for the overloaded motor. Press the reset button on the overload unit, then press and release Emergency Stop to clear the fault.

References:

PLC INP13:  indicates OL3 state: Red = 0 = okay; Green = 1 = tripped
Schematic:  Lines 38, 105

"9043 Hydraulic Oil Level Low"

The hydraulic unit reports low hydraulic oil level.

Check the oil level and fill as needed. Press and release Emergency Stop to clear the fault.

References:

PLC INP25:  indicates oil level: Green = 1 = okay; Red = 0 = low
Schematic:  Lines 15, 114

"9044 Coolant Motor Overload"

The flood coolant pump has tripped the overload on its starter (MS7).

Investigate possible causes for the overloaded motor. Press the reset button on the overload unit, then press and release Emergency Stop to clear the fault.

References:

PLC INP14:  indicates OL7 state: Red = 0 = okay; Green = 1 = tripped
Schematic:  Lines 39, 105

"9045 Coolant Level Low"

Float switch FS4 has opened, indicating that the coolant level is low.

Check the level and refill the tank as needed. Press and release Emergency Stop to clear the fault.

References:

PLC INP30:  indicates FS4 state: Green = 1 = okay; Red = 0 = low level
Schematic:  Line 116

"9046 Spindle Lube Pump Overload"

The control has started the hydraulic unit, which includes the spindle lubrication pump. However, it did not see the signal to indicate the spindle lube pump is running. This probably means that the overload on starter MS2 in the hydraulic unit has tripped.

Check the hydraulic unit behind the machine for error indications. Press the reset button on overload OL2 at the top of the hydraulic cabinet. Press and release Emergency Stop to clear the fault.

References:

PLC INP24:  indicates spindle lube status: Green = 1 = running; Red = 0 = not running
PLC OUT4:  output to turn on CR3, which turns on hydraulic unit
Schematic:  Lines 15, 16, 113, 155

"9048 Spindle Motor Overload"

Thermal switch OL1, in the spindle motor, tripped open to indicate that the motor is overheated.

Check motor temperature. Allow motor to cool. Investigate possible causes for overloading the motor.

Press and release Emergency Stop to clear the fault.

References:

PLC INP42:  indicates OL1 status: Green = 1 = okay; Red = 0 = overheat
Schematic:  Line 127

"9049 Spindle Cooling Failure"

"9055 Control Power Circuit Breaker Tripped"

"9057 Cooling Oil Level Low"

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

One of the PLCADD1616 expansion boards has failed to communicate properly with the Oak board.

Check the gray PLC expansion cable that connects the PLCADD1616 board to the header at the bottom of the Oak board. Check for green 5V power and "PLC OK" LED indicators on the PLCADD1616 board.

On this machine, there should be three I/O expansion boards connected, and Machine Parameter 900 should be set to 7.0.

References:

PLC W36: bitmap of detected PLC expansion boards.  7 = three boards detected
Machine Parameter 900: bitmap of expected PLC expansion boards.  7 = three boards expected

"9215 TOOL CLAMP/UNCLAMP BOTH ON"

"9236 POT UP/DOWN BOTH ON"

"9290 ARM UP/DOWN BOTH ON"

"9291 ARM EA/EB BOTH ON"

"9406 Magazine Panel Emergency Stop"

Error Messages

"8058 False input closure on PLC INP17"

The PLC detected an unexpected closed circuit on a vacant input. This may indicate an electrical noise or interference issue.

Report the message to your dealer.

References:

PLC INP17: An unused input.  Green = 1 = circuit closed, Red = 0 = circuit open
Schematic: Line 110

"8098 Error: Maintenance Mode Active"

You attempted to start an automatic program cycle, but Maintenance Mode (Aux12) is still active.

Press and hold the Aux12 key for one second to cancel Maintenance Mode.

"8149 Magazine Error: Pot is not up"

During an automatic cycle to change tools or to pre-stage a tool for an upcoming tool change, carousel rotation was requested, but the magazine pot was not fully in the horizontal (up) position.

Use the Maintenance Mode controls to return the pot to horizontal.

"8150 Timeout Unlocking Tool Magazine"

During an attempted tool carousel rotation, the unlocking solenoid was powered, but the lock pin did not retract within the expected time (2 seconds).

"8151 Timeout Rotating Tool Magazine"

During an attempted tool carousel rotation, the magazine encoder did not indicate arrival at the target position within the expected time (8 seconds).

If the carousel did not rotate at all, investigate possible hydraulic issues with the rotation solenoids and motor.

If the carousel rotated, but much too slowly, investigate possible hydraulic issues with the deceleration solenoid.

If the carousel did rotate at full speed, but passed by the target position before reporting this error, investigate possible mechanical or electrical issues with the magazine rotation encoder.

"8152 Timeout Locking Tool Magazine"

During a tool carousel rotation, after arriving at the target position, the unlocking solenoid was turned off, but the lock pin did not extend within the expected time (2 seconds).

"8202 ATC BIN OUT OF RANGE"

"8204 M19 ORIENT LOST"

"8205 CANNOT TURN SPINDLE WITH TOOL UNCLAMPED"

You attempted to start or orient the spindle, or shift spindle ranges, with the spindle drawbar unclamped (open). Close the drawbar, then try the operation again.

"8207 ORIENT TIMEOUT WAITING FOR SPINDLE TO STOP"

"8208 ORIENT ERROR: FAILED TO CAPTURE INDEX PULSE"

Spindle orientation was requested, but the PLC has not yet received notice that the spindle encoder count was zeroed at the index pulse.

Usually, the spindle encoder is automatically zeroed at each M5; and if needed will also be zeroed through a short spindle rotation at the beginning of an M19.

This error can appear if you use Aux2 in Maintenance Mode to attempt an orient, without first starting and stopping the spindle in Auto mode (M5), or orienting with an explicit M19 code.

If this error appears in any other circumstances, make note of what sequence of operations led up to it, then contact your dealer.

"8211 ATC NOT READY: MZ_ACK"

You attempted to start an automatic tool change, but the flag which is used by the M6 CNC macro to report when the axes are in position, was set prematurely.

Make note of what sequence of operations led up to this condition, then contact your dealer.

"8212 ATC NOT READY: TOOL CLAMP INP"

You attempted to start an automatic program cycle, but the spindle drawbar is not fully clamped.

Check whether the tool in the spindle is properly seated. Check for proper function of the tool-clamped and tool-unclamped switches.

"8213 ATC NOT READY: TOOL UNCLAMP INP"

You attempted to start an automatic program cycle, but the spindle drawbar is unclamped (open).

Check for proper function of the tool-clamped and tool-unclamped switches, and of the tool-release solenoid valve.

"8231 ATC NOT READY: ARM NOT AT HOME"

You attempted to start an automatic program cycle, but the tool changer arm is not in a parked position (EA or EB).

Use the Maintenance Mode controls to return the arm to a parked position.

"8235 ATC NOT READY: POT NOT UP"

You attempted to start an automatic program cycle, but the tool carousel pot is not up in the horizontal position.

Use the Maintenance Mode controls to swing the pot up to horizontal.

"8241 ATC MOVE Z AXIS TIMEOUT"

During an automatic tool change, the M6 CNC macro did not report to the PLC that the Z axis was in position for the tool change, within the expected length of time.

If the reason for this is not evident, then it is possible that the error was triggered by one or more incidental signals. In order to proceed from the axis-movement stage:

"8242 ATC NEW TOOL ROTATION TIMEOUT"

During an automatic tool change, the tool carousel did not complete rotation to the new tool position within the expected time (max. 15 seconds).

"8243 ATC ORIENT TIMEOUT"

During an automatic tool change, the spindle did not complete orientation within the expected time (max. 15 seconds).

"8244 ATC UNCLAMP TIMEOUT"

During an automatic tool change, either the spindle tool or the carousel tool, or both, did not unclamp within the expected time (4 seconds).

"8245 ATC CLAMP TIMEOUT"

During an automatic tool change, either the spindle tool or the carousel tool, or both, did not reclamp within the expected time (4 seconds).

"8246 ATC END TIMEOUT"

During an automatic tool change, the M6 CNC macro did not acknowledge completion within the expected time (2 seconds).

Report this error to your dealer, along with the value of PLC word variable W8.

"8271 ATC POT DOWN TIMEOUT"

During an automatic tool change, the carousel tool pot did not swing down within the expected time (5 seconds).

"8272 ATC POT DOWN ORIENT LOST"

During an automatic tool change, while waiting for the carousel tool pot to swing down, spindle orientation was lost.

"8273 ATC ARM TO CLAMP TIMEOUT"

During an automatic tool change, the changer arm did not rotate to the tool-gripping (clamp) position (ES or ER) within the expected time (5 seconds).

"8274 ATC ARM DOWN TIMEOUT"

During an automatic tool change, the changer arm did not move down to extract the old tool from the spindle and the new tool from the carousel pot, within the expected time (3 seconds).

"8275 ATC DOWN CLAMP ERROR"

During an automatic tool change, while attempting to move the changer arm down to extract tools from the spindle and the carousel pot, the tool-unclamped switch failed to remain closed, suggesting that the drawbar has re-clamped the tool.

"8276 ATC ARM 180 TIMEOUT"

During an automatic tool change, the changer arm did not make its 180° rotation, to exhange tools, within the expected time (3 seconds).

"8278 ATC ARM UP TIMEOUT"

During an automatic tool change, the changer arm did not move up to insert the tools into the spindle and the carousel pot, within the expected time (3 seconds).

"8279 ATC ARM UP CLAMP ERROR"

During an automatic tool change, while attempting to move the changer arm up to insert tools into the spindle and the carousel pot, the tool-unclamped switch failed to remain closed, suggesting that the drawbar has re-clamped and will not accept the tool.

"8281 ATC ARM TO HOME TIMEOUT"

During an automatic tool change, the changer arm did not rotate back to its parked position (EA or EB) within the expected time (3 seconds)

"8284 ATC POT UP TIMEOUT"

During an automatic tool change, the carousel tool pot did not swing back up to the horizontal position within the expected time (3 seconds)

"8292 ATC NOT READY: ARM NOT UP"

You attempted to start an automatic program cycle, but the tool changer arm is not fully up in its idle position.

Use the Maintenance Mode controls to move the arm up.

"8452 Timeout Waiting for Spindle to Stop"

A CNC program or macro requested a gear shift, but failed to stop spindle rotation first.

Always use the supplied M3, M4, M40-M43 and M49 macros for gear shifting.

If your program uses the supplied codes, and you still get this error, contact your dealer.

"8453 Gear Shift Failure"

An attempt to shift spindle gears failed to get into the requested gear, after multiple retries.

Try shifting into a different gear range, then try the desired range again.

References:

PLC INP33:  indicates LS1 status: Green = 1 = in high gear; Red = 0 = not in high gear
PLC INP34:  indicates LS2 status: Green = 1 = in mid gear; Red = 0 = not in mid gear
PLC INP35:  indicates LS3 status: Green = 1 = in low gear; Red = 0 = not in low gear
PLC INP36:  indicates LS4 status: Green = 1 = in neutral; Red = 0 = not in neutral
PLC OUT33:  shift solenoid A, SOL1: on for neutral
PLC OUT34:  shift solenoid B, SOL2: on for high or mid
PLC OUT35:  shift solenoid C, SOL3: on for low or neutral
PLC OUT36:  shift solenoid D, SOL4: on for mid
Schematic:  Lines 123-124, 193-196

Warning Messages

"5052 Warning: Lube Low"

"5056 Fans or Work Light Circuit Breaker Tripped"

"5059 Warning: Way Lube Pressure Failure"

"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 W16: 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 three I/O expansion boards installed, and Machine Parameter 900 should be set to 7.0.

References:

PLC W36: bitmap of detected PLC expansion boards.  7 = three boards detected
Machine Parameter 900: bitmap of expected PLC expansion boards.  7 = three boards expected

Informational and Prompt Messages

"2024 PLC Faults Cleared"

A previous PLC fiber communication fault (9022 or 9023) has been fixed and cleared.

"2035 KEYBOARD JOGGING DISABLED "

You pressed a keyboard shortcut key for jogging the machine or starting a cycle, but those shortcuts have been disabled on this control.

"2099 Message Cleared"

A previous fault condition has been cleared by pressing Emergency Stop.

"2201 --- ATC Initialized ---"

"4082 Clamp Magazine Tool, press CYCLE START"

The control is attempting to start an automatic tool change, but the magazine tool unclamp lever is in the unclamped position.

Shift the lever right and down to the clamped position, then press CYCLE START

"4083 Select Magazine Auto Mode, press CYCLE START"

The control is attempting to start an automatic tool change, but manual magazine rotation is selected the magazine operator panel.

Switch the Mag Int selector on the magazine operator panel off, then press CYCLE START

"4084 Press CYCLE START to Continue"

An automatic tool change was paused due to one of the above conditions. The condition has been fixed, and the control is waiting for CYCLE START.

Wiring Schematics

Schematic Page 1 - Power and drives, logic supplies, safety relay
Schematic Page 2 - Oak unit, M400 console, PLC inputs
Schematic Page 3 - PLC outputs
Schematic Page 4 - PLC outputs, axis interface detail

27-Nov-2023