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. |
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. |
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.
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.
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.
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
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.
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
M0 | Stop (wait for Cycle Start) |
M1 | Optional Stop (wait for Cycle Start) |
M2 | Program Restart (with wait for Cycle Start) |
M3 | Spindle CW / Forward |
M4 | Spindle CCW / Reverse |
M5 | Spindle Stop |
M6 | Change Tools |
M7 | Air-Blow Coolant |
M8 | Flood Coolant |
M9 | Coolant Off |
M14* | Swing Pot Down |
M15* | Swing Pot Up |
M17 | Prepare for Tool Change |
M18 | Send ATC-Reset Request to PLC |
M19 | Orient Spindle |
M20 | Start Spindle Orient, but do not Wait for Completion |
M40 | Shift Spindle to Neutral |
M41 | Shift to Low Gear |
M42 | Shift to Mid Gear |
M43 | Shift to High Gear |
M49 | Shift Spindle to Best Range for Programmed RPM |
M50 | Index Carousel Forward One Position |
M51 | Index 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.
Parameter | Meaning | Value | Notes |
---|---|---|---|
P6 | ATC installed | 1 | Enable automatic tool changing |
P34 | Spindle encoder counts | -4096 | Encoder counts per revolution, in forward run |
P35 | Spindle axis | 6 | Use axis #6 for spindle settings |
P36 | Rigid tapping | 1 | Enable rigid tapping |
P57 | Load meters | 7 | Show PLC-controlled load meters for X, Y, and Z axes |
P78 | Spindle speed | 1 | Show actual spindle speed from encoder (required for orient logic) |
P143 | DRO display | 11 | Show load meters on DRO, plus distance-to-go display |
P146 | Feedrate threshold | 3 | Activate Feed Hold if Feedrate Override is turned down below 3% |
P160 | ATC type | 2 | Enhanced ATC, random access (swing-arm type) |
P161 | ATC tools | 20 | Number of carousel positions |
P178 | Output options | 4 | Use bipolar analog spindle speed/direction signal |
P179 | Lube pump timing | 3035 | Minutes of cycle time and seconds of pump-active time |
P720 | Tool carousel slow-time time | 100 | Time (ms) after leaving position preceding target, before slowing the carousel to its low speed. |
P721 | Tool carousel low-speed time | 1000 | Time (ms) to rotate at low speed, before extending lock pin. |
P730 | Way lube pressure-up time | 30000 | Time (ms) to run lube pump before displaying warning, if the way lube pressure switch has not closed. |
P761 | Spindle motor RPM for gear-shift assist | 30 | Speed of spindle motor movement to help gears mesh during shift |
P762 | Shift retry limit | 3 | Number of times to attempt gear shift before giving up |
P773 | Analog zero | 32752 | Analog output value for zero RPM (midpoint of range) |
P774 | Orient position | -2532 | Spindle orient position for tool changes (from 0 to -4095 counts) |
P775 | Orient window | 20 | Tolerance window, in encoder counts, for spindle to be considered in orient |
P776 | Orient Kp | 4 | Proportional gain for spindle orient PID loop |
P777 | Orient Ki | 0 | Integral gain for spindle orient PID loop |
P778 | Orient Kd | 100 | Derivative gain for spindle orient PID loop |
P779 | Orient approach speed | 0.5 | Speed during initial approach to orient position |
P991 - P993 | Servo load meters scale (Volts) | -2.5 | Analog 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.
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:
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:
Input | Sensor | Name | Arm Position |
---|---|---|---|
INP59 | LS17 | EA | Parked, A gripper to front |
INP57 | LS16 | ES | Rotated 60°, A gripper to spindle |
INP58 | LS15 | ER | Rotated 60°, B gripper to spindle |
INP60 | LS14 | EB | Parked, B gripper to front |
The PLC program can generate various fault and error messages, in addition to those listed in the Centroid operator's manual.
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.
Most fault conditions must be cleared by pressing and releasing the Emergency Stop button.
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
There was an on-board communication error on the Oak control unit.
Contact your dealer.
There was an on-board communication error on the Oak control unit.
Contact your dealer.
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
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
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
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
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
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
You exited the CNCM control software without first pressing Emergency Stop.
Press and release Emergency Stop to clear the fault.
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
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
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
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
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
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
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
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
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
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.
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.
During an attempted tool carousel rotation, the unlocking solenoid was powered, but the lock pin did not retract within the expected time (2 seconds).
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.
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).
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.
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.
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.
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.
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.
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.
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.
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:
During an automatic tool change, the tool carousel did not complete rotation to the new tool position within the expected time (max. 15 seconds).
During an automatic tool change, the spindle did not complete orientation within the expected time (max. 15 seconds).
During an automatic tool change, either the spindle tool or the carousel tool, or both, did not unclamp within the expected time (4 seconds).
During an automatic tool change, either the spindle tool or the carousel tool, or both, did not reclamp within the expected time (4 seconds).
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.
During an automatic tool change, the carousel tool pot did not swing down within the expected time (5 seconds).
During an automatic tool change, while waiting for the carousel tool pot to swing down, spindle orientation was lost.
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).
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).
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.
During an automatic tool change, the changer arm did not make its 180° rotation, to exhange tools, within the expected time (3 seconds).
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).
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.
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)
During an automatic tool change, the carousel tool pot did not swing back up to the horizontal position within the expected time (3 seconds)
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.
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.
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
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
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
A previous PLC fiber communication fault (9022 or 9023) 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.
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
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
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.
27-Nov-2023