Giddings & Lewis 7" Floor Mill

with Centroid M400 Control

Startup

1. Press in the Emergency Stop button on the console
2. Switch on the main power at the magnetics cabinet
3. Wait approximately two minutes for the console to start up
4. Release the Emergency Stop button to start the hydraulic system
5. Press CYCLE START to start the machine homing sequence

Idle Periods

1. Press in the Emergency Stop button on the console. This will shut off the hydraulic system and remove motor power from the servo drives. The console will remain on, and axis positions will continue to be maintained and tracked. The servo motor holding brakes will be applied.
2. To resume operation, release the Emergency Stop button.

Shutdown

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

Spindle Speed Control

The spindle motor runs at constant speed, approximately 1760 RPM. Spindle speed is controlled with a 32-speed hydraulically shifted gearbox. The PLC automatically shifts to the appropriate gear based on the programmed spindle speed (S code).

There is no manual spindle speed control. The standard spindle speed up/down/100% buttons on the Centroid jog panel are not usable on this machine.

The M41 code shifts to the most appropriate gear for the programmed S code.

The M3 and M4 codes automatically call M41 before starting the spindle in their respective directions. Therefore speed and gear selection is generally automatic as well, without any special CNC programming required.

The spindle must be in Auto control mode, as selected on the Centroid jog panel, in order for a gear change to proceed. If you attempt to change gears while in Manual spindle mode, the control will wait indefinitely, with the message "Waiting for Auto Spindle Mode".

Gear positions (numbered 0-31) and the corresponding speeds are as follows:

*These gears were not working in July 2008, presumably due to failure of solenoid 9SOL.

Spindle Clamp and Neutral Controls

You can control the spindle clutches with the following Aux keys:

	Select spindle clamp (brake) on. LED indicates clamp requested.
	Select spindle neutral. LED indicates neutral requested.
	Select spindle normal. LED indicates neither clamp nor neutral requested.

In normal operation the spindle coasts to a stop without clamping. This reduces wear on the drive train. If you want to stop the spindle more quickly, you can apply the spindle clamp as it is coasting down.

The PLC will automatically revert to "normal" when the spindle is started.

The PLC will automatically apply the clamp while the power drawbar is engaged.

As of July 2008 spindle neutral did not seem to work. This is probably due to a failure of solenoid 16SOL.

Quill Operation

You can control the quill with the following Aux keys:

	Turn quill clamp on and off. LED indicates clamp on.
	Traverse quill in (Z+ direction). LED indicates at limit.
	Traverse quill out (Z- direction). LED indicates at limit or spindle interlock.
	Turn quill feed mode on and off. LED indicates feed mode on.

The quill clamp can be activated at any time. The Aux1 LED indicates that the clamp is selected.

The quill may be traversed in as long as it is not clamped or in feed mode, and it is not already at its quill-in limit. The Aux2 LED indicates that the quill is at its quill-in limit.

The quill may be traversed out as long as it is not clamped or in feed mode; is not already at its quill-out limit; and has not caught up with the Z axis (tripping the spindle/quill interlock switch). The Aux3 LED indicates that the quill is either at its quill-out limit or is at the spindle/quill interlock switch.

In quill feed mode, the quill travels in and out with the Z axis. Quill feed mode can be engaged as long as neither a quill limit switch nor the spindle/quill interlock switch is tripped. In other words, both the Aux2 and Aux3 LEDs must be off in order to engage quill feed mode. The Aux6 LED indicates that quill feed mode is engaged. Quill feed mode will be automatically disengaged if the quill reaches any limit or interlock switch (allowing the Z to continue moving alone).

If the quill is extended, it is possible to trip the Z axis plus overtravel switch against the quill, even though the Z may be well out from its home position. In this case the Z axis may report a stall condition ("410 Z axis position error" or "411 Z axis full power w/o motion") and the Z axis servo drive in the control cabinet will display "Pot". To clear this condition, use the Aux2 quill traverse key to move the quill clear of the Z axis.

In manual operation, you can use the Aux3 LED as a warning that the Z axis is close to the quill.

If you wish to run CNC programs with the quill extended, you will need to change the G28 return position for the Z axis to a position that is safely out in front of the quill, so that the Z-to-home movement of the M25, M6, M2 and G28 codes does not cause overtravel. The G28 return position is under F1/Setup, F1/Part, F9/WCS, F1/Return. See pages 4-5 and 4-6 in the Centroid M-Series Operator's Manual. The Z value you enter will always be negative.

Drawbar Operation

To clamp a tool

1. Insert the tool holder in the spindle.
2. Turn the selector to the tool-in position and hold it until it comes up tight. This is usually indicated by a slight rotation of the spindle.
3. Release the selector

To unclamp a tool

1. Hold onto the tool holder.
2. Turn the selector to the tool-out position until the tool holder comes free.
3. Release the selector

The instructions taped to the headstock, and the Allen-Bradley current sensor in the magnetics cabinet, are obsolete.

Yaskawa Servo Drive Parameter Settings

Most servo drive parameters are set to factory defaults.

The following parameters are set to values other than factory defaults:

See the Yaskawa Sigma II series user manual for detailed information on these and other servo drive parameters.

Errors and Faults

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.

"436 OPTIC1 fault"

The OPTIC1 servo drive interface board in the control cabinet is reporting a fault condition.

Check optical fibers 4 and 5 from the console to the OPTIC1 board; check power in and out of switching power supply PS1; check the 3-wire fault cable from the OPTIC1 board to the PLC unit. Press and release Emergency Stop to clear the fault.

References:

PLC INP62:	indicates the OPTIC1 fault condition.  Green = 0 = okay, Red = 1 = fault.
PLC OUT64:	latches fault until reset with Emergency Stop: Red = 0 = okay, Green = 1 = fault latched
Schematic:	Line nn

"9001 Primary Motor Overload"

Either the spindle motor or the counterbalance hydraulic pump motor has tripped its overload relay in the magnetics cabinet.

Investigate possible causes and reset the tripped overload. Press Emergency Stop to clear the fault.

References:

PLC INP5:	indicates the overload state. Green = 0 = okay, Red = 1 = 1MOL or 2MOL tripped
Schematic:	Line nn

"9002 Secondary Motor Overload"

One of the following seven motors has tripped its overload relay in the magnetics cabinet:

4M: Drawbar and quill drive motor

7M: Large pressure pump on main hydraulic unit

8M: Headstock lube pump on main hydraulic unit

9M: Headstock sump pump, vertical on back of headstock

11M: Scavenger pump on bottom of headstock

20M: Outdoor cooling fan for main hydraulic system

21M: Circulation pump for outdoor cooling loop, on main hydraulic unit

Investigate possible causes. Press Emergency Stop to clear the fault.

References:

PLC INP7:	indicates overload state: Green = 0 = closed = okay. Red = 1 = overload tripped
Schematic:	Line nn

"9003 Coolant Flow Failure"

The control has attempted to start the coolant pump, but the sail switch FC1 has indicated no flow for two seconds or longer.

Investigate possible causes. Press Emergency Stop to clear the fault.

Possible causes include:

• Low coolant in the coolant tank
• Obstruction in the coolant tank or lines
• Damage to the hoses or lines
• Overload of the coolant pump motor.

Note that the coolant pump starter (12M) is not part of the "Secondary Overload" circuit check above. The only indication that the pump has tripped its overload is absence of coolant flow.

References:

PLC INP18:	indicates flow switch state: Green = 0 = closed = flow; Red = 1 = open = no flow.
Schematic:	Line nn

"9004 Main Hydraulic Overheat"

Thermal sensor 2TH in the main hydraulic power unit has opened, indicating an oil temperature over 140°F.

Investigate possible causes, in particular failure of the outdoor cooling circuit. Allow the system to cool down, then press Emergency Stop to clear the fault.

References:

PLC INP4:	indicates 2TH sensor state: Green = 0 = closed = okay; Red = 1 = open = overheat.
Schematic:	Line nn

"9005 CB Hydraulic Overheat"

Thermal sensor 1TH in the counterbalance hydraulic unit has closed, indicating an oil temperature over 140°F.

Investigate possible causes, in particular failure of the adjacent fan cooling circuit. Allow the system to cool down, then press Emergency Stop to clear the fault.

Note that the counterbalance thermal sensor 1TH is normally-open, where the main hydraulic thermal sensor 2TH is normally-closed.

References:

PLC INP20:	indicates 1TH sensor state: Green = 0 = closed = overheat; Red = 1 = open = okay.
Schematic:	Line nn

"9006 Yaskawa Servo Drive Fault"

One of the three axis servo drives has reported a fault. Check the LED displays on the servo drives themselves, in the upper part of the control cabinet, to find out which drive is faulted and what the fault code is. Refer to the Yaskawa Sigma II Series Servo System User's Manual for detailed information on the LED displays and fault codes.

Investigate and resolve possible causes. Press Emergency Stop to clear the fault.

References:

PLC INP61:	indicates circuit state: Green = 0 = okay; Red = 1 = at least one drive in fault condition
Schematic:	Lines 12, 17, 22 and 85

"9007 CB Hydraulic Failure"

Emergency Stop has been released and power applied to the counterbalance hydraulic starter for at least five seconds, but control relay 3CR has not closed to indicate adequate counterbalance hydraulic pressure.

Investigate possible causes, in particular failure of the outdoor cooling circuit. Allow the system to cool down, then press Emergency Stop to clear the fault.

References:

PLC INP6:	indicates 3CR sensor state: Green = 0 = closed = okay; Red = 1 = open = low or no pressure.
Schematic:	Line nn

"9010 Internal PLC Fault"

The Centroid PLC interpreter software has encountered an error while processing the PLC logic. Notify your Centroid dealer and service technician.

References:

PLC W2:	indicates numeric fault code