Berthiez BM160
with Centroid T400 Control

Daily Operation

Startup

1. Switch on main switch, on cabinet in back
2. Wait for console to boot and display "Home not set"
3. Release Emergency Stop
4. Press the HYDRAULIC PUMP key (Aux1) to start the Hydraulic system
5. Press CYCLE START to find and set machine home

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 Emergency Stop to remove power from the servos and shut down the hydraulics.
2. To resume normal operation, release Emergency Stop, then press the HYDRAULIC PUMP key to restart the hydraulics.

Shut Down

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

Tool Setting

I recommend measuring tool X offsets relative to an imaginary tool nose, and Z offsets relative to an actual tool.

The procedure for this may be found at http://www.cncsnw.com/OLEL.htm, as "Method 3". However, on this machine the arbitrary X axis position set at machine home with no tool offset should be comparable to the maximum swing (e.g. 144").

Turret Controls

You can rotate the tool turret manually or with an M function.

Indexing by tool number is not provided.

	Rotate tool turret. You must hold the key down until the turret stops at the next position.
M6	Index to next turret position.

Note: as of November 2009, the tool turret is not operational

Table Rotation Controls

You can control table ("spindle") rotation speed and direction manually with jog panel keys, or automatically with program codes.

Note that table direction is judged by tool direction. "Forward" or "Clockwise" is the direction you would run a standard twist drill. This is opposite how you would ordinarily judge "clockwise" and "counterclockwise" if you were looking down at the face of the table.

The spindle must be in Auto mode in order to use programmed M and S codes. The spindle must be in Manual mode in order to use the jog panel keys.

Switch between Auto and Manual control modes.

In manual mode, you can control operation and direction with these keys:

	Select spindle forward (CW tool)
	Select spindle reverse (CCW tool)
	Start spindle
	Stop spindle

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

In constant-RPM mode (G97) the S code specifies RPM. In constant surface speed mode (G96) the S code specifies SFM (surface feet per minute).

In either mode, you can further control speed with these keys:

	Increase speed
	Set speed to 100% of programmed speed (Auto mode) or to half of maximum speed (Manual mode)
	Decrease speed

Table Jog for Setup

With the table stopped, you can momentarily jog it around at low speed with these keys:

	Jog table CW (looking down at table)
	Jog table CCW (looking down at table)

Note that these two keys show rotation from the operator's viewpoint, rather than reflecting tool direction.

Gear Shifters

The machine has a hydraulically shifted two-speed gearbox.

You can shift gears manually with jog panel keys, or automatically with M functions:

	Shift to high range (9-140 RPM)
M42
	Shift to low range (2-33 RPM)
M41

Overarm Jogging

Overarm movement is powered by a 7.5HP motor on top of the column, which turns the elevation screw through a right-angle gearbox.

You can jog the overarm up and down manually whenever the hydraulic system is running and no program cycle is active. The control will automatically release the hydraulic clamps when you press a jog key, and will automatically reclamp when you release the jog key. Before movement starts there will be a short delay in order to give the clamps time to release.

	Jog overarm up
	Jog overarm down

Table Base Jogging

The table base is moved by a hydraulic piston. Movement is aided by a pneumatic "float" system which directs air pressure underneath the table base.

You can jog the table base left and right manually whenever the hydraulic system is running, the table is not turning, and no program cycle is active. The control will automatically release the clamps when you press a jog key, and will automatically reclamp when you release the key. Before movement starts there will be a short delay while the control waits for the pressure switches to indicate the clamps are released.

	Jog table base left
	Jog table base right

Work Lights

The work lights will come on automatically when the control starts up. You can switch the lights off and on as needed using the jog panel key:

Switch work lights on and off

Overarm Lube System

The PLC will power the Bijur lube system whenever a program cycle, or the MDI prompt, is active.

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.

Hitachi Spindle Drive Parameter Settings

Most spindle drive parameters are set to factory defaults.

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

See the Hitachi SJ300 manual for detailed information on these and other spindle drive parameters.

Errors, Faults and Warnings

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 NOPTIC1 fault"

The NOPTIC1 servo drive interface board in the control cabinet is reporting a fault condition.

Check optical fibers 4 and 5 from the console to the NOPTIC1 board; check power in and out of switching power supply PS1; check the 2-wire fault cable from the NOPTIC1 board to the PLC unit. Press and release Emergency Stop to clear the fault.

References:

PLC INP62: indicates the NOPTIC1 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 94, 129, 130

"9001 Hydraulic Lube Pressure Failure"

The hydraulic system is running, but pressure switch Fc14 on the hydraulic power unit has not closed to indicate adequate pressure for the hydraulically fed lubrication systems.

References:

PLC INP21: indicates Fc14 state: Green = 0 = closed = pressure up, Red = 1 = open = low pressure.
Schematic: Line 85

"9002 Shifter Pressure Failure"

The hydraulic system is running , but pressure switch Fc45 on the hydraulic power unit has not closed to indicate adequate pressure to operate the gearbox shift cylinders.

References:

PLC INP22: indicates Fc45 state: Green = 0 = closed = pressure up, Red = 1 = open = low pressure.
Schematic: Line 86

"9003 Table Base Lift Pressure Failure"

While attempting to jog the table base the control powered solenoid ESS to apply air pressure to float the base, but pressure switch Fc18 on the pneumatic panel did not close to indicate adequate air pressure.

Check supply pressure; check for leaks in the lines to the table base; and check operation of the pressure switch.

References:

PLC INP26: indicates Fc18 state: Green = 0 = closed = pressure up, Red = 1 = open = low pressure.
Schematic: Line 88

"9004 Hydraulic Motor Overload"

The hydraulic pump motor overloaded and tripped the overload relay (OL2) on its starter (M2).

References:

PLC INP8: indicates OL2 state: Green = 0 = closed = tripped, Red = 1 = open = okay.
Schematic: Line 79

"9005 Scavenger Pump Overload"

The scavenger pump (return pump from the table base) overloaded and tripped the overload relay (OL3) on its starter (M3).

References:

PLC INP9: indicates OL3 state: Green = 0 = closed = tripped, Red = 1 = open = okay.
Schematic: Line 80

"9006 Arm Elevation Motor Overload"

The overarm elevation motor overloaded and tripped the overload relay (OL4) on its starter (M4U/M4D).

References:

PLC INP10: indicates OL4 state: Green = 0 = closed = tripped, Red = 1 = open = okay.
Schematic: Line 80

"9007 Spindle Brake Unit Fault"

The spindle drive dynamic brake unit (HBU-4220, inside the right cabinet door) has reported a fault or is not receiving power.

If the drive has been performing frequent braking, allow time for the brake unit to cool. Check fuses F19 and F20. Press Emergency Stop to clear the fault.

"9008 Spindle Brake Resistor Overheat"

One or more of the dynamic brake resistors for the spindle drive has overheated. Allow time for the resistors to cool, then press Emergency Stop to clear the fault.

References:

PLC INP14: indicates thermal sensor state: Green = 0 = closed = ok, Red = 1 = open = overheat.
Schematic: Line 82

"9009 Yaskawa Servo Fault"

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 INP20: indicates drives state: Green = 0 = closed = okay, Red = 1 = open = fault.
Schematic: Line 85

"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 variable W2: indicates error code.

Informational Messages

These messages do not indicate fault conditions, but provide useful information.

"9099 --- Fault Cleared ---"

A previous fault condition has been reset with Emergency Stop.

"2101 Arm not locked"

You attempted to start a cycle, but the overarm clamps were not locked.

"2102 Arm not unlocked"

You attempted to jog the overarm up or down, but the clamps failed to unlock.

"2103 Table base not locked"

You attempted to start table rotation, but the table base clamps were not locked.

"2104 Table base not unlocked"

You attempted to jog the table base left or right, but the clamps failed to unlock.

"2105 Arm at top limit"

You attempted to jog the overarm up, but it is on its top overtravel switch.

"2106 Arm at bottom limit"

You attempted to jog the overarm down, but it is on its bottom overtravel switch.

Software option unlock codes

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: 30175 -- Key A (plain): 0529081682

The following are necessary to unlock software features:

1. If at the demo mode expired screen, start at step 7.
2. Go to the Main screen of the Control software.
   (Setup, Load, MDI ... across the bottom of the screen)
3. Press <F1> to enter the Setup screen.
4. Press <F3> to enter the Configuration screen.
5. Type "137" in the window which asks for the password.
   Press <ENTER> to accept this.
6. Press <F3> to enter the Parameters screen.
7. Press <F1> and enter parameter number.
8. Enter parameter value and then press <ENTER>.
9. Repeat step 7 and 8 for each new parameter value.
10. When finished with all parameters press <F10> to save.