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 Machine Home position is fully X- (table right), Y+ (saddle out) and Z+ (head up).
The spindle will rotate for a short time during the homing sequence. Make sure it is safe to rotate with whatever tool may be in the spindle.
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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. |
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The work light will come on automatically when the machine is powered up. You can turn the light off and on by pressing the Aux3 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.
You must turn the Manual Int selector back Off when you are done, to allow
the machine to perform automatic tool changes.
In rare cases it may be necessary to operate the tool changer components manually. You can do this using "Maintenance Mode".
To activate Maintenance Mode, press and hold the Aux14 key for 5 seconds. The Aux14 LED will light to indicate that Maintenance Mode is active.
Aux14 is the rightmost blank blue key to the right of the Coolant control keys.
In Maintenance Mode you can use the other Aux keys to directly operate the tool changer components.
 |
Swing Pot Down/Up |  |
(Lube) |  |
(Work Light) |
 |
Changer Arm Up |  |
Arm 60° CCW (to park) |  |
Arm 60° CW (to grip) |
 |
Changer Arm Down |  |
Arm 180° CCW (exchange) |  |
Arm 180° CCW (exchange) |
| Aux10 | (none) | Aux11 | (none) | Aux12 | (none) |
| Aux13 | (none) | Aux14 (5s) | Maintenance Mode On/Off |
For example, if a fault occurs with the pot down, arm rotated 60°, and tools unclamped, you could:
Be sure to press cancel Maintenance Mode when you are done. You cannot run automatic program cycles (including MDI mode) 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:
| Sensor Input | Name | Arm Position |
|---|---|---|
| INP67 | EA | Parked, A gripper toward spindle |
| INP65 | ES | Rotated 60°, A gripper toward spindle |
| INP66 | ER | Rotated 60°, B gripper toward spindle |
| INP68 | EB | Parked, B gripper toward spindle |
The PLC program can generate various fault 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 these 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 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 conditions to 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 W29, on the third page. W29 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 MPU11 motion controller detected loss of fiber optic communication from the GPIO4D interface unit.
Check the optical fibers. Verify that they have not been bent, kinked, or pulled loose from their sockets. Verify that they are both plugged into the correct sockets (1 to 1 and 3 to 3, on both boards).
The GPIO4D interface unit reported back to the MPU11 motion controller a loss of fiber optic communication from the MPU11. This indicates that Fiber 3 is functioning normally, but Fiber 1 may have problems.
Check the optical fibers. Verify that they have not been bent, kinked, or pulled loose from their sockets. Verify that they are both plugged into the correct sockets (1 to 1 and 3 to 3, on both boards).
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.
The spindle drive unit is reporting a fault condition.
Check the LED display on the spindle drive itself for a fault code.
Press and release Emergency Stop to clear the fault.
You exited the CNCM control software without first pressing Emergency Stop.
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 INP39: indicates hydraulic unit status: Green = 1 = running; Red = 0 = off PLC OUT38: output to turn on CR33, which turns on hydraulic unit Schematic: Lines 10, 11, 86, 150
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 INP15: indicates OL3 state: Green = 1 = okay; Red = 0 = tripped Schematic: Lines 30, 80, 145
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 INP42: indicates oil level: Green = 1 = okay; Red = 0 = low Schematic: Lines 11, 88
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 INP16: indicates OL7 state: Green = 1 = okay; Red = 0 = tripped Schematic: Lines 32, 81, 146
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 INP38: indicates FS4 state: Green = 1 = okay; Red = 0 = low level Schematic: Line 86
The control has started the hydraulic unit, which also provides pressure for spindle lubrication. However, it did not see the signal to indicate spindle lube pressure 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 INP41: indicates spindle lube status: Green = 1 = okay; Red = 0 = low pressure PLC OUT38: output to turn on CR33, which turns on hydraulic unit Schematic: Lines 10, 11, 87, 150
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.
You attempted to start an automatic program cycle, but Maintenance Mode is still active.
Press and hold the Aux14 key for five seconds, until the Aux14 LED goes out.
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 changer arm is rotated to a change position (ES or ER).
Use the Maintenance Mode controls to return the arm to a parked position.
One of the PLCADD1616 expansion boards has failed to communicate properly with the GPIO4D board.
Check the gray PLC expansion cable that connects the PLCADD1616 board to the header near the right edge of the GPIO4D board. Check for green 5V power and "PLC OK" LED indicators on the PLCADD1616 board.
The PLC program requested display of an error message, but provided an invalid message code. Notify your dealer.
The PLC program can also generate the following non-error messages, in addition to those listed in the Centroid operator's manual.
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 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 INP33: An unused input. Green = 1 = circuit closed, Red = 0 = circuit open Schematic: Lines 83
14-Mar-2012
