M400 with all limits tripped

[Wkoenigs]

Hello my M400 is showing all 6 limits tripped and low oil level and e stop released. This unit has the Koyo plc and a plc3 board. It was working fine than these all showed up at same time. Can you point me in a direction.

[tblough]

You might check your 24 power supply for starters. Also, please refer to this before posting: viewtopic.php?f=64&t=383

[martyscncgarage]

As Tom mentioned, take the time to supply the detailed information in the post he refers to and we can help you better.
Empasis on providing the report. We have NO idea WHICH M400 control you have. Pictures of the control, would help.

Take the time to post more detailed information, we'll take the time to provide more detailed suggestions.

[cncjeff1]

So far, I have seen the exact problem on three different machines over the last five or so years. The problem was remedied each time by replacing the 10644 OPTIC232 card (in the electrical cabinet), the 10643 CPU7ADD card which plugs in to the CPU7 card at the control, and the fiber optic cables between the two cards. Invariably, it is a problem with the fibers or the fiber optic electronics on the boards.

[Wkoenigs]

CNC7CONV v. 7.17 - Centroid configuration file utility
CNC7 M-400 10.4" v. 7.17 setup file for CPU7 serial number 1007991237
DRO display units: Inches
Machine units: Inches
Max spindle (high range): 6000.0
Min spindle (high range): 60.0
Machine home at pwrup: Yes
PLC type: Dual
Console type: M-400 10.4"
Jog panel required: Yes
Screen blank delay: 40
Remote Drive & Directory: E:\CNC7\NCFILES\


Axis Slow Jog Fast Jog Max Rate Deadstart Delta Vmax
(in/min) (in/min) (in/min) (in/min) (in/min)
1 24.0000 200.0000 400.0000 5.0000 5.0000
2 24.0000 200.0000 400.0000 5.0000 5.0000
3 24.0000 200.0000 400.0000 5.0000 5.0000
4 24.0000 200.0000 240.0000 5.0000 5.0000


Axis Label Motor Encoder Lash Comp. Limit Home Dir Screw
revs/in counts/rev. (inches) - + - + Rev Comp
1 X 5.0797 8000 0.0001 5 4 5 4 Y N
2 Y 5.0800 8000 0.0003 6 7 6 7 N N
3 Z 7.6212 8000 0.0006 8 9 8 9 N N
4 N 0.2500 8000 0.0000 0 0 10 10 N N


Axis Kp Ki Kd Limit Kg Kv1 Ka Accel
X 1.000 0.00391 10.000 32000 1 16 30 0.2500
Y 1.000 0.00391 10.000 32000 2 19 27 0.2500
Z 1.000 0.00391 10.000 32000 9 27 21 0.2700
N 1.000 0.00391 15.000 32000 0 12 10 0.4000
CNC7CONV v. 7.17 - Centroid configuration file utility
CNC7 v. 7.17 job file
Last job file: C:\CNC7\NCFILES\TEST.CNC
Part count: 0 Edge Finder Diameter: 0.0000
PID Collection Axis: 1 Density: 1 Extension: DAT
Move Commands: 1
2
3
4
5
WCS: #1 X axis Y axis Z axis B axis
G92 Shift Distance: 0.0000 0.0000 0.0000 0.0000
G52 Shift Distance: 0.0000 0.0000 0.0000 0.0000
Home State: Not set Not set Not set Not set
Tool Reference: Not set Not set Not set Not set
Digitize Grid Radial Grid Radial
Filename: Multi Patch: No
Replay Feedrate: 3.0000 3.0000 Pattern: Zig Zag Zig Zag
Envelope: X 1.0000 S 0.00 Step: X 0.0100 0.0100
Y 1.0000 E 90.00 Y 0.0100
R 1.0000
Z Depth: 1.0000 1.0000 Z Step: 0.1000 0.0100
Grid First Axis: 0 Radial containment: Full Clearance Ht: 0.0100
No Job Progress Recorded. Program Stack Level (PSL) = -1
Perform 'Forced' Tool Change: Yes
CNC7CONV v. 7.17 - Centroid configuration file utility
CNC7 v. 7.17 parameters file
00 0.0000| 20 72.0000| 40 0.0001| 60 0.0000| 80 0.0000
01 0.0000| 21 0.0280| 41 0.2500| 61 0.5000| 81 -1.0000
02 0.0000| 22 0.0280| 42 0.0000| 62 115.0000| 82 0.0000
03 0.0000| 23 0.0280| 43 0.0100| 63 1.5000| 83 0.0500
04 0.0000| 24 0.0280| 44 0.0010| 64 0.0000| 84 3.0000
05 0.0000| 25 0.6800| 45 0.0000| 65 1.0000| 85 1.0000
06 0.0000| 26 0.6800| 46 0.0000| 66 1.0000| 86 0.0000
07 0.0000| 27 0.6800| 47 1.0000| 67 1.0000| 87 48.0000
08 2.0000| 28 0.6800| 48 0.1000| 68 0.0000| 88 48.0000
09 0.0000| 29 150.0000| 49 0.0000| 69 1.0000| 89 48.0000
10 0.0000| 30 180.0000| 50 1.0000| 70 0.0010| 90 48.0000
11 2.0000| 31 0.0000| 51 0.0000| 71 0.0000| 91 0.0000
12 0.0000| 32 19200.0000| 52 0.0010| 72 0.0000| 92 0.0000
13 0.0500| 33 1.0000| 53 0.0100| 73 0.0500| 93 0.0000
14 10.0000| 34 8000.0000| 54 0.0000| 74 4.0000| 94 0.0000
15 1.0000| 35 4.0000| 55 0.0000| 75 0.0000| 95 1.2000
16 10.0000| 36 0.0000| 56 32000.0000| 76 0.0000| 96 1.2000
17 0.0000| 37 10.0000| 57 32000.0000| 77 0.0000| 97 1.2000
18 0.0000| 38 0.0000| 58 32000.0000| 78 0.0000| 98 1.2000
19 0.0000| 39 120.0000| 59 32000.0000| 79 0.0000| 99 2.0000

100 1.0000| 120 0.1000| 140 0.0000| 160 0.0000| 180 0.0000
101 0.1000| 121 0.0020| 141 0.0000| 161 0.0000| 181 0.0000
102 3.0000| 122 0.0002| 142 0.0000| 162 0.0000| 182 0.0000
103 50.0000| 123 0.0000| 143 0.0000| 163 0.0000| 183 0.0000
104 0.0000| 124 0.0000| 144 0.0000| 164 0.0000| 184 0.0000
105 0.0000| 125 0.0000| 145 0.0000| 165 0.0000| 185 0.0000
106 0.0000| 126 0.0000| 146 0.0000| 166 0.0000| 186 0.0000
107 0.0100| 127 0.0000| 147 0.0000| 167 0.0000| 187 0.0000
108 0.0000| 128 0.0000| 148 0.0000| 168 0.0000| 188 0.0000
109 0.0000| 129 0.0000| 149 0.0000| 169 0.0000| 189 0.0000
110 0.0000| 130 0.0000| 150 0.0000| 170 0.0000| 190 0.0000
111 0.0000| 131 0.0000| 151 0.0000| 171 0.0000| 191 0.0000
112 0.0000| 132 0.0000| 152 0.0000| 172 0.0000| 192 0.0000
113 0.0000| 133 0.0000| 153 0.0000| 173 0.0000| 193 0.0000
114 0.0000| 134 0.0000| 154 0.0000| 174 0.0000| 194 0.0000
115 0.0000| 135 0.0000| 155 0.0000| 175 0.0000| 195 0.0000
116 0.0000| 136 0.0000| 156 0.0000| 176 0.0000| 196 0.0000
117 0.0000| 137 0.0000| 157 0.0000| 177 0.0000| 197 0.0000
118 0.0000| 138 0.0000| 158 0.0000| 178 0.0000| 198 0.0000
119 0.0000| 139 0.0000| 159 0.0000| 179 0.0000| 199 0.0000

300 30624.5102 | 200 28560.1473 | 201 5008.1663 | 202 17296.5838
203 11152.0135 | 204 29792.0691 | 205 1120.0950 | 206 23648.2220
207 0.0000 | 208 0.0000 | 209 0.0000 | 400 0.0000
401 0.0000 | 210 18528.2288 | 211 9824.1619 | 500 41312.3885
510 0.0000 | 212 0.0000 | 213 0.0000 | 214 0.0000
215 0.0000 | 216 0.0000 | 217 0.0000 | 297 0.0000
298 27424.7087 | 299 737602.0000
CNC7CONV v. 7.17 - Centroid configuration file utility
CNC7 v. 7.17 coordinate systems file
Axis Minus Plus Return Return Return Return
Limit Limit #1(G28) #2(G30) #3 #4
X 0.0000 33.5000 0.0000 0.0000 0.0000 0.0000
Y -18.0000 0.0000 0.0000 0.0000 0.0000 0.0000
Z -19.0000 0.0000 0.0000 -5.2574 0.0000 0.0000
B -0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

Axis Origin Origin Origin Origin Origin Origin
#1(G54) #2(G55) #3(G56) #4(G57) #5(G58) #6(G59)
X 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
Y 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
Z 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
B 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

[martyscncgarage]

Upload the report.zip file.

[Wkoenigs]

I don't see that as an option

[cncsnw]

In CNC7, there is no "report.zip" file. The Report feature copies key configuration files to the floppy disk, plus a "CNC7CFG.TXT" file (the precursor of "report.txt") which WKoenigs has pasted above. I am not sure whether v7.17 would have included the PLC source on a Report disk or not. That might have been included only after v8.00.

As to the original problem: a good divide-and-conquer step would be to see whether the inputs are registering on the Koyo PLC. It is likely that limit switches are the first six inputs on the first input module in the Koyo PLC. Flip the A/B selector switch on that module to the "A" position, then note whether at least the first six status LEDs (0-5) are lit up. If not, then you have a problem with the 24VDC supply for PLC inputs, or with common-side wiring to the switches.

If the Koyo PLC shows a red status LED for every closed input switch, but those devices all appear open (1) on the Centroid PLC Diagnostic screen (F7/Utility -> F6/PLC Diag), then there is a problem with communication between the Koyo CPU and the Centroid CPU7 board. These communications go through the RJ12 cable, the OPTIC232 board, and the RXD / TXD / INT optical fibers.

Before replacing the OPTIC232, CPU7ADD and fibers as Jeff suggests, I would try replacing the logic power supply that feeds the OPTIC232 board and the 3/3 PLC. If yours is original, it is probably a Toko ET-10 (a 10W supply which makes +5V, +12V and -12V). Given the right connectors, you can replace it with a MeanWell RT50B or PT45B, or a Cosel LDC15F. For either of the MeanWell supplies, you will probably want to mount the replacement supply somewhere less crowded, and run slightly longer wires.

Good luck.

[Wkoenigs]

The plc does show red leds on the switch positions.
But on the control I cannot access the plc info.

[martyscncgarage]

Thanks Marc for stepping in. I'm quite spoiled by the newer controls. When I come across the older controls, I usually try and get them upgraded to newer All in One DC.

What kind of machine is this on?