OK, it is a little perplexing. Let's think this through one problem at a time....

The M3 has a daisy chain type of communications bus for the amplifiers. The cable starts at the M3, then the S12 (X/Y), then the S11 (Z), and finally the spindle drive. The daisy chain isn't a pickoff but, rather, separate cables. So if you can move the Z axis, it means that all of the signals are running *through* the actual X/Y axis driver. That tends to make me think that wiring is likely not the problem. I am assuming that you do not have *any* errors on either the amplifiers or the display console as you have noted neither. Nonetheless, it makes sense to confirm that. Another perplexing thing for me is that, generally speaking, the Sxx series amplifiers are pretty good about showing error IDs on the displays. Yet, you haven't noted any numbers. So... maybe you can tell me what you *do* see on each of the Sxx drives and the spindle drive.

I don't think you've confirmed whether or not you have the *Dyna* manual (not the Mitsubishi one) for the DM4400m. But, Error #5 on the ATC is 'Arm not retracted to the home position'.... So... Do you happen to have air connected to the machine? Be sure you have that because it is required for the ATC. In addition, you don't want the arm to 'wander' in because it could get broken off if you lower the Z axis. Plus, there is an air pressure switch.

If you have air connected, then you might have a bad proximity switch on the air cylinder, the switch might be in the incorrect position, or you could have some wiring issue. But I think this is a good time to throw the ball back in your court for confirmation....

BTW, you should fill up the auto-oiler with oil and be sure that you have let it pump oil into the ways. You can manually do this by lifting the lever too.

Can you do me a favor... Can you send me the parameters that you've downloaded *FROM* the machine. Yes, I know I sent you parameters, but I want to see if what you download match these just to be sure that the "round robin" test is accurate (that you've actually loaded what you think you loaded). Plus, can you tell me the ID selection on *each* of the drives, including the spindle. There are TWO rotary switches on the S12, one on the S11, and one on the spindle drive.

Something is amiss on your system with regard to the switch panel. However, I think it is premature to say that this is a wiring issue. I would NOT randomly start disconnecting wiring. But, it would be interesting if you could tell me a bit of history.... Do you know if someone actually did start randomly removing wires for some reason? Is there any evidence of that? A more likely scenario here is that either the parameters are incorrect or the PLC is bad.

The PLC on the DM4400m is written in EPROM on the plugin cartridge you see on the left side of the control. EPROMs technically have a published life of 20 years or so and, well lets see.... These machines were built in the early 90s, which makes them, hmmmmm, 30 years old or so! It could be that you have bit rot. The *good* news is that I make backups of all EPROMs, so I can definitely save your bacon (sorry, using my American slang here) with regard to that. Do you have a way of burning an EPROM if I give you a file? If not, then I may have to source an EPROM and send it to you.

I wouldn't get depressed yet.... You are making progress. Actually, things are moving along pretty well, I think.