So… this may turn into a lengthy thread. I’m looking for help with a few problems regarding getting an EMCO-MAIER 320 Lathe (GA01, from the late 80s or early 90s) up and running with a Sinumerik 810T control. I bought it from a machinist, who purchased it in about 2002 from a machine shop in Beaverton Oregon. It’s had really light, limited use, so I’d really like to salvage it. I saw it running at the seller’s place. He told me that he’d let the battery go dead and it had lost it’s parameters, however, he was still able to demonstrate some working functions including:
+ Spindle turning
+ Jog both axis
+ parts catcher
+ turret switching (with indexing)
+ tailstock
+ the air-operated collet closer was not working , however we switched the air lines around from the tailstock and we were able to make it operate.
I successfully moved it to my shop, and re-commissioned the control, but have not quite finished the re-commission. if you’d like to see my initial struggles with the commissioning process, go here: http://www.cnczone.com/forums/siemen...ml#post1743358 Now, I can get some things to work, but I’m struggling because (right now) I can’t:
+ get the spindle to turn
+ make the turret index.
+ operate the parts catcher
+ operate the collet closer
The two initial problems are that I get the following alarms:
6027 Low pressure central lubrication:
per page g5 of manual, the lines have been vented and filled. Checked to make sure there's no air in the lines. I think that the pressure switch may be bad. ZVE 20 0007 is the part number in the ENCO manual This error Blocks NC start. Also, the error trips almost right away after clearing the alarm. This may be preventing other stuff from working, because the manual says that 6027 prevents the NC-on from starting. I should be able to just bypass the switch to temporarily fix this one, I just haven’t done it yet.

6025 Tool-turret index failure
6024 Tool turret encoder fault. (this happens as soon as the turret is jogged or moved.
Took off the cover of the turret, and It's interesting that there is a new witness mark for what appears to be the encoder… someone has had issues before and been in there? I DID see this thing work properly at the seller’s, so I suspect a software problem not a hardware problem.

I’ve done some initial searching on this issue. Someone else solved this by changing the phase of their inputs. www.cnczone.com | 404 - Page Cannot Be Found I tried reversing the phase, to no avail… it made my coolant pump run backwards, and restarted the controller when I pushed buttons. So I think I have the phase right. Plus, it’s hooked up just like it was at the sellers (same rotary phase converter.)

I’m wondering if these alarms might have to do with the %PCP file, and hoping someone might be able to advise. I was lucky with this lathe to have the original tapes plus a digital backup, and lots of manuals. The PCP file looked like this:

%PCP
70704801C400000005192D054D45524B4552202028300B3FA7 52FA0430400000
1351A200E713FA0E28FF0B52304000001308130A130CA200FA 05304000001301
130310FF81019168C41BC41CB1680A41281E218080409B01CA 1BCB1BCA1CCB1C
9C01CD13CC16CD169902C504BA0089028D14BF00CA069D01C2 05A16FC9129E01
EB1FE803C6989F01A440FA41AF4E8C488D488E488F48FA298A 488B48FA068048
980E8148990E2D3328040A482180930E28050A482180B30E28 060A482180940E
28070A482180B40E28080A482180950E28090A482180B50E28 0A0A482180960E
<<<<I’ve omitted a bunch of lines here>>>>
872BFA1130400000135E13601362A02BFA098301972BFA0728 010B63C107972B
FA021082872BA62BA4539C518452962B862BA452B62BB72B9D 2B10FF8001
8114840EE019982E802EC7199D2EC106992EA7218420FB0087 21C0069A2EA721
8520FB008721C703A7079B2E842D9A09852D9E09871E9C2EA7 6FFA054A000B2D
0A2E4B836500
M02
% P C P
70704802C400000000672D05414C4D2F3220202072004B00E0 00B001C900FB00
C400A421FA20810083166C0281008416540210824202280021 800A775C021082
8316821528015C0210820A77420221809A15108280006C0254 025C02C3009167
8100B616830FC4048514FA09E2008316D483F383E2008416D3 83F483C300E200
F383F4839016C400A707E900FA0F72070B05A100B6169C059D 059E059F050A05
420221809C07A407906742020A0621809A16BA008216A516FB 008516A50FBF00
E100D583C40097074A8373036500
M02

When I did the commissioning, I noticed that the PCP file loaded until it got to the first M02 which is a code that tells the controller to stop loading data… I don’t believe that the second block of %PCP was loaded. I don’t know this language at all, is that second block necessary? Does that second block possibly contain setup information about the tool changer? How does the machine know which brand/type of tool changer/encoders the lathe is equipped with? Mines a Sauter, but in the documentation apparently there were other brands besides Sauter available with these. if that second block of PCP code is important, how am I supposed to load it? it seems like loading it as a second file would overwrite the original... is it supposed to be appended to the original?

In a different thread I found the following about a Fanuc control:
Also specifies that there may be some parameters that need to be set manually:
moa, I found a list of dianostic bits for a 342 with an Fanuc O control. I believe they are the same for the 320. Been a while, I'm one of those "Once upon a time " Emco techs.

You need to check the folowing diagnostic bits...
D450 - bit 0 for OD clamping , Bit 1 for ID
D460 - bit 1 for a Sauter turret
D461 - bit 0 for a parts catcher
D365 - tool turret postitions - enter the number of stations you have 8 or 12
I can’t find anything similar in my controller unless it’s supposed to be the “R values”
On my machine under "Settings Data" the R-Parameters are mostly blank or 0. Anyone know what these are supposed to be? Currently on my machine:
R 0 through R 499 are all zero, except R 300, which is 301.
R 500 through R 800 are all blank
R 801 through R999 are all zero.
In the manual, there is a cryptic reference to “Emco-specific setting data” and how to load setting bits, but I don’t know what mine are supposed to be. I can’t find anything in the extensive documentation about setting bytes for the toolchanger, though it seems like something you might need to do in the commissioning process??