The air pressure coming to the tool is 150psig but the regulator on the tool cuts it down to 80. I'll add an upstream regulator and cut it down to 120 and see if that makes a difference.
The spindle orientation seems to work. It did miss a bit change a couple of times but mostly it seems okay. There have been occasions when I haven't run for an extended period that I will have to grab the tool holder and slow it down when it tries to oriented it. Otherwise it will keep will spin several times then alarm out. To my knowledge, I've never had a hard crash where the spindle was out of orientation. Hoping the bit displays will go away after I restart my machine now
The tool holders are clean. I bought them new with the tool and it had problems almost out of box. Doesn't seem to care which tool holder as long as it's the first one in the program.
Sounds like the fault switch in the ATC is the likely candidate or at least the sensor that is catching the issue.. The spindle does push down pretty good on the ATC when a tool is present. For both picking and placing of a tool, the carousel plates deflect down about .06 or .07 inches. If a tool is not there, there is no movement. However the spindle can still crash when the ATC station is empty.
As I finished up the run I experimented with not automatically reloading the first tool at the end of the program. It did seem like there was a reduced occurrence of crashes but I still saw some when I manually tc,1'd back to first tool and loaded it.
Yes, the machine will be largely idle for a bit. I'll probably cut a pair of good size plates in the next week or so but don't expect many atc crashes as the volume is pretty so low.
Thanks again for the help guys.