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IndustryArena Forum > MetalWorking Machines > Dyna Mechtronics > dm 4400M retrofit - How many parts are reusable?
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  1. #1
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    dm 4400M retrofit - How many parts are reusable?

    Hi all.

    I got the option to buy a dynamyte 4400m with the Meldas control. The machine is in none working state and the display is not working. The screen is just black...

    Been looking long for a decent machine that doesn't wigh too much. and this has nice a spindle 10k 5hp?, servos onn x,y and z axis and also the tool changer. Simply lots of goodies, so it's really tempting to buy it and try get it running. However if I do buy it and get cannot make it run I would like to know if I can do a cost-effective retrofit? How many of the parts can be reused?

    I have looked at centroid oak control. I (beleive) it has no problem controlling the spindle drive but I can't really determine if I could reuse the current ac servo motors for example?

    Anyone tried the retrofit combination of 4400m and centroid oak?

  2. #2
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    Re: dm 4400M retrofit - How many parts are reusable?

    Hi Jenssons,
    I tried to send you an email or message, but it looks like you haven't turned those features on. I have a DM4400M that I've been going through so I have a pretty good knowledge of the machine. I was hoping we might be able to rub each other's backs in the form of information for spare parts. I don't care if they are not working. In fact, that gives me the opportunity to figure how to fix them! Because I'm a hobbyist, I have to keep my expenses down and that means learning how to put my electronics background to use and fixing the buggers.
    ]
    Where shall we start... The 4400 is a nice machine. It doesn't have the Y travel of my old Hurco, but the machine is far more rigid and I like the head arrangement more. If you can get a full enclosure for it, that is great too, although they can be kind of large for a home shop.... The big liability on the machine is that Dyna has a unique retention knob and Dyna is no longer in business. However, I took measurements of the knob and you can fabricate them if need be.

    The Centroid Oak would work, and you can definitely use the original servos. However, be aware that these are AC servo, not DC. In addition, you cannot use any of the existing axis drives or spindle drive. The Meldas M3 used a unique control interface that is proprietary and not published. Sadly, those drives will only work in an M3 control. Sigh. That might be a problem for you! So, you will need to source spindle and servo drives, but that would likely have been the case anyhow because the Oak uses a digital control. I doubt that even if you could figure it out, that the Meldas aps would be compatible with the Oak.

    You could reuse all of the tool carousel electronics because that works pretty much independent of the Meldas. We can talk about that if you would like.

    Alan

  3. #3
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    Re: dm 4400M retrofit - How many parts are reusable?

    Hi MrMetric.

    Thanks for your reply. I will check those settings.

    So this is very informative. If I would buy this machine I can take the fact that it would require new drives to start with. I then look at this from different scenarios

    1) If it's possible to get the original controls up and running again that would be the best scenario. Perhaps it's just the battery-change and re-initialization needed to get it running.

    2) Second scenario the problem is harder to fix and just not the Battery. Then chase down and buy replace control parts on second hand market.

    3) Insert new controls and drives - reuse the servos

    4) Do a full swap - new controls, drives and motors.

    To me it seems that scenario 2 or 3 would be the option to go for. When I wrote the post I didn't know that the drives could be reused so that was very good to have cleared out.

    When you write "be aware" these are AC servo. What do you mean is it a cost be-aware or other problem I could face? Just so you know I'm also in also in a situation that I cannot spend too much on a machine and would have to do as much work as I can by myself.

  4. #4
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    Re: dm 4400M retrofit - How many parts are reusable?

    I know of no reason why you couldn't use the servo that are there. That doesn't mean that you might not have to be a bit choosy on the amplifier, but there are definitely amps out there that will work. And let's face it... The servos are already installed in a clean way, along with encoders and limit switches. So why remove any of that if you can avoid doing so? To me, it just makes sense to adjust your selection of amplifiers accordingly and reuse the servos and encoders.

    AC vs DC. They really are different beasts, although many modern AC control can work with DC servos. The reverse is generally not true though. AC servos have three wires and, essentially, are very much like normal AC motors but with better insulation. The amplifiers work basically like a VFD, changing voltage and frequency to adjust speed; AC servos are generally brushless. DC servos have only two leads and utilize brushes. They work by adjusting voltage to the motor to obtain speed control. I'm giving a simplistic view of this stuff because I've intentionally left out current monitoring, but both do that as well. The point is, they are different and what the DM4400m has right now is an AC motor.

    #2 and #3 seem the most viable, but unless you know about this stuff #2 might be more difficult than you realize. If the display isn't coming up, that isn't related to the battery. When buying a machine that is a project, I'd make sure you are comfortable with #3 before I pulled the trigger, so to speak. My guess is that you'll end up there, and it isn't necessarily a bad thing. With a modern control you get modern features and support. If you are oogling that trunnion table, well, the retrofit control is the only way to go. You can technically put a 4th axis on a Meldas, but I am looking at it right now and it is a *daunting* project.

    I'm in an odd boat. My machine was working when I got it... But, I've since learned that there were mistakes on it. The limit switches were reversed so it would do strange things on that axis, along with other things. The biggest mistake I've found so far is that the Belleville washer stack was incorrectly installed and netted only about 100lbs of force on the retention knobs. Thank goodness the previous owner only did milling work with tiny tooling or the spindle might have been trashed. I'm presently working on a spreadsheet to analyze Belleville stacks so that the optimum installation can be applied. I tried doing this manually but there were too many variables. Every minor thing you change modifies all of the calculations so you have to start again. I thought about writing a program but Excel is turning out to be an excellent alternative.

    I digressed... sorry! Back to controls.... I did a LinuxCNC installation on my last machine (well 99%). I love the flexibility of that setup, but it isn't for the feint of heart. I'd have considered doing a LinuxCNC retrofit of my 4400, but I'm not ready to do that. First, my machine works. But, more importantly, the big limitation of the Meldas is the utter lack of compatibility of the servo amps for anything other than that generation of Meldas controller. It is frustrating. On the flip side, modern amps are tiny in comparison. Now, they just have an array of FETs, a DSP and a few piece of glue logic. It is amazing where technology has gone.

    Anyhow, that is about it for now. I have to go back to my day job. If you want to take this offline, feel free to PM me.
    Alan

  5. #5
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    Re: dm 4400M retrofit - How many parts are reusable?

    Thanks for sharing info MrMetric.

    I have now accepted to buy the machine and are planning for the delivery of it (which mean sorting, throwing away garbage and making room in the garage). I was thinking of continuing in this thread with info on how things proceeds.

    I have noticed that theses machines later came equipped with Meldas m5/5X0 controllers as well. I found this when looking at another machine. At first I thought it was retrofitted but it wasn't. Also found proof of them coming with new newer versions of te Meldas controls from factory.

    I also, to learn about potential options I did look at linuxcnc. That for me feels like a much too big route to go down. Like you write MrMetric, not for the feint of heart.

    Well. To be continuned I assume...

  6. #6
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    Re: dm 4400M retrofit - How many parts are reusable?

    I know that Dyna developed other machines with later versions of the Mitsubishi control, so I can't say I am surprised. I don't think I've seen conclusive proof of this with the 4400, but as I said, it seems like a logical conclusion that they would fit newer controls onto iron that they were already producing. I really don't know what differences exist between the M3 and M5. I am fairly sure (but not positive) that there isn't an upgrade path there though (meaning that I think the amps used for the M3 were unique to that model... unfortunately).

    Congratulations on the purchase! I hope it works well for you. Let me know if you need some help. I'm going through all sorts of trials and tribulations with my Belleville washer stack right now. When I got my machine, it was only delivering 100 pounds of force, which is way way way too low.

  7. #7
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    Re: dm 4400M retrofit - How many parts are reusable?

    Well, I got the machine home and have yet to wire it up electrically. While waiting I did pull the battery out on the controller and it measured it to a whooping 0.12V.
    Tried to charge the battery but it behaved somewhat strange so I figured I will replace it. I have read here on the forum in threads that I should awoid NIMH batteries and only use NICD. However the manual states that it should be model number: gb250h-3fb2 I googled this model number a bit and I was unsure if it is a nimh or nicd battery?

  8. #8
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    Re: dm 4400M retrofit - How many parts are reusable?

    Yeah... So, you have stumbled onto something that I'm not sure I can, or want to, answer.... I've also read that using anything other than NiCD will damage the circuitry. However, I can categorically confirm that in two cases, I've found NiHM in the machines.

    First, there is my own machine. The previous owner (original owner) related a conversation that he had with Mitsubishi. He asked about using a larger battery and the service rep confirmed that he could. Now, when I looked at the battery, it was an NiMH. I am assuming the PO confirmed what he could use, but whatever the case may be, I can categorically state that the battery charges fine.

    The second case is that I wanted a second battery setup so that I can ping pong back and forth (home machine... don't use it often enough to guarantee a good charge)... Well, that battery was the original type (Energy+ V200H-3ME, 3.6V 200maH) but, lo and behold, in microscopic print, I can see that it too is an NiMH. Now, I can't say if the system from which the battery was pulled was ever damaged.

    What I can say is that the charging curves for NiCD and NiMH are very similar and I personally believe that they should behave the same. Generally speaking, they are treated as interchangeable items. But that is just me. I absolutely do not want to advise you on the matter other than to say that you should use a larger battery if you want to have the machine last more than about 45 days or so (on a full charge). Try calling the Mitsubishi guys for advice (and post here, please). They are quite nice. I never have been able to determine if you are in the States, though, so I won't give you there phone number because it might be wrong.

    Anyhow, that's about all I can say on the matter other than that there is a super capacitor which will give you a certain amount of time to change the battery before losing memory... that is assuming that the cap is in good condition. Don't change the battery with the power on. That might damage the machine.

  9. #9
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    Re: dm 4400M retrofit - How many parts are reusable?

    Many people have fixed old machines and got them to run with the old servo hw.
    But..
    Most of them were really skilled, and spent a year to several years +++ and cash and electronics bitsys to do so.

    It is cheap and easy to buy new ac brushless servos with both step/dir and analog 0-10 inputs, these days.
    About 700€ per axis for 750-1kW drives.

    The new drives will be much more accurate, silent, perfectly reliable, and very easy to hook up and or tune.
    And will work with whatever controller here and now -- or in the future you may want to use.

    For about 290€ you can get excellent ac brushless drives of 400W.
    These will likely drive your machine well, for not much money.
    Depends on sticktion on your machine, mostly, as long as you can adjust axis acceleration.

    Selling the old gear can put the net cost at near even.

    --
    But ..
    making a real near-commercial type of retrofit is a huge amount of work.

    Some of it is somewhat hard, about 2%.
    Most of it is tedious and laborious.
    And a new commercial-type retrofit controller will be expensive, will be hard to do, and will have endless issues.

    Example:
    I spent about 1700€ on a CSLabs CSMIO-IP-S controller, lathe, machx.
    Plus needed bits, about 800€.
    Dual extra IO 25 each, MPG, threading module, dual 24V PSU, box, din rails, ferrules, wiring, etc.
    More than 150 IO for ac servos, mpg, switches, etc.
    5 x 25-pin connectors, boards, cables, breakouts, etc. for each end, so x2 for purchasing.

    Almost no-one has ever done a real commercial cnc refit, and almost none of the typical kits reflect this.
    It takes about 2500€ in typical electrical hw, and about 300 io lines, to do one industrial cnc decently.
    And almost none of the typical offerings have the capacity to support such a setup.


    The Us machmotion guys are one outfit that seems to have succeeded in such stuff.
    I don´t have one of their controllers, more as the pity, but they have little negative comments.

    Excellency award goes to CSLabs stuff, for CSMIO both IP-S and -A for analog.
    It´s expensive, but it works really well and truly allows for 100+ IO with industrial reliability.
    And good support, good docs, good examples of wiring for light towers, switches, etc etc.

    CSlabs has support for hw MPG, probing, limits, encoder sync, (potentially multi-encoder).

    *HW support for limits, mpg, probing, encoder is critical.*
    *HW support for limits, mpg, probing, encoder is critical.*
    *HW support in real-time interfaces is critical.*
    (MPG, limits, probing).

    The very cheap pokeys cnc does an excellent job at 1/3 -1/5 the price, or less, with every critical piece working perfectly.
    But limited to 125 kHz, 5 volts, 4 axis (Mach 3), and unfortunately less cnc commercialised.

    A pokeys cnc (160€) "new version" if it had 24V IO, 256 - 300 kHz speed (servos), would be the world leader in cnc "maker"//industrial motion control, in a few weeks.

  10. #10
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    Re: dm 4400M retrofit - How many parts are reusable?

    I would be very interested in talking to some of the "many" people that have done this specifically with Mitsubishi Meldas M3 servo amplifiers. I'm pretty sure that these are digital amps, but their interface has never been published. At present, the amps are an oddball that only work with one family of controls. They aren't even compatible with other Mitsubishi controls, which really sucks. So, although I agree that many people have interfaced with generic amps before, I am not sure *anyone* has done it with these specific amplifiers. I'm not saying it can't be done, but I don't think anyone has really tried (or not that I've heard about). And, frankly, it probably isn't worth the effort. These amps are giant compared to new, modern amps. As you have correctly pointed out, the new ones are far superior to the older ones. About the only reason someone would want to keep the current amps is if they plan on keeping the rest of the control.

    Alan

  11. #11
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    Re: dm 4400M retrofit - How many parts are reusable?

    Quote Originally Posted by MrMetric View Post
    Yeah... So, you have stumbled onto something that I'm not sure I can, or want to, answer.... I've also read that using anything other than NiCD will damage the circuitry. However, I can categorically confirm that in two cases, I've found NiHM in the machines.

    First, there is my own machine. The previous owner (original owner) related a conversation that he had with Mitsubishi. He asked about using a larger battery and the service rep confirmed that he could. Now, when I looked at the battery, it was an NiMH. I am assuming the PO confirmed what he could use, but whatever the case may be, I can categorically state that the battery charges fine.

    The second case is that I wanted a second battery setup so that I can ping pong back and forth (home machine... don't use it often enough to guarantee a good charge)... Well, that battery was the original type (Energy+ V200H-3ME, 3.6V 200maH) but, lo and behold, in microscopic print, I can see that it too is an NiMH. Now, I can't say if the system from which the battery was pulled was ever damaged.

    What I can say is that the charging curves for NiCD and NiMH are very similar and I personally believe that they should behave the same. Generally speaking, they are treated as interchangeable items. But that is just me. I absolutely do not want to advise you on the matter other than to say that you should use a larger battery if you want to have the machine last more than about 45 days or so (on a full charge). Try calling the Mitsubishi guys for advice (and post here, please). They are quite nice. I never have been able to determine if you are in the States, though, so I won't give you there phone number because it might be wrong.

    Anyhow, that's about all I can say on the matter other than that there is a super capacitor which will give you a certain amount of time to change the battery before losing memory... that is assuming that the cap is in good condition. Don't change the battery with the power on. That might damage the machine.
    I did google on the topic - charging nimh vs nicd battery yesterday. To my understanding it could work out good to use nihm with a nicd charger, as well as it could turn out bad. But then it would most probably be bad for the battery. I don't understand why the charge circuit in the Meldas controller would take a hit? Anyway I was in this tools supermarket store yesterday and I just happen to pass by a nicd battery with 3.6V 1600mah capacit so I though why not? Bought the battery and made a quick mounting box/bracket out of aluminium. Worked out well...

    Also, did google about that original battery part-code-number and it was probably a nicd one back in the days. Now, mostly I just find replacement for that actual number and them being of nihm type.

    I'm in Europe. But I don't mind calling Mitsu in the States. If I do and find an answer for this I will post it.

    And you can count 3 macinhes. In my machine there was a Varta 250mh nimh battery. But definitly not original.

  12. #12
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    Re: dm 4400M retrofit - How many parts are reusable?

    Oh, you won't find an original one! These machines are twenty years old or more. A NiCD (or NiMH, for that matter) would be something that you'd want to replace every two years or so. You might be able to squeak more out of it, but it just wouldn't be worthwhile doing so.

    I think the controls were actually designed by Mitsubishi here in the States, not Japan. So, you may end up getting the best responses from the folks here. I know that the one time I called them, they were extremely knowledgeable without needing to do any research. The guy was literally down to the keystrokes from his memory. Now, it is certainly possible (probable even) that they kept most of the entry similar over the years, but I was still impressed by his knowledge specific to the M3.

    From a charging perspective, a NiCD charger should be able to handle an NiMH without any issues. The other way around is possibly more problematic, but that isn't really the possibility here. I have somewhat come to the conclusion that previous posters on this topic may have been confusing an NiMH with a LiON battery. Those are definitely different beasts.

  13. #13
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    Re: dm 4400M retrofit - How many parts are reusable?

    Great news!
    I managed to get the screen up and running.

    I will try to be extra clear if someone else stumbles upon this as I did. To begin with the machine had a blank/black crt screen. The CNC Control came to life when hitting the ON buttonn on the operators control but no screen at all.

    I also would like to give cred to Mr. Caprirs here on the forum who has written guidelines on how to carry out the procedure to re-initialize after battery went low and machine lost its concept.
    In this thread there is a good write up. This one clearly states that you should start from top with the dip-switches and count 1,3 and 5.
    https://www.cnczone.com/forums/mazak...tml#post594116


    What I did was exactly these steps:
    0) Replaced battery (pre-requirement)

    1) Main switch turned off.
    2) On the MC1619 card flip switches 1,3 and 5 to the right.
    (counting from top, I was confused by them being labeled 0-7 and unsure if guidelines referred to the actual count of labeling of dip switch)
    3) Turned main switch on
    4) Hit the green ON button on the control panel
    5) Waited for 30sec
    6) Hit the red OFF button on the control panel
    7) Turned off main switch
    8) Flipped switch 1,3 and 5 back to the left
    9 Tuned on main switch
    10) Hit green ON button
    11) BLAAM Screen comes back to life

    Unsure if the main switch has to be turned on/off. But I felt safer when standing with my nose in the electric cabin.

    Next step would be to try load canned cycles and params. But that will have to wait for some days. Right now I'm just happy to get this far..

  14. #14
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    Re: dm 4400M retrofit - How many parts are reusable?

    Quote Originally Posted by MrMetric View Post
    I think the controls were actually designed by Mitsubishi here in the States, not Japan. So, you may end up getting the best responses from the folks here. I know that the one time I called them, they were extremely knowledgeable without needing to do any research. The guy was literally down to the keystrokes from his memory. Now, it is certainly possible (probable even) that they kept most of the entry similar over the years, but I was still impressed by his knowledge specific to the M3.
    Ok, good to know. I found some old paper copies in a folder that came with the machine. Papers are stamped with mitsubishi electronics europe... I just assumed that was a mirror thing to what mitsu has in the States.

    I'm gonna look for some oil for the lubrication. It looks to be quite low so I should fill up some. Says "Shell Tonna T32". That has problably cease to exist as well over the years

  15. #15
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    Re: dm 4400M retrofit - How many parts are reusable?

    That is good news indeed! Congrats!

    Be aware that I am pretty sure you need the front panel keyswitch in the unlocked position so that you can access the memory. But, that is a soft input so it is possible that it really won't matter if you are in the guts of the parameter entry.

    One thing that has always confused me on these machines is that I don't know where the tuning data for the amps is stored. It is possible that it is written into non-volatile memory in the amplifiers themselves.

    You have a lot of entry to do. I would give you my files, but I haven't validated them and I also don't know of a way for me to send them to you. Even with these, however, I understand that there is a fair amount of info that you still need to hand enter. Frankly, I'm very curious to see how this turns out. I've been worried about what happens when there is a need for a complete system restart. I really don't know how hard it is to recover from that. Other controls typically have actual machine specific values that need to be entered (gains, etc), but I haven't really seen where that is located. Things like "tool changer macros" would be common. Tuning parameters would not be. Plus, my 4400M has a different front panel than most do. it has an extra row of switches that expose some PLC capabilities. I think I know where that information is located, but I'm not 100% sure (hmmm, this is actually one reason my files might not work for you anyhow...)

    Anyhow, good progress... congratulations!

    Alan

  16. #16
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    Re: dm 4400M retrofit - How many parts are reusable?

    I'm presently using Vactra #2 because it seems pretty common for way use over here. At least one other person on this forum is using it on his Dyna 4400 as well.

    It will be interesting to hear what Mitsu Europe tells you. As I said, I'm pretty sure the controls were designed in the States, but that doesn't mean that Mitsubishi doesn't train their staff elsewhere. Also, I'm not sure what the actual lineage of the M3 is. It almost seems as though there is a tight coupling between this vintage of control and some of the Fanuc too. I get the feeling that either they were the same company or Fanuc branded the Mitsubishi M3 too. I may be way off base with that one though. I really don't know commercial controls and their history.

  17. #17
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    Re: dm 4400M retrofit - How many parts are reusable?

    Quote Originally Posted by MrMetric View Post
    That is good news indeed! Congrats!

    Be aware that I am pretty sure you need the front panel keyswitch in the unlocked position so that you can access the memory. But, that is a soft input so it is possible that it really won't matter if you are in the guts of the parameter entry.

    One thing that has always confused me on these machines is that I don't know where the tuning data for the amps is stored. It is possible that it is written into non-volatile memory in the amplifiers themselves.

    You have a lot of entry to do. I would give you my files, but I haven't validated them and I also don't know of a way for me to send them to you. Even with these, however, I understand that there is a fair amount of info that you still need to hand enter. Frankly, I'm very curious to see how this turns out. I've been worried about what happens when there is a need for a complete system restart. I really don't know how hard it is to recover from that. Other controls typically have actual machine specific values that need to be entered (gains, etc), but I haven't really seen where that is located. Things like "tool changer macros" would be common. Tuning parameters would not be. Plus, my 4400M has a different front panel than most do. it has an extra row of switches that expose some PLC capabilities. I think I know where that information is located, but I'm not 100% sure (hmmm, this is actually one reason my files might not work for you anyhow...)

    Anyhow, good progress... congratulations!

    Alan
    Thanks!

    Now that you mentioned , I think I read something about the amps data, not sure if it was online or in some part of the huge amount of paper that came with the machine.

    Yes the param-entering parts... Right now I'm comparing the data in the manual to a file I downloaded here on the forum. It will be some days before I take the next steps most probably. New working week and who knows how this whole Corona situation turns out.

    Any idea why your panel is different? Something added diy or is it added by dyna already?

  18. #18
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    Re: dm 4400M retrofit - How many parts are reusable?

    No, the panel is Dyna original. If you look in the manual, you'll see two different styles of panels. One has a single row of toggle switches and the other has two. My machine is the only one I've seen with two. Basically the functions are available in the single row, but you have to access them through software switches. Mine are just physically exposed (that really doesn't sound right, but you get the idea). If you search through my postings, someplace in there I have a photo of the machine. I think it was when I was trying to find dimensions.

  19. #19
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    Re: dm 4400M retrofit - How many parts are reusable?

    When you talk to Mitsubishi, I have a question that I'd appreciate you asking them.... I can't see how to access the system and machine parameter entry area. It seems like you need to somehow set a value so that the menu will show additional options, but I can't figure out how to do it. The manuals are not the best on this control, frankly, and that is part of the problem. The manual says,

    "By selecting the PARAM screen, the user parameter screen is usually displayed. If the PARAM screen is selected after the machine parameter mode has been set, the following menu is displayed:"

    OK, that is the menu I want. But I can't can't figure out where this 'machine parameter mode' switch is located! Argh!

  20. #20
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    Re: dm 4400M retrofit - How many parts are reusable?

    Quote Originally Posted by MrMetric View Post
    "By selecting the PARAM screen, the user parameter screen is usually displayed. If the PARAM screen is selected after the machine parameter mode has been set, the following menu is displayed:"

    OK, that is the menu I want. But I can't can't figure out where this 'machine parameter mode' switch is located! Argh!
    ...I see something about needing to "Key-in "Y" in # ( ), and then press INPUT key." Chapter 4.4 Setup Parameters or maybe this is the wrong manual link
    https://dl.mitsubishielectric.com/dl...2180(eng)j.pdf

    DJ

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