FANUC Operator Guide: IC Card Transfer, Axis and ATC Recovery

FANUC control systems, the most widely used on CNC vertical machining centers and lathes, demand strong technical command of correct program transfer steps, recovery procedures for mechanical lock-ups or interrupted cycles, and parameter interventions. In this guide we cover topics commonly encountered in the field, from transferring programs via IC card to recovering from an axis over-travel, to the mechanical and software recovery steps used when an ATC (automatic tool changer) cycle is interrupted mid-way.

This article does not re-cover core parameters such as 1815 (APC/APZ), 1850 (Grid Shift), 4077/6577 (spindle orientation), 3401#0 (decimal point setting), 569#0, 903#7, and 8940 — for a detailed explanation of those, see our Comprehensive Parameter Guide for FANUC CNC Controls. The focus here is on procedures and parameters not covered on that page.

📥 PROGRAM TRANSFER VIA IC CARD AND DNC OPERATION

A. Transferring a Program from an IC Card to NC Memory

Switch the control panel to EDIT mode. Press PROG on the keyboard next to the screen, then press the right arrow (>) key below the screen.
Select the CARD option from the menu that opens. Press (OPRT), then tap the F READ tab on the screen that appears.
Enter the sequence number shown on the left of the file list (e.g. 0019) into the FILE NO field and press F SET.
Enter the name you want the program saved as in NC memory (e.g. 4444) and press O SET.
Once you see the name you specified in the PROGRAM NO = …. field, press EXEC.
In the bottom-right corner of the screen, an LSK message appears first, followed by several flashes of INPUT before disappearing; once that message clears, the transfer is complete.

B. Transferring a Program from NC Memory to an IC Card (Backup)

Switch the machine to EDIT mode and press PROG.
Press the right arrow (>) key on the screen, then tap DIR to view the list of programs currently in NC memory.
Select the O…. file to be transferred and follow, in order: right arrow (>) → (OPRT) → right arrow (>) → (PUNCH).
In the highlighted line, type the name of the program to transfer in the form O1234 (a 4-digit number preceded by the letter O) and press EXEC.
Once the flashing OUTPUT text in the bottom-right corner stops, the operation is complete. You can check the contents of the card via PROG → right arrow (>) → CARD.

C. Running a Program Directly from an IC Card in DNC Mode

(Applies if your system has an Ethernet / M-Card infrastructure)

Insert the IC card into its slot and press OFFSET SETTING.
Select the SETTING tab; while in MDI mode, set the I/O CHANNEL value to 4.
Turn the mode selector to DNC, press PROG, and tap the DNC-CD tab at the bottom of the screen. The files on the card are listed.
Press OPRT and enter the number of the program you want to run.
When you press DNC-ST, the program name appears in the DNC FILE = …. field. The moment you press Cycle Start, the program runs directly from the card.

⚠️ AXIS OVER-TRAVEL AND LIMIT RECOVERY PROCEDURES

Double Column Machines – Y-Axis Recovery

Move the Z axis to a safe position and send it to reference.
In MDI mode, enter M21 and press Cycle Start.
Switch the mode to JOG. Using the direction keys, move the axis in the direction opposite to the one it exited in.

Column-Free (C-Type) Machines – Axis Recovery

Turn the mode selector to JOG.
While holding down the O.T. (Over Travel) button on the panel, press the button for the direction opposite to the one the axis is stuck in.
Use the handwheel (MPG) to bring the axis back to a safe zone.

⚠️ These procedures can vary by machine manufacturer and panel layout. The O.T. button may have a different name or location on some panels; if you’re unsure, consult your machine manual or an authorized service provider.

🔧 ATC (TOOL CHANGE) INTERRUPTED CYCLE – RECOVERY PROCEDURE

During an ATC (Automatic Tool Changer) cycle, the arm can be left mid-way due to a drop in air pressure, a sudden power outage, or a sensor timeout. This is a delicate process that requires mechanical intervention, not just a software fix.

Step-by-Step Mechanical and Software Recovery

1. Safety and Part Inspection

First check whether a tool is still held in the spindle or the magazine arm, and whether the tool is in contact with the workpiece.
If the tool has plunged into or is jammed against the part, release the mechanical tension on the arm before retracting the Z axis with the handwheel, so you don’t put the part or axis at risk.

2. Mechanically Repositioning the Arm

Power off the machine, or switch it to Manual/Reset mode, to make it safe.
Use an appropriate wrench (usually a hex/Allen key fitting) on the manual turning shaft at the back or top of the magazine motor.
Manually rotate the magazine arm a full turn (360°), or bring the arm mechanically to its starting (0-degree home) position. Make sure the arm’s locking pawls seat properly and the spindle is released.

3. PWE and Parameter Intervention

Power the machine on and switch to PWE = 1 mode (clear the 100 P/S alarm with RESET + CAN).
On vertical machining centers, set parameter bit 569#0 to 1 to reset the system’s tool-change status flag (PLC flag) (a general explanation of this parameter is available on our Parameter Guide page).
Entering this value clears the system’s record that the ATC cycle was interrupted and returns the mechanical assembly to its starting position (home position).

4. System Confirmation and Closing PWE

Check the status of the magazine sensors (Tool Clamped / Unclamped, Arm at Home) on the PLC screen.
Set PWE = 0 to re-lock the parameters.
Test the ATC once at low speed with an idle M06 command.

🔐 PWE (100 P/S ALARM) AND BIT STRUCTURE EXPLAINED

PWE (Parameter Write Enable) Mode: When PWE = 1 is set on the SETTING page to allow parameter changes, the system raises a 100 P/S alarm for safety.

Clearing the Alarm: While this alarm is active, pressing RESET + CAN at the same time clears it from the screen and opens the parameters for editing.

Bit Reading Logic: Parameters are made up of 8-bit blocks (0 through 7). For example, the notation X10.2 = 1 means bit 2 of the parameter on line 10 has been set to 1 (e.g. 0 = chuck closed, 1 = chuck open).

Macro Protection: Parameters 9000 and above hold tool-change and custom manufacturing macros. Bit 10#4 locks or unlocks these parameters.

📍 PART ZEROING AND DECIMAL DIGIT LOGIC

Work Offset (G54-G59) Measurement

From the panel, go to OFFSET → WORK. Select the G54 or G55 field.
After touching the part with a probe or a gauge, press X0. MEASURE, Y0. MEASURE on screen.
To zero the Z axis, touch the part surface with the reference tool and press Z0. MEASURE. When you touch the same surface with a second tool, record the difference value read on the Absolute screen into the GEOMETRY OFFSET table.

Decimal Digit Logic and Parameter Corrections

When entering parameter or Grid Shift (1850) values, pay attention to the system’s decimal-digit resolution. In units with 4 digits after the decimal point (0.0001 mm resolution):

To shift by 20 mm, you must enter 20000 on the screen.
If you enter 2000, the system reads it as 0.2 mm.

⚠️ This is one of the most common parameter-entry mistakes made in the field — especially when entering Grid Shift or offset values, being one digit short or long can cause an unexpected axis shift. Always confirm the value on screen after entering it.

📋 ADDITIONAL PARAMETERS — QUICK REFERENCE

The table below lists additional parameters not covered on our Parameter Guide page.

Parameter No.	System / Model	Technical Description and Purpose
1240 / 1241	General FANUC	Z-axis 2nd reference point / ATC tool-change position value.
1320 / 1321	General FANUC	Positive and negative software stroke limit (over-travel) values for the axis.
4020	18i-M	Spindle M19 orientation parameter.
10#4	0-MD	Bit that locks editing of 9000-series macro programs.
910#6	0-T	Enables the 3rd axis (C axis) on lathes.
915#7	0-T	Increases the maximum number of programs that can be stored in machine memory.
3620 – 3624	General FANUC	Pitch Error Compensation (start, end, and measurement interval for ballscrew pitch error correction).

Custom Manufacturer Tip (Accuway Vertical Machining): The Leader PLC interface password is 22108758. The automatic way-lubrication wait time is set via Counter 10, and the oil-dispensing time via Timer 14.

⚠️ DISCLAIMER

⚠️ MENTOR CNC DISCLAIMER
All technical information, parameter numbers, and procedural steps in this blog post were obtained from machine manuals and technical documentation. However, these details may vary depending on your machine’s brand, model, manufacturer configuration, PLC software, and parameter structure.
For this reason, always record the original values of any parameter before changing it during testing. This lets you revert the change if something goes wrong.
If you have not previously made a Leader PLC, software, or parameter change, be sure to get help from an authorized service provider. Full responsibility for any actions taken rests with the user. Mentor CNC and its content authors cannot be held liable for any malfunction, data loss, or damage that may result.

The procedures on this page complement the core FANUC parameters covered on the following pages: