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CENTURY STAR MILLING CNC SYSTEM

HNC-18/19M OPERATOR’S MANUAL

V2.01

Wuhan Huazhong Numerical Control Co., Ltd.

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CONTENT

PRECAUTIONS................................................................................ I 1 INTRODUCTION........................................................................... 1

OVERALL LAYOUT ............................................................................ 1 MACHINE CONTROL KEYS ................................................................ 2 ALPHA NUMERIC KEYBOARD............................................................. 8 MENU TREE................................................................................... 10

2 SET UP ....................................................................................... 17 POWER ON.................................................................................... 18 RESET/ EMERGENCY STOP ............................................................ 19 HOMING (REFERENCE–POINT APPROACH) ....................................... 20 SOFTWARE LIMITS DEFINITION......................................................... 22 TOOL DATA SETTING ....................................................................... 24 ORIGIN OFFSET............................................................................. 27

3 MANUAL OPERATION............................................................... 29 JOG FEED..................................................................................... 30 INCREMENTAL FEED....................................................................... 35 MANUAL HANDWHEEL .................................................................... 39 SPINDLE OPERATIONS ................................................................... 42 AUXILIARY OPERATIONS................................................................. 45

4 AUTOMATIC OPERATION ...................................................... 47 PROGRAM LOADING....................................................................... 49 PROGRAM TESTING ....................................................................... 51 RUNNING CONTROL....................................................................... 53 BREAK POINT OPERATION............................................................... 57 MDI OPERATION ........................................................................... 62

5 PROGRAM OPERATION ........................................................... 65 OPEN A PROGRAM ......................................................................... 66 CREATE A NEW FILE ....................................................................... 67 DELETE AN EXISTED FILE ................................................................ 69 EDIT A PROGRAM FILE .................................................................... 70 PROGRAM FORMAT ........................................................................ 72

6 DATA EXCHANGE VIA RS232................................................... 73 CONFIGURATION............................................................................ 74 SET UP THE RS232 CONNECTION ................................................... 76

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UPLOAD DATA FILE TO NC.............................................................. 77 DOWNLOAD DATA FILE FROM NC .................................................... 80

7 SETTING AND DISPLAYING ..................................................... 83 POSITION AND COORDINATES CHOICE............................................. 83 VIEW OPTIONS .............................................................................. 84

8 DIAGNOSIS................................................................................ 88 ALARM DIAGNOSIS ........................................................................ 89 I/O CHECK.................................................................................... 90 REGISTERS WATCH........................................................................ 91

9 PARAMETERS ........................................................................... 93 PARAMETERS BROWSING ............................................................... 95 PARAMETERS OPERATION .............................................................. 96 PARAMETERS DESCRIPTION ............................................................ 99

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Precautions

This section enumerates safety precautions for protecting the user and preventing damage to the machine. Read the contents of this part thoroughly before attempting to use the machine. 1. The working temperature for the Numerical Control (NC) unit and its cable cabinet is 0 to 45°C (32°F to 113°F). No freezing is allowed. The temperature variation should be less than 1.1°C/min (2°F/min). Humidity should be kept below 90% Relative Humidity, non-condensing and without frost; 75% Relative Humidity or lower is more desirable. 2. For storage, the temperature range should be kept within –20°C to 60°C (-4°F to 140°F) non-condensing and without frost. All devices should be placed indoors and away from sunshine, dust, eroding gases and moisture. 3. Impact during transportation or other situations should be less than 5.9 m/s (0.6 g) for vibrations in the range between 10 to 60 Hz. 4. Correct grounding is critical for the NC unit and other electrical devices. No grounding or incorrect grounding may injure the operator or damage components of the NC devices. If the devices are not correctly grounded, inductive interference from electric motors and appliances can give errors and unexpected results. 5. Filters are used on cooling fans to prevent dust from entering into devices. However, after time filters become clogged, preventing adequate cooling. Clean the filters every three months. In dusty environments such as wood routers, clean the filters more often. 6. After a long period of non-operation, NC devices should be cleaned and dried. Also check the wiring and ground connections. Once power is resumed after non-operation, observe the operation for several hours to make sure there is no unexpected behavior. 7. Never machine a workpiece without first checking the

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machine's status. Before using the machine for a production run, make sure that the machine operates correctly by doing a trial run including, for example, a single block with a feedrate override or a machine lock function. Another possibility is to do the trial run without a tool or workpiece mounted. Failure to confirm the correct operation with a trial run may result in unexpected motion or behavior that can damage the workpiece, damage the machine, or injure the operator. 8. Before operating the machine, thoroughly check the entered data, including parameters, program and settings. Operating the machine with incorrectly specified data may also result in unexpected motion or behavior that can damage the workpiece, damage the machine, or injure the operator. 9. Ensure that the specified feedrate is appropriate for the intended operation. The appropriate feedrate varies with the operation. Generally each machine has a maximum allowable feedrate found in the machine's operation manual. If a machine is run at other than the correct feedrate or if the maximum allowable feedrate is exceeded, unexpected motion or behavior may result that can damage the workpiece, damage the machine, or injure the operator. 10. When using the tool compensation function, thoroughly check the direction and amount of compensation for each tool. Operating the machine with incorrectly specified data may produce unexpected motion or behavior that can damage the workpiece, damage the machine, or injure the operator. 11. Usually, there is no need to change the factory-set parameters of the NC unit and PMC. However, when there is no choice other than to change a parameter, be sure you fully understand the function of the parameter before making any change. Failure to set a parameter correctly may produce unexpected motion or behavior that can damage the workpiece, damage the machine, or injure the operator. 12. Immediately after switching on the power, do not touch any of

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the keys on the Manual Data Input (MDI) panel until the position display or alarm screen appears on the NC unit. Since some of the keys on the MDI panel are dedicated to maintenance or other special operations, pressing any of these keys may prevent the NC unit from entering its normal state. Starting the machine in the wrong state may cause unexpected motion or behavior. 13. While the operator’s manual supplied with an NC unit provides an overall description of the machine’s functions, some functions are specific for that machine alone and may not be available for another model. Check the specification of the machine if in doubt as to its machine-specific functions.

HNC-18/19T Operator’s Manual

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1 Introduction

Overall layout

The user operates the mill either through the Numerical Control Unit (NCU) or a Hand Pendant (optional). RS232 allows the user to exchange data between the NCU and other computers. A PS/2 connector in the Data Exchange Port lets the user plug in a keyboard.

-+

Front face of Numerical Control Unit (NCU)

Alpha numeric keyboard

LCDScreen

Soft keys

Machine control keys

MPG(Manual pulse generator) unit is a hand pandent that compose of an Emergency Stop button, an axis switch and a pulse generator. It can be used for the user to operate the machine at a convenient place.


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There are four main areas on the front face of NCU: LCD Screen, Soft keys, Alpha numeric keyboard and Machine Control keys. These are shown in detail below.

a) LCD Screen The LCD screen in the upper right displays the machine’s status, the tool’s position, the program’s content and other information.

b) Menu keys

Beneath the LCD screen are the “Soft keys” from F1 to F10. They change their function depending on which menu is being used. c) Alpha numeric keyboard On the right side of the LCD screen is the Alphabetic keyboard. These keys are used for editing a program, as well as changing or viewing parameters.


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d) Machine Control keys At the bottom of the front panel are the Machine Control keys. These keys operate the machine directly.

e) Other Controls An emergency stop button is on the front panel to deal with abnormal situations. Pushing down on the button stops the machine from any further motion and sets the electronic brakes on the motor axes and spindle. Pulling upon a stopped button resets the software system and the machine can operate again under computer or manual control

Alpha Numerical keys

Function keys


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A green “Cycle Run” button starts the automatic machining process. A red “Feed Hold” button pauses machining under computer control.

1 Introduction

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Machine Control Keys

a) Mode Selection Switches. To the right are shown the five switches that select the operation mode of the machine. Note that the small LED “activation” light on the upper left of each key indicates in which mode the machine is working.

KEY DESCRIPTION

Automatic (AUTO) mode key: Pressing this key switches to Auto mode. In AUTO mode, workpiece can be machined automatically from a program.

Single Block (SBL) mode key: Pressing this key switches to “SBL” mode. In SBL mode, a program can be run block by block.

Manual (MAN) mode key: Pressing this key switches to manual operation or “jog” mode. In manual mode, any axis of the tool can be manually controlled.

Incremental (INC) mode key: Pressing this key switches to “INC” operation mode. In INC mode, the tool can be moved a number of steps along any axis by either the Axis keys or the hand wheel (Manual Pulse Generator). The number of steps depends on which of the multiple-step keys is selected.

Reference (REF) mode key: Pressing this key switches to “Reference” mode. In Reference mode, each motion axis can home exactly on its reference position.

Activation light


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b) Multiple Step Keys: Shown on the right are the four multiple step selection keys used during incremental operation. Again, the LED light on the key’s upper-left corner indicates the corresponding multiple selected. First the INC key is pushed to set the Incremental Mode, then the desired number of multiple steps is pressed and finally the desired Axis key is pressed.

The multiple step selection keys are:

KEY DESCRIPTION

Each key push moves that axis one step

Each key push moves that axis 10 steps



A step is equal to one micrometer (1 μm) for each linear axis (X, Y, Z) and 0.001 degrees for each rotational axis.

On the same row as the Multiple Step keys, is the Verify key used in conjunction with the Automatic Mode key. When the Verify key is activated, a program runs at a higher speed than during normal machining. The operator can run a program quickly be sure the program performs the proper function.

1 Introduction

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c) Spindle and Auxiliary Operation keys:

These nine keys usually function in Manual mode. They control spindle, turret tool selection, coolant and chuck functions. These functions are activated only when no program is running. Details of the keys are shown below:

Coolant Switch key: This key opens or closes the coolant flow

Lubrication key: Turn on the lubrication system with this key.

Tool lock/unlock: After pressing this key, the tool will be release if it is locked before and will be locked if it is to be replaced in.

Spindle Clockwise Rotation key: Pressing this key begins spindle rotation in the clockwise direction (top of workpiece moves toward operator).

Spindle Stop key: Stop the spindle rotation by pressing this key.

Spindle Counter-clockwise Rotation key: Pressing this key begins spindle rotation in the counter-clockwise direction (top of workpiece moves away from operator).


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d) Speed Adjustment keys: By pressing these keys the spindle speed, rapid traverse rate and feed rate (machining speed) can be adjusted. The first row controls the spindle speed, the second row controls the rapid traverse speed and the bottom row controls feed rate. These keys work by adjusting the speed relative to a ”base” speed. Different modes (Automatic, Single Block and Manual) may have different base speeds. The base speed is set by the G-code program or the parameter setting. For each row, pressing the center key sets the speed at 100% of the base speed; the LED light in the key’s upper-left corner is lit to signify that the machine is running in base speed. Pressing the minus (-) key, decreases the base speed by a fixed percent; pressing the plus (+) key, increases the base speed by a fixed percent. Below is an example where the speeds are changed by 2%:

KEY DESCRIPTION

Pressing this key decreases the speed 2% for each press. The current speed or rate is displayed on the LCD screen.

Once this key is pressed, the override ratio is set to 100%. The LED light indicates that the current speed is the base speed.

Pressing this key increases the speed 2% for each press. The current speed or rate is displayed on the LCD screen.

1 Introduction

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e) Axis Operation keys:

These five keys select 1) the desired axis and 2) the direction of motion in various modes. These keys only function in Manual Mode, INC Mode and Reference Mode. The LED light in the upper-left corner specifies which axis or direction is selected.

KEY DESCRIPTION

In INC mode or Manual Mode, the tool moves the X axis in the positive direction while +X is pressed and in the negative direction while –X is pressed. In Reference mode, pressing the +X key homes the X axis (finds the machine reference on the X axis).

In INC mode or Manual Mode, the tool moves the Y axis in the positive direction while +Y is pressed and in the negative direction while –Y is pressed. In Reference mode, pressing the +Y key homes the Y axis (finds the machine reference on the Y axis).

In INC mode or Manual Mode, the tool moves the Z axis in the positive direction while +Z is pressed and in the negative direction while –Z is pressed. In Reference mode, pressing the +Z key homes the Z axis (finds machine reference on the Z axis).

This key speeds up tool motion in Manual mode. It must be pressed in conjunction with one of the Axis keys.


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f) Other keys: The five keys below are other keys that control various machining functions.

KEY DESCRIPTION

Servo enable key: Press this key to enable

or disable the servo.

Block Bypass key: Activating this key

bypasses program blocks that start with a “/”

character

Program Stop key: Activating this key

enables the M01 G-code stop function,

stopping the program at a desired block.

Not used.

Machine Lock key: Activating this key

prevents any motion from the spindle, the tool

changer turret or any axis; it is used for system

testing

1 Introduction

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Alpha Numeric Keyboard

The Alpha Numeric keyboard lets the operator input either letters or numbers for programs, parameters or conversational commands.

KEY DESCRIPTION

Delete keys

Backspace key deletes the character in front of the cursor

Delete key deletes the character at the cursor

Page change keys

There are two kinds of page change keys:

PageUp key moves the page one screen up

PageDown key moves the page one screen down.

Cursor keys

Right key: moves the cursor to the right, selects a soft key to the right or selects a column to the right.

Left key: moves the cursor to the left, selects a soft key to the left or selects a column to the left.

Down key: moves the cursor down, selects a soft key on the bottom or selects a row on the bottom.

Up key: moves the cursor up, selects a soft key on the top or selects a row on the top.


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Shift Up key

The Shift Up key toggles the status of

double-character keys in the Alpha

Numeric keyboard. The LED light in the

upper-left corner indicates whether the

upper character is selected. When

the LED light is on, the upper character

is selected, otherwise the lower

character will be input. For example,

“X” will be input if is pressed

when LED light of is off, while

“A” will be input when the LED light is

on.

1 Introduction

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Menu tree

For HNC-18/19 CNC system, there are seven function keys below the alpha numeric keyboard that bahave as seven different function keys.

They are:

KEY DESCRIPTION

PROGRAM submenu key: Press this key to do operations related with program such as open, edit or test a part program.

SETTING submenu key: Press this key to activate setting submenu.

MDI submenu key: Press this key to switch to MDI (Manual Data Input) submenu.

OFFSET submenu key: Press this key to enter into OFFSET submenu which enable the operator to set a tool’s offset data.

DIAGONOSIS submenu key: Activating this key will present DIAGONOSIS submenus, which can help user to tell what is the cause of faults happened.

POSITION submenu key: This key will bring up the POSITION submenus. Which allow the operator to choose different axes coordinates type to monitor. PARAMETER submenu key: Press this key to enter into PARMAETER submenu, where the user can check or modify the system’s parameters.


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There are six soft keys to navigate each of the above key. The functions of the soft keys change according to which function key is active.

Each function is corresponding to one submenu. Let’s go through the seven submenus one by one.

a) PROGRAM SUBMENU The key “PRG” has six submenus.

F1, corresponding to OPEN, picks which program is to be run or edited. By default or switched from EDIT to OPEN, F3~F6 are attached with TST, REW, BP and DNC.

TST, stands for PROGRAM TEST, verifies whether the opened program has correct syntax and tool path.

REW, abreviation of REWIND, restarts a program from the first block.

PRG

OPEN (F1)

EDIT (F2)

DNC (F6)

REW (F4)

TST (F3)

BP (F5)

TST (F3)

REW (F4)

DNC (F6) BP (F5)

SAVE BP (F1)

BACK (F6)

LOAD BP (F2)

NEW (F3)

SAVE (F4)

STOP (F6)

ROW (F5)

1 Introduction

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BP, means breakpoint operation, has three submenus, SAVE BP(Save the break point information to a file), LOAD BP(Load the break point information from a file) and BACK(Back to OPEN function menus).

DNC, enable the NC to receive program from a computer.

F2, corresponding to EDIT, allows the user to do edit operation and some running process control operation. When EDIT is active, F3~F6 are used for NEW, SAVE, ROW and STOP(Stop the program from running)

NEW, creates a new program.

SAVE, saves the current program.

ROW, allows the user to run the program from a specified row rather than from the first.

STOP, Stop the program from running.

b) SETTING SUBMENU

The key “SET” has three submenus.

F1, WCS, workpiece coordinate system. Lets the user to set coordinates system’s origin offset for G54 to G59 and RCS.

F2, RCS, relative coordinate system. This function has two

SET

WCS (F1) G54~G59, RCS(PgUp PgDw)

HPI (F3)

RCS (F2)

X RST (F4)

Z RST (F6)X HPI (F4)

Y HPI (F5)

Z HPI (F6)

Y RST (F5)


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MDI

BAK.BP (F5)

ALIGN TOOL (F6)

submenus: X RST, resets the X position of RCS’s origin. Y RST, resets the Y position of RCS’s origin. Z RST, resets the Z position of RCS’s origin.

F3, corresponding to HPI(Home position input), also has three submenus: X HPI, resets the X position of home point. Y HPI, resets the Y position of home point. Z HPI, resets the Z position of home point.

c) MDI SUBMENU The key “MDI” has two submenus.

F5, corresponding to BAK BP, lets the tool go back to the break point after an interactive intervention during automatic machining.

F6, corresponding to ALGN TOOL, allow operator to re-align the tool’s dimension.

d) OFFSET SUBMENU

The key “OFT” has two submenus.

F1, corresponding to Len Comp, allows the user to measure and set the tool’s length compensation value.

DIA Comp (F2)

OFT

LEN Comp (F1)

1 Introduction

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F2, corresponding to DIA Comp, used for the user to input the tool’s diameter compensation value.

e) DIAGNOSIS SUBMENU

The key “DGN” has five submenus.

F1, corresponding to IO, displays the status of I/O points.

F2, corresponding to REG, presents the value of the system registers.

F3, corresponding to MSG, lists the contents of alarms.

F5, corresponding to ABT(ABOUT), presents version information of the software.

F6, corresponding to JOB NOTE, is a statistic function which has three submenus, NEW JOB, RST JOB and BACK.

NEW JOB, allows the user to set the planned workpieces number.

RST JOB, lets the user to reset the statistic value.

BACK, back to the previous menu.

I/O (F1)

REG. (F2)

DGN MSG(F3)

ABT(F5)

JOB NOTE (F6)

NEW JOB (F3)

RST JOB (F4)

BACK (F6)


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f) POSITION SUBMENU

The key “POS” has six submenus.

F1, corresponding to MCS, displays machine coordinate system.

F2, corresponding to WCS, displays workpiece coordinates system.

F3, corresponding to ALL, displays overall information of the axes.

F4, corresponding to TEXT, displays the G code of the program.

F5, corresponding to GRPH, displays the graphical figure of the part.

F6, corresponding to GRPH PARM, allows the user to set graphical figure’s parameters.

g) PARAMETER SUBMENU

MCS (F1)

WCS (F2)

POS ALL (F3)

TEXT (F4)

GRPH (F5)

GRPH PARM (F6)

BACK PARM (F1)

LOAD PARM (F2)

PAR DNC PARM (F3)

BACK PLC (F5)

LOAD PLC (F6)

PASSWORD (F4)

1 Introduction

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The key “PAR” has five submenus.

F1, corresponding to BACK PARM, makes a backup parameters.

F2, corresponding to LOAD PARM, loads a saved parameter file.

F3, DNC PARM, used to set the DNC parameters.

F4, PASSWORD, inputs the password to access the parameters.

F5, corresponding to BACK PLC, backs up the PLC program.

F6, corresponding to LOAD PLC, loads a saved PLC program.


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2 Set up Before machining a part, the operator needs to set up the machine

coordinates, the work piece coordinates, define tools parameters

and other machine preparations.

The general setup procedure includes six steps:

(1) Power On

(2) Reset

(3) Reference home (point approach)

(4) Define software limits

(5) Set tool data

(6) Set workpiece coordinates

The first three steps are always necessary each time the machine is

powered on. Step 4 is necessary only when the machine is set up

for the first time. Step 5 is done for each tool cutter before it is

used to cut the parts. Step 6 is done each time a new program

used.

Let’s go through these steps in detail:

2 Set up

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Power on

Sequence:

a) Check and make sure the machine is safe to run.

b) Press down the Emergency Stop button on the machine’s front control panel.

c) Turn on the power supply of the machine (usually located in back of the machine and/or beneath the control panel).

d) Make sure the fans run normally

e) Make sure the lamps on the MCP have been lighted on.


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Reset/ Emergency Stop

After Power On, reset the control unit by twisting the Reset Button on the front face clock-wise, resetting servo and spindle power to enable the machine to run. Pushing the RESET button down generates an Emergency stop event and disables the servo and spindle.

Feed motion from the axis motors and the spindle motor will stop immediately when the Emergency Stop (ES) button is pressed. This button can be used:

when there is a machine malfunction

before powering the system on or off

Once the ES button is pressed, the system enters into the “ES Mode”. In this mode, no operation except reset is allowed. After curing the cause of the machine malfunction or to enable the machine after the machine is powered on, the emergency stop button can be released by the RESET operation (twisting the ES button clock-wise).

Reset button

Turn clock-wise

2 Set up

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Homing (Reference–point Approach)

In homing (sometimes called reference point approach), there is a reference point for each axis. These reference points are used to set up the machine’s coordinate system. Homing should always be performed each time the machine is powered on. By homing each time the machine is powered on, the axis’ original positions are the same as the previous time. Shown below is a diagram of a typical axis homing. The present location in red is a distance from the Origin. When the axis homes, the axis motion moves the present location toward the origin until it touches the Reference Switch (RSW). Now it is roughly located near the origin. Next, machine control moves the tool very slowly until the “home signal” encoder signal is triggered. This is the exact location of the origin, accurate to the resolution of the encoder.

Origin

Reference Switch (RSW)

Motion Axis

Tool location

Origin

Reference Switch (RSW)

Motion Axis

Present location


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For proper homing, the direction for reference point approach must first be defined for each axis. This setup is done once only.5).

The button sequence for homing is as follows. First switch the mode to Home mode by pushing the Home key on the control panel. Next, press “+X” to home the X axis and last press “+Z” to home the Z axis.

Switch the mode to home mode by pressing the home key on the MCP.

Press “+X” to approach reference point of x axis

Press “+Z” to approach reference point of z axis

Press “+Y” to approach reference point of y axis

2 Set up

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Software limits definition

Each axis has a hardware limit and a software limit on each end of the axis. In the figure below, the hardware switches (shown in black) are at the extreme left and right of the axis. Software switches (shown in white) are interior to the hardware switches. The limits on one end of the axis are the negative limits, those at the other end are positive limits. By convention, the positive X axis moves the cutter away from the workpiece in the crossfeed direction while the positive Z axis moves the cutter away from the workpiece along the spindle (i.e., turning) axis. When the axis is commanded to go beyond these limits (overtravel), first the software switch will be encountered. At this point motion ceases and no further motion in this direction is permitted.

The tool can be retrieved from a software overtravel by using manual or incremental commends to move the tool back towards the middle of the axis. Software limits are defined for each axis using machine parameters. With software limits set, the control unit can decelerate and stop the tool safely before the tool gets to the hardware limit switches.

Hardware Limit (-)

Software Limit (-)

Tool location

Software Limit (+)

Hardware Limit (+)

Motion


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If the tool goes beyond the software limit, the hardware limit switch is encountered. This can occur if the software switches are not set properly of if the tool is moving too fast to stop when the software limit is reached.

Tool location

Hardware Limit (-)

Software Limit (-)

Software Limit (+)

Hardware Limit (+)

Motion

2 Set up

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Tool data setting

There are three kinds of tool data, length compensation value, radious compensation value and life expectancy. To access the tool data, click OFT from the function keys of the alpha numeric keyboard to get to the Offset Data screen: Here, the tool data input windows displayed.

Sequence to set tool length compensation value: a) Press F1 (corresponding to LEN Comp) under OFT function. b) Move the cursor to the tool’s row with ▲or ▼. c) Press “Enter” to make the tool’s length editable. d) Enter the tool’s length compensation value. e) Press “Enter” again to confirm.


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Sequence to set tool diameter compensation: a) Press F2 (corresponding to DIA Comp) under OFT function. b) Move the cursor to the tool’s row with ▲or ▼. c) Press “Enter” to make the tool’s diameter editable. d) Enter the tool’s diameter compensation value. e) Press “Enter” again to confirm.

2 Set up

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Sequence to set tool life expectancy: a) Press ► under OFT function to move the cursor to tool’s life column. b) Move the cursor to the tool’s row with ▲or ▼. c) Press “Enter” to make the tool’s life editable. d) Enter the tool’s life expectancy value. e) Press “Enter” again to confirm.


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Origin Offset

Usually workpiece coordinates system (WCS) instead machine coordinates system(MCS) are used to simplify programming. User can define 6 workpiece coordinates with G54~G59. To use these 6 workpiece coordinates, user need to define the offset of their origin to machine coordinates’ origin. Sequence:

a) Press “SET” key to enter into the setting submenu.

b) Press F1, corresponding to WC.S on the LCD screen, gets into the coordinates system setting interface.

Press this key to SETTING submenu

Press F1 [WCS] to bring out WCS screen

2 Set up

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c) Press PgUp or PgDw button on the alpha numerical keyboard to browse the six WCS offsets (origin position of G54~G59) and RCS offset.

d) Input the offset value on the command row. For example, if the offset of G54 is 100 and 100, type in “X100 Z100”

e) Press Enter to confirm. f ) The new origin position of the W.C.S will be displayed on the screen

Type in the WCS value for G54 at this area

The new origin position take effect.


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3 MANUAL OPERATION

Manual Operation (MAN) uses various input devices to carry out operations much like those of a manual mill. While the internal computer is actually controlling the machine tool during these operations, they are familiar to an operator that has machined parts on a manual mill.

MAN operations are primarily used for setting up parts. In MAN mode, the cutter can be moved into position near the workpiece where sample cuts can be made for setting the workpiece reference. In addition the cutter can be moved out of the way to get access to the part for measuring. For an experienced mill operator that has little or no experience on an NC mill, these operations are a good place to start. You can understand how familiar operations are implemented on an NC machine.

The five MAN operations include:

JOG feed: Moving the cutting tool along a motion axis while an axis button is being pressed.

INCremental feed: Moving the cutting tool a fixed amount along a motion axis

Manual Handwheel: Move the cutting tool by manually rotating the handwheel

Spindle operation: Turn spindle rotation clockwise, counter-clockwise or off.

Auxiliary operation: Change other devices such as chuck, coolant and turret

3 MANUAL OPERATION

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Jog Feed

JOG feed is used to move the cutting tool along a motion axis. The motion continues as long as the axis key is pressed. In JOG, pressing a feed axis with its direction on the machine control panel continuously moves the tool along the selected axis in the selected direction.

The feedrate in JOG is a fixed fraction of the rapid traverse rate. The factory default fraction is one third (1/3): the JOG feedrate is one third of the rapid traverse speed. However, other fractions for each axis can be set using the axis parameter (See Chpt. 8, Parameters). For example, if the rapid traverse feedrate were set at 600 in/min, the JOG feedrate would be 200 in/min using the factory default setting.

In addition, the JOG feedrate can be adjusted with the manual feed "override ratio". Pressing the rapid traverse key and an axis key at the same time moves the tool at the "rapid traverse feedrate" (also called the "rapid traverse speed"). This let's you move the cutting tool quickly during setup or other manual operations. The rapid traverse speed in MANual mode can also be adjusted by the override keys.

JOG Feed Functions: Below are details of each of the five JOG feed functions.

Requirements: The machine is in JOG mode. If not, switch to JOG mode by pressing on the Machine Control Panel (MCP) key area on the bottom of the front panel:


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After pressing the JOG mode button, the LED indicator light on that key lights to verify that you are in the JOG mode.

JOG feedrate: Press one of the feed axis keys: +X, -X, +Y, -Y, +Z or -Z. For moving the cutting tool toward the workpiece use a minus key (-X, -Y, -Z). For moving the cutting tool away from the workpiece use a plus key (+X, +Y, +Z). The tool will continue to move at a fixed rate (the JOG feedrate) along the selected axis so long as the key is pressed. The tool motion stops when the axis key is released.

Adjusting JOG feedrate: The JOG feedrate is adjusted with the feedrate override keys located in the middle of the Machine Control Panel (MCP) key area on the bottom of the front panel. Below are the three override keys that control the JOG feedrate: a minus (-) key on the left, the 100% key and a plus (+) key on the right. As in other keys, an LED light in the upper left

JOG mode key

JOG mode LED indicator light

For example, this key moves the X axis continuously in the plus direction (away from the workpiece)

This key moves the X axis continuously in the minus direction (toward the workpiece)

3 MANUAL OPERATION

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corner of the 100% key specifies that the feedrate is set to full value (i.e., 1/3 the rapid traverse value for factory default). Note the feedrate icon that tells that the JOG feedrate is being adjusted: Pressing the 100% key sets the JOG feedrate at full value. Pressing the minus (-) key reduces the feedrate by the factory default amount of 2% of the 100% JOG feedrate. By pressing the minus (+) key, the JOG feedrate is increased by the 2% factory default amount. For example if the JOG feedrate were 200 in/min and you pressed the plus (+) key, the new feedrate would be 204 in/min.

LED light shows when feedrate is 100% of full value

Feedrate icon

Set the JOG feedrate to its full value—1/3 of the axis’s rapid traverse speed.

Increase the JOG feedrate by 2%.

Decrease the JOG feedrate by 2%.


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LED light shows when feedrate is 100% of full value

Rapid Traverse icon

Rapid Traverse feedrate: The icon for the Rapid Traverse key is

The Rapid Traverse feedrate moves the cutting tool at the Rapid Traverse rate. As explained above (see Adjusting JOG feedrate above), the Rapid Traverse speed is the maximum feedrate on each axis that the machine can move. By contrast, the feedrate for JOG functions is usually set at a small fraction of the Rapid Traverse speed (factory default set at 1/3).

To move the cutting tool at the Rapid Traverse speed, press the Rapid Traverse key while simultaneously pressing one of the feed axis keys: +X, -X, +Y, -Y,+Z, -Z. Like the JOG feedrate, a minus key (-X, -Y, -Z) moves the cutting tool toward the workpiece while a plus key (+X, +Y, +Z) moves the cutting tool away from the workpiece. In either case, the motion will be at the Rapid Traverse speed.

The override keys can be used for Rapid Traverse feedrate in a similar manner as the JOG feedrate. Pressing the 100% key, sets the Rapid Traverse speed at its full value. The LED indicator light in the upper left corner lights to indicate that the speed is at its full value.

The Rapid Traverse speed can be used and adjusted in a similar manner as the JOG feedrate.

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Adjust Rapid Traverse speed: The rapid jog feedrate can be adjusted with the rapid traverse feedrate override keys.

Set the Rapid Traverse speed to its full value—1/3 of the axis’s rapid traverse speed.

Increase the Rapid Traverse speed by 2%.

Decrease the Rapid Traverse speed by 2%.


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Incremental Feed

INC feed is used to move an axis a fixed increment of travel. Pressing a key in incremental or INC mode, moves the cutting tool one increment in that axis and direction. When in INC mode, the cutting tool moves at the JOG feedrate (See JOG Feed Functions above for adjusting the JOG feedrate).

Pressing an axis/direction key on the Machine Control Panel (MPC) keys moves the tool one "minimum step" along the selected axis in the selected direction. The minimum step can be magnified by 1, 10, 100, or 1000 times giving a "step length".

The INC feed is useful for adjusting the cutting tool a small fixed amount from a surface being turned or faced. For example, in making a sample cut, the cutting tool can be adjusted toward the workpiece until it just begins to cut. Then using a small (say 5 thou) incremental -X movement lets the operator clean up surface of the workpiece by removing 5 thou from the diameter.

Requirements: The machine is in INC mode. If not, switch to INC mode by pressing the INC mode key in the Machine Control Panel (MCP) key area on the bottom of the front panel. The icon for the INC mode is After pressing the INC mode button, the LED indicator light on that key lights to verify that you are in the INC mode.

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INC mode key

INC mode LED indicator light For each press of the feed axis keys: +X, -X, +Y, -Y, +Z or -Z, the tool cutter moves a certain distance. To move the cutting tool toward the workpiece use a minus key (-X, -Y, -Z). For moving the cutting tool away from the workpiece use a plus key (+X, +Y, +Z).

Step length selection: Step length is the amount of INC movement that occurs for each press of the feed axis keys: +X, -X, +Y, -Y, +Z or -Z. To move the cutting tool toward the workpiece use a minus key (-X,-Y, -Z). For moving the cutting tool away from the workpiece use a plus key (+X, +Y, +Z).

The "minimum step" is the smallest distance that an axis can move. It is determined by the machine's encoder. The minimum step is a certain rotation of the ball screw moving each axis. Depending on the number of steps on that axes' encoder, the step size is either in English or metric units. For an English unit encoder, the minimum step is 50 millionths of an inch (half a tenth of a thou). For a metric unit encoder, the minimum step is 1 micron (0.001 mm).

The step length is a "magnified" length. The distance moved in a step length is the minimum step multiplied by the magnifier value. For example, if the magnifier were set at 1 and you pressed the +X key twice, the distance moved would be 1 X 2 = 2 minimum steps. In English units, that's a tenth of a thou, in metric units that's 2 microns. But if the magnifier were set at 100, the distance moved would be 100 x 2 = 200 minimum steps. In English units, it moves ten thou (0.012 inch), in metric units it moves 200 microns (0.2 mm).


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The distance is the number of minimum steps times the magnifier value.

The four keys below select the step length magnification in the INC mode. Pressing any key changes the magnification of the corresponding distance. As before, the LED light associated with the selection lights up indicating which magnification is chosen. Incremental feed: Press one of the feed axis keys: +X, -X, +Y, -Y, +Z or -Z to move the cutting tool one step in the desired direction. As in JOG feedrate or Rapid Traverse speed, for moving the cutting tool toward the workpiece use a minus key (-X, -Y, -Z). For moving the cutting tool away from the workpiece use a plus key (+X, +Y, +Z). The tool will move one step for each press of the key. Remember: each step length consists of the "minimum step" multiplied by the magnifier (see Step length selection above).

LED light shows which magnification is selected

100 X magnification

No magnification; each key press moves one minimum step.

Each key press moves ten minimum steps.

Each key press moves one hundred minimum steps.

Each key press moves one thousand minimum steps.

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For example, this key moves the X axis one step in the plus direction (away from the workpiece)

This key moves the X axis one step in the minus direction (toward the workpiece)


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Manual Handwheel

In the handwheel mode, the cutting tool can be moved small amounts by rotating the handwheel on the handwheel unit. During part setup with the handwheel, the operator can adjust the cutting tool from closer to the workpiece than from the front panel. There are two selection switches on the handwheel unit. One is for axis selection (X, Y, Z) and the other is for magnification (X1, X10, X100, X1000).

To use the handwheel unit, press the same INC mode key as for INCremental feed. When the handwheel is enabled, the INC mode on the front panel is disabled (i.e., the incremental feed operation is disabled).

Handwheel Feed Functions: Requirements: The machine is in INC mode. If not, switch to INC mode by pressing the INC mode key in the Machine Control Panel (MCP) key area on the bottom of the front panel. The icon for the INC mode is

After pressing the INC mode button, the LED indicator light on that key lights to verify that you are in the INC mode.

Handwheel unit

Magnification selection knob

Axis selection/ OFF knob

Handwheel

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Once in INC mode, the handwheel unit is activated by turning the Axis Selection knob from the OFF position to one of the mill's axes.

Axis selection/ OFF knob: The left knob on the Handwheel unit is the Axis Selection/ OFF knob. By rotating the knob, you both turn on the Handwheel unit and also select the axis of handwheel motion.

Magnification selection knob: The right knob on the Handwheel unit is the Magnification Selection knob. By rotating the knob, you select the amount of magnification to the step length for each increment of handwheel motion. The amount of magnification can be 1, 10, 100 or 1000.

INC mode key

INC mode LED indicator light

OFF: The handwheel unit is disabled; control is through the INC mode on the front panel.

X: Handwheel movement controls the X axis.

Y: Handwheel movement controls the Y axis.

Z: Handwheel movement controls the Z axis.


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Note:

A minimum step for linear axes is 0.5 tenths (English encoders), one micron (metric encoders) or 0.001 degrees for rotational axes.

Handwheel rotation: Rotating the handwheel on the handwheel unit moves the selected axis one step length (minimum step times magnifier) for each click of the handwheel. Clockwise rotation moves the selected axis away from the workpiece (positive axis direction: +X, +Y, +Z). Counter-clockwise rotation moves the selected axis toward the workpiece (negative axis direction: -X, -Y, -Z). Always be cautious when moving the handwheel counter-clockwise because you are moving it toward the cutting zone.

X1: No magnification; each click of the handwheel moves one minimum step.

X10: Each click of the handwheel moves ten minimum steps.

X100: Each click of the handwheel moves a hundred minimum steps.

X1000: Each click of the handwheel moves a thousand minimum steps.

Clockwise Rotation (CW): Moves the cutting tool away from the workpiece (i.e., positive axis direction) on the selected axis.

Counter-clockwise Rotation (CCW): Moves the cutting tool toward the workpiece (i.e., negative axis direction) on the selected axis.

Step length: The motion is one step length (minimum step times the magnifier) per click of the handwheel.

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Spindle Operations

The middle keys of the Manual Control Panel (MCP) area of the front panel manually operate the spindle and other common auxiliary devices.

The spindle is the most important of these keys since no cutting takes place unless the spindle is rotating. For most mills, the spindle can be manually operated when the mill is not machining. However, some mill manufacturers do not allow manual operation of the spindle except in JOG mode.

Spindle Control Keys


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Spindle keys:

Requirements: The machine is in JOG mode. If not, switch to JOG mode by pressing the INC mode key in the Machine Control Panel (MCP) key area on the bottom of the front panel. The icon for the

JOG mode is . After pressing the JOG mode button, the LED indicator light on that key lights to verify that you are in the JOG mode. Make sure there is no potential danger from the spindle turning before you run the spindle manually.

Spindle Operation: The four keys shown below control the spindle operation. The lower left key starts spindle rotation in the clockwise (CW) direction, the middle key stops the spindle manually and the right key starts spindle rotation in the counter-clockwise (CCW) direction. The upper spindle key turns on the spindle only for as long as it is pressed.

JOG mode key


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Note:

If the spindle is turning one way and you want to change the rotation

direction to the other way, you must first stop it and then press the

desired rotation direction.

RUN SPINDLE CCW: Rotate the spindle in counter-clockwise direction. The LED is lit if the spindle is running.

RUN SPINDLE CW: Rotate the spindle in clockwise direction. The LED is lit if the spindle is running.

STOP SPINDLE: Stop the spindle manually.


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Auxiliary Operations

The middle keys of the Manual Control Panel (MCP) area of the front panel manually operate the auxiliary devices: Coolant, Lubrication, Turret and Chuck functions.

Auxiliary keys: Requirements: The machine must be in JOG mode. If not, switch to JOG mode by pressing on the JOG key in the Machine Control Panel (MCP) key area on the bottom of the front panel. The icon on the JOG key is:

After pressing the JOG mode button, the LED indicator light on that key lights to verify that you are in the JOG mode.

Auxiliary Function keys

JOG mode key


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Auxiliary Operation: The five keys shown below control auxiliary operation. The upper left key turns coolant flow on while the other two upper keys rotate the tool changer clockwise (CW) and counter-clockwise (CCW). The bottom two keys control the chuck: the right key clamps the chuck and the left key selects the chuck.

COOLANT ON/OFF: Press this key to start coolant flow. Coolant flow is ON if the LED light is lit and OFF if the LED light is off.

Coolant key Tool key LUB key

LUBRICATION ON: Turn on the lubrication system.

TOOL LOCK/UNLOCK: Provided the tool is exchangeable, once this key is pressed, the tool will be release if it is locked before and will be locked if it is to be replaced in.


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4 AUTOMATIC OPERATION

Automatic (AUTO) operation is used to machine parts under program control. In an NC machine tool, most production machining is done as an AUTO operation. In Automatic mode, you can execute part programs fully automatically. If you are a manual mill operator, it is the AUTO operations that will be most unfamiliar to you. AUTO operation requires a program to execute. Several sample programs are already included in the controller's memory. If you are a beginner, execute one of the sample programs in AUTO mode. If you are an advanced NC operator, execute a program that you have written yourself. Softkeys: Programming functions require “softkeys”. These are keys whose function changes depending on the key’s description on the LCD screen. The physical keys are located just below the LCD screen. Each softkey function shown on the LCD screen is actuated by pushing the corresponding physical key just below:

Softkey description on LCD screen

Physical keys

Corresponding physical key


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After pressing the physical key, the softkey descriptions will change to bring in functions only available when the physical key is pressed.

Requirements:

1. The mill has already been homed. That is, the “Reference Point Approach” procedure has been completed. 2. The part program has already been stored in the mill's memory 3. You have verified or entered tool data (offset and compensation values), zero offsets and other necessary data.

4. Machine lock is off.

5. Machine is in AUTO mode. If not, switch to AUTO mode by

pressing on the Machine Control Panel (MCP) key area

Automatic operation includes five parts:

AUTO mode key

AUTO mode LED indicator light

Running Control: running part of the program to debug it

Program Verifying: finding errors in a new program

Program Loading: putting the program into the lathe’s memory computer

Manual Data Input (MDI): operating the lathe by typing blocks into the lathe’s computer by hand

Single block running: running one block of the program at a time; a block is one or more operations that fits on one line of the program


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Program Loading

A program file must be “loaded” into the mill’s memory before it can be “executed” (i.e., cut a part or do some other operation automatically). The program file itself is a series of program lines called blocks that direct the mill through a series of various operations automatically. The programmer who writes the program file sets these operations.

Only one program at a time can be “loaded” for execution by the mill. Usually many programs that have been written are stored in the mill’s computer. “Loading” is the process of picking one of these programs to be executed.

Sequence: The following steps are used to load a program for execution.

1) From the physical keys located below the Alpha numerical keyboard, press the PRG.

There six soft keys for PROG function. They are displayed on the LCD screen once “PRG” is pressed.

This Key directs to PROG function


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2) Now press the F1 physical key, which correspond to OPEN softkey.

3) On pressing the OPEN softkey, the LCD screen shows a file directory: a list of program files like the ones below. The left column shows the name of the program file, the middle column shows the size of the file and the rightmost file shows the last date the file was changed. Note that program files always start with the letter “O”. The example below has 2 program files, each 1K long (one kilobyte).

4) Use the up-down keys to select one of the program files from the program file directory. Each press of the down key moves the blue selected line to the next file down in the file listing.

5) Last, press the Enter key in lower right corner of the keyboard area to load the selected program to memory.

F1 OPEN softkey


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Program Testing

A program which has just been created or changed should be tested or tested before it is actually used to cut parts. Program verifying can find errors in the program without actually running the machine and possibly damaging the mill or the workpiece.

Sequence: 1) Load the program to the mill’s memory as shown above.

2) To verify, you must be in either AUTO mode or SBL

mode (Single Block mode). 3) Press the F5 key corresponding to TST (ProgramTest) in

the Program Functions submenus.

4) Press the Cycle Run button on the Machine Control Panel (MCP) keys area to start the VERIFY process.

5) As the program is tested, the lines of the program are

displayed. The line being tested is highlighted in yellow. As testing progresses, the yellow line moves line-by-line from the top to the bottom of the program. The LCD screen will display an error message if an error is found. Otherwise the cursor (yellow highlighted line) will return to the start of the program.

F5 PRogram Test softkey


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Note that there is no motion of the cutter or any other action that takes place. The TEST process is a simulation of the motion or action that would take place.


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Running Control

Once tested successfully, the program can be confirmed by

executing automatically with AUTO mode or by stepping through each block of the program in the SBL mode (Single Block

mode) . This confirmation is important on new or recently modified programs to be sure the cutting tool does not run into fixtures and that the feeds and speeds are properly set. Most operators will step through the program in Single Block (SBL) mode before trying it in AUTO mode.

The program running process – either testing or executing -- can be paused, canceled or run from the start again. You can also run the program from a specific location in the program other than from its start to more easily confirm the program a section at a time. There are four softkey functions for running process control. REW(Rewind) and BP(Break point operation) are visible when OPEN is pressed. ROW(Run from speicfied row) and STOP are visible when EDIT is pressed.

These are the four softkey functions for running process control


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Beside these four softkey functions, there are two hard key functions to control the running process. Totally there are eight different operations to control the running process:

Cycle Run: cycles through the program

Feed Hold: stopping the motion of the program with a softkey press

Restart: begin the program operation again after a pause

Pick Start Block: begin the program at other than its first line

Save Break Point: shut down the machine and save the restart point

Load Break Point: load the restart point after machine shutdown

Break Point recover: restart after machine shutdown

Align Tool: change tools and realign the new cutter at the same location


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Cycle Run: This function begins program execution.

Requirements: 1) The program has been successfully tested. 2) The machine is in Single Block (SBL) mode or

Automatic (AUTO) mode. Sequence:

1) Press the green Cycle Run button and the program will be executed. 2) If the machine is in AUTO mode, the machine will keep

running until it is finished or until the FEEDHOLD softkey is pressed to cancel the AUTO mode.

3) If the machine is in SBL mode, the machine stops after each block of the program is executed. Press Cycle Run again and the next block in the program will be executed.

Feedhold:

Requirements: 1) The program has been successfully tested.

2) The machine is in Single Block (SBL) mode or Automatic (AUTO) mode.

Sequence: 1) During execution, pressing the red

Feedhold button pauses the program. Pressing the Cycle Run button recovers the running process again. These two – Cycle Run and Feedhold -- work together to stop and restart the program being executed.


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2) After the Feedhold button is pressed, you can stop all

action by pressing the Emergency Stop button. If you just want to exit the program, cancel it with the PAUSE operation below.

Restart: If the program has been canceled, it can be restarted from the program beginning by pressing the REW(REWind) softkey.

Sequence: 1) Press F4, corresponding REWind, under PRG

function.

2) Now press the Cycle Run button on the Manual Control Panel (MCP) and the program will be executed from the beginning.

Press REW softkey to restart a program


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Break point operation

For complex or large parts, more than one day may be required to finish machining. You may need to power off the machine before it’s done. In this case, the mill’s memory should store the current block location and recover from this location to continue machining later. Break point functions do this.

B.P. SAVE: The first of the three break point functions is saving the break point when you stop the mill.

Sequence: 1) Press Feedhold button to pause the machine. 2) Press the F5 [BP] softkey to bring out the break

operation functions keys.

The softkeys will changed to these:

3) Press F1[SAVE BP] to save the breakpoint to a file. The system will give a default name for the breakpoint information file. But the user can name the file as he would.

Press BP to enter into break point operation submenu


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4) Here we adopt the default name “OTEST1” perhaps naming the part number being machined

5) Press Enter to confirm the operation. The mill will store the current status information to the typed file.

B.P. LOAD: If you haven’t turned the mill power off after the B.P. SAVE, you can restore the breakpoint directly with B.P. LOAD. For example, if you just leave for a lunch break, you can do a B.P. SAVE before you leave and then resume again quickly when you return.

However, If machine has been powered off after a B.P. SAVE operation, you must recover the break point: first the mill must be homed (i.e., perform the “Reference Point Approach” procedure) after turning the power back on. Since the workpiece will still be in the chuck, you should be careful on which axis you home first (X, Z and perhaps C) to avoid a collision between the cutting tool and the workpiece.

Requirements: 1) The break point program has been loaded into

memory. Sequence:

2) Press the F6 B.P. LOAD softkey to load the break point file.

User can rename the breakpoint information file here


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3) After pressing the B.P. LOAD softkey, a table of break point files is displayed. The first column is the name of the file, the second is the size of the file in Kilobytes and the last column is the date on which the break point file was last saved.

4) Use the up/down keys to select the desired break point file.

5) Press Enter to confirm your selection 6) If there were absolutely no changes since the B.P.

SAVE operation, press Cycle Run button to continue the machining process. Otherwise switch to the MDI mode to recover the breakpoint

B.P. LOAD softkey

Break point file

Size in Kilobytes

Date last saved


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B.P. Recovery: If there have been ANY manual operations of the mill or if the mill power has been turned off, you must move the tool back to where it was before the break point in order to run the machine again using the break point file.

Sequence: 1) Move the cutting tool near its position at the break

point, making sure there won’t be a collision during this operation.

2) Switch to the MDI mode by press MDI function key below the alpha numerical keyboard.

3) Press the F5, corresponding “BAK BP”(BACK TO B.P.) softkey

4) Press PRG in order to exit the MDI mode and go into PROG mode

5) Now press the Cycle Run button on the Manual Control Panel (MCP). The mill will go automatically to the break point position when it was saved before powering off

6) After the machine has stopped at the saved break point, press the Cycle Run button to continue machining from the saved break point.

Press F5[BAK. BP] softkey to move back to break point

Switch to MDI by pressing this key


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ALIGN TOOL: Another use of break points is when the cutter gets dull and the mill must be stopped to change cutters. To install a new cutter you first stop the mill and B.P. SAVE before you remove the old cutter. However , when you put the new cutter back into the toolholder, the tool must be realigned so the new cutter is in the same position as the old one.

Sequence:

1) Move the new tool near the position of the break point, making sure the cutter could not collide with the workpiece or fixturing during this operation.

2) Switch to the MDI mode by press MDI function key below the alpha numerical keyboard.

3) Press F6, corresponding to ALIGN TOOL submenu and press Cycle Run button on the Manual Control Panel (MCP). the mill will align the tool automatically and update the tool data.

4) Press the Cycle Run button on the Manual Control Panel (MCP). the mill will align the tool automatically and update the tool data.

5) Press PRG in order to exit the MDI mode and go into PROG mode.

After the machine has finished the tool alignment operation, press the Cycle Run button to continue machining from the break point.

Switch to MDI by pressing this key


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MDI Operation

The Manual Data Input (MDI) mode is used to set mill data values and operations without using a program. G-codes, M-codes and T-codes can all be entered manually through the keyboard. The MDI mode is useful not only for break point recovery as was done above

Sequence:

1) From main function keys, press MDI and the mill will enter MDI.

2) The MDI screen show the previously executed

G-codes which set the functioning of the mill. Also shown are values of different parameters such as feedrate, spindle speed and axis position.

MDI Function key


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3) Input one or several commands representing one

block of data on the MDI RUN command input line. In this example, the manually input G-code commands will set the mill for linear interpolation (G01), set the X position from zero to 100 (X100), and set the feedrate from 500 to 1000 (F1000). Note that only one block of commands can be executed for each cycle run.

4) Press Enter to confirm the commands.

5) Press Cycle Run button to execute the commands.

MDI RUN command Input line


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5 PROGRAM OPERATION

Operator can create new Program and modify existed programs stored in CF. On how to write a new program, please refer to the PROGRAM MANUAL. Besides program file operations such as create, delete and rename a file, editing and testing functions are also grouped as program functions under PRG function.

From function keys, press PRG, the program file management submenus are displayed.

Functions:

F1[OPEN]: open a program file existed in CF. F2[EDIT]: Edit the current program file. F3[TST]: Test a program before it actually make the cut. F4[REW]: REWind a program to its start line. F5[BP]: Breakpoint operation. F6[DNC]: Direct Numerical Control, run the program receiving from a computer.

PRG, PROGRAM FUNCTION KEY

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Open a program

Before machining a part, or editing an existed part program, you need to load the program to the memory. This operation is realized by OPEN.

Sequence:

1) From PRG’s submenu menu, press F1, which is corresponding to OPEN in the submenu.

And the program files browsing dialog is displayed as following:

2) Use to select an existed file at the source directory. Press “Enter” to open the file. The contents of the program will be listed on the screen.

Press OPEN to browse the program files stored in CF


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Create a new file

Usually, the user need to machine a new part. This request the user to write the part program and type the code to the program memory. And the program is different from the existed ones, so the user need to create a new program file to store the new part program.

Sequence: 1) From the PRG submenus, press F2, corresponding to

EDIT, to enable the “NEW” submenu

2) Then Press F3, corresponding to NEW, to create a new

program file.

3) Give the new file’s name and type it in.

4) Confirm the name by “Enter” and edit the new file.

Press EDIT to bring out he NEW function

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6) Once finished editing, just Press F4 and Enter to

save it.


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Delete an existed file

Some time it is necessary to delete some useless files on the CF to save some disk space for new program file. In this case, the operator need to delete an existed file from the program list.

Sequence: 1) From the PRG submenus, press F1, corresponding to OPEN, to browse the program file list:

And all the program files on the CF or the memory will be displayed on the screen.

2) Use or to select the file you want to delete.

3) Press “Del” key on the alpha numerical keyboard or a PS/2 keyboard connected with the NCU. The file will be deleted.

Press OPEN to browse the file list

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Edit a program file

This part describes how to edit a program in the CNC. Program edit

operation involves editing, deleting, finding and replacing characters

in a program file.

User can either edit an existed program file or create a new one and

then edit it.

Character Input The basic EDIT operation is to input the character to the memory

through keyboard. For HNC-18/19’s operators, the alpha numerical

keyboard at the front face of the NCU is usually used to input

characters.

There are 45 keys on the alpha numerical keyboards. Except the

letters and numbers, there are 12 keys used for locating the edit

position, delete and content browsing operation.


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These keys are: Name Key Explanation

Delete

Delete a char that behind the cursor, while the cursor holding still and the other chars which behind it left move a char position;

BS

Delete a char that before the cursor, while the cursor and the other chars which behind it left move a char position;

Page Up

Roll the program upward, while the cursor holding still.

Page Down

Roll the program downward, while the cursor holding still.

Left

Left-move the cursor on the screen;

Right

Right-move the cursor on the screen;

UP

Up-move the cursor on the screen;

Down

Down-move the cursor on the screen;

5 PROGRAM OPERATION

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Program format

A program must have its start symbol and end symbol.

The start symbol should be “%” or “O”. Following by a program

number.

The end symbol should be M02 or M30.

Characters after “;” or between “(” and “)” are interpreted as

comments. All the comments are printed in green color.

Letters and symbols are printed in white color and numbers are in

yellow.


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6 DATA EXCHANGE VIA RS232

For simple program, user can edit it with the alpha numerical keyboard on the NCU’s front face. For complex program that may generated from CAM software, RS232 is usually used to upload the program to HNC-18/19 from a desktop computer. Besides part program file, PLC program, parameter data and configuration data file are also uploaded to HNC-18/19 via RS232 cable. The steps to upload a file from a desktop computer to HNC-18/19 are as following: 1 Configuration 2 Set up the RS232 connection 3 Upload data file to the HNC-18/19 4 Download data file from the HNC-18/19


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Configuration

The baudrate and port number must be same between the computer and the NC system to ensure the communication between a computer and the NC system. The sequence to check and set the parameters for RS232 at the NC system is as following:

1 Enter into SETTING submenu

2 Press F3[DNC PARM] to get into the configuration interface

Press PAR to enterinto PARAMETER

submenu


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3 Type in the port number and baudrate as the above figure illustrated. And confirm by “ENTER”.

Type in port

number here

Type in baudrate value here


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Set up the RS232 connection

To set up the RS232 connection at the NC system’s end, you need to get into the “PROGRAM” submenu.

Here, Press F3, which is corresponding to DNC” to let the NC system be waiting for a connection message from the computer. The following figure is the waiting interface.

Press F6 [DNC]


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Upload data file to NC

With RS232, the user can upload data file such as G code program file, PLC program or parameter file from the computer to the NC system. Here is an example on how to upload a G code file to the NC system from a desktop computer.

1 Let the NC system be waiting for RS232 connection as illustrated above.

2 At the end of the desktop computer, run the HCNC COM

SOFT (WINDNC.EXE) program provided by Wuhan Huazhong Numerical Control Ltd.

3 Configure the RS232 to let its baudrate and port number

same as the NC system. Click the button, a parameter dialog will pop up.


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4 Click the button, an “OPEN FILE” dialog will pop up.

5 Select the G code file you want to send and double click it. The file will be uploaded to the NC system. At the NC system’s end, the interface would looks like this:


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While at the computer’s end, the “SEND button would turn gray.

6 Once the uploading process is finished. Words at the NC system would tell you how many bytes have been received and how many files have been accepted. And it turns ready for next connection. If there no more file to upload, just press F3 to exit as it prompts.

This button turns gray

The file’s name

displayed here

Data bytes been sent out


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Download data file from NC

When more than one machine tools of the same model are to equipped with the same kind of controller, it would be convenient to do configuration and calibration only on one machine, and clone the parameters to others. In this case, the user needs to down load parameters from the NC to a computer and the upload the files to other controllers. Here are the steps on how to download a parameters file from the NC to the computer. And the uploading parameters file to NC is identical with the operations for G code program file.

1 Prepare the NC to let it be ready for connection. 2 Click “Download PARA” button

Click download

PARA button here


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3 In the pooped up directory dialog, choose the directory where the parameters are to be downloaded in.

4 Double click the selected directory, the transferring process will begin. At the end of NC, the interface will looks like this:

This number is data bytes sent out

The parameter file’s number

being downloaded


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5 When the downloading process is finished, the interface at the NC will be ready for next connection. And at the computer’s side, it will prompts that the receiving process has been finished and the file size will be printed out.

Here prompts that receiving is completed

This number says how many data bytes received


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7 SETTING AND DISPLAYING

Machine tool’s status is changing dynamically during operation, user can select the certain information to focus or choose his favorite visualization style. There are four kinds of information can be displayed to show the machining progress: graphical figure, numerical figure, overall positions and G code. Different positions or value such as command position, actual feedback position, distance to go, track error and compensation value are available for choosing. Also, the tool’s position can be expressed in either workpiece coordinates system(W.C.S), machine coordinates system(M.C.S) or relative coordinates system(R.C.S).

Position and Coordinates Choice

From the seven function keys below the alpha numerical keyboard, select “POS” .

.

Press POS to enter into POSITION submenu


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View Options

Four kinds of information contents are available for choosing to be displayed in the center of LCD screen. They are graphical figure, numerical figure, overall positions and G code. Press F9 to switch among these four options.

The default view is numerical figure.

Default option is to display the position in large sized numerical letters


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Overall positions figure:

There are four types of positions displayed in the overall option:

MCS: position in machine coordinates WCS: Tool’s position in workpiece coordinates RCS: Tool’s position in relative coordinates Left to go: Left distance to go of the current block

Sometime it is helpful to know which block is going on during testing or machining. In this case, the user can switch the displaying type to G code option.

Press F3[All] to have an overall displaying of the X and Z positions


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When the G code is selected to be displayed, other useful information are also displayed:

WCS: Tool’s position in workpiece coordinates Left to go: Left distance to go of the current block M/S/T/F: The M code/S code/T code and the current

feedrate.Graphic figure, presents a the toolpath in 2D graphic realtime.

Press F4[TEXT] to display G code on the screen

Press F5[GRAPH] to display toolpath in realtime


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To display the graphic figure in right way, workpiece size should be defined. From Setting and displaying menu, press F6 to set the right workpiece size.

There are three parameters to define the offset value of the workpiece display position:

X: Offset value on x. Y: Offset value on y. Z: Offset value on z.

Note: When you switch from the graphic to other display mode, the current figure is not saved. The previous shape can’t be recovered when you switch back.

Press F6[GRAPH] to set graphic parameters

8 DIAGNOSIS

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8 DIAGNOSIS

Sometime the machine may not work because of some fault, the system provide some tools to do diagnosis.

Diagnosis tools are available when “DGN” is pressed.

The first three submenus are commonly used for diagnosis.

Press DGN to enter into DIAGNOSIS submenu

These three are usually used for DIAGONOSIS


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Alarm Diagnosis

When a fault occurs, the CNC system will give an alarm message. User can read these message to analyze the reason of the fault.

When an alarm occurs, the user can use diagnosis function to check what is wrong.

Press F3 [MSG] under the DIAGNOSIS submenu, the cause of the alarm will be displayed on the screen. The following is an example.

In the above figure, there is a syntax error in the G code. Alarm signal will be displayed. Once F3[MSG] is pressed under the “DGN” submenu, the content of the alarm will be printed out on the LCD screen. It prompts “—G-Code Format is error”.

Press F3 [MSG] to read the alarm’s content

8 DIAGNOSIS

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I/O Check

Some of the faults are related with I/O, such as there is no input signal from the machine because of a bad wire connection. The user can check the I/O status, registers status to make out what is wrong.

In this interface, “ON” indicates the I/O points is on. “OFF” indicates the I/O points is off. For example, in the above figure, the status of Y0.1 and Y0.7 are ON.

Press F1 [IO] to check I/O status

X: Input nodes

Y: Output nodes


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Registers watch

Besides “X” and “Y” registers, other five kinds of registers are also used in PLC programming. They are:

“G” registers, control word from PLC to CNC, “F” registers, status words of CNC to PLC “R” registers, intermediate registers used in PLC program, “B” power off protection data “P” Parameters

The value of these registers are also useful to detect what is the fault’s causes.

To watch one of the above registers, just click the correspond letter of the register type. For example, if the user want to watch the value of “G” registers, just hit “G” on the alpha numerical keyboard.

Press F2 [REG] to check register’s value

8 DIAGNOSIS

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For each type of the registers, more than one page are needed to

display them all. and are used to browse all the items of a kind of register.

For “X” and “Y” registers, there are two kinds of digital forms to display the register value. Binary and heximal. For “G”, “F”, “P” and “B” registers, heximal and decimal forms are available. For “R” registers, binary, heximal and decimal are all available. The forms

can be switched from one to another with and .


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9 PARAMETERS

User can check or modify the parameters. Passwords are used to protect the parameters from being changed unauthorized. Different parameters can be accessed With different passwords.

To access parameters, the user need to press PAR function key to enter into the PARAMETER submenus. The following figure is the interface to navigate or edit parameters

Press PAR to access parameters submenu

Parameter Index

Description

Parameter group

Parameter value

9 PARAMETERS

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The words at the upper right corner indicates which group of the parameters are displayed at the current interface. The “List” column is the parameter’s index in this group. The “parameter” column is the value. Below the four column’s data is the description of the parameter in focus. In the above figure, Servo parameters for axis 0 are displayed. The fourth (0004) paramter is on focus, its meaning is described below as ”Speed-loop integral time constants”.


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Parameters browsing

Parameters are categorized into 11 groups:

MAC. PRM, Machine tools parameters Axis PRM axis 0, parameters for X axis Axis PRM axis 1, parameters for Y axis (not used for mill) Axis PRM axis 2, parameters for Z axis S. PRM axis 0, parameters for X servo S. PRM axis 1, parameters for Y servo (not used for mill) S. PRM axis 2, parameters for Z servo PMC user PRM, parameters defined by user ACP. PRM axis 0, compensation parameters for X axis ACP. PRM axis 1, compensation parameters for Y axis (not

used for mill) ACP. PRM axis 2, compensation parameters for Z axis

The current selected is indicated at the upper right corner of the LCD

screen. and are used to browse different groups of parameters.

For each group, and can be used to move the cursor up and down to a certain parameter item.

9 PARAMETERS

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Parameters operation

Edit parameters

To edit a certain parameter, the user need to input the correct password. If the password is wrong or the privilege is lower, modification of the password is not allowed.

Once the password is accepted, the user can edit a specified

parameter. While editing, and can be used to move the cursor up and down to a certain parameter item.

Press F4 [PASSWORD] to input the password.

Area to type in the password


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Back up parameter file

If the user want to make a backup for the current parameters, he can use the “BAK PRM” function if he has given the right password.

Sequence:

a) Press F1 [BACK PARM] to make a backup parameters file.

b) Type into the backup file name. c) Press Enter to confirm, the current parameters will be

backed up in the named file.

Press F1 [BACK PARM] to backup parameters

Area to type in the backup file’s name

9 PARAMETERS

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Load a previous parameters

A suggestion before changing parameter is to make a backup file first as illustrated above. Then if the machine does not work after changes, you can reload the previous working parameters.

Following is the steps on how to load a previous parameters file.

a) Press F2 [LOAD PRM.] to load a previous parameter

backup file.

b) Use or to select the backup file from the file list.

c) Press Enter to confirm, the parameters will be loaded. Usually it will take effect after boot up again

Press F2 [LOAD PARM] to load a backup parameters


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Parameters description

Machine parameters

Turret direction(0/1) 0: positive direction of X axes in graphic displaying is downward. 1: positive direction of X axes in graphic displaying is upward.

Diameter/Radius at X(1/0) 0: dimension along X axes is given as radius 1: dimension along X axes is given as diameter

Metric/Inches(1/0) 0: unit of dimension is thousandth of an inch 1: unit of dimension is thousandth of a minimeter

Power off protection(1/0) 0: data protection in case of power off is disabled 1: data protection in case of power off is enabled

Tool Comp. Type(0:Abs. 1:Rel.) 0: compensate the tool nose radius in absolute coordinates 1: compensate the tool nose radius relative to standard tool

Pulse type(0:uni-dir,1:bi-dir,2:AB) 0: pulse is uni-direction 1: pulse is bi-direction 2: pulse is AB phase

Spindle encoder direction(32:+,33:-) 32: direction of encoder on spindle is positive 33: direction of encoder on spindle is negative

Spindle encoder part number

9 PARAMETERS

100

Part number of the spindle encoder.


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Axis parameters

Pulse/um(um) Movement distance of the axis per revolution of the motor. The unit is um for linear axis, a thousandth of 1° for rotational axis.

Pulse/um(pulse) Encode counter per revolution of the motor.

Note: this two numbers can be common divided to prime numbers.

Software limits positive(um) Position of this axis’s positive software in M.C.S Software limits negative(um) Position of this axis’s positive software in M.C.S Reference approach mode(1:+-,2:+-+)

Method to approach the reference point of this axis. 1: Move forward to find the encoder’s zero position after touch the reference switch. 2: Moving backward to find the encoder’s zero position after touch the reference switch

Reference approach direction('+','-') Rapid traverse direction during reference point approaching. +: positive direction. Use this option if the tool is at the minus side of the reference switch -: negative direction. Use this option if the tool is at the negative side of the reference switch

Reference point position(um) Coordinates value of the reference point in the M.C.S

Reference point offset(um)

9 PARAMETERS

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Offset distance after find the encoder’s zero position. Rapid traverse speed for reference approach

Speed before touch the reference switch. Slow speed for reference approach(mm/m)

Speed used to find the encoder’s zero position after touch the reference switch

Deceleration distance for G60 Distance between the deceleration point and the command position while use G60 to do uni-direction position.

Rapid traverse rate(mm/min) Speed for rapid traverse. G0 use this speed.

Maximum feedrate(mm/min) Maximum feed rate for this axis.

Acc. time constant for rapid traverse(mm/min) Acceleration time to get a speed increase of 1000mm/min during rapid traverse motion.

Jerk time constant for rapid traverse(ms) Jerk time to get an acceleration increase of 1000mm/sec2 during rapid traverse motion

Acc. time constant for feeding Acceleration time to get a speed increase of 1000mm/min during machining feeding.

Jerk time constant for feeding Jerk time to get an acceleration increase of 1000mm/sec2 during machining feeding

Track tolerance Maximum tracking error.


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Servo parameters

Feedback to NC(45:YES,46:NO) 45: Encoder counter is feedback to NC. This is always true if servo driver is used. 46: No encoder or no position feedback to NC. This is always true if stepper motor is used.

Servo part number. Part number of the servo driver. Value is from –1~31. While –1 means none and zero is the first one.

Position loop gain(open-loop) Gain coefficient of the position loop. For open loop control. The bigger this value, better rigidity the system can reach. But if the value is too high, the system may become unstable and vibration may occur. The value ranges from 1~10000. The unit is 0.01sec-1. Default value is 3000.

Position loop feedforward coefficient(kf) The value ranges from 0~65535. Default value is 0.

Velocity loop proportion coefficient(kp) Ranges from 0~65535. Default value is 2000. 3000~7000 is recommended.

Velocity loop integral(ki) Ranges from 0~65535. Default value is 100. 20~50 is recommended.

Maximum torque Ranges from 0~255. Default value is 150. Only effective for HSV-11.

Rated torque Ranges from 0~255. Default value is 100. Only effective for HSV-11.

Tracking error

9 PARAMETERS

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Tracking error threshold. Alarm will be displayed if the actual tracking supersede this value.

Pulse per revolution Pulse counter value the NC get per revolution of the motor.


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Axis Compensation parameters

Backlash(um) This value should be calibrated by measurement instrument. The unit is 0.001mm. It should be set as 0 if bi-directional pitch compensation is used.

Pitch err. comp. type(1:uni-dir,2:bi-dir) Pitch error compensation type. 1: Compensate the pitch error in one direction. 2: Compensation the pitch error in two directions.

Compensation points number: Range from 0~127. Can be extended to 5000. The maximum measure point is 128 if uni-direction compensation type is used. The maximum measure point is 64 if bi-direction compensation type is used.

Index of reference point. Index of the compensation point in the compensation table.

Compensation gap Distance between two adjacent compensation points.

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