Professional Documents
Culture Documents
Operation Manual
V3.3
December,, 2007
December
Preface
Organization of documentation
1. Introduction
2. Setting up
3. Manual Operation
4. Automatic Operation
5. Program File Operation
6. Setting and Displaying
7. Network Services
8. Diagnosis
9. PLC Function
10. Parameters
Applicability
This Operation Guide is applicable to the following CNC system:
HNC-21MD/22MD v05.62.07.10
Internet Address
http://www.huazhongcnc.com/
i
Table of Contents
Table of Contents
Preface............................................................................................................................................. i
Safety Precautions.......................................................................................................................... v
1 Introduction............................................................................................................................ 1
1.1 Overall Layout............................................................................................................ 1
1.2 LCD Screen................................................................................................................ 2
1.3 Soft Keys.................................................................................................................... 4
1.3.1 Main Menu..................................................................................................... 4
1.3.2 PROG Submenu..............................................................................................5
1.3.3 RUN Submenu................................................................................................6
1.3.4 MDI Menu...................................................................................................... 7
1.3.5 TOOL Submenu..............................................................................................8
1.3.6 SET Submenu................................................................................................. 9
1.3.7 Diagnosis Submenu...................................................................................... 10
1.3.8 EXTEND MENU Submenu..........................................................................11
1.4 Manual Data Input Keyboard................................................................................... 13
1.5 Machine Control Keys..............................................................................................15
1.5.1 Mode Selection Switches..............................................................................15
1.5.2 Verify Key.....................................................................................................16
1.5.3 Multiple Step Keys....................................................................................... 16
1.5.4 Other Control Keys.......................................................................................17
1.5.5 Spindle and Auxiliary Operation Keys......................................................... 18
1.5.6 Speed Adjustment Keys................................................................................ 19
1.5.7 Axis Operation Keys.....................................................................................20
1.6 Other Control Keys...................................................................................................21
1.6.1 Emergency Stop............................................................................................21
1.6.2 Cycle Run..................................................................................................... 21
1.6.3 Feed Hold..................................................................................................... 21
1.7 Auxiliary Devices..................................................................................................... 22
1.7.1 Hand Pendant................................................................................................22
1.7.2 Data Exchange Port...................................................................................... 22
2 Setting Up............................................................................................................................. 23
2.1 Power-on...................................................................................................................24
2.2 Reset/Emergency Stop..............................................................................................25
2.3 Homing (Reference-point Approach)....................................................................... 26
2.4 Hardware Limit and Software Limit.........................................................................28
2.5 Setting Tool Data...................................................................................................... 30
2.5.1 Tool Magazine.............................................................................................. 30
2.5.2 Tool Data Table.............................................................................................31
2.6 Coordinate System....................................................................................................32
3 Manual Operation................................................................................................................. 33
3.1 Jog Feed....................................................................................................................34
3.1.1 Requirements................................................................................................ 34
3.1.2 JOG Feedrate................................................................................................ 35
3.1.3 Adjusting JOG Feedrate............................................................................... 36
3.1.4 Rapid Traverse Feedrate............................................................................... 37
3.1.5 Adjusting Rapid Traverse Speed...................................................................38
3.2 Incremental Feed...................................................................................................... 39
3.2.1 Requirement..................................................................................................39
3.2.2 Incremental Feedrate.................................................................................... 40
ii
Table of Contents
3.2.3 Step Length...................................................................................................41
3.3 Manual Handwheel...................................................................................................42
3.3.1 Requirement..................................................................................................42
3.3.2 Axis Selection/Off Knob.............................................................................. 43
3.3.3 Magnification Selection Knob...................................................................... 43
3.3.4 Handwheel Rotation..................................................................................... 44
3.4 Spindle Operation..................................................................................................... 45
3.4.1 Requirements................................................................................................ 45
3.4.2 Spindle Control Keys....................................................................................46
3.4.3 Adjusting Spindle Speed...............................................................................47
3.5 Auxiliary Operation.................................................................................................. 48
3.5.1 Requirements................................................................................................ 48
3.5.2 Auxiliary Keys..............................................................................................48
4 Automatic Operation............................................................................................................ 49
4.1 Requirements............................................................................................................ 50
4.2 Program Loading...................................................................................................... 51
4.3 Program Verifying.................................................................................................... 53
4.4 Running Control....................................................................................................... 55
4.4.1 Cycle Run..................................................................................................... 57
4.4.2 Feed Hold..................................................................................................... 58
4.4.3 Pause Processing...........................................................................................59
4.4.4 Restart........................................................................................................... 60
4.4.5 Pick Start Block............................................................................................ 61
4.4.6 B.P. Save.......................................................................................................63
4.4.7 B.P. LOAD....................................................................................................64
4.4.8 B.P. Recovery................................................................................................66
4.4.9 Align Tool..................................................................................................... 67
4.5 MDI Operation......................................................................................................... 68
5 Program File Operation........................................................................................................ 70
5.1 Opening a Program................................................................................................... 71
5.2 Creating a new Program File.................................................................................... 72
5.2.1 Program Format............................................................................................ 72
5.3 Editing a Program File..............................................................................................73
5.3.1 Editing an existing Program File.................................................................. 73
5.3.2 Editing a new Program File.......................................................................... 74
5.3.3 Keys for Editing............................................................................................75
5.3.4 Deleting a Block........................................................................................... 75
5.3.5 Making a Blocks Group................................................................................76
5.3.6 Deleting a Blocks Group...............................................................................76
5.3.7 Cutting a Blocks Group................................................................................ 77
5.3.8 Copying a Blocks Group.............................................................................. 77
5.3.9 Pasting a Blocks Group................................................................................ 78
5.3.10 Finding a String............................................................................................ 79
5.3.11 Replacing a String.........................................................................................80
5.3.12 Background Editing (Optional).................................................................... 80
5.4 Saving a Program File.............................................................................................. 81
5.5 Deleting an existing Program File............................................................................ 82
5.6 Changing a Program File Name............................................................................... 83
6 Setting and Displaying..........................................................................................................84
6.1 Setting Coordinates...................................................................................................85
6.2 Workpiece Size......................................................................................................... 86
iii
Table of Contents
6.3 Position and Coordinate Choice............................................................................... 87
6.4 System Time............................................................................................................. 88
6.5 View Switch..............................................................................................................89
7 Network Services (Optional)................................................................................................ 91
7.1 Ethernet Connection................................................................................................. 91
7.2 Network Connection.................................................................................................92
7.3 RS232 Connection.................................................................................................... 95
7.3.1 Setting the Parameters.................................................................................. 95
7.3.2 Setting Up the Connection............................................................................96
7.4 Sending Serial Procedures........................................................................................ 97
7.5 Receiving Serial Procedures..................................................................................... 98
8 Diagnosis.............................................................................................................................. 99
9 PLC Function......................................................................................................................100
9.1 F3: I/O Status..........................................................................................................101
9.2 F4: Watch................................................................................................................102
10 Parameters.................................................................................................................. 104
10.1 F1: Parameter Index................................................................................................105
10.1.1 Machine Parameters....................................................................................106
10.1.2 Axis Parameters.......................................................................................... 107
10.1.3 Servo Parameters........................................................................................ 109
10.1.4 Compensation Parameters...........................................................................110
10.1.5 PMC User Parameters................................................................................. 111
10.2 F2: Password Change..............................................................................................112
10.3 F3: Password Input................................................................................................. 113
10.4 F5: Load Default.....................................................................................................113
10.5 F6: Back to Last......................................................................................................113
10.6 F7: Backup..............................................................................................................114
10.7 F8: Load..................................................................................................................115
iv
Safety Precautions
Safety Precautions
This section enumerates the 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. Operation Manual
While this operation manual supplied with an numerical control 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.
2. Working Environment
� Working temperature: 0°C - 45°C (32°F to 113°F), no freezing
� Temperature variation: less than 1.1°C/min (2°F/min)
� Humidity: below 90% Relative Humidity, non-condensing and without frost
Less than 75% Relative Humidity is more desirable.
95% Relative Humidity is for the shot-term use (within one month)
� Storage: –20°C to 60°C (-4°F to 140°F), non-condensing and without frost.
� Environment: All devices should be placed indoors and away from sunshine, dust,
eroding gases and moisture.
� Height: 1000 meter above the sea level (2000meter)
� Vibration: Impact during transportation or other situations should be less than 5.9m/s
(0.6g) for vibrations in the range between 10 to 60Hz.
3. Grounding
Correct grounding is critical for the numerical control unit and other electrical devices.
� No grounding or incorrect grounding may injure the operator or damage components
of the numerical control devices.
� If the devices are not correctly grounded, inductive interference from electric motors
and appliances can lead to errors and unexpected results.
v
Safety Precautions
4. Power
Electronic control tank is to supply the power for the milling machine. Please refer to
the machine installation instruction manual.
5. Filter
Filters are used on cooling fans to prevent dust from entering into devices. However, it
would prevent adequate cooling if the filters become clogged. It is recommended that
the user clean the filters every three months. In dusty environments such as wood
routers, clean the filters more often.
6. Non-Operation
After a long period of non-operation, numerical control 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.
8. Check
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.
vi
Safety Precautions
9. Trial Run
Never machine a workpiece without checking the machine's status at first. 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.
10. Feedrate
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.
12. Parameters
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.
vii
1. Introduction
1 Introduction
1.1 Overall Layout
The user operates the milling either through the Machine Control Panel (Figure 1.1) or a
Hand Pendant (optional) (Figure 1.2). A Data Exchange Port (optional) (Figure 1.3) allows
the user to exchange data between the NCU and other computers through an Ethernet
connection, RS232 or floppy disk. A PS/2 connector in the Data Exchange Port let the user
plug in a keyboard.
LCD MDI
Screen keyboard
Soft keys
Machine
control
keys
1
1. Introduction
As it is shown in Figure 1.1, there four main areas on the Machine Control Panel: LCD
Screen, Soft keys, Manual Data Input (MDI) keyboard and Machine Control keys. These are
shown in detail below.
3
7
1) Machine information
� Mode: automatic, single block, manual, incremental, reference, emergency stop.
� Current status: running or error.
� System time: current system time.
2
1. Introduction
3) View
Different views can be selected: graphical figure, numerical figure, overall positions,
and G code.
5) Program Index
It shows the program name and the program block number
7) Origin Position
It shows the origin position of the workpiece in the machine coordinate system.
8) Auxiliary Information
It shows the M code, S code, and T code in the program.
9) Menu
It is corresponded to the soft keys on the machine control panel.
3
1. Introduction
RUN selects the submenu which let the operator control the program running interactively.
MDI stands for Manual Data Input; it let the operator manually write G-code programs and
input data.
TOOL selects the tool submenu to let the operator choose tool offsets and parameters.
SET picks the setting submenu letting the operator set axis and machine parameters.
DIAG selects the diagnosis submenu to alter alarms and machining statistics.
DNC stands for Direct Numerical Control, letting a program load from another computer.
4
1. Introduction
PROG.
F1
NEW creates a new program while SAVE stores an edited program in memory.
VER verifies whether the opened program has correct syntax and tool path.
5
1. Introduction
RUN
CTRL.
F2
PICK BLOCK picks a block of the selected program and let the program run from this
block.
BP stands for break point, is used for operator to suspend and resume the machining
process.
BP SAVE allows the operator to save information at the current break point to memory.
B.P LOAD is to load the information at the saved breakpoint so that the program can be
executed at the break point.
6
1. Introduction
GOTO BP let the tool go back to the breakpoint after an interactive intervention during
automatic machining.
7
1. Introduction
TOOL
Data
F4
DATA let the operator type the tool’s parameter such as length, radius, life expectancy and
group number.
8
1. Introduction
SETT
F5
Position Coordinates
Command M.C.S
Actual W.C.S
Dist. to Go R.C.S
Trace Error
Compensation
WCS, stands for Workpiece Coordinate System, is used for user to define the origin position
of workpiece coordinates.
PART SIZE let the operator provide the workpiece dimension for graphical.
DNC PARA allows the user to change the communication parameters for RS232.
DIAG
F6
10
1. Introduction
PLC, stands for Programmable Logic Circuits, and allows the user to do PLC operations.
REG, stands for register, let the operator register the software.
11
1. Introduction
EXTEND
MENU
F10
Machine Parameters F1
Axis Parameters F2
Servo Parameters F3
Trans-quadrant Compensation F6
System F1
Optional F2
X:[Mac->PMC] F1
Y:[PMC->Mac] F2
F:[CNC->PMC] F3
G:[PMC->CNC] F4
R:[REGIN PMC] F5
P:[Parameter] F6
B:[BLIFFER] F8
Cancel F9
Figure 1.14 Manual Data Input keyboard on the machine control panel
13
1. Introduction
The following table is the description of the MDI keys.
Table 1 1 Description of MDI Keyboard
KEY DESCRIPTION
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.
Cursor keys
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.
14
1. Introduction
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.
15
1. Introduction
KEY DESCRIPTION
16
1. Introduction
KEY DESCRIPTION
Over-travel release key: When mechanical over-travel on any axis
occurs, press this key until the system is reset, then move the axis out of
over-travel.
Not used
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.
Machine Lock key: Activating this key prevents any motion from the
spindle, the tool turret change or any axis; it is used for system testing.
17
1. Introduction
KEY DESCRIPTION
Coolant Switch key: This key opens or closes the coolant flow
Tool exchange enable key: Press this key to enable or disable tool
exchange operation.
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 orientation: Pressing this key to let the spindle approach a certain
position that can align the spindle to its seat.
Spindle jog key: This key rotates the spindle for a short time after each
press.
Spindle brake: Pressing down this key will brake the spindle.
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.
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 at 100 percent
of the 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%:
Table 1 6 Description of Speed Adjustment Keys
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.
19
1. Introduction
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).
The 4TH axis is only valid for servo-driven spindle mills. In INC mode or
Manual Mode, the spindle moves in the positive direction while +4TH is
pressed and in the negative direction while –4TH is pressed. In Reference
mode, pressing the +4TH key homes the spindle (finds the spindle reference).
20
1. Introduction
21
1. Introduction
Emergency Stop
PC Keyboard
LAN
22
2. Setting Up
2 Setting Up
Before machining a part, the operator needs to set up the machine coordinates and the
workpiece coordinates, define tools parameters and other machine preparations.
The first three steps are always necessary once 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 if a new program is used.
23
2. Setting Up
2.1 Power-on
The procedure to turn the power on:
1) Check and make sure the machine is safe to run.
2) Press down the Emergency Stop button on MCP.
3) Turn on the power of the machine (usually located in back of the machine and/or
beneath the control panel).
4) Make sure the fans run normally
5) Make sure the lamps on the machine control panel have been lighted on.
24
2. Setting Up
Reset button
Turn clock-wise
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:
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 the
machine is turned on, the emergency stop button can be released by the RESET operation
(twisting the ES button clockwise).
25
2. Setting Up
The following figure shows 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).
Present location
Origin
Motion Axis
Reference Switch (RSW)
Figure 2.2 Reference Position
As it is shown in Figure 2.3, 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.
Tool location
Origin
Motion Axis
For proper homing, the direction for reference point approach must first be defined for each axis.
This setup is done once only in the parameters (see setting Parameters, Chapter 10).
26
2. Setting Up
The sequence for homing is as follows (Figure 2.4). First switch the mode to Reference
mode by pushing the Home key on the control panel. Next, press “+X” to home the X axis,
and press “+Y” to home the Y axis. At last, press “+Z” to home the Z axis.
Switch the mode to home mode by pressing the home key on the MCP.
27
2. Setting Up
Tool location
Motion
Software Software
Limit (-) Limit (+)
When the axis is commanded to go beyond these limits (over-travel), first the software
switch will be encountered (Figure 2.5). At this point the motion ceases and no further
motion in this direction is permitted.
The tool can be retrieved from a software over-travel by using manual or incremental
commands to move the tool back towards the middle of the axis. The sequence of releasing
the software over-travel is as follows:
1) Press the mode key: Manual mode key or Automatic mode key
2) Press the over-travel release key until the system is reset.
3) Move the axis out of over-travel
Software limits are defined for each axis using machine parameters. With the software limits
set, the control unit can decelerate and stop the tool safely before the tool gets to the
hardware limit switches.
28
2. Setting Up
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, or if the tool is moving too fast to
stop when the software limit is reached.
Tool location
Motion
Software Software
Limit (-) Limit (+)
29
2. Setting Up
2) Position: position of the tool in the ATC magazine. This column is fixed and can not be
edited.
30
2. Setting Up
3) Press Enter to input the tool index or the tool’s group number.
31
2. Setting Up
User can define six workpiece coordinates with G54~G59. To use these six workpiece
coordinates, user needs to define the offset of their origin to the machine coordinates’ origin.
3) Input the offset value on the command row. For example, if the offset of G54 is
100 and 100, type in “X100 Z100”
5) The new origin position of the W.C.S will be displayed on the screen.
32
3. Manual Operation
3 Manual Operation
MAN
Manual Operation (MAN
MAN) uses various input devices to carry out operations much like
those of a manual milling. 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 milling.
MAN operations are primarily used for setting up parts. In MAN mode, the cutter can be
moved into position near the workpiece where sample facing and turning 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 milling operator that has little or no
experience on an NC milling, these operations are a good place to start. You can understand
how familiar operations are implemented on an NC machine.
1) Jog feed: Move the cutting tool along a motion axis while an axis key is being
pressed.
3) Manual Handwheel: Move the cutting tool by manually rotating the handwheel
5) Auxiliary operation: Change other devices such as tool selection and coolant.
33
3. Manual Operation
3.1.1 Requirements
Figure 3.1 shows the Jog Feed Mode key.
� After pressing the JOG mode button, the LED indicator light on that key lights to
verify that you are in the JOG mode.
34
3. Manual Operation
� The tool moves at a fixed speed along the selected axis. This fixed speed is called JOG
feedrate. The JOG feedrate is a fixed fraction of the rapid traverse rate. The factory
default JOG feedrate is one third (1/3) of the rapid traverse speed. For example, if the
rapid traverse feedrate were set at 600 inch/min, the JOG feedrate would be 200
inch/min using the factory default setting. Moreover, this default JOG feedrate for each
axis can be set by the axis parameter (See Chapter 10).
35
3. Manual Operation
Feedrate icon
Decrease the JOG feedrate by 2%.
Set the JOG feedrate to its full value—1/3 of the axis’s rapid traverse speed.
� The feedrate icon tells that the JOG feedrate is being adjusted.
� Pressing the 100% key sets the JOG feedrate at full value (i.e., 1/3 the rapid traverse
value for factory default). The LED light in the upper left corner of the 100% key
specifies that the feedrate is set to full value.
� Pressing the minus (-) key reduces the feedrate by 2% of the factory default amount of
the 100% JOG feedrate.
� Pressing the minus (+) key increases the feedrate by 2% of the factory default amount
of the 100% JOG feedrate. For example if the JOG feedrate were 200 in/min and you
pressed the plus (+) key, the new feedrate would be 204 in/min.
� The override ratio could be 10%, 7%, 4%, 2%, 1%, 0%, the range of adjustment is
0-150%.
36
3. Manual Operation
� 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, +4TH
or -4TH. The minus key (-X, -Y, -Z, -4TH) moves the cutting tool toward the
workpiece, while the plus key (+X, +Y, +Z, +4TH) moves the cutting tool away from
the workpiece. In either case, the motion will be at the Rapid Traverse speed.
37
3. Manual Operation
38
3. Manual Operation
3.2.1 Requirement
Figure 3.6 shows the increment mode key.
39
3. Manual Operation
� For each press of the feed axis keys: +X, -X, +Y, -Y, +Z or -Z, the tool cutter moves a
certain distance. If your milling has a fourth axis (4TH axis), you can also press the
+4TH or -4TH keys. To move the cutting tool toward the workpiece use a minus key
(-X, -Y, -Z, -4TH). For moving the cutting tool away from the workpiece use a plus key
(+X, +Y, +Z, +4TH).
� The distance is the number of minimum steps 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 × 2 = 2 minimum step . In inch 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 × 2 = 200 minimum step . In inch units, it moves ten thou (0.012inch),
in metric units it moves 200 microns (0.2mm).
40
3. Manual Operation
The step length is a “magnified” length. The distance moved in a step length is the
minimum step multiplied by the magnifier value:
step length = minimum step × magnifier
� Minimum step
The “minimum step” is the shortest distance that an axis can move. The minimum step is a
certain rotation of the ball screw moving each axis. It is determined by the machine's
encoder. Depending on the number of steps on that axes' encoder, the step size is either in
inch or metric units. For an inch 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).
� Magnifier
The four keys below (Figure 3.8) are the step length magnification in the INC mode.
Pressing any key changes the magnification of the corresponding distance. The minimum
step can be magnified by 1, 10, 100, or 1000 times giving a "step length". As before, the
LED light associated with the selection lights up indicating which magnification is chosen.
Magnifier
41
3. Manual Operation
Handwheel unit
Handwheel
3.3.1 Requirement
To use the handwheel unit, the machine should be in the incremental mode.
� press the INC mode key . When the handwheel is enabled, the INC mode on the
machine control panel is disabled (i.e., the incremental feed operation is disabled).
� Once in INC mode, the handwheel unit is activated by turning the Axis Selection knob
from the OFF position to one of the milling's axes.
42
3. Manual Operation
X1: No magnification; each click of the handwheel moves one minimum step.
X100
X100: Each click of the handwheel moves a hundred minimum steps.
X1000
X1000: Each click of the handwheel moves a thousand minimum steps.
Note: A minimum step for linear axes is 0.5 tenths (inch encoders), one micron (metric
encoders) or 0.001 degrees for rotational axes.
43
3. Manual Operation
44
3. Manual Operation
3.4.1 Requirements
The machine should be in JOG mode.
45
3. Manual Operation
46
3. Manual Operation
Spindle icon
47
3. Manual Operation
3.5.1 Requirements
The machine must be in JOG mode.
Coolant key
Tool exchange keys
48
4. Automatic Operation
4 Automatic Operation
AUTO
Automatic (AUTO
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 automatically. If you are a manual milling 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.
49
4. Automatic Operation
4.1 Requirements
The requirements below are all necessary before the milling can be run automatically.
� Programming functions require “soft keys”. 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 soft key function shown on the LCD screen is
actuated by pushing the corresponding physical key just below. After pressing the
physical key, the soft key descriptions will change to bring in functions only available
when the physical key is pressed.
LCD Screen
Physical keys
� You have verified or entered tool data (offset and compensation values), zero offsets
and other necessary data.
50
4. Automatic Operation
Only one program at a time can be “loaded” for execution by the milling. Usually many
programs that have been written are stored in the milling’s computer. “Loading” is the
process of picking one of these programs to be executed.
LCD Screen
Program sources
Program Functions
51
4. Automatic Operation
2) OPEN]] soft key.
Now press the F1 physical key again, corresponding to the F1 [OPEN
Program
file
directory
4) Use the left-right keys (located on the keyboard area just to the right
of the LCD screen) to change the selected item from among the Program Sources:
CF (hard disk or memory chip), DNC and floppy disk.
5) Once the source is selected, 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.
6) Last, press the Enter key in lower right corner of the keyboard area to load the
selected program to memory.
52
4. Automatic Operation
Program Functions
5) Press the Cycle Run button on the Machine Control Panel (MCP) to start the
VERIFY process.
53
4. Automatic Operation
6) As the program is verified, the lines of the program are displayed. The line being
verified is highlighted in yellow. As the verification 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.
54
4. Automatic Operation
The program running process – either verifying 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 section at a time.
1) From the Main Menu, press the F2 RUN CTRL soft key.
LCD Screen
F10 BACKTO
MAIN soft key
55
4. Automatic Operation
Running Control has nine different operations available:
2) Feed Hold: stop the motion of the program with a soft key press
6) Save Break Point: shut down the machine and save the restart point
7) Load Break Point: load the restart point after machine shutdown
9) Align Tool: change tools and realign the new cutter at the same location
56
4. Automatic Operation
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 Feed Hold button 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.
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4. Automatic Operation
1) During execution, pressing the red Feed Hold button pauses the program.
Pressing the Cycle Run button recovers the running process again. These two –
Cycle Run and Feed Hold – work together to stop and restart the program being
executed.
2) After the Feed Hold 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.
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4. Automatic Operation
1) Press F6 PAUSE and the program pauses and issues a prompt (words in green
with blue background) asking the operator a question.
2) Pressing the Y (Yes) key on the NC keyboard cancels the program. All the current
mode information will be unloaded. The program can not run from this point
3) Pressing the N (No) key pauses the program; it can be run again from the stopping
point by pressing the RESTART soft key.
59
4. Automatic Operation
4.4.4 Restart
If the program has been canceled by pressing Y (Yes) after the Pause soft key prompt,
restart from the program beginning by pressing the RESTART soft key.
RESTART prompt
1) Press F7 RESTART
2) Press N (No) to cancel RESTART
RESTART.
3) Answer Y (Yes) on the NC keyboard to run the program again from the beginning.
4) Now press the Cycle Run button on the Manual Control Panel (MCP) and the
program will be executed from the beginning.
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4. Automatic Operation
Main menu
Block submenu
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4. Automatic Operation
3) A dialog window appears on the LCD screen giving instructions for the next
operation. Now you have three choices.
� Press F1: Start block is shown by the red bar. Use the Up/Down keys
4) Press the F9 VIEW key to cycle through different views until you come to the
program view shown above.
5) Press the Cycle Run button to begin execution at the start block
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4. Automatic Operation
For complex or large parts, more than one day may be required to finish machining. You
may need to turn off the machine before it’s done. In this case, the milling’s memory should
store the current block location and recover from this location to continue machining later.
Break point functions do this. In order to save the location for restarting the program later,
you need to know three procedures: saving the break point when you stop, loading the
saved break point and recovering from the break.
Main menu
Block submenu
63
4. Automatic Operation
4) Type the break point file name using the keyboard to the right of the LCD screen.
In the example below, the file is named “03453.BP1” perhaps naming the part
number being machined.
However, if machine has been powered off after a B.P. SAVE operation, you must recover
the break point: first the milling must be homed (i.e., perform the “Reference Point
Approach” procedure) after turning the power 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.
Main menu
Block submenu
64
4. Automatic Operation
3) Press the F6 B.P. LOAD soft key to load the break point file.
Break point
Size in Kilobytes
file name
B.P. LOAD
function
Figure 4.25 The sequence of loading a break point (3)
5) Use the up/down keys to select the desired break point file.
6) Press Enter to confirm your selection
7) 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.
65
4. Automatic Operation
F3 MDI
soft key
F7 GO TO
B.P. soft key
Figure 4.26 The sequence of recovering a break point
66
4. Automatic Operation
1) Move the new tool near the position of the break point, making sure the cutter
could not collide with the workpiece or fixture during this operation.
2) Switch to the MDI mode from the Main Menu and press F8 ALIGN TOOL
TOOL:
F3 MDI
soft key
F8 ALIGN TOOL
soft key
67
4. Automatic Operation
MDI screen
Parameter values
Previously executed G-code list
68
4. Automatic Operation
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 milling 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.
New G-code
New X axis position value
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5. Program File Operation
Functions:
1) F1[OPEN]: Open a program file saved in CF, DNC or floppy disk.
2) F2 [EDIT]�F3[NEW]: Create a new file.
3) F2[EDIT]: Edit the current program file.
4) F4[SAVE]: Save the current program file. If you specify another name as, this
function is “Save as”.
70
5. Program File Operation
2) Use to select the program source: CF(or hard disk or memory chip), DNC
or floppy disk.
71
5. Program File Operation
Letters and symbols are printed in white color and numbers are in yellow.
Characters after “;” or between “(” and “)” are interpreted as comments. All the comments
are printed in green color.
72
5. Program File Operation
73
5. Program File Operation
74
5. Program File Operation
Delete a char that is behind the cursor. The cursor is holding still
Delete
and the other chars which are behind it move a char to left.
Delete a char that is before the cursor. The cursor and the other
BS
chars which are behind it move a char to left.
PageUp Roll the program upward, while the cursor is holding still.
PageDown Roll the program downward, while the cursor is holding still.
75
5. Program File Operation
B
2) Press + to mark the start row of the blocks group
E
4) Press + to mark the end of blocks
D
2) Press +
3) The blocks group will be deleted.
X
2) Press + . The blocks group will be cut. Different from the deleting
operation, the blocks group will be saved in clipboard when the cutting operation
is used.
C
2) Press +
3) The blocks group will be copied to the clipboard.
77
5. Program File Operation
V
2) Press +
3) The blocks group you have copied or cut to the clipboard before will be pasted
here.
78
5. Program File Operation
F
2) Press +
3) Input the string
4) Press
Note:
1. If the string to find is in the current program, the cursor will stop at front of the first
string. At the same time, the color of the string and its background will be changed;
otherwise, there would be a prompt:
L
2. Press + to find the next string.
79
5. Program File Operation
R
1) Press +
2) Input the string to be replaced
3) Press
4) Input a string to replace that string input at the second step
5) Press
Y N
6) Press to replace; Press to cancel.
L
replaced, please press + to replace the next string.
80
5. Program File Operation
Note: If you want to cancel any of the above operation, just press “ESC”.
81
5. Program File Operation
2) Select the file you want to delete from the list with .
4) Type “Y” to confirm the operation. The file will be deleted from the media.
82
5. Program File Operation
list with .
7) Press “Del” key.
8) Type “Y” to confirm the operation. The file will be deleted from the media.
83
6. Setting and displaying
From Main menu, press F5[SETT.], Setting and Displaying menu is displayed.
84
6. Setting and displaying
85
6. Setting and displaying
86
6. Setting and displaying
87
6. Setting and displaying
88
6. Setting and displaying
� Graphic View
� Numerical View
89
6. Setting and displaying
� Overall Positions View
90
7. Network Services
91
7. Network Services
92
7. Network Services
� If it can not be connected, the screen would be as follows:
93
7. Network Services
94
7. Network Services
95
7. Network Services
96
7. Network Services
97
7. Network Services
98
8. Diagnosis
8 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.
9 PLC Function
From Main Menu, press F10[EXTEND MENU]. Press F1[PLC] to enter into PLC
functions.
100
9. PLC Function
101
9. PLC Function
102
9. PLC Function
The procedure is as follows:
1) Use or to select a register from the above list. Press Enter to confirm
the selection.
2) For example, if we want to monitor the current values of G register, we can press F4.
The values of all G registers will be displayed:
3) Then there are three kinds of digital forms to display the value
103
10. Parameters
10 Parameters
User can check or modify the parameters. Users are divided into three groups. Different
group are allowed to access different parameters. The three groups are: CNC vendor,
Machine tool’s vendor and machining operator. The group is identified by the password.
Users from different group have different password.
From Main menu, press F10[EXTEND MENU], enter into extend menu. Then press
F3[PARA], parameter function menu will be displayed.
104
10. Parameters
105
10. Parameters
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 mini-meter
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
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
Pulse/um(pulse)
Encode counter per revolution of the motor.
Note: this two numbers can be commonly divided into prime numbers.
107
10. Parameters
Reference point offset(um)
Offset distance after the encoder’s zero position is found.
Maximum feedrate(mm/min)
Maximum feed rate for this axis.
108
10. Parameters
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.
109
10. Parameters
Tracking error
Tracking error threshold. Alarm will be displayed if the actual tracking supersede this
value.
Compensation gap
Distance between two adjacent compensation points.
110
10. Parameters
111
10. Parameters
112
10. Parameters
113
10. Parameters
F7:: Backup
10.6 F7
This function is to make a backup file for the current parameters.
1) Press “Y” if you want to backup the current parameters
114
10. Parameters
1) Use or to select the backup file source among CF, DNC or Floppy
disk.
115