intituivo

ES0609 rev C 6/07 1

IntuitiveProgrammingSystemWalk-ThroughFor Lathes

ROT AT INGPART S INS IDE ,

K E E P HANDS AWAY .

ES0609 rev C 6/07 2

INTRODUCTION

These instructions are an in-depth look at each of the Intuitive Programming System (IPS) menus. A moreformal description is given for each of the entries to help better define the on-screen help for new users.

These instructions are to be used with the Lathe Operator’s Manual (96-8700) and Toolroom Lathe/HPCLOperator’s Addendum (96-0112)

The IPS initial screen displays the X and Z position of the lathe and a spindle speed indicator.

The menus are navigated by using the left and right arrow keys. To select a menu item, press Write/Enter.Some menus have sub-menus, in which case, use the left and right arrow keys and press Write/Enter to selecta sub-menu.

Use the arrow keys to navigate through the variables, enter values by using the number pad, and then pressWrite/Enter.

To exit, or go back to another selection, press Cancel.

Pressing any of the buttons under the “Display” heading will exit the IPS menus, as will any of the mode keys(i.e. Edit, Mem, MDI, etc.). To return to the IPS menu, press Handle Jog.

A representation of the front of the Operator’s Pendant is included at the end of this document for your conve-nience.

This guide will help the user develop full CNC programs by means of the IPS screen. Note that a programentered through the Toolroom Lathe screens is also accessible by going to full CNC MDI mode. The programcan be edited and saved from the full CNC mode.

NOTE: The IPS menu is displayed at power up, and is available in the followingconfigurations:

• 10” LCD and software version 7.xx and earlier - IPS

• 15” LCD and software version 8.03 and earlier - IPS (upgradable to Profile Creator)

• 15” LCD and software version 8.04A and later - IPS with Profile Creator

ES0609 rev C 6/07 3

MANUAL MODE

Select Manual Mode by moving the highlighted tab to “Manual Mode” and press Write/Enter. The followingscreen will appear.

SYSTEMGROOVINGTHREADINGDRILL & TAPCHAMFER & RADIUSCHAMFER & RADIUSTURN & FACETURN & FACECHAMFERSETUPSETUPMANUALMANUAL

X AND Z AXESTHE AXES CAN BE ELECTRONICALLY LOCKED AND UNLOCKED. THIS IS SHOWN BYXZ-MAN DISPLAYED AT THE BOTTOM OF THE SCREEN. IN THIS MODE BOTH THEX AND Z AXES ARE UNLOCKED AND CAN BE POSITIONED USING THE MANUAL HANDWHEELS. PRESSING SHIFT AND EITHER +X OR -X, OR +Z OR -Z WILLELECTRONICALLY LOCK THAT AXIS. PRESSING SHIFT AND THE SAME BUTTON ASECOND TIME WILL UNLOCK THE AXIS.

SPINDLETHE SPINDLE IS COMMANDED BY ENTERING A VALUE FOR THE SPINDLE SPEEDAND PRESSING EITHER THE FWD OR REV BUTTONS. THE SPINDLE SPEEDOVERRIDE KEYS (+/-10%) CAN BE USED TO ADJUST THE COMMANDED SPEED.

XZ-MAN

IPS <JOG> N00000000

G 54Active WorkActive Work

XAxis Work Distance To GoAxis Work Distance To Go

Z

Feed RateFeed Rate

Last Cycle TimeLast Cycle Time

This Cycle TimeThis Cycle Time

Load %Load %

Load %Load %

Load %Load %

X OFFSET:

X WEAR :

Z OFFSET:

Z WEAR :

X OFFSET:

X WEAR :

Z OFFSET:

Z WEAR :

FEED TIME:TOOL USAGE:

TOOL LIFE:

FEED TIME:TOOL USAGE:

TOOL LIFE:

in

in

in

in

Load %Load %

RPM

X and Z AxesJust below the on-screen text is a line of text that shows the state the lathe is in. For example, “X -MAN”means the X -axis is in manual mode. No text beneath the on-screen help means both axes (X and Z arelocked. In this case the axes can be jogged, by pressing +X/-X or +Z/-Z and then using the jog handle on thependant. Select a jog speed before using the jog handle.

SpindleThe spindle is controlled using the keys on the control pendant. Enter a spindle speed; for example, press 5,then 0, then Write/Enter. This will enter a speed of 50RPM. Ensure the area around the spindle is free of toolsand workpieces, press the hold to run switch and then press either the FWD or REV button.

The spindle speed override keys ( +/- 10%) can be used to adjust the commanded speed. This also works onmost screens.

The spindle is stopped by letting go of the hold to run switch, pressing Reset, or the pressing the Stop button.

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OFFSETS

Work OffsetsSYSTEMGROOVINGTHREADINGDRILL & TAPDRILL & TAPCHAMFER & RADIUSCHAMFER & RADIUSTURN & FACETURN & FACE

X OffsetX Offset

Z OffsetZ Offset

MANUAL CHAMFER

WORK TOOL

SETUP

Wrk Zero OfstWrk Zero Ofst

Work Zero Offset – Press the Up and Down arrows to change the displayed Work Zero Offset.

X Offset – Press Write to add or F1 to set position. Enter a value and either press Write to add the value to thecurrent value, or F1 to replace the value with the entered value.

Z Offset – Press Write to add F1 to set or Part Zero Set to record current position. Enter a value and eitherpress Write to add the value to the current value, or F1 to replace the value with the entered value. Press PartZero Set to record the Z Offset current position.

Tool OffsetTool offsets are described in detail in the Operator’s manual. See the “Tool Nose Compensation” section withinthe “Operation/Programming” Tab for specific instructions on Radius, Radius Wear, Taper, and Tip.

SYSTEMGROOVINGTHREADINGDRILL & TAPDRILL & TAPCHAMFER & RADIUSCHAMFER & RADIUSTURN & FACETURN & FACEMANUAL CHAMFER

X offsetX offset0.

X wearX wear0.

Z offsetZ offset0.

Z wearZ wear0.

RadiusRadius0.

Radius wearRadius wear0.

Taper0.

Tip0.

WORK TOOL

Press TURRET FWD or TURRET REVto change the displayed tool.Press NEXT TOOL to change the tool.

SETUP

Tool – The current tool number. Use the turret FWD/REV or the Next Tool buttons to set-up another tool.

X Offset – The X axis offset for the current tool. Press X Dia Meas to record this position.

X Wear – The amount of tool wear, in the X axis for the current tool.

Z Offset – The Z axis offset for the current tool. Press Z Face Meas to record this position.

Z Wear – The amount of tool wear, in the Z axis for the current tool.

Radius** – The tip radius of the current tool.

Radius Wear – The amount of wear in the radius.

Taper – Compensation value for part deflection.

Tip** – Tool tip direction will be a value of 0-9. Must be entered to use Cutter Compensation

**Must be entered to use Cutter Compensation; See the Operator’s manual for information on Cutter Compen-sation.

ES0609 rev C 6/07 5

SEMI-AUTOMATIC MODE

This mode performs dual axis movement using a single handwheel. The active handwheel is highlighted on thescreen display. This feature is limited to cuts that can be performed with a single tool pass. Large radii andchamfers must be programmed in Multi-Pass mode.

ChamferThe Chamfer mode is used to cut both I.D. and O.D. chamfers in a workpiece. Use the arrow keys to movethrough the variables, enter a value and then press “Write/Enter”. Once the values have all been entered, thedisplay shows the chamfer to be cut against the model.

SYSTEMGROOVINGTHREADINGDRILL & TAPDRILL & TAPCHAMFER & RADIUSCHAMFER & RADIUSTURN & FACETURN & FACE

ANGLEANGLE0.000 deg0.000 deg

0.0000 in0.0000 in

RUN (Z)RUN (Z)0.0000 in0.0000 in

MANUAL SETUP CHAMFER

ID Chamfer

OD Chamfer

RISE (X)RISE (X)

ID Chamfer – Press the upper left arrow key to activate.

OD Chamfer – Press the lower left arrow key to activate.

Angle – The value entered will set the angle for the chamfer.

Rise (X) – The rise (change in X) for an OD taper.

Run (Z) – The run (change in Z) for an OD taper.

To start the spindle, enter a value and press either spindle FWD or REV.

NOTE: I.D chamfers and tapers are at right angles to the O.D. chamfer or taper.

ES0609 rev C 6/07 6

AUTOMATIC MODE

On each of the following interactive screens, the user will be asked to enter data needed to complete commonmachining tasks. When all the data has been entered, pressing “Cycle Start” will begin the machining process.

The following are examples of the types of the Automatic Mode screens and the definitions of the variables thatwill need to be entered.

Turn and FaceRapidThis mode is for making a rapid move.

MANUAL SETUP SYSTEMGROOVINGTHREADINGDRILL & TAPDRILL & TAPCHAMFER & RADIUSCHAMFER & RADIUS

TOOL NUMBER1

WORK OFFSETWORK OFFSET54

X POSITIONX POSITION0.0000 in0.0000 in

Z POSITIONZ POSITION0.0000 in0.0000 in

CHAMFERTURN & FACETURN & FACE

RAPID FEED OD TURN ID TURN FACE

Tool Number – Enter the tool to be used.

Work Offset – Enter the work offset to be used.

X Position – Enter an end point or move the tool to the end point desired. Press X DIA. MEAS to record thisposition.

Z Position – Enter an end point or move the tool to the end point desired. Press Z FACE MEAS to record thisposition.

Turn and FaceFeedThis mode provides for straight line (linear) motion from the machines current position to the specified ‘X’and ‘Z’ end points.

NOTE: The Feed command is a single pass movement for features that are smallerthan the maximum cut depth for the tool. For larger features use the turn andface programs.


TOOL NUMBER1


DELTA X0.0000 in0.0000 in

DELTA Z0.0000 in0.0000 in



FEED PER REVFEED PER REV0.0000 in0.0000 in

SPINDLE RPMSPINDLE RPM0.0000 in0.0000 in

PROFILEPROFILE



Delta X – Enter the X-coordinate of the end point of the linear motion desired.

ES0609 rev C 6/07 7

Delta Z – Enter the Z-coordinate of the end point of the linear motion desired.

*Feed Per Rev. – Enter the feed per revolution (in inches or millimeters).

*Spindle RPM – Enter the spindle RPM.

*Mandatory Values

Advanced Users: In the full CNC mode this is a G01 command.

Turn & FaceO D TurnThis mode is for an outside diameter cut.


TOOL NUMBER1


Z START PTZ START PT0.0000 in0.0000 in

OUTSIDE DIA.OUTSIDE DIA.0.0000 in0.0000 in



DIA. TO CUTDIA. TO CUT

Z DIMENSIONZ DIMENSION54

DEPTH OF CUTDEPTH OF CUT0.0000 in0.0000 in


MAX RPMMAX RPM1000

SFM500

FILLET RADIIFILLET RADII0.0000 in0.0000 in

TOOL NOSE0.0000 in0.0000 in

PROFILEPROFILE

0.0000 in0.0000 in



Z Start Pt – Enter the Z axis starting point.

Outside Dia. – Enter the current diameter of the work piece. Manually measure the diameter.

Dia. to Cut – Enter the finished diameter.

Z Dimension – Enter the Z axis dimension of the part from the Z start point.

Depth of Cut – Enter the depth of cut for each pass of the stock removal.

Feed Per Rev – Enter the feed per revolution.

MAX RPM – Enter the maximum spindle turning speed.

SFM – Enter the Surface Feed per Minute.

Fillet Radii – Enter the corner fillet radii or enter ‘0’ for none.

Tool Nose – Enter the tool nose radius.

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Turn & FaceID TurnThis mode is for an inside diameter cut.


TOOL NUMBER1



INSIDE DIA.INSIDE DIA.0.0000 in0.0000 in



DIA. TO CUTDIA. TO CUT

Z DIMENSIONZ DIMENSION54



MAX RPMMAX RPM1000

SFM200

FILLET RADIIFILLET RADII0.0000 in0.0000 in


PROFILE

0.0000 in0.0000 in




Inside Dia. – Enter the current diameter of the work piece. Manually measure the diameter.







Fillet Radii – Enter the corner fillet radii or enter ‘0’ for none.



Turn & FaceFaceThis mode is for making an end facing cut.


TOOL NUMBER1



DIA. TO CUTDIA. TO CUT0.0000 in0.0000 in



Z DIMENSIONZ DIMENSION0.0000 in0.0000 in

0.0500 in0.0500 in

0.0000 in0.0000 in

1000

SFM200

DEPTH OF CUTDEPTH OF CUT

FEED PER REVFEED PER REV

MAX RPMMAX RPM

PROFILE



ES0609 rev C 6/07 9





Feed per Rev – Enter the feed per revolution. This is the distance the tool will move for each revolution of thespindle.




NOTE: Entering a negative value for “Dia to Cut” causes the tool to pass spindle centerand machine the entire face of the part; Do Not enter a value larger than -.100”.

Turn & FaceProfileThis tab is only available if the machine has a control pendant with a 15” screen and lathe softwareversion 8.04A or later.

MANUAL SETUP SYSTEMGROOVINGTHREADINGDRILL & TAPCHAMFER & RADIUSCHAMFER & RADIUS

TOOL NUMBER1


CUT TYPEHORIZONTAL

X STOCK ALLOWX STOCK ALLOW0.0200 in0.0200 in



NUM OF PASSESNUM OF PASSES1

X DISTANCEX DISTANCE

Z DISTANCEZ DISTANCE0.0000 in0.0000 in


SPINDLE DIRSPINDLE DIR

CUTTER COMPCUTTER COMP

COOLANT

MIRROR XMIRROR X

PROFILEPROFILE

Z STOCK ALLOWZ STOCK ALLOW0.0050 in0.0050 in


MAX RPMMAX RPM1500

SFM350

GRAPHIC MODEGRAPHIC MODE

PROFILE NUMBRPROFILE NUMBR1

FORWARD

OFF

OFF

OFF

ON

0.0000 in0.0000 in



Cut Type – Use the left/right cursor keys to select the type of cut (Horizontal, Vertical, Profile, Finish Fwd,Finish Rev).

X Stock Allow – Enter the amount to leave on the diameter of the profile.

Z Stock Allow – Enter the amount to leave on the faces of the profile.


Num of Passes – Enter the number of cutting passes. (Must be a positive number).

X Distance – Enter the X-axis distance and direction from first cut to last. (Radius value).

Z Distance – Enter the Z-axis distance and direction from first cut to last.



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Spindle Dir – Use the left/right cursor keys to select spindle direction (Forward/Reverse). This depends on tooltype.

Cutter Comp – Use the left/right cursor keys to select cutter compensation (Off/Left/Right).

Coolant – Use the left/right cursor keys to turn coolant on or off (On/Off).

Mirror X – Use the left/right cursor keys to mirror the X axis (On/Off). This allows you to cut on the other sideof the part.

Graphic Mode – Use the left/right cursor keys to turn on/off Graphic Mode. This allows you to view theprocess in graphics.

Profile Number – Enter the number of the profile to use, press Enter to open Profile Select or press F1 key.

Advanced Users: In the full CNC Mode, this is a G71 command.

Basic Profile Creation (Example)1. Start the machine with IPS active.

2. Clear any alarms, then press Power Up/Reset to zero the machine.

3. Select the Setup tab, then the Work tab to set up the work offsets.

4. Select the Tool tab (under the Setup tab) to set up the tools to be used.

5. Press Cancel a few times to get out of the Setup tab. Select the Turn & Face tab, then the Profile tab.

6. Enter the tool number (1), set Cut Type to Horizontal, set X Stock Allow to 0.02, set Z Stock Allow to 0.005,set Depth of Cut to 0.075, set Feed per Rev to 0.01, set Max RPM to 1500, set SFM to 350, set GraphicMode to ON and Profile Number to 1.

7. Select the Profile Number data box and press Write/Enter or press F1 when in the Profile tab. A ProfileSelector popup window is displayed. The Profile Selector popup is used to select a profile, alter an existingprofile, choose a storage location for a new profile or delete a profile.

Profile Selector F3 - Exit

*EmptyEmptyEmptyEmptyEmptyEmptyEmptyEmptyEmptyEmptyEmpty

ES0609 rev C 6/07 1 1

8. Select an 'Empty' slot and press Write/Enter to display the Profile Creator screen. This is used to draw aprofile on the screen using either the jog handle or entering data directly into the table.

IPS <EDIT> N00000000

Profile Creator

X 1.0000Z - 1.0000

Profile Part Number: 1Profile Part Number: 1

Jog step size: 0.1

Delta X: 2.0000Delta Z: 0.0000

F1 - HelpF2 - Exit & Save profileF3 - Exit without saveF4 - Activate Zoom

Jog step size: 0.1

Delta X: 2.0000Delta Z: 0.0000

F1 - HelpF2 - Exit & Save profileF3 - Exit without saveF4 - Activate Zoom

RAPD PT

START

1 FEED

1 FEED

1 FEED

RAPD PT

START

1 FEED

1 FEED

1 FEED

TYPE

3.5000

0.0000

0.5000

1.0000

1.0000

3.5000

0.0000

0.5000

1.0000

1.0000

0.1000

0.0000

1.0000

-0.2500

-1.0000

0.1000

0.0000

1.0000

-0.2500

-1.0000

0.0000

0.0000

90.0000

135.0000

180.0000

0.0000

0.0000

90.0000

135.0000

180.0000

0.0000

0.0000

0.0000

0.0000

0.5000

0.0000

0.0000

0.0000

0.0000

0.5000

0.0000

0.0000

0.0000

0.0000

0.0000

0.0000

0.0000

0.0000

0.0000

0.0000

X POSX POS Z POSZ POS ANGLE CHAMFER RADIUS

Profile Creator Screen Hot keys:F1 – Help screen popup. Lists available keys used in the Profile Creator along with a short description ofeach key's function.

F2 – Saves the profile on the screen, exits the Profile Creator screen and transfers control back to theProfile tab.

F3 – Exits the Profile Creator screen and transfers control back to the Profile tab screen. Does not savethe profile's data.

F4 – Activates and de-activates the zoom and scrolling feature.

INSERT – Inserts a line into the table. This feature will not work if the table is full (all 30 lines used).

ORIGIN – Clears all data in the table.

X JOG KEY – Jumps to the X-axis position in the data table for the currently selected row.

Z JOG KEY – Jumps to the Z-axis position in the data table for the currently selected row.

CURSOR KEYS – Moves around in the data table. If zoom is active, the cursor keys move the part aroundon the screen.

(.0001), (.001), (.01), (.1) – Changes the jog step size while drawing in the graphic window.

To Build the Profile Shown:a. Select the Rapd Pt row. Use the arrow keys to select the X POS column and enter 3.5. Use thearrow keys to select the Z POS column and enter 0.1. Use the arrow keys to go to the beginning of theStart row.

b. Leave the Start PT at X0 Z0. Use the arrow keys to go to the beginning of the next line in thetable (4 None). Press 1 to activate a Feed move.

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c. Jog X POS to 0.5 by turning the handwheel clockwise, and press Write/Enter.

NOTE: Each click on the handwheel either increments or decrements the position by0.1".

Use the arrow keys to go to the beginning of the next line in the table and press 1 to activate aFeed move.

d. Press Write/Enter until X POS is selected. Jog X to 1.0 and press Write/Enter until Z POS isselected. Jog Z to -0.25 and press Write/Enter.

Go to the beginning of the next line. Press 1 to activate a Feed move.

e. Press Write/Enter until Z POS is selected. Jog Z to -1.0 and press Write/Enter.


f. Press Write/Enter until X POS is selected. Jog X to 2.0 and press Write/Enter.


ES0609 rev C 6/07 1 3

g. Press Write/Enter until Z POS is selected. Jog Z to -1.5 and press Write/Enter.

Use the cursor keys to go back to the previous line and select the Radius column. Enter 0.25, pressWrite/Enter and use the cursor keys to come back to this line.


h. Press Write/Enter until X POS is selected. Jog X to 3.0. Press Write/Enter until Z POS is selected. Jog Z to -2.0 and press Write/Enter.


i. Press Write/Enter until Z POS is selected. Jog Z to -3.0 and press Write/Enter.

j. Press F2 to Save and exit the Profile Creator.

k. Press Cycle Start to cut the profile.

NOTE: The program may be saved to memory from MDI by typing in 0xxxxx and pushingthe Alter key. This action moves the program from MDI memory.

If Graphic Mode is set to ON in the Turn & Face Profile screen, when Cycle Start is pressed to run a profile, agraphic screen is displayed showing the graphical representation of the profile.

ES0609 rev C 6/07 1 4

Graphic Mode

GRAPHICS (MDI) N00080201

To cut the profile on the other side of the workpiece, set Mirror X to ON in the Turn & Face Profile screen (it isnot necessary to change Mirror X in Settings). When Cycle Start is pressed, the opposite side of the workpieceis cut, and if Graphic Mode is set to ON, a graphical representation of the mirrored profile is displayed.

GRAPHICS (MDI) N00080201

Recalling ProfilesThe Profile Selector popup is used to select a profile, alter an existing profile, choose a storage location for anew profile or delete a profile, and is accessed by pressing F1 in the Profile tab or by selecting the ProfileNumber box and pressing Write/Enter.

Once in the Profile Selector popup screen, cursor to the number of the previously created profile and pressAlter. Cursor to any data cell to change its information, then press F2 to Exit the Profile Selector popup screenand Save the new information, or F3 to Exit without Saving.

Profile Creator HelpPress F1 when in the Profile Creator screen to display a Profile Creator Help popup screen. This popup screenlists available keys used in the Profile Creator along with a short description of each key's function.

ES0609 rev C 6/07 1 5

Profile Creator Help F1 - Exit

Exit and Save Profile

Exit without Saving Profile

Activate Zoom

--- ZOOM HELP ---

Zoom In

Zoom Out

Scroll Up

Scroll Down

Scroll Right

Scroll Left

Exit Zoom

--- DATA TABLE HELP ---

Enter Data Into Table

Insert Line Into Table

Clear All Data In Table

Go To X Axis Data Box

Go To Z Axis Data Box

Move Up To Next Data Box

Move Down To Next Data Box

Move Right To Next Data Box

Move Left To Next Data Box

Exit and Save Profile

Exit without Saving Profile

Activate Zoom

--- ZOOM HELP ---

Zoom In

Zoom Out

Scroll Up

Scroll Down

Scroll Right

Scroll Left

Exit Zoom

--- DATA TABLE HELP ---

Enter Data Into Table

Insert Line Into Table

Clear All Data In Table

Go To X Axis Data Box

Go To Z Axis Data Box

Move Up To Next Data Box

Move Down To Next Data Box

Move Right To Next Data Box

Move Left To Next Data Box

(F2)

(F3)

(F4)

(PAGE UP)

(PAGE DOWN)

(UP CURSOR KEY)

(DOWN CURSOR KEY)

(RIGHT CURSOR KEY)

(LEFT CURSOR KEY)

(F4)

(WRITE/ENTER)

(INSERT)

(ORIGIN)

(X JOG KEY)

(Z JOG KEY)

(UP CURSOR KEY)

(DOWN CURSOR KEY)

(RIGHT CURSOR KEY)

(LEFT CURSOR KEY)

(F2)

(F3)

(F4)

(PAGE UP)

(PAGE DOWN)

(UP CURSOR KEY)

(DOWN CURSOR KEY)

(RIGHT CURSOR KEY)

(LEFT CURSOR KEY)

(F4)

(WRITE/ENTER)

(INSERT)

(ORIGIN)

(X JOG KEY)

(Z JOG KEY)

(UP CURSOR KEY)

(DOWN CURSOR KEY)

(RIGHT CURSOR KEY)

(LEFT CURSOR KEY)

Exit and Save Profile - Exit the Profile Creator screen and saves the profile you were working on into programmemory.

Exit without Saving Profile - Exit the Profile Creator screen and does not save the profile you were workingon.

Activate Zoom - Turns on the Zoom and Scrolling function.

Zoom In - Allows you to zoom into a part for a closer look.

Zoom Out - Allows you to zoom out from the part and see more in the window.

Scroll Up - Allows you to scroll the view window up.

Scroll Down - Allows you to scroll the view window down.

Scroll Right - Allows you to scroll the view window to the right.

Scroll Left - Allows you to scroll the view window to the left.

Exit Zoom - Turns off the zoom and scrolling function.

Enter Data Into Table - Transfers the data from the command line into the selected data box or accepts thevalue jogged.

Insert Line Into Table - Moves selected line down and inserts a new line into the table. Will not work if tableis full!

Clear All Data In Table - Clears all the data in current table and puts the table in its home position.

Go To X Axis Data Box - Highlights the X axis data box and changes the drawing cursor to only move in the Xdirection.

Go To Z Axis Data Box - Highlights the Z axis data box and changes the drawing cursor to only move in the Zdirection.

Move Up To Next Data Box - Moves up to next data box above its current location. Will not move if already atthe top of the table.

Move Down To Next Data Box - Moves down to next data box below its current location. Will not move ifalready at the bottom of the table.

Move Right To Next Data Box - Moves to the next data box to the right of its current location. Will wrap ifalready at the far right.

Move Left To Next Data Box - Moves to the next data box to the left of its current location. Will wrap ifalready at the far left.

ES0609 rev C 6/07 1 6

Chamfer & RadiusO D RadiusThis mode is used to cut an outside diameter radius.

MANUAL SETUP SYSTEMGROOVINGTHREADINGDRILL & TAP

TOOL NUMBER1





OD RADIUSOD RADIUS ID RADIUSID RADIUS OD CHAMFEROD CHAMFER ID CHAMFERID CHAMFER

RADIUS0.0000 in0.0000 in

0.0000 in0.0000 in

0.0000 in0.0000 in

MAX RPMMAX RPM1000

SFM200

CHAMFER & RADIUSCHAMFER & RADIUS






Z Start PT – Enter the Z axis starting point.


Radius – Enter the desired radius. This is the desired corner radius. Note that the larger the radius or materialto be removed, the more passes required to rough out the profile.

Depth of Cut – Enter the depth of cut for each pass of the stock removal. This is the amount of the stock to beremoved on each tool pass. A pass must be less than or equal to the maximum single pass cut depth for theselected tool.

Feed Per Rev – Enter the feed per revoultion. This is the distance the tool will move for each revolution of thespindle.


Tool Nose – Enter the tool nose radius. This is the radius of the selected tool. Normally this information isincluded with the tool.



Chamfer & RadiusI.D. RadiusThis mode is used to cut an inside diameter radius.

MANUAL SETUP SYSTEMGROOVINGTHREADINGDRILL & TAP

TOOL NUMBER1






RADIUS0.0000 in0.0000 in

0.0000 in0.0000 in

0.0000 in0.0000 in

MAX RPMMAX RPM1000

SFM200






ES0609 rev C 6/07 1 7



Inside Dia. – Enter the current diameter of the work piece. Manually measure the diameter.

Radius – Enter the desired radius. This is the desired corner radius. Note that the larger the radius or materialto be removed, the more passes required to rough out the profile.

Depth of Cut – Enter the depth of cut for each pass of the stock removal. This is the amount of the stock to beremoved on each tool pass. A pass must be less than or equal to the maximum single pass cut depth for theselected tool.

Feed Per Rev – Enter the feed per revoultion. This is the distance the tool will move for each revolution of thespindle.


Tool Nose – Enter the tool nose radius. This is the radius of the selected tool. Normally this information isincluded with the tool.



Chamfer & RadiusO D ChamferThis mode is used to cut an outside diameter chamfer.

MANUAL SETUP SYSTEMGROOVINGTHREADINGDRILL & TAPDRILL & TAP

TOOL NUMBER1






CHAMFER0.0000 in0.0000 in

0.000 deg.0.000 deg.

0.0000 in0.0000 in




ANGLEANGLE


MAX RPMMAX RPM1000

200SFM




Outside Dia. – Enter the outside diameter of the part. Manually measure the work piece.

Chamfer – Enter the Z dimension of the chamfer desired. Entered value must be positive.

Angle – Enter the angle of the chamfer (0°–90°). Entered value must be positive.







ES0609 rev C 6/07 1 8

Chamfer & RadiusI D ChamferThis mode is used to cut an outside diameter chamfer.

MANUAL SETUP SYSTEMGROOVINGTHREADINGDRILL & TAPDRILL & TAP

TOOL NUMBER1






CHAMFER0.0000 in0.0000 in

0.000 deg.0.000 deg.

0.0000 in0.0000 in




ANGLEANGLE


MAX RPMMAX RPM1000

200SFM




Inside Dia. – Enter the current diameter of the work piece. This is the outside diameter of the part. Manuallymeasure the work piece.

Chamfer – Enter the Z dimension of the chamfer desired. Entered value must be positive.

Angle – Enter the angle of the chamfer (0°-90°). Entered value must be positive.







Drill & TapDrillThis mode is a drill cycle that can pause at the bottom of the hole.

MANUAL SETUP CHAMFERTURN & FACETURN & FACECHAMFER & RADIUSCHAMFER & RADIUS SYSTEMGROOVINGTHREADINGDRILL & TAPDRILL & TAP

TOOL NUMBER1



DEPTH OF HOLEDEPTH OF HOLE0.0000 in0.0000 in

DRILLDRILL PECK DRILLPECK DRILL TAP REVERSE TAP

0.0000 in0.0000 in

0.0000 sec0.0000 sec


DWELL

MAX RPMMAX RPM1000




ES0609 rev C 6/07 1 9

Depth of Hole – Enter the depth to drill.

Feed Per Rev – Enter the feed per revolution. This is the distance the tool will move for each revolution of thespindle.

MAX RPM – Enter the spindle RPM.

Dwell – Enter the dwell time. This is a time, in seconds, that the tool will pause at the bottom of the hole toclear chips


Drill & TapPeck Drill


TOOL NUMBER1



DEPTH OF HOLEDEPTH OF HOLE0.0000 in0.0000 in


0.0000 in0.0000 in

0.0000 sec0.0000 sec

PECK DISTANCEPECK DISTANCE

SPINDLE RPMSPINDLE RPM

FEED PER REVFEED PER REV1000




Depth of Hole – Enter the depth to drill. Entered value must be positive.

Peck Distance – Enter the length of each ‘peck’ before retracting to clear chips. This is the distance the toolwill advance at each “peck”. This value cannot be negative.

Feed Per Rev – Enter the feed per revolution. This is the distance the tool will move for each revolution of thespindle.

Spindle RPM – Enter the spindle RPM. This is the commanded spindle speed.


Drill & TapTap*This mode is for cutting right hand threads using a tapping tool.


TOOL NUMBER1



TAP DEPTH0.0000 in0.0000 in


0.0000 in0.0000 inTPI

SPINDLE RPMSPINDLE RPM350


ES0609 rev C 6/07 2 0



Tap Depth – Enhter the depth to tap. Entered value must be positive.

TPI – (Threads per Inch) – Enter the number of Threads per Inch. This is how many threads to cut per inch.

Spindle RPM – Enter the spindle RPM. This is the commanded spindle speed. The spindle speed should notexceed 500 RPM.


(*Rigid Tapping Option needed.)

Drill & TapRev. Tap*This mode is for cutting left hand threads using a tapping tool.


TOOL NUMBER1



TAP DEPTH0.0000 in0.0000 in


0.0000 in0.0000 inTPI





Tap Depth – The depth to tap. Entered value must be positive.

TPI – How many threads to cut per inch.

Spindle RPM – The commanded spindle speed. The spindle speed should not exceed 500 RPM.


(*Rigid Tapping Option needed.)

ThreadingOD ThreadThis mode is used for cutting outside diameter threads using multiple passes.

MANUAL SETUP CHAMFERTURN & FACETURN & FACECHAMFER & RADIUSCHAMFER & RADIUS SYSTEMGROOVINGDRILL & TAPDRILL & TAP

TOOL NUMBER1



THREAD LENGTHTHREAD LENGTH0.0000 in0.0000 in

OD THREAD ID THREAD OD THREAD REPAIROD THREAD REPAIR ID THREAD REPAIRID THREAD REPAIR

MINOR0.0000 in0.0000 in

0.0000 in0.0000 in

0.0000.000


TAPER0.0000 in0.0000 in

MAJOR

TPI


0

CHAMFER0

THREAD DIRTHREAD DIR

THREADING

THREAD DIR: RIGHTCHAMFER: ON

ES0609 rev C 6/07 2 1




Thread Length – Enter the length of the threaded portion of the part. This value cannot be negative.

Minor – Enter the minor diameter of the threads. This is the smallest part of the thread (Min Diameter). Thisvalue cannot be negative.

Major – Enter the major diameter of the threads. This is the largest part of the thread (Max Diameter). Thisvalue cannot be negative. Manually measure the diameter of the work piece at the point where “X Dia Meas”was pressed.

TPI (Threads per Inch) – Enter the number of Threads per Inch. This is how many threads to cut per inch oflength.

Depth of Cut – Enter the amount of stock to be removed on each pass. Must be less than or equal to themaximum single pass cut depth for the selected tool.


Taper – Enter a positive value for thread taper per ft.

Thread Dir – Enter ‘0’ for right hand threads or enter ‘1’ for left hand threads.

Chamfer – ‘0’ turns on chamfer at end of thrds. ‘1’ turns off chamfer at end of thrds. (Check setting 95, 96, 86,99).

Advanced Users: Additional Settings may need to be modified to create the required groove. These settingnumbers are: 22, 28, 72, 73, 86, 95, 96, 99. See the definitions of the setting in the Operator’s Manual.In the full CNC mode this is a G76 command.

ThreadingID ThreadThis mode is used for cutting inside diameter threads using multiple passes.


TOOL NUMBER1





MINOR0.0000 in0.0000 in

0.0000 in0.0000 in

0.0000.000


TAPER0.0000 in0.0000 in

MAJOR

TPI


0

CHAMFER0

THREAD DIRTHREAD DIR

THREADING





Thread Length – Enter the length of the threaded portion of the part. This value cannot be negative.

Minor – Enter the minor diameter of the threads. This is the smallest part of the thread (Min Diameter). Thisvalue cannot be negative.

Major – Enter the major diameter of the threads. This is the largest part of the thread (Max Diameter). Thisvalue cannot be negative. Manually measure the diameter of the work piece at the point where “X Dia Meas”was pressed.

ES0609 rev C 6/07 2 2

TPI (Threads per Inch) – Enter the number of Threads per Inch. This is how many threads to cut per inch oflength.

Depth of Cut – Enter the amount of stock to be removed on each pass. Must be less than or equal to themaximum single pass cut depth for the selected tool.




Chamfer – ‘0’ turns on chamfer at end of thrds. ‘1’ turns off chamfer at end of thrds. (Check setting 95, 96, 86,99)

Advanced Users: Additional Settings may need to be modified to create the required groove. These settingnumbers are: 22, 28, 72, 73, 86, 95, 96, 99. See the definitions of the setting in the Operator’s Manual.In the full CNC mode this is a G76 command.

ThreadingOD Thread RepairThis mode is for repairing outside diameter threads using multiple passes.


REFERENCE0

NO OF THREADSNO OF THREADS0


TPI0.000 in0.000 in



350350

0.0000 in0.0000 in

X OFFSETX OFFSET0.0000 in0.0000 in

THREAD DIRTHREAD DIR0


TAPER

Z OFFSETZ OFFSET0.0000 in0.0000 in

0CHAMFER

THREADING


Reference – Jog the tool into the threads, then press the X DIA MEAS key. 1 = reference point recorded.

No Of Threads – Enter the number of threads from the tool to the end of the part.

Thread Length – Enter the length of the threaded portion of the part.

TPI – Enter the number of Threads per Inch (or Threads per Millimeter).

Depth of cut – Enter the amount of stock to be removed on each pass.

Spindle RPM – Enter the spindle RPM.


X Offset – Enter a value only if minor adjustments are needed in the X axis.

Z Offset – Enter a value only if minor adjustments are needed in the Z axis.



ES0609 rev C 6/07 2 3

ThreadingID Thread RepairThis mode is for repairing outside diameter threads using multiple passes.


REFERENCE0

NO OF THREADSNO OF THREADS0

THREADS LENGTHTHREADS LENGTH0.0000 in0.0000 in

TPI0.000



350

0.0000

X OFFSETX OFFSET0.0000 in0.0000 in

THREAD DIRTHREAD DIR0


TAPER

Z OFFSETZ OFFSET0.0000 in0.0000 in

0CHAMFER

THREADING


Reference – Jog the tool into the threads, then press the X DIA MEAS key. 1 = reference point recorded.

No Of Threads – Enter the number of threads from the tool to the end of the part.

Thread Length – Enter the length of the threaded portion of the part.

TPI – Enter the number of Threads per Inch (Threads per Millimeter).

Depth of cut – Enter the amount of stock to be removed on each pass.

Spindle RPM – Enter the spindle RPM.


X Offset – Enter a value only if minor adjustments are needed in the X axis.

Z Offset – Enter a value only if minor adjustments are needed in the Z axis.



Grooving ModeOD GrooveThis mode is used for an outside diameter groove.

MANUAL SETUP CHAMFERTURN & FACETURN & FACECHAMFER & RADIUSCHAMFER & RADIUSDRILL & TAPDRILL & TAP

TOOL NUMBER1




OD GROOVEOD GROOVE ID GROOVEID GROOVE PART OFF PART OFF WITH PECKPART OFF WITH PECK


0.0000 in0.0000 in

0.0000 in0.0000 in

TOOL WIDTH0.0000 in0.0000 in

MAX RPMMAX RPM1000

Z DIMENSIONZ DIMENSION

GROOVE WIDTHGROOVE WIDTH


200SFM

THREADING SYSTEMGROOVING




ES0609 rev C 6/07 2 4

Outside Dia – Enter the current diameter of the work piece. Manually measure the diameter.

Dia to Cut (Diameter to Cut) – Enter the finished diameter.

Z Dimension – Enter the Z-axis dimension of the groove. Entered value must be positive.

Groove Width – Enter the finished width of the groove. Entered value must be positive.

Tool Width – Enter the actual width of the tool.

Feed per Rev – Enter the feed per revolution.



Advanced Users: Additional Settings may need to be modified to create the required groove. These settingnumbers are: 22, 28, 72, 73, 86. See the definitions of the setting in the Operator’s Manual.In the full CNC mode this is a G75 command.

Grooving ModeI D GrooveThis mode is used for an outside diameter groove.


TOOL NUMBER1






0.0000 in0.0000 in

0.0000 in0.0000 in

TOOL WIDTH0.0000 in0.0000 in

MAX RPMMAX RPM1000

Z DIMENSIONZ DIMENSION

GROOVE WIDTHGROOVE WIDTH


200SFM





Outside Dia – Enter the current diameter of the work piece. Manually measure the diameter.

Dia to Cut (Diameter to Cut) – Enter the finished diameter.

Z Dimension – Enter the Z-axis dimension of the groove. Entered value must be positive.

Groove Width – Enter the finished width of the groove. Entered value must be positive.

Tool Width – Enter the actual width of the tool.

Feed per Rev – Enter the feed per revolution.



Advanced Users: Additional Settings may need to be modified to create the required groove. These settingnumbers are: 22, 28, 72, 73, 86. See the definitions of the setting in the Operator’s Manual. In the full CNCmode this is a G75 command.

ES0609 rev C 6/07 2 5

Grooving ModePart OffThis mode is for parting off.


TOOL NUMBER1






0.0000 in0.0000 in

0.0000 in0.0000 in


SFM1000

PART LENGTH

TOOL WIDTH

MAX RPMMAX RPM0.0000 in0.0000 in





Outside Dia. – Enter the actual diameter of the part. This is the current diameter of the workpiece. Manuallymeasure the diameter.

Dia. to Cut – (Diameter to Cut) – Enter the depth the tool is to cut into the part.


Part Length – Enter the finished part length. Entered value must be positive.

Tool Width – Enter the parting tool width.

Feed per Rev – Enter the feed per revolution. This is the distance the tool moves for each spindle revolution.




Grooving ModePart Off with PeckThis mode is for parting off with a peck.


TOOL NUMBER1






0.0000 in0.0000 in

0.0000 in0.0000 in


PECK VALUEPECK VALUE1000

PART LENGTH

TOOL WIDTH

MAX RPMMAX RPM0.0000 in0.0000 in

200SFM




ES0609 rev C 6/07 2 6


Outside Dia. – Enter the actual diameter of the part. This is the current diameter of the workpiece. Manuallymeasure the diameter.

Dia to Cut (Diameter to Cut) – Enter the depth the tool is to cut into the part.


Part Length – Enter the finished part length. Entered value must be positive.

Tool Width – Enter the parting tool width.

Feed per Rev – Enter the feed per revolution. This is the distance the tool moves for each spindle revolution.


Peck Value – Enter the distance the tool will advance at each ‘PECK’.



ES0609 rev C 6/07 2 7

SYSTEM MODE

The System Mode is displayed by moving to the System tab and pressing Write/Enter. The System Modescreens are set up to show the user current alarms, an alarm history, an alarm viewer and write displaymessages. In addition the “Recorder” feature is in this group.

RECORDER TAB

The Recorder tab is displayed in System Mode by selecting the tab and pressing Write/Enter. Additionally, theRecorder mode can be entered quickly by pressing F4 from any IPS screen. F4 will toggle the Recorder modeon and off. The Player/Recorder is used to create programs for multi-feature parts by combining part programscreated using single feature automatic part programming.

MANUAL SETUP FACE DRILL POCKET MILLING ENGRAVING SYSTEM

RECORDER ALARMS ALARM HISTORYALARM HISTORY ALARM VIEWERALARM VIEWER MESSAGES

STOP PLAY RECORDER DELETE ALL DELETE ONE

SKIP START SKIP END BACK ONE FORWARD ONE

1 - DRILL2 - TAP3 - FEED

Recorder Parameters:Stop – Stops the recording.

Play – Starts the playback, starting with the highlighted process. Mill will not start until Cycle Start is pressed.

Record – Begins recording the functions and entered data.

Delete All – Deletes all the recorded processes.

Delete One – Delete a single queued process. Note that it will only delete the last process within theplay list. If a process is not last, you will have to delete all the processes that occur after it until you get to theone you need. Pressing the “Delete” key will delete the last process too.

Skip Start – Rewinds program to the first process. Pressing “Home” will also return to the first process.

Skip End – Forwards the program to the last process. Pressing “End” will also skip to the last process.

Back One – Steps backwards through the processes. Pressing the up arrow on the keypad will do the same.

Forward One – Steps forwards through the processes. Pressing the down arrow on the keypad will do thesame.

Creating a Part ProgramTo develop a part program, set the Recorder/Player to “Record”, exit the System mode and enter the mode forthe first process. Notice that when the control is in “Record” mode a blinking red “Recording” will display in theupper left.

Set up the machining process, enter the values and press “Cycle Start”. The mill will run the program and cutthe first feature. Once finished, repeat the previous steps for the remaining part features.

NOTE: Once Cycle Start is pushed, the operation is recorded, even if the operation isnot completed.

ES0609 rev C 6/07 2 8

Once all the machining processes are entered, return to the Recorder/Player (or press F4 to bring up theRecorder), highlight “Stop” and press “Enter” (or press F4), to stop the recording session.

You will notice that there is now a list of processes in the recorder window. These can be edited from this pageby using the other Recorder/Player buttons. An alternative for editing the operations is to execute the operation,then enter MDI mode. MDI mode reveals the machine code and can be edited there.

NOTE: The operator must change tools, if required, prior to pressing Cycle Start forthe next operation. The mill will start, once Cycle Start is pressed. If themachine is equipped with a tool changer the mill will automatically changetools as needed in the program.

Running a PartLoad a part, go to the Recorder/Player mode, highlight “Play” and press “Enter” to initiate the Player. Pressingthe Cycle Start button will start the recorded machining process. The Player will start on the highlighted line inthe queue.

The consecutive operations will execute, if desired, but Cycle Start must be pressed for each operation tocontinue.

The program features can be verified by opening the Recorder/Player menu, highlighting “Play”, and pressing“Enter”. Enter MDI mode, then press the “Graphics” key. This graphics display allows the user to view eachoperation prior to live cutting.

From the MDI mode, it is also possible to create a new G-code program in memory by placing the cursor at thetop line. Type Onnnnn (the letter “O” followed by a program number), then press the “Alter” button. This willcreate a new program in memory. This is useful for editing, backup, etc.

Editing the ProcessesYou can remove processes by deleting them one at a time, by highlighting “Delete One” and pressing enter, orremoving the whole list, by highlighting “Delete All” and pressing “Enter”. Use the arrows keys to scroll withinthe list.

The other editing buttons, Skip Start, Skip End, Back One and Forward One, can be used to start the partprogram at a specific place. The operator can add operations anytime by pressing the F4 key (to enter theRecorder/Player mode and executing a new operation.

ALARMS TAB

The Alarms tab is displayed in System Mode by selecting the tab and pressing Write/Enter. The Alarms tabdisplays lines of text relating the type of alarm that has occurred, and the reason for it.



102 SERVOS OFFIndicates that the servo motors are off, the tool changer is disabled, thecoolant pump is off, and the spindle motor is stopped. Caused by EMERGENCYSTOP, motor fault, or power failure.

102 SERVOS OFFIndicates that the servo motors are off, the tool changer is disabled, thecoolant pump is off, and the spindle motor is stopped. Caused by EMERGENCYSTOP, motor fault, or power failure.

ES0609 rev C 6/07 2 9

ALARM HISTORY TAB

The Alarm History tab is displayed in System Mode by selecting the tab and pressing Write/Enter. The AlarmHistory tab displays the alarms that have previously occurred, and the time and date of each occurrence.



ALARM HISTORY:CNC MACHINE POWERED UP 08:37:56 01-08-2007

ALARM HISTORY:CNC MACHINE POWERED UP 08:37:56 01-08-2007

TO WRITE ALARM HISTORY TO DISK FILE PRESS F2 OTHERWISE PRESS SEND RS232TO WRITE ALARM HISTORY TO DISK FILE PRESS F2 OTHERWISE PRESS SEND RS232

ALARM VIEWER TAB

The Alarm Viewer tab is displayed in System Mode by selecting the tab and pressing Write/Enter. The AlarmViewer tab provides the capability to scroll through all the machine alarms, lists what they are, and offerspossible reasons for the alarm.



ALARM VIEWER:

903 CNC MACHINE POWERED UPWhen the machine is powered up, alarm 903 will be added to the alarmhistory along with the date and time. Note that this is not a resetablealarm; it is for information purposes only.

ENTER ALARM NUMBER TO VIEW (OR USE UP/DOWN KEYS TO SCROLL):ENTER ALARM NUMBER TO VIEW (OR USE UP/DOWN KEYS TO SCROLL):

ES0609 rev C 6/07 3 0

MESSAGES TAB

The Messages tab is displayed in System Mode by selecting the tab and pressing Write/Enter. The Messagestab is an operator message display and has no other affect on operation. Use the keypad to enter the mes-sages. The Space button can be used to remove existing messages (by overwriting existing text) and theDelete button can be used to remove one line at a time. If no alarms are present the Messages screen isdisplayed upon power-up.



OPERATOR PENDANT

The keyboard is broken up into eight sections: Function Keys, Jog Keys, Override Keys, Display Keys, CursorKeys, Alpha Keys, Mode Keys and Number Keys. In addition there are miscellaneous keys and featureslocated on the pendant.

SHIFT

/ [ ]

& @ :

%

*

+

$

,

=

!

?

#

PARAM SETNGGRAPH

HELPCALC

NEXTTOOL Z

X ZFACE

MESURDIA

MESUR

MESGSALARM

DGNOS

POSIT OFFSET COMDSPRGRM

CONVRS

DISPLAY

CURNT

OVERRIDES

CURSOR

PAGE

CHIP

CHIP

CHIPTS

TS

TS

RAPID STOP

FWD

REV

7 8 9

4

1

-

CANCEL

5

2

0

SPACE

6

3

WRITE

ENTER

SHIFT EDCBA

K

Q

W

)

J

P

V

(

I

O

U

EOB

H

N

T

Z

G

M

S

Y

F

L

R

X

-10 100% +10

FWD STOP REV

FEED RATE FEED RATE FEED RATE

-10 100% +10SPINDLE SPINDLE SPINDLE

RAPID5%

RAPID RAPID RAPID25% 50% 100%

INSERT ALTER DELETE UNDO

SINGLE DRY OPTION BLOCKBLOCK RUN STOP DELETE

COOLNT JOGTURRET TURRET

FWD REV

.0001 .001 .01 .1.1 1. 10. 100.

ALL ORIGINHOMEG28

SELECTSEND RECV

ERASEPROG PROG

SINGL

EDIT

MEM

MDIDNC

HAND

ZERO

LIST

JOG

RET

PROG

F1 F2 F3 F4

POWERUP

RESTART

AUTO

-X

+X

-Z +ZRAPID

OFF

XSPINDLE

UPHOME

ENDDOWNPAGE

SPINDLE

SPIN

HANDCNTRL

RESET

FEED

HANDCNTRL

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