VMC600II VMC800II VMC1000II

Transcription

1 OPERATOR S MANUAL Revised: March 15, 2001 VMC600II VMC800II VMC1000II Vertical Machining Centers Equipped with the Hardinge / Fanuc Control System II Manual No. M-378 Litho in U.S.A. Part No. M August, 1999

2 - NOTICE - Damage resulting from misuse, negligence, or accident is not covered by the Hardinge Machine Warranty. Information in this manual is subject to change without notice. This manual covers the operation of Hardinge VMC600II, VMC800II, and VMC1000II Vertical Machining Centers equipped with the Hardinge / Fanuc Control System II. In no event will Hardinge Inc. be responsible for indirect or consequential damage resulting from the use or application of the information in this manual. Reproduction of this manual in whole or in part, without written permission of Hardinge Inc., is prohibited. CONVENTIONS USED IN THIS MANUAL - WARNINGS - Warnings must be followed carefully to avoid the possibility of personal injury or damage to the machine, tooling, or workpiece. - CAUTIONS - Cautions must be followed carefully to avoid the possibility of damage to the machine, tooling, or workpiece. - NOTES - Notes contain supplemental information. Hardinge Inc. One Hardinge Drive P.O. Box 1507 Elmira, New York USA , Hardinge Inc. M-378 Revised: August 31, 2000

3 READ COMPLETE INSTRUCTIONS CAREFULLY BEFORE OPERATING OR PROGRAMMING HARDINGE VMC600II, VMC800II, OR VMC1000II VERTICAL MACHINING CENTERS. - WARNING - Occupational Safety and Health Administration (OSHA) Hazard Communication Standard , effective September 23, 1987, and various state employee right-to-know laws require that information regarding chemicals used with this machine be supplied to you. The list of chemicals appears in manual SP-134, the Material Safety Data Sheets (MSDS). Refer to the applicable section of the MSDS supplied with your machine when handling, storing, or disposing of chemicals. Store MSDS of other chemicals used with this machine in the same packet with manual SP-134. HARDINGE SAFETY RECOMMENDATIONS Your Hardinge machine is designed and built for maximum ease and safety of operation. Since some previously accepted shop practices may not reflect current safety regulations and procedures, they should be re-examined to insure compliance with the current safety and health standards. Hardinge Inc. recommends that all shop supervisors, maintenance personnel, and machine tool operators be advised of the importance of safe maintenance, setup, and operation of all equipment. Our recommendations are described below. READ THESE SAFETY RECOMMENDATIONS BE- FORE PROCEEDING ANY FURTHER. READ THE APPROPRIATE MANUAL OR INSTRUCTIONS before attempting operation, programming, or maintenance of the machine. Make certain that you understand all instructions. DON T ALLOW the operation or repair of equipment by untrained personnel. CONSULT YOUR SUPERVISOR when in doubt as to the correct way to do a job. WEAR SAFETY GLASSES AND PROPER FOOT PROTECTION at all times. Wear a respirator, helmet, gloves, and ear muffs or plugs when necessary. DON T OPERATE EQUIPMENT unless proper maintenance has been regularly performed and the equipment is known to be in good working order. WARNING and INSTRUCTION TAGS are mounted on the machine for your safety and information. Do not remove them. DON T ALTER THE MACHINE to bypass any interlock, overload, disconnect switch, or other safety devices. DON T OPERATE ANY MACHINE while wearing rings, watches, jewelry, loose clothing, or neckties. Long hair must be contained by a net or shop cap for safety. MAKE CERTAIN that the equipment is properly grounded. Consult and comply with the National Electric Code and all local codes. M-378 i

4 DISCONNECT MAIN ELECTRICAL POWER before attempting repair or maintenance. DON T OPERATE EQUIPMENT if unusual or excessive heat, noise, smoke, or vibration occurs. Report any excessive or unusual conditions as well as any damaged parts to your supervisor. ALLOW ONLY AUTHORIZED PERSONNEL to have access to enclosures containing electrical equipment. DON T REACH into any control or power case area unless electrical power is OFF. DON T TOUCH ELECTRICAL EQUIPMENT when hands are wet or when standing on a wet surface. REPLACE BLOWN FUSES with fuses of the same size and type as originally furnished. ASCERTAIN AND CORRECT the cause of any shutdown before restarting the machine. KEEP THE AREA AROUND THE MACHINE well lighted and dry. KEEP CHEMICALS AND FLAMMABLE MATERIAL away from operating equipment. HAVE THE CORRECT TYPE OF FIRE EXTINGUISHER handy when machining combustible material and keep the chips clear of the work area. DON T USE a toxic or flammable substance as a solvent cleaner or coolant. INSPECT ALL SAFETY DEVICES AND GUARDS to make certain that they are in good condition and are functioning properly. MAKE CERTAIN THAT PROPER GUARDS are in place and that all doors and covers are in place and secured before starting a machining cycle. DON T OPEN GUARDS while any machine component is in motion. Make certain that all people in the area are clear of the machine when opening the guard door. MAKE SURE that all spindle tools and any tool-holding devices are properly mounted. MAKE SURE that fixture plates and all other table-mounted work-holding devices are properly mounted. MAKE CERTAIN that all tooling is secured either in the tool magazine or spindle before starting the machine. DON T USE worn or defective hand tools. Use the proper size and type tool for the job being performed. ii M-378

5 USE CAUTION around exposed mechanisms and tooling especially when setting up. Be careful of sharp edges on tools. USE ONLY a soft-faced hammer on table work-holding devices and fixtures. MAKE CERTAIN that all tool mounting surfaces are clean before mounting tools. DON T USE worn or broken tooling on the machine. INSPECT ALL WORK-HOLDING DEVICES daily to make certain that they are in good operating condition. Replace any defective devices before operating the machine. ANY ATTACHMENT, TOOL, OR MACHINE MODIFICATION obtained from any source other than Hardinge Inc., must be reviewed by a qualified safety engineer before installation. USE MAXIMUM ALLOWABLE gripping pressure on work-holding devices. Consider the weight, shape, and balance of the tooling. DON T EXCEED the rated capacity of the machine. DON T LEAVE tools, workpieces, or other loose items where they can come in contact with a moving component of the machine. REMOVE ANY LOOSE PARTS OR TOOLS from the work area before operating the machine. Always clear the machine and work area of tools and parts, especially after work has been completed by maintenance personnel. REMOVE SPINDLE WRENCHES before starting the machine. CHECK THE SETUP, TOOLING, AND SECURE THE WORKPIECE if the machine has been turned OFF for any length of time. CHECK THE LUBRICATION AND COOLANT LEVELS and the status of control indicator lights before operating the machine. KNOW where all EMERGENCY STOP push buttons are located. MAKE CERTAIN THAT PROPER FUNCTIONS are programmed and that all controls are set in the desired modes before pressing the Cycle Start push button. DRY CYCLE a new setup to check for programming errors. DON T ADJUST tooling, workpiece, or coolant hoses while the machine is running. KEEP CLEAR of any pinch point and any potentially hazardous situation. DON T LEAVE the machine unattended while it is operating. M-378 iii

6 DON T REMOVE OR LOAD workpieces while any part of the machine is in motion. BE CAREFUL of sharp edges when handling newly machined workpieces. DON T CHECK the finish or dimension of a workpiece near a running spindle or moving slide. DON T ATTEMPT to brake or slow the machine with hands or any makeshift device. DON T REMOVE CHIPS with hands. Make certain that all machine movement has stopped and then use a hook or similar device to remove chips and shavings. DON T CLEAN the machine with an air hose. KEEP TOTE PANS a safe distance from machine. Don t overfill the tote pans. Unless otherwise noted, all operating and maintenance procedures are to be performed by one person. To avoid injury to yourself and others, be sure that all personnel are clear of the machine when opening or closing the coolant guard door and any access covers. FOR YOUR PROTECTION - WORK SAFELY iv M-378

7 Table of Contents CHAPTER 1 - MACHINE CONTROL FUNCTIONS Introduction Control Display Panel Control Display Screen Manual Data Input Keyboard Operator Control Panel Selector Switches Program Cycle Push Buttons Axis Direction Push Buttons and Indicator Lights Miscellaneous Push Button Functions Spindle Jog Function Display Indicator Lights Alarm Indicator Lights Control Power Panel Main Power ON Indicator Light Control Power ON Push Button Control Power OFF Push Button Tool Magazine Push Buttons Push Button Location Tool Magazine Manual Index Push Buttons Emergency Stop Push Button Tool Release Push Button Manual Pulse Generator Introduction Axis Select Switch Increment Select Switch Manual Pulse Generator Dial Axis and Spindle Monitor Display Introduction Accessing the Monitor Display CHAPTER 2 - POWER-UP AND CONTROL STATUS Basic Machine Power-Up Zero Return (Reference Home) Procedure Power-Down Procedure Reviewing Control Status M-378 v Revised: March 9, 2001

8 CHAPTER 3 - OPERATIONAL MODES AND EDITING Automatic Mode Single Mode Edit Mode Word Scan Word Search Editing a Program Setting the Protect Key General Edit Procedure Alter a Word Insert a Word Delete a Word Delete Up to an End of Block Delete Data Blocks Delete a Program Jog Mode X, Y, and Z Axis Spindle Control Manual Data Input Mode Using Manual Data Input Handwheel Mode Moving the Axes in Handwheel Mode Programs Entering a Program from the Keyboard Activating a Stored Program Running a Part Program for the First Time Stopping a Program Running in Automatic Mode Restarting a Stopped Program Zero Return Mode Dry Run and Machine Lock Activating Dry Run and Machine Lock Exiting Dry Run and Machine Lock Mode Z Axis Machine Lock Background Editing Entering Background Editing Mode Editing an Existing Program Creating a New Program from the Keyboard Ending Background Editing Extended Part Program Editing Introduction Copy an Entire Program Copy Part of a Program Move Part of a Program Merge a Program Search and Replace Reorganizing Part Program Memory Displaying the Program Directory Editing Machine Parameters vi M-378 Revised: March 9, 2001

9 CHAPTER 4 - WORK COORDINATE SYSTEMS Zero Return (Reference Home) X, Y, and Z Axes Coordinate System Displays Programmable Work Coordinate Systems Establishing a Work Shift Offset Determining the Z Axis Work Shift Offset Determining an X and Y Axis Work Shift Offset Referencing to External Surfaces Referencing to an Internal Diameter Storing Coordinate System Data from the Manual Data Input Keyboard CHAPTER 5 - TOOLING AND TOOL OFFSETS Automatic Tool Changer Description Tool Holders Tooling Geometry Manually Indexing the Tool Magazine Tool Location Table Description Tool Change Position Diagnostic Addresses Sample Tool Data for Magazine 1 (Standard) Sample Tool Data for Magazine 2 [Option] Tool Installation and Removal Non-Preset Tooling Preset Tooling Tool Wear Offsets Accessing the Tool Wear Offsets Tool Offsets Introduction Tool Length Offsets (H Word) Tool Diameter Offsets (D Word) Storing Tool Offsets CHAPTER 6 - OPERATOR MAINTENANCE Introduction Machine Air System Air Line Filter/Regulator To Adjust the Machine Air Pressure Air/Oil Lubricator To Fill the Air/Oil Lubricator Coolant System Coolant Tank Capacity Chip Removal M-378 vii Revised: February 9, 2000

10 CHAPTER 7 - INPUT/OUTPUT DEVICES Data Communications Settings Baud Rate Parity Stop Bits Checking and Modifying Communications Parameters I/O Port Assignment I/O Port Parameter Settings Baud Rate Parameter Settings Stop Bit Parameter Settings Data Transfer to the Control Uploading Control Parameters into Memory Uploading Part Programs into Memory Uploading Tool Offsets into Memory Data Transfer from the Control Downloading Control Parameters from Memory Downloading Part Programs from Memory Downloading Tool Offsets from Memory CHAPTER 8 - TOOL LIFE MANAGEMENT General Information Introduction Tool Life Measurement Units Number of Parts Amount of Machining Time General Program Description Determining Maximum Groups and Group Sizes To Verify Maximum Groups and Group Sizes To Set Maximum Groups and Group Sizes Determining the Default Measurement Unit To Verify the Measurement Unit Parameter Setting To Switch the Measurement Unit Parameter Setting Resetting a Tool Group Counter viii M-378

11 CHAPTER 9 - OPTIONS AND MISCELLANEOUS FEATURES Fault Recovery Tool Changer Tool Changer 2 [Option] Clearing a Software Overtravel Clearing a Hardware Overtravel Activating / Deactivating the 4th Axis [Option] APPENDIX Travel Specifications X and Y Axis VMC600II Machining Center A-1 VMC800II Machining Center A-2 VMC1000II Machining Center A-3 Z Axis A-4 Tool Slot Locations and Configuration VMC600II Machining Center A-5 VMC800II Machining Center A-6 VMC1000II Machining Center A-7 G Code List A-8 M Code List A-11 Alarm Messages A-13 M-378 ix Revised: March 15, 2001

12 - NOTES - x M-378

13 CHAPTER 1 - MACHINE CONTROL FUNCTIONS INTRODUCTION Most machine control functions are located on the front of the machine. The exceptions are: - The Tool Release push button, located on the headstock cover inside the work envelope. - The tool magazine index push buttons. Refer to page 1-17 for additional information. Refer to the appropriate section in this chapter for specific information on the control functions. CONTROL DISPLAY PANEL The control display panel, shown in Figures 1.1 and 1.2, consists of a display screen with associated soft keys and a manual data input keyboard. CONTROL DISPLAY SCREEN SOFT KEYS The soft keys have various functions, depending on the application. The soft key functions are displayed at the bottom of the control display screen. LEFT-HAND SOFT KEY This key is used to return to the initial state after a function has been accessed by pressing one of the soft keys. RIGHT-HAND SOFT KEY This key is used to display further soft key functions which are not currently displayed. This key is also called the soft key expansion key. MANUAL DATA INPUT KEYBOARD ALTER This key permits changes to an existing entry in an active program while in Edit mode. Refer to Edit mode in Chapter 3. CAN (Cancel) This key is used to cancel or delete the last character or symbol which has been entered into the input buffer. It is also used, together with the appropriate function key, to clear the data displayed on the screen. CURSOR CONTROL KEYS These keys will shift the cursor forward or backward through the program or parameters, depending on which mode is active. M

14 DATA INPUT KEYS These keys are used to manually enter data into the control. These keys input alphabetic, numeric, and other characters. In addition to these keys, the Alter, Insert, Delete, EOB, and Cancel keys are active. Data entered with the data input keys is indicated on line 14 of the display screen. Each data input key is used as an address key and a numeric key. The address and numeric input is switched automatically by the control according to the page menu displayed at the bottom of the screen or it may be switched manually by pressing the key. EXAMPLE: To select I, press the K, J, I key once. To select J, press the K, J, I key twice. To select K, press the K, J, I key three times. The Rapid Traverse symbol on the 5 key has no function. DELET (Delete) This key causes the data word directly above the cursor to be deleted. Refer to Edit mode in Chapter 3. EOB This key is used to input an End of Block (;) character. INPUT This key is used to set data, which has been entered into the input buffer area, into the appropriate area in the control memory. Refer to Manual Data Input mode in Chapter 3. INSRT (Insert) This key allows additional commands to be inserted in a program line while in Edit mode. Refer to Edit mode in Chapter 3. OUTPT / START (Output / Start) This key will initiate down-loading of programs to a cassette, disk, or tape through the RS-232-C (serial) interface port. PAGE UP PAGE DOWN The Page keys are used to display information which requires more than one display page. Pressing Page or Page causes the control the display the previous or next page, respectively. 1-2 M-378

15 Soft Keys Data Input Keys Figure Display Screen and Data Input Keyboard TI4029A Figure Display Screen and Data Input Keyboard TI4065A RESET This key can be activated any time while a part program is being executed. When the Reset key is pressed, axis and spindle motion are stopped. The M and G codes are reset to the power-up default status. The Reset key is also used to clear an alarm state after a fault has been corrected. - NOTE - To return to the start of a main part program, select Edit mode and press Reset. M Revised: August 31, 2000

16 AUX / GRAPH (Auxiliary / Graphics) No function. MENU / OFSET (Menu / Offset) This key allows the setting and display of offset values. Refer to Chapter 5 - Tooling and Tool Offsets. OPR / ALARM (Operator / Alarm Messages) This key allows the operator to: - access the software operator panel. - display alarm messages and operator messages issued by the machine control due to NC programming errors or machine hardware failures. Refer to the Appendix for information on alarm messages issued by the machine control due to machine failures detected by the control software. DGNOS / PARAM (Diagnostic / Parameter) This key allows the setting and display of parameters and diagnostic data. Refer to Chapter 2 for more information on the diagnostic and parameter screens. POS (Position) Pressing the POS key will display the position data in one of three ways: 1. In the absolute mode of the work coordinate system by pressing the Absolute soft key. 2. In the relative coordinate system by pressing the Relative soft key. 3. In the overall mode, indicating relative, absolute, machine coordinate, and distance to go, by pressing the ALL soft key. Use the Page keys to switch between the various position display screens. Refer to Chapter 2 for more information on the position display screens. PRGRM (Program) This key allows the operator to perform the following: In Edit mode - edit and display program memory. In Manual Data Input mode - Input and display Manual Data Input data. In Automatic mode - display the active part program. 1-4 M-378

17 OPERATOR CONTROL PANEL Refer to Figure 1.3 for the location of the switches, push buttons, and indicator lights described in this section. SELECTOR SWITCHES Emergency Stop The Emergency Stop push button is located in the upper left corner of the operator control panel, which is shown in Figure 1.3. When pressed, all machine and chip conveyor motion is stopped. Pull the Emergency Stop push button UP to release. Refer to Tool Magazine Push Buttons, page 1-17, for the location of an additional Emergency Stop push button. Rapid Override Switch This switch can modify the machine rapid traverse rate on the X, Y, and Z axes in steps from 0% ~ 100%. It is active in Positioning Mode (G00). It is also active during return passes for machining cycles. Feedrate/Jog Override Switch In Automatic or Manual Data Input mode, this switch allows the operator to modify programmed feedrates from 0% ~ 150%. A setting of 0" will stop G01, G02, & G03 motion. In Jog mode, this switch establishes the rate of motion when manually jogging the machine axes. A setting of 0" will inhibit axis motion. The rate of motion is: Inch mode: 0 ~ 50 inches/minute Metric mode: 0 ~ 1260 millimeters/minute Spindle Override Switch This switch allows the operator to modify programmed spindle speeds from 50% ~ 120%. M

18 Figure Operator Control Panel TI4504 Mode Select Switch Edit Mode This switch setting activates Edit mode. Edit mode allows the operator or programmer to enter a new program or edit a stored program. To deactivate Edit mode, select another operating mode. Refer to Chapter 3 for more information on Edit mode. Automatic Mode This switch setting activates Automatic mode. Automatic mode allows execution of a part program stored in control memory and modification of part programs using the Back Edit function. Refer to Chapter 3 for more information on Automatic mode. Manual Data Input Mode This switch setting activates Manual Data Input mode. Manual Data Input mode allows manual input of a temporary program block. Refer to Chapter 3 for more information on Manual Data Input mode. Direct Numerical Control (DNC) Mode This switch setting activates Direct Numerical Control mode. Direct Numerical Control mode allows execution of a part program read directly from an input device connected to the machine control. 1-6 M-378

19 Jog Mode This switch setting activates Jog mode. Jog mode allows non-programmed movement of the axes through the use of the axis direction push buttons. Refer to Chapter 3 for more information on Jog mode. Handwheel (Manual Pulse Generator) Mode This switch setting activates Handwheel mode. Refer to Manual Pulse Generator, page 1-19, for information on incrementally jogging the machine axes. Zero Return Mode This switch setting activates Zero Return mode. Zero Return mode allows the selected axis to be moved to the Home position. This mode is activated automatically at Power-Up. Refer to Chapter 2 for more information on the Zero Return procedure. PROGRAM CYCLE PUSH BUTTONS Cycle Start This push button is a latching type switch that initiates program execution when the control is in Automatic mode or Single mode. An additional function of this switch is to execute Manual Data Input commands. This push button is illuminated when Cycle Start is active. Feed Hold The Feed Hold push button allows the operator to stop all programmed slide motion. However, the active spindle speed is not affected. Feed Hold can be activated while in Automatic, Single Block, Dry Run, or Machine Lock modes. Cycle Start turns OFF when Feed Hold is activated. Press Cycle Start to resume normal operation after a feed hold. This push button is illuminated when Feed Hold is active. M

20 AXIS DIRECTION PUSH BUTTONS AND INDICATOR LIGHTS The X, Y, Z, and 4 th axis push buttons are used to allow manual axis movement in Jog mode. The X, Y, and Z axis push buttons are also used in conjunction with the Jog Feedrate switch. X Axis Table motion to the left or right, as viewed from the front of the machine. Pressing one of the X directional push buttons causes the table to move in the corresponding direction. Refer to Figure 1.4 for direction of table motion. Y Axis Table motion toward or away from the operator, as viewed from the front of the machine. Pressing one of the Y directional push buttons causes the table to move in the corresponding direction. Refer to Figure 1.4 for direction of table motion. Z Axis Refers to the head, which contains the machine spindle. The head moves toward or away from the machine table on the vertical axis. Pressing one of the Z directional push buttons causes the head to move in the corresponding direction. Refer to Figure 1.5 for direction of head motion. 4th Axis [Option] Refers to the optional rotary table. Indicator Lights An indicator light will turn ON when the associated axis is at the Home position. 1-8 M-378

21 -Y Motion +X Motion -X Motion Front of Machine +Y Motion Figure X and Y Axis Table Movement TI4061 +Z Motion -Z Motion Machine Table Figure Z Axis Headstock Movement TI4062 M

22 MISCELLANEOUS PUSH BUTTON FUNCTIONS Rapid - CAUTION - When jogging the machine axes, be sure no interference exists between fixtures, spindle, tooling, or workpiece. This push button allows the machine operator to activate manual rapid traverse mode. Activating this push button with Jog mode active and pressing one of the axis directional push buttons causes the selected axis to move at the rapid jog rate. The Rapid Override switch can be used to adjust the rapid traverse rate. Refer to Jog Mode, in Chapter 3. M01 (Option Stop) - CAUTION - It is the responsibility of the part programmer to program M03, M04, M13, or M14 to restart the spindle and coolant when program execution is resumed after an Option Stop. This push button allows the machine operator to alternately activate and deactivate Option Stop. This function causes the control to stop execution of the part program AFTER executing an active block that contains an M01 code. The M01 code is ignored when Option Stop is not active. This function may be activated before or during execution of the block containing the M01 code. The indicator light is illuminated when Option Stop is active. When a block containing an M01 code is encountered and this function is active, the following occurs: The block is executed. All slide motion and spindle motion stops. The coolant pump turns OFF and Feed Hold turns ON. To resume program execution, press the Cycle Start push button. The Feed Hold push button light will turn OFF. BDT (Block Skip) This push button allows the machine operator to alternately activate and deactivate Block Skip. When Block Skip is active, the control will ignore any program data block preceded by a slash (/) code. The indicator light is illuminated when Block Skip is active M-378

23 SBK (Single Block) This push button allows the machine operator to activate Single Block. The indicator light is illuminated when Single Block is active. Single Block provides the operator with the ability to execute one block of data each time the Cycle Start push button is pressed. MLK (Machine Lock) - NOTE - This mode must be OFF for normal machine operation. This push button allows the machine operator to alternately activate and deactivate Machine Lock mode. When this mode is active, all axis and spindle motion is inhibited. M, S, and T functions are also inhibited. The indicator light is illuminated when Machine Lock is active. Refer to Chapter 3 for information on using Machine Lock. ZMLK (Z Axis Machine Lock) This push button allows the machine operator to disable all Z axis motion. When Z Axis Machine Lock is OFF, Z axis motion will occur as programmed. When Z Axis Machine Lock is active, all Z axis motion is inhibited. When a part program is executed, all other machine activity will occur as programmed. This push button is illuminated when Z Axis Machine Lock is active. Refer to Chapter 3 for information on using Z Axis Machine Lock. DRN (Dry Run) - NOTE - This mode must be OFF for normal machine operation. This push button allows the machine operator to alternately activate and deactivate Dry Run mode. When this mode is active, programmed feedrates are ignored and cutting moves are performed at a Jog feedrate of 50 inches [1260 millimeters] per minute. The indicator light is illuminated when Dry Run is active. Refer to Chapter 3 for information on using Dry Run. M

24 Coolant ON This push button turns the coolant pump ON, regardless of the programmed M codes for coolant control. Coolant ON deactivates Coolant Automatic and Coolant OFF. Coolant OFF This push button turns the coolant pump OFF, regardless of the programmed M codes for coolant control. Coolant OFF deactivates Coolant Automatic and Coolant ON. Coolant Automatic This push button enables automatic coolant control from the part program. Coolant is turned ON when an M08, M13, or M14 is read from the part program by the control. Coolant is turned OFF when an M00, M01, M02, M05, M09, or M30 is read from the part program. Coolant Automatic deactivates Coolant OFF and Coolant ON. Chip Conveyor ON/OFF This push button allows the machine operator to turn the chip conveyor ON or OFF. This push button is illuminated when the chip conveyor is turned ON. Chip Conveyor Direction This push button allows the machine operator to reverse the direction of the chip conveyor motion. This push button is illuminated when the chip conveyor is running in the reverse direction. Chip Flush No function M-378

25 SPINDLE JOG FUNCTION Spindle Jog Speed Control This variable switch allows the machine operator to adjust the spindle speed while jogging the machine spindle. Clockwise Rotation This push button allows the machine operator to jog the machine spindle in the clockwise direction (as viewed from the top of the machine) when Jog mode is active and the guard doors are closed. Spindle Stop This push button allows the machine operator to cancel the spindle jog. Counterclockwise Rotation This push button allows the machine operator to jog the machine spindle in the counterclockwise direction (as viewed from the top of the machine) when Jog mode is active and the guard doors are closed. Work Light Turns the work light ON or OFF. M

26 Alarm Cancel - NOTE - Deactivating the audible alarm does not correct the condition that caused the alarm. This push button allows the machine operator to cancel the audible alarm, which is activated when an alarm is issued by the machine control. Emergency Stop Reset - NOTE - The condition that caused the machine to go into emergency stop MUST be corrected before Emergency Stop can be cleared. The Emergency Stop Reset push button, when pressed and held, also allows the machine operator to jog the axes out of an overtravel condition. The Emergency Stop Reset push button is used to reset the control once the Emergency Stop push button has been released or the problem that caused the Emergency Stop condition has been corrected. To return the control to normal operation: 1. Correct the problem that caused the Emergency Stop condition. 2. If necessary, release the Emergency Stop push button by pulling it OUT. 3. Press the Emergency Stop Reset push button. 4. Move all axes to a safe program restart position M-378

27 DISPLAY INDICATOR LIGHTS - NOTE - The Display indicator lights are the upper row of indicator lights. COL. (Coolant) Indicates that the coolant pump is ON. M19 Indicates that the spindle is oriented to the tool change position. ATC (Automatic Tool Changer) Indicates that Tool Change mode is active. TCL (Tool Clamp) Indicates that a tool is clamped in the spindle. ALARM INDICATOR LIGHTS - NOTE - The Alarm indicator lights are the lower row of indicator lights. EM (Emergency Stop) Indicates that an Emergency stop condition exists. ATC (Automatic Tool Changer) Indicates that an alarm associated with the tool magazine has occurred. OL (Overload) Indicates that a servo drive or electrical overload has occurred. AL (Alarm) Indicates that a general machine alarm has occurred. Refer to the control display screen for the specific alarm message. M

28 CONTROL POWER PANEL The control power panel, shown in Figure 1.6, consists of a main power ON indicator light and power ON/OFF push buttons. MAIN POWER ON INDICATOR LIGHT Indicator light A turns ON when the main disconnect switch is turned ON. CONTROL POWER ON PUSH BUTTON Press Control ON push button B to apply power to the machine control. Refer to Chapter 2 for the power-up procedure. CONTROL POWER OFF PUSH BUTTON Press the Control OFF push button C to remove power from the machine control. Refer to Chapter 2 for the power-down procedure. A B C Figure Control Power Panel TI M-378

29 TOOL MAGAZINE PUSH BUTTONS - WARNING - Read and understand the Fault Recovery section in Chapter 9 before using these push buttons. PUSH BUTTON LOCATION The tool magazine manual index push buttons and an Emergency Stop push button are located on the left side of machines equipped with one tool changer. Tool magazine manual index push buttons and Emergency Stop push buttons are located on the left and right sides of machines equipped with two tool changers. TOOL MAGAZINE MANUAL INDEX PUSH BUTTONS Push buttons D and E, Figure 1.7, allow the machine operator to manually cycle the tool magazine when Jog mode is active. EMERGENCY STOP PUSH BUTTON When Emergency Stop push button F is pressed, all machine and chip conveyor motion is stopped. Pull the Emergency Stop push button UP to release. The operator control panel is also equipped with an Emergency Stop push button. D E F TP3651 Figure Tool Magazine Push Buttons M Revised: March 9, 2001

30 TOOL RELEASE PUSH BUTTON - WARNING - Read and understand the Fault Recovery section in Chapter 9 before using these push buttons. Be sure the spindle is stationary before attempting to remove or install a tool in the spindle. Exercise caution when releasing a tool holder held in the machine spindle. DO NOT attempt to grip the cutting tool, personal injury may result. Be prepared to accept the weight of the tool and tool holder. Do not drop the tool and tool holder. Personal injury or damage to the tool, tool holder, or workpiece may result. Push button G, Figure 1.8, activates Tool Release, which will remain active as long as this push button is held IN. The spindle clamps the tool when this push button is released. G Figure Tool Release Push Button TP M-378

31 MANUAL PULSE GENERATOR - CAUTION - When jogging the machine axes, be sure no interference exists between fixtures, tooling, or workpiece. INTRODUCTION The portable manual pulse generator, shown in Figure 1.9, allows the operator to jog the selected axis by specific increments. The axis to be jogged is selected with axis select switch I and the increment is selected with increment select switch J. The Mode Select switch must be set to Handwheel mode for the manual pulse generator to function. Refer to: Page 1-6 for information on the Mode Select switch. Chapter 3 for information on Handwheel mode. Figures 1.4 and 1.5 for axis definitions. - NOTE - The axis velocity (rate of travel) is determined by the rate at which the manual pulse generator dial is rotated. Be aware that the axis velocity will not be allowed to exceed the maximum velocity of 157 in/min [4000 mm/min]. Any pulses produced by the manual pulse generator that would cause the velocity to exceed this maximum value will be ignored by the machine control. Accurate position data will be maintained by the machine control. H I J TP3650 Figure Manual Pulse Generator M

32 AXIS SELECT SWITCH Axis select switch I determines which machine axis will move when the manual pulse generator dial is turned while the control is in Handwheel mode. INCREMENT SELECT SWITCH X1 Selects the increment jog rate when Handwheel mode is active. The incremental jog rate per division on the dial is.0001 inches in English mode or.001 mm in Metric mode. X10 Selects the increment jog rate when Handwheel mode is active. The incremental jog rate per division on the dial is.001 inches in English mode or.01 mm in Metric mode. X100 Selects the increment jog rate when Handwheel mode is active. The incremental jog rate per division on the dial is.01 inches in English mode or.1 mm in Metric mode. MANUAL PULSE GENERATOR DIAL After Handwheel mode has been activated and the desired axis and increment have been selected, rotate dial H as follows: Clockwise: Positive Axis Motion Counterclockwise: Negative Axis Motion 1-20 M-378

33 AXIS AND SPINDLE MONITOR DISPLAY INTRODUCTION The monitor display provides access to the following data: X, Y, & Z axis load meters Display the percentage of recommended maximum full load current being drawn by the specified axis drive. Each asterisk displayed to the right of the axis designation represents 10% of the recommended maximum full load current. Spindle load meter (S1) Displays the percentage of recommended maximum full load current being drawn by the spindle drive. Each asterisk displayed to the right of the S1" designation represents 20% of the recommended maximum full load current. Speed Meter (Spindle rpm) Displays the speed of the spindle in rpm. Each asterisk displayed to the right of the axis designation represents 10% of the maximum spindle speed. ACCESSING THE MONITOR DISPLAY 1. Press the Position key. 2. Press the right-hand soft key. 3. Press the Monitor soft key. M

34 - NOTES M-378

35 CHAPTER 2 - POWER-UP AND CONTROL STATUS - CAUTION - The recommended operating temperature range is 50 to 114 F [7 to 46 C]. BASIC MACHINE POWER-UP - NOTE - It is important that the power-up procedure is followed as described to ensure safe, accurate, and repeatable machine operation. 1. Turn main disconnect switch A, Figure 2.1, ON. 2. Push main air valve B, Figure 2.2, IN to turn the machine air ON. - NOTE - Refer to Chapter 6 - Operator Maintenance for information on refilling the coolant tank. 3. Check the coolant level. Add coolant, if necessary. - CAUTION - When pressing the Control ON push button, DO NOT press any other push buttons or keys until the position or alarm screen is displayed. Some push buttons and keys are used for control maintenance or special operation commands. 4. Press the Control ON push button and wait until the control display screen is ON. A B Figure Power Case Door TI2966 Figure Main Air Valve TP3664 M

36 5. Pull the Emergency Stop push button OUT to release.6 6. If necessary, release the Emergency Stop push button that is located next to the tool magazine manual index push buttons. 7. Be sure the coolant guard doors are closed. 8. The machine is now ready for the Zero Return (Reference Home) procedure. ZERO RETURN (REFERENCE HOME) PROCEDURE - CAUTION - When homing the axes with the Zero Return (Reference Home) procedure, be sure that no interference exists between the fixtures, tooling, or workpiece. DO NOT attempt to home the machine axes if the tool magazine is not at the Home position. 1. Verify that the tool magazine is at the Home (retracted) position. 2. Select Jog mode. 3. If necessary, move the axes to a safe location for axis motion. 4. Set the Jog Feedrate switch to the desired feedrate. 5. Use the -Z push button to jog the head approximately 1 inch (25 mm) in the minus (downward) direction. 6. Use the +X push button to jog the table approximately 1 inch (25 mm) in the plus direction. 7. Use the -Y push button to jog the table approximately 1 inch (25 mm) in the minus direction. 8. Select Zero Return mode. 9. Press the +Z push button. The Z axis will move to the Home position. 10. Press the -X push button. The X axis will move to the Home position. 11. Press the +Y push button. The Y axis will move to the Home position. 12. If the machine is equipped with an optional rotary table, press the +B push button to index the rotary table to the Home position. 2-2 M-378

37 POWER-DOWN PROCEDURE - CAUTION - DO NOT power down the machine while Edit mode is active. Powering down the machine while Edit mode is active will result in the loss of all macro programs and machine parameters. If data loss occurs, all macro programs and parameters must loaded into the control memory from the backup disk supplied with the machine. 1. Be sure Cycle Start is not active. The Cycle Start push button light will be OFF. 2. Be sure the program has been completed and that the spindle and slides are stationary. 3. Press the Emergency Stop push button. 4. Press the Control OFF push button. 5. Pull main air valve B, Figure 2.2, OUT to turn the machine air OFF. 6. Turn main disconnect switch A, Figure 2.1, OFF. REVIEWING CONTROL STATUS The following descriptions refer to the control status displays. Refer to Chapter 1 for the locations of the various keys: Position Key There are three (3) pages of position display data. After the Position key is pressed, the position display page that was last active will appear on the control display screen. Use the Page or Page key to access the other position display pages. The three position display pages are as follows: 1. ALL (Overall Position Display): This page shows the active program number and block number are displayed in the upper right-hand corner of the control display screen if the control is in automatic mode. a) Relative: The axis position on the Relative Coordinate System. Position is displayed as X, Y, and Z coordinates. b) Absolute: Axis position on the Work Coordinate System. After power-up, the origin of the Work Coordinate System is the intersection of the spindle face and the spindle centerline. Position is displayed as X, Y, and Z coordinates. This origin can be relocated by any one of the following: Active Tool Offset Position Reset Operation Work Shift Offset c) Machine: Displays the axis position in relation to the Reference Zero position. Refer to the Appendix for the location of the X, Y, and Z axis reference zero positions. d) Distance to Go: This is the distance remaining between the current axis position and the programmed axis position. This register is displayed only while the control is in automatic or manual data input. 2. Absolute Position Display. Refer to part b under ALL (Overall Position Display). 3. Relative Position Display. Refer to part a under ALL (Overall Position Display). M Revised: March 9, 2001

38 Program Key Press the Program soft key to display the active program number, and active block sequence number and eleven blocks of the active program on the control display screen. To display other pages of the program, select Edit mode and use the Page or Page keys to read through the program. During execution of the active part program, the cursor will be positioned under the sequence number of the active block. To return to the start of the program, press the following keys in the sequence shown: 1. Reset 2. Program key 3. Cursor key Menu Offset key Pressing the Menu Offset key displays the following soft keys: Wear, Geometry, Work Shift, and Macro. Wear: Tool Wear offsets. Geometry: Tool Geometry offsets. Work Shift: Work Shift offsets. Macro: Macro Variables. One of the chapters will appear on the control display screen. The displayed page will be the page that was active when the Offset display was last viewed. To display other chapters, press the corresponding soft key. To view other pages within a chapter, press the Page or Page key. Offset chapters are broken down as follows: 1. Work shift 01 displays the X, Y, and Z work shift offset. The work shift offset shifts the origin of the work coordinate system, usually to a specific location on the workpiece. Work shift offsets remain active until they are set to zero by the machine operator or the part program. 2. The tool offset chapter contains the data registers used for the tool length and diameter offsets. 2-4 M-378

39 Diagnostic Parameter Key Press the Diagnostic Parameter key to display one of two parameter chapters on the control display screen. The displayed page will be the page that was active when the key was last deactivated. To display the other chapter, press the Diagnostic Parameter key again or press the soft key for the desired chapter. To view other pages within a chapter, press the Page or Page key. Pressing the Diagnostic soft key will display the page that was active when the key was last deactivated. To view other pages within the chapter, press the Page or Page key. The parameter chapter is broken down as follows: SETTING PAGE #1 Press the Parameter soft key to access the system variables pages, which allows the operator or programmer to assign the system variables listed below. To modify these variables, move the cursor to the variable which is to be modified, enter the desired value, and press the Input key. SETTING 1 REVX = _ REVY = _ TVON = _ ISO = _ (0:EIA 1:ISO) INCH = _ (0:MM 1:INCH) I/O = _ ABS = _ (0:INC 1:ABS) SEQ = _ REVX This parameter allows the activation or deactivation of mirror imaging on the X axis. When set to 0", mirror imaging on the X axis is inactive. When set to 1", mirror imaging on the X axis is active. REVY This parameter allows the activation or deactivation of mirror imaging on the Y axis. When set to 0", mirror imaging on the Y axis is inactive. When set to 1", mirror imaging on the Y axis is active. TVON This parameter allows the activation or deactivation of parity checking. When set to 1", parity is checked from the beginning of each block to the beginning of the next block. When set to 0", vertical parity checking is disabled. ISO This parameter allows the selection of EIA or ISO data input format through the RS-232 serial port. When set to 0", the data input format is set to EIA. When set to 1", the data input format is set to ISO. M Revised: February 9, 2000

40 INCH This parameter allows the selection of metric or inch operating mode. When set to 0", the operating mode is Metric. When set to 1", the operating mode is set to Inch. I/O This parameter allows the selection of the logical I/O to be used by the control. The valid selections for the I/O port assignments are 0 or 1. Refer to Chapter 7 for an explanation of the I/O ports. ABS This parameter determines whether a travel command executed in Manual Data Input mode is incremental or absolute. When set to 0", incremental is active. When set to 1", absolute is active. SEQ This parameter allows the selection of automatic sequence number insertion. When active, sequence numbers will be automatically inserted into a program which is entered into memory from the manual data input keyboard. When set to 0", automatic sequence number insertion is inactive. When set to 1", automatic sequence number insertion is active. 2-6 M-378 Revised: February 9, 2000

41 SETTING PAGE #2 Press the Parameter soft key to access the system variables pages, which allows the operator or programmer to assign the system variables listed below. To modify these variables, move the cursor to the variable which is to be modified, enter the desired value, and press the Input key. SETTING 2 PWE = _ (0:DISABLE 1:ENABLE) REV4 = _ TAPEF = _ PWE This parameter allows the control parameters to be edited. When set to 0", parameter editing is disabled. When set to 1", parameter editing is enabled. Refer to Chapter 3 for information on editing machine parameters. REV4 This parameter allows the activation or deactivation of mirror imaging on the 4th axis. When set to 0", mirror imaging on the 4th axis is inactive. When set to 1", mirror imaging on the 4th axis is active. TAPE FORMAT Not Active MACHINE PARAMETERS The machine parameters establish many of the characteristics, specifications, and functions of the machine tool. If the desired parameter page is not displayed on the control display screen, press the Page or Page key to move to the desired page. Refer to Chapter 3 for information on editing machine parameters. M Revised: February 9, 2000

42 Operator Alarm key If ALM is displayed at the bottom right-hand corner of the control display screen during machine operation, press the Operator Alarm key. The control will display one of the two single-page chapters. To display the other chapter, press the Operator Alarm key a second time. The Alarm chapters are broken down as follows: 1. Alarm Message chapter. This chapter displays alarms that create a feed hold condition. The control displays one alarm on the control display screen at a time. 2. Operator Message chapter. Operator messages do not initiate a feed hold condition. They call the operator s attention to a particular condition that exists. - NOTE - Alarm and Operator messages caused by an error generated in Background Edit will have no affect on a part program which is executing in foreground. 2-8 M-378 Revised: February 9, 2000

43 - NOTES - M

44 - NOTES M-378

45 CHAPTER 3 - OPERATIONAL MODES AND EDITING AUTOMATIC MODE - CAUTION - Before executing any part program in Automatic mode, it is recommended that the program be cycled through one time in Single mode. Refer to the instructions for Running a Part Program for the First Time, page 3-9. Automatic mode allows selection and execution of the active part program. The guard doors must be closed to enable Automatic mode. When Automatic mode is active, the following soft keys are displayed on the control display screen: Program Current Next Check Press the right hand soft key to display the Background Edit and Extended Part Program Edit soft keys. Refer to page 3-13 for an explanation of Background Edit. Refer to page 3-14 for an explanation of Extended Part Program Edit. SINGLE MODE Single mode allows the operator to execute one block of data each time the Cycle Start push button is pressed. Canned cycles are executed one pass at a time. Single mode is activated by pressing Single push button. The Single push button indicator light is ON when Single mode is active. The guard doors must be closed to enable Single mode. Refer to the Programmer s Manual (M-377) for descriptions of the machining cycles. EDIT MODE - CAUTION - DO NOT power down the machine while Edit mode is active. Powering down the machine while Edit mode is active will result in the loss of all macro programs and machine parameters. If data loss occurs, all macro programs and parameters must loaded into the control memory from the backup disk supplied with the machine. Edit mode allows creation of new part programs or modification of existing part programs held in memory. There are two ways to search through the program: Word Scan and Word Search. (Continued on next page) M Revised: March 9, 2001

46 WORD SCAN The Word Scan function permits the operator to search through the program one word at a time. - NOTE - The cursor is displayed below the address character of the selected word. 1. Press the Cursor key to move the cursor forward word by word on the screen. 2. Press the Cursor key to move the cursor backward word by word on the screen. 3. Continue pressing the Cursor and Cursor keys to make a continuous search. 4. Press the Page or Page key to display the preceding or following pages and search for the first word of that page. WORD SEARCH Word Search a specified word to be searched for from the current cursor position using the following procedure: 1. Key in the data word to be searched for. 2. Press the Cursor key to search forward or Cursor to search backward. If the data word entered in step 1 is located, the cursor will be displayed below the first character in the data word. EDITING A PROGRAM Setting The Protect Key - NOTE - The Protect Key must be turned ON to enable program editing. The Protect Key should be turned OFF whenever program editing is not required. 1. Press the Operator Alarm key. 2. Press the Operator soft key. 3. Use the cursor keys to move the cursor to the Key field on the control display screen. 4. Press the left or right arrow keys, as indicated in Figure 3.1, to set the Protect Key as needed. TI4072 Figure Data Input Keys 3-2 M-378 Revised: March 9, 2001

47 General Edit Procedure 1. Select Edit mode. - NOTE - The Protect Key MUST be turned ON to allow creating, editing, or deleting of part programs. Refer to page 3-2 for information on setting the Protect Key. 2. Set the Protect Key to ON. 3. Press the Reset key. 4. Activate the program as follows: a) Press the Program key. b) Key in the letter O followed by the number for the desired program. Example: O1111 c) Press the Cursor key. 5. Search for the word to be modified using the Word Scan or Word Search function. 6. Alter, insert, or delete the word/block/program as described in the sections that follow. - CAUTION - If the Reset key is not pressed before selecting Automatic mode and the part program is executed, the program will begin executing at the point in the program where the cursor was located when Edit mode was exited. 7. Press the Reset key to rewind the part program back to the beginning. 8. Set the Protect Key to OFF. Alter a Word - NOTE - The cursor MUST be positioned under the word to be altered. 1. Use the Word Scan or Word Search function to locate the data word to be changed. 2. Key in the letter address and the new value. 3. Press the Alter key. Insert a Word - NOTE - The cursor MUST be positioned under the word immediately preceding the location of the new data word. 1. Use the Word Scan or Word Search function to find the data word or EOB (;) immediately preceding the point in the program where the new data word will be inserted. 2. Key in the data word to be inserted. 3. Press the Insert key. M

48 Delete a Word - CAUTION - The cursor MUST be positioned under the word which is to be deleted. 1. Use the Word Scan or Word Search function to find the data word which is to be deleted. 2. Press the Delete key. Delete Up to an End of Block 1. Position the cursor at the point where the deletion is to begin. 2. Press the EOB key. 3. Press the Delete key. - NOTE - The data between the cursor and the next End of Block character will be deleted. The cursor will move to the address character of the next data word in the program. Delete Data Blocks - NOTE - In the procedure which follows, all data from the cursor to, and including, the block specified by the sequence number will be deleted. The cursor will move to the next sequence number in the program. 1. Position the cursor at the point where the deletion is to begin. 2. Key in the sequence number where the deletion is to end. 3. Press the Delete key. Delete a Program 1. Press the Program key. 2. Key in the letter O and the number of the program to be deleted. Example: O Press the Delete key. The selected program will be deleted. 3-4 M-378 Revised: February 9, 2000

49 JOG MODE - NOTE - The coolant guard doors must be closed to enable Jog mode. X, Y, AND Z AXIS Jog mode permits non-programmed movement of the axes. Jog mode is activated by setting the mode select switch to Jog mode. While in Jog mode, press the axis direction push buttons to obtain the desired X, Y, or Z axis movement. The Jog Feedrate switch has a direct affect on the X, Y, and Z axis jog speeds. The Rapid push button will increase normal jog speeds on the X, Y, and Z axes. SPINDLE CONTROL Pressing the Spindle Clockwise push button while Jog mode is active will allow the spindle to be jogged in the forward (M03) direction. Pressing the Spindle Counterclockwise push button while Jog mode is active will allow the spindle to be jogged in the reverse (M04) direction. Spindle jog speed can be controlled with the spindle jog speed control switch. Press the Spindle Stop push button or the control Reset key to cancel spindle motion. M

50 MANUAL DATA INPUT MODE - NOTE - The coolant guard doors must be closed to enable execution of data in Manual Data Input mode. Manual Data Input mode allows the operator to input a single block of non-stored data into Manual Data Input memory. The data can then be executed by pressing the Cycle Start push button. Once the data in Manual Data Input memory has been executed, it is automatically erased from memory. USING MANUAL DATA INPUT - NOTE - Pressing the Reset key clears the Manual Data Input buffer. 1. Select Manual Data Input mode. 2. Press the Program key. 3. Press the Reset key. 4. Enter the data into the Manual Data Input buffer using the data input keys. The Insert key must be pressed after each data word. - NOTE - If an error is made while keying in the data and the Input key has not been pressed, press the Cancel key and key in the correct data. To alter data after it has been entered into the Manual Data Input memory, key in the correct data and press the Input key. If it is necessary to delete a word, press the Reset key and re-enter the data. 5. Close the coolant guard door and press the Cycle Start push button to execute the data. 3-6 M-378

51 HANDWHEEL MODE Handwheel mode permits the head or table to be moved incrementally through the use of a manual pulse generator. The axis to be moved is selected with axis select switch B, Figure 3.2. The movement increment is selected with increment switch C. The selected axis will move incrementally when handwheel A is rotated. The direction and distance is determined by the direction and amount of rotation of the handwheel. MOVING THE AXES IN HANDWHEEL MODE - CAUTION - When jogging the machine axes, be sure no interference exists between fixtures, tooling, or workpiece. 1. Select Handwheel mode. 2. Set switch B, Figure 3.2, to the desired axis. 3. Set switch C to the desired increment (X1, X10, or X100). Refer to the following table. Switch Setting Incremental Jog Rate per Division Inch Mode Metric Mode X X X A B C Figure Manual Pulse Generator TP3650 M

52 4. To view axis position on the control display screen: a) Press the Position key. b) Press the Page key until the desired position display appears on the control display screen. 5. Turn handwheel A in the appropriate direction to obtain the desired movement. Observe the axis position registers to determine when the axis has been moved the required distance. - If the X axis was selected in step 2, turn the handwheel in the plus direction to move the table to the left and turn the handwheel in the minus direction to move the table to the right. - If the Y axis was selected in step 2, turn the handwheel in the plus direction to move the table toward the front of the machine and turn the handwheel in the minus direction to move the table toward the back of the machine. - If the Z axis was selected in step 2, turn the handwheel in the plus direction to move the head away from the table and turn the handwheel in the minus direction to move the head toward the table. PROGRAMS ENTERING A PROGRAM FROM THE KEYBOARD 1. Select Edit mode. 2. Set the Protect Key to ON. Refer to page 3-2 for information on setting the Protect Key. 3. Press the Program key. 4. Key in the letter O and the program number at the Manual Data Input panel. Example: O Press the EOB key. - NOTE - Each letter address and value must be inserted separately. 6. Key in the letter address and value. 7. Press the Insert key. 8. Press the EOB key and the Insert key at the end of each data block. 9. Repeat steps 6 through 8 until all data has been entered. 10. Set the Protect Key to OFF. Refer to the Programmer s Manual (M-377) for descriptions of the data words used with this machine. Refer to Chapter 7 of this manual for information on loading part programs through the RS-232 serial port. 3-8 M-378

53 ACTIVATING A STORED PROGRAM 1. Select Edit mode. 2. Press the Program key. 3. Key in the letter O followed by the number for the desired program. Example: O Press the Cursor key. 5. Select Automatic mode. RUNNING A PART PROGRAM FOR THE FIRST TIME - CAUTION - Before executing any part program, be sure that all offsets are correct and that no interference exists in the working area of the machine tool. 1. Press the Reset key. 2. Select Edit mode. 3. Press the Program key. 4. Key in the letter O followed by the number for the desired program. Example: O Press the Cursor key. 6. Select Automatic mode. - NOTE - Single mode is used for first part set up (Block-by-Block execution). 7. Press the Single Block push button. 8. Close the guard door. - NOTE - Program Check displays the Absolute Position and Distance to Go to complete the move. 9. Press the Check soft key. 10. Press the Option Stop push button. 11. Turn the Rapid Override switch to 25%. - NOTE - Turning the Feedrate Override switch to zero percent stops axis motion. Axis motion will resume when the switch is turned to another setting. 12. Turn the Feedrate Override switch to 10%. 13. Press the Cycle Start push button to execute each block of data. M Revised: February 9, 2000

54 STOPPING A PROGRAM RUNNING IN AUTOMATIC MODE - CAUTION - Pressing either the Reset key or Emergency Stop push button while a program is running in Automatic mode will leave the tool against the workpiece if performed at the wrong time. DO NOT stop the program with a tool against the workpiece unless absolutely necessary. Damage to the workpiece and/or tooling may result. There are several ways to stop a program running in Automatic mode: 1. Program a stop command in the part program where it is to be stopped. 2. Press the Feed Hold push button. - NOTE - Automatic operation can be restarted by pressing the Cycle Start push button when the Feed Hold push button has been used. 3. Press the Reset key. 4. Press the Emergency Stop push button. RESTARTING A STOPPED PROGRAM If the program was stopped by pressing the Emergency Stop push button, perform steps 1 through 7. If the program was stopped by pressing the Reset key, perform steps 4 through Release the Emergency Stop push button. 2. Press the Reset key. 3. Key in the letter O; then, press Cursor. The control will go to the beginning of the program. 4. Key in the letter N and the block number. For example, N5". 5. Press Cursor. The control will search the program for the block specified in step Press the Cycle Start push button. Program execution will resume at the block specified in step 5. ZERO RETURN MODE - NOTE - The coolant guard doors must be closed to enable axis motion in Zero Return mode. Zero Return mode is used to synchronize the control to the machine absolute coordinate system. This mode is used: - at power-up - after machine lock is used Refer to Zero Return, in Chapter M-378 Revised: February 9, 2000

55 DRY RUN AND MACHINE LOCK - CAUTION - If Machine Lock is not activated with Dry Run, slide motion will occur at a feedrate that is set using the Feedrate Override switch. The operator must make certain that no interference exists between the tooling, workpiece, or spindle before running the machine in Dry Run. Cycle Start must be inactivate before Dry Run and Machine Lock modes can be activated. By activating Dry Run and Machine Lock modes together, the operator can execute part programs without axis or spindle motion. ACTIVATING DRY RUN AND MACHINE LOCK 1. Activate the program as follows: a) Select Automatic mode. b) Press the Program key. c) Press the Reset key. d) Key in the letter O followed by the program number. e) Press the Cursor key. 2. Activate the Dry Run and Machine Lock functions. 3. Close the coolant guard door. 4. Press the Single push button if it is desired to run the program block-by-block. - NOTE - If Single mode is active, the Cycle Start push button must be pressed for each program block. 5. Press the Cycle Start push button. EXITING DRY RUN AND MACHINE LOCK MODE 1. Deactivate the Dry Run and Machine Lock functions. The indicator lights will turn OFF. 2. Zero Return (Reference Home) the axes as outlined in Chapter 2. M

56 Z AXIS MACHINE LOCK Z Axis Machine Lock can be activated when Single Block mode is active to inhibit Z axis motion. - When Z Axis Machine Lock is OFF all Z axis motion occurs as programmed. - When Z Axis Machine Lock is ON, all Z axis motion is inhibited. When a part program is executed, all other machine activity occurs as programmed. Deactivating Z Axis Machine Lock If the Z axis position register displays the same Z axis position as when Z Axis Machine Lock was activated, it is not necessary to home the Z axis. If the Z axis position register does not display the same Z axis position as when Z Axis Machine Lock was activated, the machine axes must be homed. Refer to Chapter 2 for information on homing the machine axes (Zero Return) M-378

57 BACKGROUND EDITING The Background Edit function enables the operator or programmer to edit or create a part program while a second program is being executed by the machine tool. Background Edit takes place while the control is in Automatic mode. An alarm or warning in Background Edit mode does not affect the program being executed in the foreground or vice-versa. ENTERING BACKGROUND EDITING MODE 1. Set the Protect Key to ON. Refer to page 3-2 for information on setting the Protect Key. 2. Press the Program key. 3. Press the far right soft key to display additional functions of the soft keys. 4. Press the Background Edit soft key. - NOTE - The editing functions which may be performed in Background Edit mode are the same as the foreground editing functions. Descriptions of the foreground editing functions begin on page 3-2. EDITING AN EXISTING PROGRAM 1. Key in the letter O and the desired program number. 2. Press the Cursor key. CREATING A NEW PROGRAM FROM THE KEYBOARD 1. Key in the letter O and the desired program number. 2. Press the EOB (;) key. 3. Refer to Entering a Part Program from the Keyboard, page 3-8. ENDING BACKGROUND EDITING - CAUTION - If the Reset key is pressed while background edit is active, the part program that is being executed will stop and the offset will be canceled. The operator must escape Background edit (Press the Background End soft key) to return to the main program. With the main program displayed, the operator must jog the turret to a safe area and restart the program at the beginning of the tool operation. 1. Press the Background End soft key. 2. Set the Protect Key to OFF. M

58 EXTENDED PART PROGRAM EDITING INTRODUCTION Extended Part Program Editing provides the following capabilities: - Copy or move all or part of a program to another program. - Merge a program at any location within another program. - Search for or replace one or all occurrences of a data word in a program. COPY AN ENTIRE PROGRAM This procedure creates a new program by duplicating an existing program. 1. Select Edit mode. - NOTE - The Protect Key MUST be turned ON to allow program editing. Refer to page 3-2 for information on setting the Protect Key. 2. Set the Protect Key to ON. 3. Press the Reset key. 4. Activate the program as follows: a) Press the Program key. b) Key in the letter O followed by the number for the desired program. Example: O1111 c) Press the Cursor key. 5. Press the right-hand soft key. 6. Press the Extended Edit soft key. 7. Press the Copy soft key. 8. Press the All soft key. 9. Key in only the number for the new program. DO NOT key in the letter O. 10. Press the Execute soft key M-378

59 COPY PART OF A PROGRAM This procedure creates a new program by duplicating part of an existing program. 1. Select Edit mode. - NOTE - The Protect Key MUST be turned ON to allow program editing. Refer to page 3-2 for information on setting the Protect Key. 2. Set the Protect Key to ON. 3. Press the Reset key. 4. Activate the program as follows: a) Press the Program key. b) Key in the letter O followed by the number for the desired program. Example: O1111 c) Press the Cursor key. 5. Press the right-hand soft key. 6. Press the Extended Edit soft key. 7. Press the Copy soft key. 8. Select the beginning of the range to be copied by moving the cursor to the beginning of the range and pressing the Cursor~ soft key. 9. Select the end of the range to be copied by: Moving the cursor to the end of the range and pressing the ~Cursor soft key. - or - Pressing the ~Bottom soft key to indicate the end of the program as the end of the range to be copied. 10. Key in only the number for the new program. DO NOT key in the letter O. 11. Press the Execute soft key. M

60 MOVE PART OF A PROGRAM This procedure creates a new program by extracting part of an existing program. 1. Select Edit mode. - NOTE - The Protect Key MUST be turned ON to allow program editing. Refer to page 3-2 for information on setting the Protect Key. 2. Set the Protect Key to ON. 3. Press the Reset key. 4. Activate the program as follows: a) Press the Program key. b) Key in the letter O followed by the number for the desired program. Example: O1111 c) Press the Cursor key. 5. Press the right-hand soft key. 6. Press the Extended Edit soft key. 7. Press the Move soft key. 8. Select the beginning of the range to be copied by moving the cursor to the beginning of the range and pressing the Cursor~ soft key. 9. Select the end of the range to be copied by: Moving the cursor to the end of the range and pressing the ~Cursor soft key. - or - Pressing the ~Bottom soft key to indicate the end of the program as the end of the range to be copied. 10. Key in only the number for the new program. DO NOT key in the letter O. 11. Press the Execute soft key M-378

61 MERGE A PROGRAM This procedure inserts a specified existing program within the currently active program. 1. Select Edit mode. - NOTE - The Protect Key MUST be turned ON to allow program editing. Refer to page 3-2 for information on setting the Protect Key. 2. Set the Protect Key to ON. 3. Press the Reset key. 4. Activate the program as follows: a) Press the Program key. b) Key in the letter O followed by the number for the desired program. Example: O1111 c) Press the Cursor key. 5. Press the right-hand soft key. 6. Press the Extended Edit soft key. 7. Press the Merge soft key. 8. Select the location where the specified program will be inserted by: Moving the cursor to the position where the program is to be inserted and pressing the ~Cursor soft key. - or - Pressing the ~Bottom soft key to indicate the end of the program as the position where the program is to be inserted. 9. Key in only the number for the program to be inserted. DO NOT key in the letter O. 10. Press the Execute soft key. M

62 SEARCH AND REPLACE This procedure locates or replaces the specified data. 1. Select Edit mode. - NOTE - The Protect Key MUST be turned ON to allow program editing. Refer to page 3-2 for information on setting the Protect Key. 2. Set the Protect Key to ON. 3. Press the Reset key. 4. Activate the program as follows: a) Press the Program key. b) Key in the letter O followed by the number for the desired program. Example: O1111 c) Press the Cursor key. 5. Press the right-hand soft key. 6. Press the Extended Edit soft key. - NOTE - Be sure the cursor is located at the appropriate position in the program. The search or replace function will begin at the cursor position. 7. Move the cursor to the desired position in the program. 8. Press the Change soft key. - NOTE - A maximum of 15 characters can be input when specifying the Before or After data. Data words specified as Before or After data must be valid data words. 9. Key in the data word to be replaced. 10. Press the Before soft key. 11. Key in the new data word. 12. Press the After soft key. 13. Press the Execute soft key to replace all occurrences of the specified data word. - or - Press the 1-Execute soft key to replace only the first occurrence of the specified data word. - or - Press the Skip soft key to search for the first occurrence of the specified data word M-378

63 REORGANIZING PART PROGRAM MEMORY When Background Editing is used to edit an existing program, the program being edited will be copied from memory and stored in a new location in the control memory after editing is completed. The memory location of the old version of the program is unusable until the control memory is reorganized to eliminate all unusable data stored in control memory. - NOTE - Reorganizing of program memory can only be done while the control is in Edit mode. It is usually not necessary to reorganize program memory immediately. Reorganize program memory at some convenient point in time. Use the following procedure to reorganize the program memory: 1. Select Edit mode. 2. Press the Program key. 3. Press the Library soft key. 4. Press the Reorganize soft key. 5. Press the far left soft key to exit. DISPLAYING THE PROGRAM DIRECTORY Use the following procedure to display program memory: 1. Select Edit mode. 2. Press the Program key. 3. Press the Library soft key. The program library (directory) will be displayed. M

64 EDITING MACHINE PARAMETERS - CAUTION - Use extreme caution when editing machine parameters. Making incorrect changes in the parameter table may disable the machine or cause undesirable machine behavior. 1. Select Manual Data Input mode. 2. Set the Protect Key to ON. Refer to page 3-2 for information on setting the Protect Key. 3. Press the Diagnostic Parameter key. 4. Press the Parameter soft key. 5. If necessary, press the Page key to display the Parameter Write Enable parameter on Setting Page #2. 6. Key in the number 1 to enable parameter editing. 7. Press the Input key. The control is placed in alarm No Press the Diagnostic Parameter key. 9. Press the Parameter soft key. 10. Use one of the following methods to position the cursor at the parameter to be modified: - Press the No. data input key, key in the parameter number, press the Input key. - Use the Page and/or Cursor keys. 11. Key in the new parameter value. 12. Press the Input key. 13. Repeat steps 10 through 12. as needed. 14. Press the Parameter soft key. 15. Press the Page key to display the Parameter Write Enable parameter on Setting Page # Key in the number 0 (zero) to disable parameter editing. 17. Press the Input key M-378

65 18. Set the Protect Key to OFF. 19. Press the Reset key to cancel alarm No NOTE - Depending on which parameters have been modified, the control may output alarm No If this alarm message is displayed, it will be necessary to re-initialize the control. 20. If necessary, re-initialize the control: a) Press the Emergency Stop push button. b) Press the Control OFF push button. c) Wait approximately ten seconds. d) Press the Control ON push button. e) Release the Emergency Stop push button. f) Perform a Zero Return (Reference Home) operation as outlined under Zero Return, in Chapter 2. M Revised: February 9, 2000

66 - NOTES M-378

67 CHAPTER 4 - WORK COORDINATE SYSTEMS ZERO RETURN (REFERENCE HOME) When the Control ON push button is pressed to start up the machine, the control does not know the position of the slides. To synchronize the control/machine tool system, each slide must be moved to its Zero Return (Reference Home) position. This position is also referred to as Reference Zero. - NOTE - The coordinate position values shown in this section assume that the Work Shift is set to X0. Y0. Z0. and that no tool offset is active. After the slides have been moved to the zero return position, the Absolute position registers are automatically set at X0. Y0. Z0. X, Y, AND Z AXES The three standard machine axes are labeled as follows: X Axis: Y Axis: Z Axis: Horizontal motion of the table parallel to the spindle face and parallel with the front of the machine. Horizontal motion of the table parallel to the spindle face and perpendicular with the front of the machine. Vertical motion of the head, which houses the machine spindle. Throughout this manual we will refer to the table as the X and Y axes and the head, which houses the machine spindle, as the Z axis. These letter designations for the three axes are recommended by the Electronic Industries Association (EIA) and the International Standards Organization (ISO). In an effort to promote interchangeability and prevent misunderstandings between NC manufacturers and purchasers, EIA has set forth recommended standards for such things as axis and motion nomenclature, character codes for perforated tape, operational command and data format, and electrical interface between numerical controls and machine tools. M

68 COORDINATE SYSTEM DISPLAYS The power-up procedure calls for a Zero Return operation to synchronize the control/machine tool system. This operation sets the registers at their initial values. After performing the Zero Return procedure, press the Position key; then, press the All soft key to display the following position registers on the control display screen: - ABSOLUTE - DISTANCE TO GO - MACHINE - RELATIVE - NOTE - The Distance To Go registers are only displayed in Automatic or Manual Data Input mode. For this discussion, we are concerned with the Machine and Absolute position registers. The Machine registers display the position of axis reference points relative to the machine Zero Return (Reference Zero) position. The Zero Return coordinates are X0. Y0. Z0. The Machine registers display the position of axis reference points relative to this position. These registers cannot be modified. They always display the true axis position relative to the Reference Home position. Of greater interest to the programmer are the Absolute position registers, which can be modified. The Absolute position registers display the position of the tool reference point as a coordinate on the work coordinate system. The work coordinate system is a rectangular coordinate system with it s origin (origin = X0 Y0 Z0) equal to the origin of the Absolute registers. Unless a Work Shift offset is used after a Zero Return operation, the Z axis origin of the work coordinate system is the face of the spindle. Unless a tool offset is used, the tool reference point is the intersection of the spindle face and the spindle centerline. To simplify programming, the programmer can modify the coordinate system to relate the location of the tool to coordinates on the workpiece. 4-2 M-378

69 PROGRAMMABLE WORK COORDINATE SYSTEMS The control is equipped with 6 programmable work coordinate systems. These work coordinate systems are selected through the use of the G54 through G59 commands. G54 is the power-up default and is active after a control reset. The work shift offset moves the origin of the work coordinate system according to the X, Y, and Z values stored in the active work shift file. Immediately after a work shift is commanded, the control adds it to the Absolute position registers. The values stored in a commanded G54 coordinate system are active until canceled by another coordinate system command. The values stored in a commanded G55, G56, G57, G58, or G59 coordinate system are active until canceled by another coordinate system command, a control reset, or an end of program command. Multiple work coordinate systems allows the programmer to use the same part program to machine several workpieces mounted on the machine table. Instead of programming each workpiece, the program shifts the coordinate system to the next workpiece to be machined. Refer to the illustration in Figure CAUTION - Any non-zero value entered into the Z axis field of the active work shift file must be a negative number. The values stored in the work shift file are subtracted from the Absolute position registers, thus shifting the origin of the work coordinate system by the amount stored in the work shift file. For example, if the X axis is at 8 inches and the operator stores X2.5 in the active work shift file, the Absolute position registers would then display X5.5 [8-2.5]. It may be desirable to store the location of a reference surface on the workpiece as the Z axis work shift offset. When this value is stored and activated, the reference surface of the workpiece becomes Z0". The Z axis work shift is stored as a NEGATIVE value. The X and Y work shift offsets are used to shift the X and Y zero coordinates as specified by the values in the active work shift. The X axis work shift is stored as a POSITIVE value. The Y axis work shift is stored as a NEGATIVE value. SAMPLE WORK COORDINATE SYSTEM SHIFT Figures 4.2 and 4.3 illustrate the work coordinate system shift when the registers for the active programmable work coordinate system contain the following values: X8. Y-6. Z M Revised: August 31, 2000

70 Machine X0. Y0. Z0. Shifted X0. Y0. Z0. Shifted X0. Y0. Z0. Shifted X0. Y0. Z0. G54 Coordinate System Shift G55 Coordinate System Shift G56 Coordinate System Shift Shifted X0. Y0. Z0. Shifted X0. Y0. Z0. Shifted X0. Y0. Z0. G57 Coordinate System Shift G58 Coordinate System Shift G59 Coordinate System Shift TI4094 Figure Sample Coordinate System Shifts 4-4 M-378

71 8.000 Machine X0. Y Shifted X0. Y0. TI4073 Figure X and Y Axis Work Coordinate System Shift Spindle Home Position (Machine Z0.) Shifted Z0. Table Surface TI4074 Figure Z Axis Work Coordinate System Shift M

72 ESTABLISHING A WORK SHIFT OFFSET The machine has an established X, Y, and Z axis reference position. Unless modified by a work shift offset, the machine X, Y, and Z axis reference position will be the program reference position. The program reference position is the location from which all programmed absolute movements will be referenced. Typically a location on the workpiece will be established as the program reference position, through the use of a work shift offset. -CAUTION It is recommended that the Z axis work shift be established before the X and Y axis work shifts are established. DETERMINING THE Z AXIS WORK SHIFT OFFSET 1. Power up the machine and zero return the machine axes, as outlined in Chapter Mount the fixture and workpiece at the desired location on the machine table. 3. Select a gauge block that is at least 1 inch [25 mm] in thickness. - CAUTION - The machine operator must be sure that no interference occurs between the spindle, fixture, and workpiece. 4. Jog the spindle face within 2 inches [50 mm] of the Z axis surface of the workpiece that is to be used as the Z axis reference position. 5. Use the handwheel to move the spindle face closer to the workpiece than the thickness of the gauge block. 6. Place the gauge block on the workpiece, next to the spindle. 7. Constantly check the clearance between the spindle and the workpiece with the gauge block while gradually moving the spindle in the +Z direction (upward). 8. Stop moving the spindle when the gauge block will fit between the spindle and the workpiece. The spindle is positioned correctly when a slight drag is felt when moving the gauge block between the spindle and workpiece. Refer to Figure Record the Z axis coordinate on the Machine position register. This coordinate will be a negative value. 10. Use the handwheel to move the spindle face at least 2 inches [50 mm] from the workpiece 11. Calculate the Z axis work shift by subtracting the thickness of the gauge block from the coordinate recorded in step 9. Example: Z Axis Coordinate = Gauge Block = Z Axis Work Shift = M-378 Revised: February 9, 2000

73 Machine Spindle Gauge Block Workpiece Machine Table TI4088 Figure Z Axis Work Shift Calculation 12. Press the Menu/Offset key. 13. Press the Work Shift soft key. 14. Use the page and cursor keys to position the cursor at the work shift offset to be modified: SHIFT (G54) G55 G56 G57 G58 G Press address key Z. 16. Key in the Z axis value calculated in step 11 as a negative number. 17. Press the Input key. The Z axis Work Shift will be displayed in the Z axis Work Shift register. M Revised: February 9, 2000

74 DETERMINING AN X AND Y AXIS WORK SHIFT OFFSET REFERENCING TO EXTERNAL SURFACES - NOTE - This procedure establishes the X and Y axis reference position at a corner of the workpiece. Refer to Figures 4.5 and If not already performed, establish the Z axis work shift according to the procedure beginning on page Mount the fixture and workpiece at the desired location on the machine table. 3. Mount a gauge bar in the machine spindle. 4. Jog the gauge bar within 1 inch [25 mm] of the X axis surface of the workpiece that intersects the corner to be used as the reference position. 5. Place a shim against the X axis surface of the workpiece. 6. Use the handwheel to move the gauge bar to gently touch the shim so that a slight drag is felt when moving the shim. 7. Record the X axis coordinate on the Machine position register. 8. Referring to Figures 4.5 and 4.6, calculate the X axis location of the surface of the workpiece. This calculated value will be the X axis work shift. 9. Use the handwheel to move the gauge bar away from the workpiece at least 1 inch [25 mm]. 10. Jog the gauge bar within 1 inch [25 mm] of the Y axis surface of the workpiece that intersects the corner to be used as the program reference position. 11. Place a shim against the Y axis surface of the workpiece. 12. Use the handwheel to move the gauge bar to gently touch the shim so that a slight drag is felt when moving the shim. 13. Record the Y axis coordinate on the Machine position register. 14. Referring to Figures 4.5 and 4.6, calculate the Y axis location of the surface of the workpiece. This calculated value will be the Y axis work shift. 15. Use the handwheel to move the gauge bar away from the workpiece at least 1 inch [25 mm]. 16. Jog the gauge bar away from the workpiece. 4-8 M-378 Revised: February 9, 2000

75 17. Press the Menu Offset key to display the offset pages. 18. If necessary, press the Work Shift soft key to display the Work Shift registers. 19. Press address key X. 20. Key in the value recorded in step 7 as a positive number. 21. Press the Input key. The X axis Work Shift will be displayed in the X axis Work Shift register. 22. Press address key Y. 23. Key in the value recorded in step 13 as a negative number. 24. Press the Input key. The Y axis Work Shift will be displayed in the Y axis Work Shift register. M Revised: February 9, 2000

76 X and Y Axis Reference Position Before Work Shift Work Shift Calculations: X Axis Work Shift = X1 + X2 Y Axis Work Shift = Y1 + Y2 Y 1 Y 2 X 1 X 2 X and Y Axis Reference Position After Work Shift Shim DEFINITIONS: X1 = the X axis position of the gauge bar center line. X2 = the X axis distance from the gauge bar center line to the workpiece. Y1 = the Y axis position of the gauge bar center line. Y2 = the Y axis distance from the gauge bar center line to the workpiece. X and Y Axis Reference Position Before Work Shift X 1 Y 1 Work Shift Calculations: X Axis Work Shift = X1 - X2 Y Axis Work Shift = Y1 + Y2 Y 2 X and Y Axis Reference Position After Work Shift X 2 Shim TI4085 Figure X and Y Axis Work Shift Calculations 4-10 M-378 Revised: February 9, 2000

77 X and Y Axis Reference Position Before Work Shift Work Shift Calculations: X Axis Work Shift = X1 + X2 Y Axis Work Shift = Y1 - Y2 Y 1 X 1 X 2 Shim X and Y Axis Reference Position After Work Shift Y 2 X and Y Axis Reference Position Before Work Shift X 1 Work Shift Calculations: X Axis Work Shift = X1 - X2 Y Axis Work Shift = Y1 - Y2 Y 1 Shim X 2 X and Y Axis Reference Position After Work Shift Y 2 DEFINITIONS: X1 = the X axis position of the gauge bar center line. X2 = the X axis distance from the gauge bar center line to the workpiece. Y1 = the Y axis position of the gauge bar center line. Y2 = the Y axis distance from the gauge bar center line to the workpiece. TI4086 Figure X and Y Axis Work Shift Calculations M Revised: February 9, 2000

78 REFERENCING TO AN INTERNAL DIAMETER - NOTE - This procedure establishes the X and Y axis reference position at the center of a bore in the workpiece. Refer to Figure If not already performed, establish the Z axis work shift according to the procedure beginning on page Mount the fixture and workpiece at the desired location on the machine table. 3. Mount a dial indicator in the machine spindle. 4. Jog the indicator into position OVER the bore to be used as the program reference position. 5. Visually position the indicator as close to the centerline of the bore as possible. 6. If necessary, adjust the position of the indicator such that no contact with the workpiece will occur when the indicator is moved into the bore. 7. Use the handwheel to CAREFULLY move the indicator needle into the bore, as shown in Figure Position the indicator needle against the bore. 9. Sweep the bore and adjust the X and Y axis position of the spindle until runout shown on the indicator is within an acceptable range. 10. Record the X and Y axis positions. These values will be the X and Y axis work shifts. 11. Use the handwheel to CAREFULLY move the indicator out of the bore at least 1 inch [25 mm]. Workpiece Figure Reference to an Internal Diameter TI M-378 Revised: February 9, 2000

79 12. Jog the indicator away from the workpiece. 13. Press the Menu Offset key to display the offset pages. 14. If necessary, press the Work Shift soft key to display the Work Shift registers. 15. Press address key X. 16. Key in the X axis value recorded in step 10 as a positive number. 17. Press the Input key. The X axis Work Shift will be displayed in the X axis Work Shift register. 18. Press address key Y. 19. Key in the Y axis value recorded in step 10 as a negative number. 20. Press the Input key. The Y axis Work Shift will be displayed in the Y axis Work Shift register. STORING COORDINATE SYSTEM DATA FROM THE MANUAL DATA INPUT KEYBOARD Coordinate system data can be input directly from the Manual Data Input keyboard. 1. Press the Menu Offset key. 2. Press the Work Shift soft key. 3. Use the page and cursor keys to position the cursor at the data field to be modified. 4. Enter the new value and press the Input soft key to enter the value in the data register. 5. Repeat steps 3 and 4 as needed to enter the required coordinate system data. 6. Press the left-hand soft key to exit the coordinate system screen. M Revised: February 9, 2000

80 - NOTES M-378

81 CHAPTER 5 - TOOLING AND TOOL OFFSETS AUTOMATIC TOOL CHANGER DESCRIPTION The standard configuration for the machining center is to be equipped with a single 20 station tool magazine (Magazine 1), located toward the left side of the machining center. A second 20 station tool magazine (Magazine 2) is available as an option. This optional tool magazine is located toward the right side of the machining center. During a programmed tool change, the tool magazine automatically takes the shortest path to move the selected tool to the tool change position. TOOL HOLDERS - WARNING - Be sure to use the correct type of tool holder, based on the configuration of the machine. - CAUTION - All tool holders must conform to the appropriate specification, based on the spindle configuration of the machine tool. Consult a Hardinge Applications Engineer concerning ALL special tooling applications that require deviation from the specification. Apply Loctite 242 threadlocker to the threads on each retention knob before installing on the tool holder body. Refer to Figure NOTE - A spindle configuration tag is located on the spindle enclosure, to the left of the Tool Release push button. The machine spindle is configured to use 40 taper V-Flange tool holders that conform to one of the following specifications: V40 CT [Standard] BT-40 JIS [Optional] Retention Knob Tool Holder TI4083 Figure Tool Holder Retention Knob M

82 TOOLING GEOMETRY The tool magazine is designed to handle tooling that does not exceed the specifications shown in the table below. Refer to Figure NOTE - The maximum diameter is measured in relation to the centerline of the tool holder. MAXIMUM VALUE SPECIFICATION English Metric Tool Length 9.84 in. 250 mm Tool Diameter 3.5 in mm Tool Weight 13.2 lb 6.0 Kg Gauge Line Maximum Length Maximum Diameter Figure Tooling Geometry TI M-378

83 MANUALLY INDEXING THE TOOL MAGAZINE - NOTE - The tool pockets in the tool magazine are labeled 1" through 20" for identification. The tool magazine push buttons, shown in Figure 5.3, are used to manually index the tool magazine in the clockwise or counterclockwise direction, as viewed from the top of the machine. The tool magazine can be manually indexed when Jog mode is active. To Index the Tool Magazine: 1. Activate Jog mode. 2. Press the appropriate tool magazine push button ( A or B ), shown in Figure 5.3, to rotate the tool magazine in the desired direction. 3. Release the push button when the required tool pocket is positioned at the desired position. A B TI3651 Figure Tool Magazine Push Buttons M

84 TOOL LOCATION TABLE DESCRIPTION The tool location table monitors the position of the tool magazine and the location of the tools installed on the machine. Diagnostic registers are used to store the tool number data. The tools are loaded into the tool magazine such that the tool number matches the socket number of the tool magazine. The valid ranges of programmable tool numbers are: Magazine 1 [Standard]: 1 through 20 Magazine 2 [Option]: 21 through 40 The tool numbers commanded from the part program through the use of the T data word match the tool numbers in the tool location table. Accessing the Tool Location Table: 1. Press the Diagnostic Parameter key to access the diagnostic data screens. 2. If necessary, press the Diagnostic soft key. 3. Use the page and cursor keys to access the diagnostic screen containing the diagnostic register to be viewed. TOOL CHANGE POSITION The tool change position is the tool magazine position aligned with the machine spindle. Refer to Figure 5.4. TI4084 Tool Magazine Spindle Tool Change Position Front of Machine Figure Top View of Tool Magazine and Spindle (Magazine 1) 5-4 M-378

85 DIAGNOSTIC ADDRESSES Sample Tool Data for Magazine 1 (Standard) Address D451 contains the number of the tool magazine pocket located at the tool change position. Address D450 contains the number of the tool currently in the spindle. Addresses D460 through D479 contain the tool numbers and do not change. Location Diagnostic Address Number Tool Number Tool Magazine in Active Position D Tool in Spindle D Position 01 D460 1 Position 02 D461 2 Position 03 D462 3 Position 04 D463 4 Position 05 D464 5 Position 06 D465 6 Position 07 D466 7 Position 08 D467 8 Position 09 D468 9 Position 10 D Position 11 D Position 12 D Position 13 D Position 14 D Position 15 D Position 16 D Position 17 D Position 18 D Position 19 D Position 20 D M

86 Sample Tool Data for Magazine 2 [Option] Address D452 contains the number of the tool magazine pocket located at the tool change position. Address D453 contains the number of the tool currently in the spindle. Addresses D480 through D499 contain the tool numbers and do not change. Location Diagnostic Address Number Tool Number Tool Magazine in Active Position D Tool in Spindle D Position 01 D Position 02 D Position 03 D Position 04 D Position 05 D Position 06 D Position 07 D Position 08 D Position 09 D Position 10 D Position 11 D Position 12 D Position 13 D Position 14 D Position 15 D Position 16 D Position 17 D Position 18 D Position 19 D Position 20 D M-378 Revised: February 15, 2001

87 TOOL INSTALLATION AND REMOVAL - WARNING - DO NOT attempt to hold the tool and tool holder by gripping the cutting tool. Personal injury could result. Be sure to have a firm grip on the tool holder body. When removing tooling from the machine spindle, be prepared to accept the weight of the tool and tool holder. - CAUTION - When using non-preset tooling, the currently active work shift MUST be set before the tool offsets are determined. Refer to Chapter 4 for information on setting work shift(s). NON-PRESET TOOLING - NOTE - The tool pockets are labeled numerically for identification. 1. Verify that the work shift is set. If necessary, refer to Chapter 4 for information on setting work shift(s). 2. Refer to the tooling sheet supplied by the part programmer to determine the required tooling, assigned tool numbers, and assigned offset numbers. 3. Place a shim on the reference surface of the workpiece for tool touch-off. 4. Close the main guard doors. 5. Activate Manual Data Input mode. - NOTE - Tool stations are identified by the T word, with a valid range of: One Tool Magazine [Standard]: T01 through T20 Two Tool Magazines [Option]: T01 through T40 6. At the manual data input keyboard, key in the tool change command and the desired tool station: a) Key in: M06 b) Press the Insert key. c) Key in T and the desired tool number. d) Press the EOB (End of Block) key. M Revised: February 9, 2000

88 7. Press the Cycle Start push button. The tool magazine will execute a tool change: If a tool is currently in the spindle, it will be removed from the spindle and loaded back into the tool magazine. If a tool is currently in the tool magazine specified in step 5, it will be loaded into the spindle. The tool magazine will be positioned with the specified tool pocket at the tool change position. 8. Activate Jog mode. 9. Open the main guard doors. 10. If the spindle is empty, proceed to step 11. If a tool needs to be removed from the spindle, proceed as follows: a) Obtain a firm grip on the tool holder body. b) Press and hold Tool Release push button C, Figure 5.5, long enough to release the tool holder. c) Release Tool Release push button C. 11. Press and hold Tool Release push button C, Figure 5.5. C Figure Tool Release Push Button TP M-378

89 - WARNING - The tool holder will not be secured in the spindle until Tool Release push button C is released. Maintain a grip on the tool holder until step 13 is completed. - NOTE - On machines configured for V40 CT tooling, insert the tool holder into the spindle with the short key slot facing toward the right side of the machine. Refer to Figure 5.6 to identify the short key slot in the tool holder. On machines configured for BT-40 tooling, the tool holder can be oriented in either direction. 12. Insert the tool holder into the spindle. 13. Release Tool Release push button C, Figure 5.5, to clamp the tool. 14. Verify the tool holder is clamped properly in the spindle. 15. Jog the tip of the tool to within 1 inch [25 mm] of the reference surface of the workpiece. 16. Carefully turn the handwheel counterclockwise until the tip of the cutting tool in the spindle gently touches the shim on the workpiece. 17. Press the Menu Offset key. 18. If necessary, press the Geometry soft key. Short Key Slot TP4095 Figure Key Slot Identification (End View of a V40 CT Tool Holder) M

90 - NOTE - Refer to page 5-14 for additional information on tool offsets. 19. Set the tool length offset: a) Move the cursor to the required offset number for the tool length offset. b) Observe Z axis position displayed at the bottom of the screen. This will be a positive value. c) Subtract the thickness of the shim from the Z axis position observed in step 19b. d) Key in the value calculated in step 19c and press the Input key. 20. If required, set the tool diameter offset: a) Move the cursor to the required offset number for the tool diameter offset. b) Key in the radius value of the tool and press the Input key. 21. Repeat steps 4 through 20 until all required tooling has been loaded. 22. If necessary, reset the tool wear offsets to 0". Refer to Tool Wear Offsets, on page M-378

91 PRESET TOOLING 1. Verify that the work shift is set. If necessary, refer to Chapter 4 for information on setting work shift(s). 2. Refer to the tooling sheet supplied by the part programmer to determine the required tooling, assigned tool numbers, and assigned offset numbers. 3. Close the main guard doors. 4. Activate Manual Data Input mode. - NOTE - Tool stations are identified by the T word, with a valid range of: One Tool Magazine [Standard]: T01 through T20 Two Tool Magazines [Option]: T01 through T40 5. At the manual data input keyboard, key in the tool change command and the desired tool station: a) Key in: M06 b) Press the Insert key. c) Key in T and the desired tool number. d) Press the EOB (End of Block) key. 6. Press the Cycle Start push button. The tool magazine will execute a tool change: If a tool is currently in the spindle, it will be removed from the spindle and loaded back into the tool magazine. If a tool is currently in the tool magazine specified in step 5, it will be loaded into the spindle. The tool magazine will be positioned with the specified tool pocket at the tool change position. 7. Activate Jog mode. 8. Open the main guard doors. 9. If the spindle is empty, proceed to step 11. If a tool needs to be removed from the spindle, proceed as follows: a) Obtain a firm grip on the tool holder body. b) Press and hold Tool Release push button C, Figure 5.5, long enough to release the tool holder. c) Release Tool Release push button C. M Revised: February 9, 2000

92 10. Press and hold Tool Release push button C, Figure WARNING - The tool holder will not be secured in the spindle until Tool Release push button C is released. Maintain a grip on the tool holder until step 12 is completed. - NOTE - On machines configured for V40 CT tooling, insert the tool holder into the spindle with the short key slot facing toward the right side of the machine. Refer to Figure 5.6 to identify the short key slot in the tool holder. On machines configured for BT-40 tooling, the tool holder can be oriented in either direction. 11. Insert the tool holder into the spindle. 12. Release Tool Release push button C, Figure 5.5, to clamp the tool. 13. Verify the tool holder is clamped properly in the spindle. 14. Press the Menu Offset key. 15. If necessary, press the Geometry soft key. - NOTE - Refer to page 5-14 for additional information on tool offsets. 16. Set the tool length offset: a) Move the cursor to the required offset number for the tool length offset. b) Key in the preset tool length offset value and press the Input key. 17. If required, set the tool diameter offset: a) Move the cursor to the required offset number for the tool diameter offset. b) Key in the radius value of the tool and press the Input key. 18. Repeat steps 3 and 17 until all offset values have been entered. 19. If necessary, reset the tool wear offsets to 0". Refer to Tool Wear Offsets", on the next page M-378

93 TOOL WEAR OFFSETS - NOTE - Refer to page 5-14 for additional information on tool offsets. Accessing the Tool Wear Offsets 1. Press the Menu Offset key. 2. If necessary, press the Wear soft key. 3. Adjust the Tool Wear Offset as needed. To Set a Tool Wear Offset: 1. Move the cursor to the offset number to be adjusted. 2. Key in the new wear offset and press the Input key. To Clear a Tool Wear Offset: 1. Move the cursor to the offset number to be adjusted. 2. Key in 0" (zero) and press the Input key. M

94 TOOL OFFSETS INTRODUCTION The tool offset file consists of 400 offset registers (Offsets 001 through 400). The tool offset file allows the operator to easily make adjustments that may result from tool changes, thus large-scale modifications to the part programs are eliminated. These offset registers are used for tool length and tool diameter offsets. The type of offset (length or diameter) is determined by which data word is used to call the offset. Examples: If offset 01 is called as a tool length offset: H01 (or H1) If offset 01 is called as a tool diameter offset: D01 (or D1) If offset 02 is called as a tool length offset: H02 (or H2) If offset 02 is called as a tool diameter offset: D02 (or D2) - CAUTION - Information stored in the tool offset files is NOT automatically converted into the correct units when a programmed G20 or G21 command switches the programming units from inch to metric or vice versa. Offsets in the desired unit of measure should be entered after the control has been set to the proper mode, inch (G20) vs metric (G21). If a G20 or G21 is programmed after the tool offsets are entered, the decimal point will be shifted one place to the left or right. If start-up mode is G20 (inch) and the program switches to G21 (metric), the offset decimal point will shift one place to the right. If start-up mode is G21 (metric) and the program switches to G20 (inch), the offset decimal point will shift one place to the left. Gauge Line H Word D Word TI2986 Figure H and D Word Definitions 5-14 M-378

95 TOOL LENGTH OFFSETS (H WORD) Tool length offsets shift the spindle reference point from the spindle face to the tip of the tool. This value is entered into the tool offset register as a positive value. Refer to Figure 5.7. Tool length offsets are activated by commanding G43 with a valid H word from the part program. The machine control uses the value in the specified tool offset register to properly position the tool on the Z axis. The H word has the data word format H3, with a valid range from H0" to H400". When the control reads an H0" from the part program, the currently active tool length offset is canceled. When the control reads an H1" through H400" from the part program, the specified offset is activated for tool length compensation. Decimal point programming is not allowed with the H word. The machine operator can make adjustments to the tool offset register to compensate for tool wear or variation. All adjustments for tool wear are negative values that are added to the value in the offset register. TOOL DIAMETER OFFSETS (D WORD) The distance from the cutting edge to the center of the tool. Tool length geometry offsets shift the spindle reference point from the spindle centerline to the cutting edge to the center of the tool. This value is entered into the tool diameter geometry offset register as a positive value. Refer to Figure 5.7. Tool diameter offsets are activated by programming a tool compensation command (G41 or G42) with a valid D word from the part program. When a tool compensation command is active, the machine control uses the value in the specified tool offset to properly position the tool on the X and Y axes. The D word has the data word format D3, with a valid range from D0" to D200". When the control reads a G40 command (Tool Compensation Cancel) or D0" from the part program, the currently active tool diameter offset is canceled. When the control reads an D1" through D200" from the part program, the specified tool offset is activated for tool diameter compensation. Decimal point programming is not allowed with the D word. The machine operator can make adjustments to the tool offset register to compensate for tool wear or variation. All adjustments for tool wear are negative values that are added to the value in the offset register. Refer to Chapter 2 in the Programmer s Manual (M-377) for information on the tool compensation commands. STORING TOOL OFFSETS Tool offsets can be input from either the part program or the Manual Data Input keyboard. Refer to the Programmer s Manual (M-377) for information on inputting tool offsets from the part program. Refer to Non-Preset Tooling, page 5-7, or Preset Tooling, page 5-11, for information on setting tool offsets from the Manual Data Input keyboard. M Revised: February 9, 2000

96 - NOTES M-378

97 CHAPTER 6 - OPERATOR MAINTENANCE INTRODUCTION Operator maintenance is normally confined to cleaning the machine, maintaining the lubrication oil and coolant levels, and chip removal. It is a good practice to check all fluid levels at the beginning of each shift. The operator should also check the cooling fans periodically to see that they are free of obstructions and functioning properly. For more extensive maintenance procedures, refer to the Maintenance Manual (M-379). MACHINE AIR SYSTEM The machine is equipped with a heavy duty air filter/regulator and air/oil lubricator assembly, shown in Figures 6.1 and 6.2. A B AIR LINE FILTER/REGULATOR C - NOTE - Main air valve D, Figure 6.1, should be turned OFF when the machine is not in use. To Adjust the Machine Air Pressure The recommended range for machine air pressure is 58 psig [4.0 bars] to 87 psig [6.0 bars]. The machine is equipped with an air pressure sensor that will force the machine into Emergency Stop if the air pressure is outside of this range. Machine air pressure is displayed on gauge C, Figure 6.1. If necessary, adjust the air filter/regulator to set the machine air pressure to within the recommended range. 1. Push main air valve D, Figure 6.1, IN to turn the machine air ON. D E Figure Air Control System F TP Loosen lock nut B. 3. Turn handle A clockwise or counterclockwise to increase or decrease machine air pressure. 4. Tighten lock nut B. Figure Air/Oil Lubricator Filler Cap TP3668 M

98 AIR/OIL LUBRICATOR - NOTE - The air/oil lubricator DOES NOT mix oil with the air supplied to the operator air nozzle located at the front of the machine. Air/oil lubricator E, Figure 6.1, mixes oil with the air supplied to the machine. TO FILL THE AIR/OIL LUBRICATOR - WARNING - Failure to properly relieve the machine air pressure can result in personal injury. - NOTE - Refer to the tag mounted near the air/oil lubricator to identify the lubrication oil to be used. 1. Pull main air valve D, Figure 6.1, OUT to turn the machine air OFF. 2. Relieve the air system pressure: a) Disconnect the air line from the main air valve. b) Push the main air valve IN to open the valve and relieve the air pressure. c) Pull the main air valve OUT to close the main air valve when system pressure is relieved. 3. Unthread filler cap F, Figure Fill the lubricator bowl to the top of the sight window with the specified oil. 5. Replace filler cap F. 6. Connect the air line to the main air valve. 7. Push the main air valve IN to turn the machine air ON. 8. Press the control Reset key to clear the alarm message. 6-2 M-378

99 COOLANT SYSTEM Hardinge machine tools are designed using the latest technology and highest quality materials available. However, due to the ever-increasing number of coolant selections available, it is impossible to test material compatibility with each and every coolant. For additional information regarding the coolant facilities on this machine, refer to the Maintenance Manual (M-379). - CAUTION - Whenever water-soluble coolants are used it is important to use the manufacturer s recommended mix ratio (concentration). It is also important to maintain the coolant by keeping the proper concentration level when coolant solution is added to compensate for evaporation. Another important factor is coolant ph (acidity). Typically, the coolant ph should be in the range of 8.5 to 9. Below 8.5 the rust inhibitors in the coolant start depleting, which can result in corrosion of machine components. In addition, the quality of the water should be tested by the coolant manufacturer so that the proper coolant additives can be administered. Failure to follow these recommendations could result in damage to the machine, seals, and paint. If the coolant you have selected starts to react (cause material to rust, pit, swell, soften, crack, blister etc.) with any portion of the machine tool, Hardinge suggests that you discontinue use and contact your coolant representative for alternative coolants. It should also be noted that certain chemicals react with different metals. Hardinge recommends that you consult with your coolant representative to assure that the material you are cutting does not react with the coolant you have selected. The coolant level should not be allowed to fall below sight gauge K, Figure 6.4. To fill the coolant tank, open the front coolant guard doors and pour the required amount of coolant directly into the chip pan. Fill the coolant tank to the FULL line on the sight gauge tag. Either water-based or oil-based coolant can be used. The coolant tank should be drained and cleaned at least every six months or whenever the type or brand of coolant is changed. More frequent cleaning may be required if the material being machined contaminates the coolant. Refer to the Maintenance Manual (M-379) for instructions on draining and cleaning the coolant system. COOLANT TANK CAPACITY The coolant tank has a capacity of approximately 40 gallons [150 liters]. M

100 CHIP REMOVAL (Machines Without an Optional Chip Conveyor) The machine is equipped with two chip pans. The chip pans are accessed from each side of the machine. The chip pans are indicated by I, Figure 6.3, and J, Figure Power down the machine as outlined in Chapter Wait a few minutes to allow the coolant to drain into the coolant tank. 3. Position the chip receptacle near the chip pan to be emptied. 4. Remove the chip pan from the machine. - WARNING - DO NOT remove chips with your hands. 5. Pour, rake, or shovel the chips into the chip receptacle. 6. Replace the chip pan. 7. Repeat steps 4 through 6 for the other chip pan. J I K Figure Left Side Chip Pan TP3656 Figure Right Side Chip Pan TP M-378

101 - NOTES - M

102 - NOTES M-378

103 CHAPTER 7 - INPUT/OUTPUT DEVICES DATA COMMUNICATIONS SETTINGS BAUD RATE Baud rate is the speed at which data is transmitted from one device to another. To successfully transmit data between two devices, it is necessary to have both devices set to the same baud rate. The baud rate is set by two different parameters, depending on which I/O port is active. Refer to the I/O setting on Setting Page #1 to determine which I/O port is active. Refer to I/O Port Assignment, page 7-3. Refer to the appropriate manual to set the tape punch, tape reader, or computer to the required baud rate. PARITY Tapes punched in EIA format (EIA Standard RS-244-B) contain an odd number of holes in each character and tapes punched in ASCII (ISO), (EIA Standard RS-358-B) contain an even number of holes in each character. This characteristic of having an odd or even number of holes punched in every character is called parity. The control accepts tape punched in either code, but each tape must be programmed in only one of the accepted codes. The control automatically determines the particular type of coding by decoding the first End of Block (;) character on the tape. Each character is checked for parity as it is read by the tape reader or computer. Refer to the appropriate manual to set the tape punch, tape reader, or computer to the required parity. STOP BITS The control is capable of operating with 1 or 2 stop bits, depending on the requirement. The number of stop bits active in the machine control is controlled by three different parameters, depending on which I/O port is active. These parameters can be modified as required. Refer to I/O Port Assignment, page 7-3. Refer to the appropriate manual to set the tape punch, tape reader, or computer to the required number of stop bits. M Revised: August 31, 2000

104 CHECKING AND MODIFYING COMMUNICATIONS PARAMETERS Use the following procedure to check communications protocol parameters: 1. Press the Diagnostic Parameter key. 2. Press the Parameter soft key. 3. Use the Page keys to display the parameter page to be viewed. Use the following procedure to check and modify communications protocol parameters as needed: 1. Select Manual Data Input mode. 2. Set the Protect Key to ON. Refer to Chapter 3 for information on setting the Protect Key. 3. Press the Diagnostic Parameter key. 4. Press the Parameter soft key. 5. If necessary, use the Page/Cursor keys to position the cursor at the Parameter Write Enable field on Setting Page #2. 6. Press the 1 key. 7. Press the Input key. Parameter editing will be enabled. 8. Press the Diagnostic Parameter key. 9. Press the Parameter soft key. 10. Use one of the following methods to position the cursor at the parameter to be modified: - Press the No. data input key, key in the parameter number, press the Input key. - Use the Page and/or Cursor keys. 11. Key in the new parameter value. 12. Press the Input key. 13. Repeat steps 10 through 12, as needed. 14. Press the Parameter soft key. 15. If necessary, use the Page/Cursor keys to position the cursor at the Parameter Write field. 16. Press the 0 (zero) key. 17. Press the Input key. Parameter editing will be disabled. 18. Set the Protect Key to OFF. 19. Press the Reset key. 7-2 M-378

105 I/O PORT ASSIGNMENT The standard configuration for Hardinge VMC600II, VMC800II, & VMC1000II machines is to be equipped with one physical RS-232 port. When the machine tool is configured in this manner, two independent port assignments are available to allow the operator or programmer to establish two different I/O port configurations for the same physical I/O port. These two configurations are designated as channels 0" and 1". Instead of changing the associated parameters to reassign the baud rate and stop bits, it is possible to select a different I/O port assignment and have the changes implemented by the control automatically. Refer to the description for Setting Page #1, in Chapter 2, for information on setting the desired I/O port assignment. Refer to I/O Port Parameter Settings, on the next page, for a listing of the parameter settings for the I/O port assignments. M

106 I/O PORT PARAMETER SETTINGS Refer to Checking and Modifying Communications Parameters, starting on page 7-2, for information on modifying the parameter settings for the three I/O ports. These parameters can be modified as required. BAUD RATE PARAMETER SETTINGS I/O Port Parameter Number The valid parameter settings are as follows: Setting Number Baud Rate STOP BIT PARAMETER SETTINGS I/O Port Parameter Number Bit Number The valid parameter settings are 0" for 1 Stop Bit and 1" for 2 Stop Bits. - NOTE - The Stop Bit parameter settings are displayed as one bit in an 8 bit binary number (0 or 1). The bits are read 0" to 7", from right to left. 7-4 M-378

107 DATA TRANSFER TO THE CONTROL UPLOADING CONTROL PARAMETERS INTO MEMORY - CAUTION - Always connect the RS-232 cable before applying power to the external device and always remove power from the external device before disconnecting the RS-232 cable. 1. Refer to the appropriate manual to set the tape reader or computer to the required communications settings. 2. Remove cover A, Figure 7.1, to gain access to the control serial port. 3. Connect the interface cable from the tape reader or computer to the control serial port. 4. Press the Diagnostic Parameter key. 5. Press the Parameter soft key. 6. Use the Page/Cursor keys to position the cursor at the Parameter Write Enable field on Setting Page #2. 7. Select Manual Data Input mode. 8. Press the 1 key. 9. Press the Input key to enable parameter editing. 10. Press the Diagnostic Parameter key. 11. Press the Parameter soft key. 12. Select Edit mode. 13. Press the Input key. 14. Set the tape reader or computer to transmit data to the machine control. 15. After the control parameters have been uploaded, select Manual Data Input mode. 16. Press the Parameter soft key. 17. If necessary, use the Page/Cursor keys to position the cursor at the Parameter Write A Enable field on Setting Page #2. Figure Control Serial Port TP3913 M Revised: February 9, 2000