Page 1 Tool Setup Running a Job Utility Menu Digitizing Probing 10-1 Intercon Conversational Programming CNC Program codes 11-1 12-1 G- Codes 13-1 M code functions Configuration 14-1 www.centroidcnc.com CNC Software Messages 15-1 v3.14_CENTROID_mill_operators_manual.pdf 4-9-2015 Copyright © 2013-2015 CENTROID U.S. Patent #6490500...
Page 2 As CNC control products from CENTROID can be installed on a wide variety of machine tools NOT sold or supported by CENTROID, you MUST consult and follow all safety instructions provided by your machine tool manufacturer regarding the safe operation of your machine and unique application.
Page 3 CENTROID CNC controls provide facilities for a required Emergency Stop circuit which can be used to completely disable your machine tool in the event of an emergency or unsafe condition. Proper installation of your CNC control MUST include the necessary wiring to disable ALL machine tool movement when the Emergency Stop button is pressed.
Page 4 Basic safety precautions must be followed to reduce the risk of personal injury and property damage. •Your local safety codes and regulations must be consulted before installation and operation of your machine and CENTROID CNC control. Should a safety concern arise, always contact your dealer or service technician immediately.
Page 5 CNC Control Warning Labels High Voltage Electrocution Hazard. Death by electric shock can occur. Turn off and lock out system power before servicing. High Voltage Electrocution Hazard. Death by electric shock can occur. Turn off and lock out system power before servicing.
Page 6: Table Of Contents
TABLE OF CONTENTS CHAPTER 1 - Introduction CHAPTER 10 - Intercon Software Window Description Intercon Main Screen 10-1 Conventions File Menu 10-2 Machine Home Rapid Traverse 10-7 Mill M and G Codes Linear Mill 10-8 Software Unlocks Arc Mill 10-10 Tool Functions 10-12 CHAPTER 2 - Operator Panels...
Page 7: Chapter 1 - Introduction
Chapter 1 Introduction Window Description The CNC software display screen is separated into five areas called windows. A sample screen is shown below for reference. The five windows are the DRO display window, the status window, the message window, the options window, and the user window.
Page 8: Main Screen
Status window The first line in the status window contains the name of the currently loaded job file. Below the job name are the Tool Number, Program Number, Feedrate Override, Spindle Speed, and Feed Hold indicators. The Feedrate Override indicator displays the current override percentage set on the Jog Panel. The Feedrate label will turn RED if the rapid override is turn off.
Page 9: Conventions
Conventions *Bold capitalized characters represent keystrokes. For example, the A key is written as A, and the enter key is written as ENTER. The "Escape" key is written as ESC. Key combinations such as ALT- D mean that you should press and hold ALT then press D.
Page 10: Machine Home
Machine Home When the M-Series control is first started, the Main screen will appear as below. Before you can run any jobs, you must set the machine home position. If your machine has home/limit switches, reference marks or safe hard stops, the control can automatically home itself. If your machine has reference marks, jog the machine until the reference marks are lined up, (see below), before you press CYCLE START to begin the automatic homing sequence.
Page 11: Mill M And G Codes
Mill M and G Codes This is a summary list of M and G codes. See Chapters 12 – 13 for more information. M00 Stop for Operator G00 - Rapid to Position M01 Optional Stop for Operator G01 - Linear Move M02 Restart Program G02/G03 - CW/CCW Arc Move M03 Spindle On Clockwise...
Page 12 How to unlock software features or unlock your Control The following are necessary to unlock software features: 1. If you are at the "Demo mode expired" screen, start at step 4. 2. Go to the Main screen of the Control software. 3.
Page 13: M-Series Jog Panel
Chapter 2 Operator Panel The M-Series operator panel is a sealed membrane keyboard that enables you to control various machine operations and functions. The panel contains momentary membrane switches. The M-Series jog panel can be customized as to the location of various keys. The jog panel displayed in the figure above is representative of a default configuration found on most M-series controls.
Page 14 The MPG is housed in a separate hand-held unit. Press the MPG key to set the control jog to respond to the MPG hand wheel, if equipped. When selected, the LED will be on. Select the Jog Increment and desired axis and slowly turn the wheel.
Page 15 Cycle Cancel Press CYCLE CANCEL to abort the currently running program. The control will stop movement immediately, clear all M-functions, and return to the Main Screen. It is recommended that you press FEED HOLD first before CYCLE CANCEL. If you press CYCLE CANCEL, program execution will stop; if you wish to restart the program you must rerun the entire program or use the search function.
Page 16 Spin Start Press the SPIN START key when manual spindle mode is selected to cause the spindle to start rotating. Press SPIN START when automatic mode is selected to restart the spindle if it has been paused with SPIN STOP. Spin Stop Press the SPIN STOP key when manual spindle mode is selected to stop the spindle.
Page 17: Keyboard Jog Panel
Keyboard Jog Panel The PC keyboard may be used as a jog panel. Press Alt-J to display and enable the keyboard jog panel. The jog panel appears as shown below: Some controls, such as coolant on/off, spindle on/off, feedrate and spindle override will work without the “jog panel” being displayed but for full functionality (and jogging) of the keyboard jog panel, the “jog panel”...
Page 18 Legend Key(s) Function Description Availability (Notes) Ctrl M Toggle Auto Toggles coolant mode between auto and Always, with few Coolant manual. exceptions. Ctrl N Turns on/off Toggles Flood coolant if in manual mode Always, with few Flood exceptions. Ctrl K Turns on/off Toggles Mist coolant if in manual mode Always, with few...
Page 19: Keyboard Shortcut Keys
Legend Key(s) Function Description Availability (Notes) Delete Decrease Decreases current jog increment to the next Always, with few lower available increment exceptions. increment Insert Increase Jog Increase current jog increment to the next Always, with few Increment higher available increment exceptions.
Page 20 Hot Key Action ALT J Enables keyboard jogging* ALT K Displays current ATC tool bin location ALT M Ctrl T Tool check* ALT P Live PID display CTRL P Clear max and min error display Ctrl C Spindle CW* Ctrl W Spindle CCW* Ctrl S Start Spindle*...
Page 21: Chapter 3 - Cnc Software Main Screen
Chapter 3 CNC Software Main Screen Menu Options: F1 – Setup Used to set part zeroes, set or change tool offsets, and change the control configuration. F2 – Load Use this menu to load a job F3 – MDI The MDI menu allows you to a single line command such as: G1 X2 Y3 F20 F4 –...
Page 22 F1- Setup Menu Setup Menu: F1 – Part This key displays the Part Setup menus that are explained in Chapter 4. F2 – Tool This key displays the Tool Setup menus that are explained in Chapter 5. F3 – Config This key displays the Configuration menu that is explained in Chapter 14.
Page 23 F2- Load Job Menu Job Name: c:\cncm\ncfiles\bracket.cnc Use arrow keys to select file to load and press F10 to Accept. Use arrow keys to select file to load and press F10 to Accept. Use arrow keys to select file to load and press F10 to Accept. Use arrow keys to select file to load and press F10 to Accept.
Page 24 F3 –MDI MDI mode allows you to directly enter M and G-codes one line at time. After entering the M and G- codes you wish to run, press cycle start to have the controller execute the command. When the command has finished executing the command, it will prompt you for another line.
Page 25 F5 – CAM Current Position ( Current Position ( Inches Current Position ( Current Position ( Inches Inches Inches ) ) ) ) Job Name : : : : b b b b racket.cnc racket.cnc racket.cnc racket.cnc +4.0000 +4.0000 +4.0000 +4.0000 Tool : Tool :...
Page 26: Utility Menu
F6 – Edit This key causes the control to load the current job into a text editor for viewing and/or editing. When editing, care must be taken to save the file and to quit and exit the text editor before running the file (the current job).
Page 27 F8 – Graph This function plots the tool path of the current program loaded. Canned drilling cycles are shown in gray. Rapid traverse movements are shown in red. Feedrate movements are shown in yellow and cutter compensated moves are in gray. F1 - 2D/3D Press this key to view your part isometrically (3D).
Page 28 Accelerated Graphics Backplot Accelerated Graphics Backplot is a new tool path graphics display that takes advantage of the latest video graphics technology. This option is enabled by setting Parameter 260 to 1 (See Chapter 14). Under Accelerated Graphics Backplot, the operation of the user interface is slightly different from the regular Graphing described above.
Page 29 F4 - Dimension Menu Press this key to access the following sub-menu of options: F1 – Prev Line: Press this to walk forward to the next G-code line and graphically highlight it. If this G-code line contains movement, the Start and End points will be displayed at the bottom of the screen.
Page 30 F9 – Digitize Use this to bring up the Digitize screen. This screen allows you to set up and run touch probe digitizing. See Chapter 8 for a detailed description of the digitizing operation. F10 – Shutdown Use to enter the Shutdown menu. This menu allows you to park the machine, power off the control, start a command window or exit CNC software.
Page 31: Chapter 4 - Part Setup
Chapter 4 Part Setup (F1 from Setup) The Part Setup menu is used to set the part position or the coordinate system origin for the part. F1 – Next Axis Will toggle to the next axis. If changes were made to the current axis, but not yet accepted, they will be discarded.
Page 32: Operation Description
Operation Description Setting the part position establishes a coordinate system with an origin at the part zero. The F1 - Next Axis option selects the axis to be defined next. This field toggles between axis X, Y, Z, 4 , and 5 Axes.
Page 33 Example 1 (You are using the reference tool to find the Z-axis part zero): Set Tool Number to 0: setting the Tool Number to zero tells the controller that you are using the reference tool. Example 2 (You are using a tool other than the reference tool, and not a ball nose cutter): Set Tool Number to a number tool that is assigned in the tool library (make sure its height offset is set).
Page 34: Part Setup Examples
Part Setup Examples Example 1: Setting the X-axis Part Zero with no offset (See diagram below) If you wanted the left edge of the part to be the origin for the X-axis: 1. Move the Edge Finder to the left edge of the part 2.
Page 35 Example 2: X-Axis origin offset into part 1 inch. If you wanted the origin offset 1 inch into the part: 1. Move the Edge Finder to the left edge of the part 2. Press F1 – Next Axis until the axis field displays 'X' 3.
Page 36: Work Coordinate Systems Configuration
Work Coordinate Systems (WCS) Configuration Press F9 – WCS Table from the Part Setup screen to display the Work Coordinates System (WCS) menu. The Work Coordinate Systems screen provides access to reference return points, coordinate system origins, and work envelope. Make sure your Home position has been set properly. Otherwise, the positions of each coordinate system will not be in the appropriate position.
Page 37: Coordinate Systems Rotation
F3 – Work Envelope Use the F3 – Work Envel key to specify the ‘+’ and ‘-‘work envelope locations (in machine coordinates) used in conjunction with the G22 G code. The X, Y, Z and I, J, K parameters specified in the G22 G code are stored here, so subsequent G22 codes do not need to specify the limits unless they change.
Page 38: Transformed Wcs
F1 - Orient is used to select the orientation for the CSR measurement. There are four possible orientations, which are: from the front (pictured above), the back, and the left and right sides. F2 - Manual is used to determine the CSR angle without probing. The user jogs an edge finder to two positions along one wall.
Page 39: Chapter 5 - Tool Setup
Chapter 5 Tool Setup (from Main Screen: F1 Setup ► F2 Tool) Tool Setup allows you to specify information about the tools you will be using. Press F1 - Offset Library, to edit the Height Offset and Diameter (H and D) values, or Press F2 - Tool Library to edit the tool descriptions., or Press F3 - Tool Life to edit the Tool Life Management settings.
Page 40 Height Offset This is the distance the control adjusts Z-axis positions when tool length compensation (G43 or G44) is used with a particular H value. For example, if H001 is -1.0 and the job contains G43 H1, then the CNC software will shift all Z-axis positions down 1.0 to compensate for the shorter tool.
Page 41: Automatic Tool Measurement
Automatic Tool Measurement Z-minus single-surface probing, using the TT-1 tool touch-off post, is available in the Tool Offset Library. First Time Setup Make sure the proper parameters are set as per Chapter 9 and Chapter 14, and the detector is plugged in and is at the correct location on the table! When first testing the TT-1, hold the TT-1 in hand and manually touch the unit to the tool to confirm correct electrical connection and parameter setup.
Page 42: Setting Up Tool Height Offsets
Setting up Tool Height Offsets Before manually jogging any probe to a position, make sure the machine Feedrate is turned NOTICE down (less than 10 in/min) or damage to the probe may result!!! Using a Probe as the Reference Tool Before you set the Z Reference, make sure the probe Tool # is entered into Parameter 12 on the Machine Parameters screen.
Page 43: Tool Library
Tool Library (from Main Screen: F1 Setup ► F2 Tool ► F1 Tool Lib) WCS #1 (G54) WCS #1 (G54) Current Position (Inches) Current Position (Inches) WCS #1 (G54) WCS #1 (G54) Current Position (Inches) Current Position (Inches) Job Name : b b b b racket.cnc Job Name : racket.cnc Job Name :...
Page 44 Height This field specifies a default Height Offset (H) number to use with each tool. Possible values are 1 to 200. Intercon uses this information to provide a default H value at each tool change. The CNC software also uses this information to correct for the length of the tool that is used to establish the Z-axis position in Part Setup (see Chapter 5).
Page 45: Tool Life Management
Tool Life Management menu (from Main Screen: F1 Setup ► F2 Tool ► F1 Tool Life) The Tool Life Management feature allows you to set up each tool’s pre-determined life, and have its usage tracked and monitored for end-of-life condition. By default, Tool Life Management is turned off, but can be enabled for each tool individually.
Page 46 Detailed description of each field is as follows. Type This is the type of tool – either Drill or EM (end mill). Whent the Mode field is set to Auto, this field determines the type of tool activity that will be automatically tracked and monitored for the purpose of accounting for consumed tool life.
Page 47 Tool Life Management – Effect on Job Run and Backplot At Start of Job Tool life expirarations will be checked at the beginning of a job run. If any managed tools are expired at the beginning of a job, the following dialog will show up and you will have one of 3 choices to make: When a job is first started, the CNC software will not yet know which tools are going to be used in the job until the job is successfully completed.
Page 48 Tool Life Management – Using G-Code User Variables If a tool’s Mode field is set to Manual, there will be no updates to the Used field of the Tool Life data during a job run, unless the job’s G-code is programmed to modify it. The following is an example of how a G-code program would modify tool life data.
Page 49: Chapter 6 - Running A Job
Chapter 6 Running a Job To start the currently loaded job, go to the Main Screen and press the CYCLE START button on the jog panel. If your control is not equipped with a jog panel, press ALT-S on the keyboard. Active Job Run Screen with G-code Display If the Run-Time Graphics option is set to Off, the following screen is displayed while a job is running: On this screen, the following F-keys are available:...
Page 50: Run-Time Graphics
Run-Time Graphics Screen When a job is running with Run-Time Graphics set to On, the following screen is displayed: The following keys are available while the job is running in Run Time Graphics. Clears the trail up to the tool’s current position in the program. F7 –...
Page 51: Resuming A Canceled Job
Resuming a Canceled Job If a job is canceled using one of the methods described above, it can be resumed in one of three ways: CYCLE START Pressing the CYCLE START button will restart the job at the BEGINNING of the part program.
Page 52 F2 – Search Invoking this option will bring you to the “Search and Run” menu. This menu will allow you to specify the program line, block number, or tool number at which execution of a program is to begin. Program lines are numbered from the top of the file down with the first line numbered 1.
Page 53: Power Feed
F8 – Graph Graphs the part. For more information, see the "F8 - Graph" section in chapter 3. If this feature is invoked from the Run and Search screen or the Resume Job screen, then the graphics will show exactly where the searched line or block begins. Dotted lines indicate the portion of the part that is skipped.
Page 54 M-Series Operator’s Manual 4/9/15...
Page 55: Chapter 7 - The Utility Menu
Chapter 7 The Utility Menu To get to the Utility Menu, press F7 - Utility at the CNC software Main Screen. The model will vary depending on your M-Series Control model. F2 – Restore Report This option is used primarily for restoring a system configuration from a previously saved report.zip file (See F7 –...
Page 56: F5 - File Ops
F5 – File Ops Use this menu to perform file and directory operations such as: Importing and Exporting (copying) files to and from the control, rename or delete files, create or delete directories. F1 – Toggle Press once to select or press again to unselect a single file. F2 –...
Page 57 F6 – User Maint Use this menu to perform user maintenance such as checking an axis for excessive drag or setting backlash F1 – Drag The Drag Factor utility is used to determine if an axis has an excessive amount of drag. To run a drag test, use the F1 key to select the axis which you wish to test, position the axis at or near the home position and press CYCLE START.
Page 58 M-Series Operator’s Manual 4/9/15...
Page 59: Chapter 8 - Digitize
Chapter 8 Digitize (F9 from Main Menu) The Digitize feature of the CNC software can be used to digitize surfaces in a variety of scenarios. The digitizing process creates a file with M & G codes that represent the digitized surface. If the digitizing probe tip is chosen to match the milling cutter size, the digitized file can be loaded and run to produce an exact copy of the digitized part.
Page 60: Grid Digitize
Grid Digitize (F1 from Digitize Menu) Grid Digitize Run Setup To set up a digitizing run, edit the parameters shown and then press CYCLE START. The control will move through the area to be digitized in a rectangular pattern. At each X-Y point in the pattern, it will measure the Z height of the sample surface, and record the coordinates in the data file.
Page 61 Y Step Over: The distance to move between points on the Y-axis. A smaller value should be used for a fine digitize along the Y-axis. A larger value should be used for a rough digitize along the Y-axis. This distance should be a positive incremental value.
Page 62 Grid Digitize Notes 1. A guide to the possible grid digitizing paths is as follows: 2. A digitizing patch can be located anywhere in the coordinate system. The digitizing starting point is referenced from the part zero. For example, setting up digitizing, as shown in the figure on the right below, will record the first point at (X5, Y5, Z1) and the last point at (X7, Y7, Z1).
Page 63 3. A good technique for calculating Z maximum depth is to touch off the lowest surface of the part to be digitized and set the part zero's Z value to Z0. Then jog the probe tip to a point higher than the highest surface of the part to be digitized.
Page 64: Radial Digitize
Radial Digitize (F2 from Digitize Menu) Setting up a Radial Digitize Run To set up a digitize run, edit the parameters shown. Jog the probe tip to the starting height and to the center of the bore to be digitized. Then press F1 - Center to define the center position for digitizing. This center position will be used as the center of all radial digitizing runs until you leave the radial digitize menu or redefine the center.
Page 65 Z Patch Depth: The depth of the patch to be digitized, along the Z-axis. A positive value will cause digitizing to proceed in the Z+ direction from the starting point; a negative value will cause digitizing to proceed in the Z- direction.
Page 66 Radial Digitize Notes 1. A guide to possible radial digitizing paths is as follows: 2. When radial digitizing, make sure the probe can fully retract to the center position without obstructions. Observe the two parts below. The cross section on the left has no obstructions that could keep the probe from full retraction to the center position.
Page 67 Partial Digitizing Sector Setup If you set the Radial Digitize Containment Angle to “Partial” then you must set up the Digitizing Setup by pressing F2 - Partial from the CNC software Radial Digitize Screen. The partial sector can be setup one of two methods: One method is by editing the start and end angles directly.
Page 68: Contour Digitize
Contour Digitize (F3 from Digitize Menu) Contour Digitize Run Setup To set up a digitizing run, jog the probe tip to the center of the part and hit F1 - Center to assign that as your center point. Select CAM for a true CAM shape contour, or Wall for irregular shapes for wall following. Enter the rest of the parameters for the part and digitizing job as shown below.
Page 69 Contour Digitize Parameters Copy Type: Toggle between CAM or Wall. Use CAM for regular shapes (no extreme direction changes) and use Wall following for contours with irregular shapes. See example below. X Patch Length: The length of the contour to be digitized, along the X-axis. Y Patch Width: The width of the contour to be digitized, along the Y-axis.
Page 70 Contour Digitize Notes Contour digitizing creates an M&G code file with a .cam extension. The structure of the .cam file starts with a header of comments indicating some of the parameters used when digitizing the contour. Next is the contour itself, which is outputted as a subprogram.
Page 71: Wall Following Digitizing
Wall Following Digitizing (F8 from Digitize Menu) Setting up a Wall Following Digitizing Run To set up a digitize run, edit the parameters shown. Jog the probe tip to the XY starting location (inside or outside of the part to be digitized), and then jog Z to the level of the first digitize pass. Press CYCLE START to start the digitize run.
Page 72 Cut Feedrate: The replay feedrate. This is the feedrate that will be output to the file specified by the Digitize File Name above. This will cause the digitized data to be replayed at this specifed feedrate when the output data is run as a CNC job.
Page 73: Dig To Cad
Dig to CAD (F6 from Digitize Menu) The Dig to CAD feature of the CNC software is used to export digitized files for use with CAD/CAM software. The digitized files are converted to point cloud data that is easily readable by most CAD/CAM systems.
Page 74 Converting Digitized Data To export digitized data, first select the files you wish to convert by highlighting the files with the arrow keys and using either F1-Toggle or the Space bar to select the files. When a file has been selected an asterisk (*) will appear to the left of the filename.
Page 75: Chapter 9 - Probing
Chapter 9 Probing Attention!! Refer to the Probe Parameters sections at the end of this chapter before using any probe. Part Setup with Probing Single axis, single surface probing is available on the Set Part 0/Position screen using the F4 - Auto key. This allows you to probe various surfaces to define the part coordinate system.
Page 76: Calibrating The Probe Tip Diameter
3. If you want this probed surface to be something different than 0, enter the value by the using arrow keys to highlight Part Position, and then type in the value and press F10 - Set. Repeat steps 1-3 to set the remaining axes using the probe. Any previously entered Edge Finder Diameter or Tool Number value will be discarded.
Page 77 F1 – Bore Press F1 - Bore to enter the Bore screen. A picture similar to the one shown at right will appear, with instructions. Follow these steps: 1 - Make sure the probe is clear of any obstacles. 2 - Manually jog the probe inside the hole. The probe tip should be just below the top edge of the surface. 3 - Press CYCLE START to start the probing.
Page 78 F3 – Slot Press F3 - Slot to enter the Slot screen. A picture similar to the ones shown will appear along with instructions: 1 - Press F1 - Orient to select the orientation of the probe with respect to the slot. 2 - Slowly jog the probe to the approximate position shown in the picture.
Page 79 F5 - In Corner (Inside Corner) Press F5 - In Corner to enter the Inside Corner screen. One of the pictures will appear with instructions. This cycle is similar to that of a slot cycle; the main difference is that you need to enter a clearance amount. 1 - Press F1 Orient and the screen will cycle through one of the probe orientations shown here.
Page 80 F7 - 1 Axis (Single Axis) Press F7 - 1 Axis to enter the Single Axis screen. Follow these steps: 1 - Press F1 - Orient to select the orientation of the probe. You will see one of the screens shown below. 2 - Slowly jog the probe to the approximate position as shown in the picture.
Page 81: Probe Parameters
Probe / TT-1 Parameters Various probing parameters can be set on the Machine Parameters screen (see Chapter 14). Make sure you enter these parameters before you begin using the probe and/or TT-1. If these parameters are not entered properly, damage to the probe or TT-1 may result. Probe Type (Parameter 155) –...
Page 82: Dsp Probe Parameters
DSP Probe Parameters When using a DSP type probe (such as DP-4D), a few of the probing parameters have a slightly different behavior than described above. These differences are noted below: Probe Type (Parameter 155) – This specifies the probe type being used. This needs to be set to 1 for a DP-4D probe or set to 2 for a DP-7 probe.
Page 83: Intercon Main Screen
Chapter 10 Intercon Software Introduction Intercon (Interactive Conversational) software allows you to quickly create a part program right at the control without having to be a G-code expert. Intercon will prompt you to enter values from your print that describes the geometry of the part.
Page 84: File Menu
File Menu (Intercon Main Screen ► F1 – File) F1 – File Choosing F1 - File will display the screen below. Intercon stores part programs with an extension of .icn. For example, if you choose to name your new part program flange, Intercon will save the program as flange.icn. ICN files are only readable by Intercon.
Page 85 To navigate the files in the load menu, use the arrow keys to move the cursor around and highlight the file to be loaded. The HOME, END, PAGE UP and PAGE DOWN keys can be used to navigate the list of files. Names that are bracketed, for example [..], are the names of directories in the current directory, which is displayed at the top of the screen.
Page 86 F1 – File ► F9 - Details on/off The F9 - Details On/Off changes the format of the display such that each file or directory is on a separate line and there are columns displayed for Programmer, Description, and Date Modified, i.e., the information that is contained in the program header operation.
Page 87 F9 – Setup Choosing F9 - Setup will display the Setup menu where certain options can be set. The Setup menu appears as below. Use the up and down arrow keys to move. Clearance Amount, Spindle/Coolant Delay, and Corner Feedrate Override require a value to be typed in.
Page 88 Insert Operation (Intercon Main Screen ► F3 – Insert) When you press F3 - Insert, or when you choose New Part from the Main Screen, you will see the Insert screen: The new operation will be inserted right before the currently highlighted one. The operation types that you can insert are listed across the bottom of the screen.
Page 89: Rapid Traverse
F1 - Rapid Traverse Press F1 - Rapid from the Insert Operation screen to insert a Rapid Traverse. You may see the following screen: End: When you first access the rapid traverse screen, the cursor will be highlighting the first field, End X. This is the X coordinate of where the cutter will be after the rapid traverse has been completed.
Page 90: Linear Mill
F2 - Linear Mill If you press F2 - Linear from the Insert Operation screen, the following screen appears: The numbers in the different fields on the screen correspond to the following Linear Mill example shown here graphically: End: When you first access the linear mill screen, the cursor will be highlighting the first field, End X. This is the X coordinate of where the cutter will be after the linear move has been completed.
Page 91 The feedrate can be toggled to modal, fixed, or slave. This is indicated by the symbol beside the feedrate field. If the feedrate is modal then it will have the “M” symbol or if it is fixed it will have the “F” symbol shown below. The slave feedrate has no symbol and is set to the last modal feedrate set in the program, when the modal feedrate changes all the following slave feedrates change until the next modal feedrate is encountered.
Page 92: Arc Mill
F3 - Arc Mill If you press F3 - Arc for Arc Mill from the Insert Operation screen, the following screen appears: The numbers in the different fields on the screen correspond to the following Arc Mill example shown here graphically: Operation Type: There are four ways to specify your ARC: using an endpoint and a radius (EP&R), using a center point and an angle (CP&A), using a center point and an end point (CP&EP), or using a mid-point and an end point (3-...
Page 93 Angle: Number of degrees through which the cutter will travel. This value must lie between 0 and 360 degrees. You will be able to edit this field only if you are specifying a center point and angle (CP&A) arc. Radius: Distance from the center of the arc to its edge. This value must be greater than 0. You will only be able to edit this value if you are specifying an end point and radius (EP&R) arc.
Page 94: Tool Functions
F4 - Tool Functions When you select the tool functions by pressing F4 - Tool the following screen appears: The following parameters for this tool change are as follows: Tool Number: Number of the tool (between 1 and 200) to use. Entering this value pulls the current settings for this tool from the CNC software tool library.
Page 95: Canned Cycles
Actual Tool Change: Determines whether an M6 code is generated (answer Yes) during the tool change. If you do not want to remove the current tool, but instead want to alter its diameter or length offsets (e.g. for doing a finish pass while using cutter compensation, you may want to use a diameter offset which is slightly larger than the actual tool for the first passes, then use the actual tool diameter for the finish pass), answer No to this question.
Page 96 Canned Cycle Introduction #1: Using Pattern and Repeat (Drilling, boring, tapping) Selecting F1 - Drill will give you four choices; F1 – Drill, F2 – Drill BHC, F3 – Drill Array, or F4 – Drill Repeat. F2 - Bore and F3 - Tap will have the same menu selections as drill except they will display Bore or Tap cycles All canned cycle operations using the Drill BHC (Bolt Hole Circle) or Drill Array are identical to their equivalent using the F1 - Drill single hole selection.
Page 97 Canned Cycle Introduction #2: Linear Repetition of Operations (Drilling, Boring, Tapping) If you want to perform one operation several times in a linear pattern, simply define Position X, Y or both as incremental values. To do this, use the F1 – Abs/Inc Key. This key will toggle the Position value mode between incremental and absolute.
Page 98: Drilling
Drilling (F1 in the Canned Cycle Menu: option #1) If you press F1 - Drill from the Canned Cycle Menu, you will gain access to three types of drilling operations: Drilling, Chip Breaking, and Deep Hole drilling. The current drilling operation in use is reflected in the field “Cycle Type”...
Page 99: Chip Breaking
Clearance Height: This parameter specifies the Z-axis height used when performing rapid moves to the position of each hole being drilled. 'Rapid To' Depth: The depth to which the cutter rapid moves before beginning to drill the hole at the specified Plunge Rate.
Page 100 Where: Cycle Type: Selects one of three drilling operations: Drilling, Chip Breaking, or Deep Hole drilling. Press F3 - Toggle or SPACE to toggle between the three choices. Position: Specifies the X and Y coordinates where the drilling will take place. If either the X or Y coordinate is an incremental value, you will have the option to drill multiple holes in a linear pattern (See Canned Cycle Introduction #2).
Page 101: Deep Hole Drilling
Deep Hole Drilling (F1 in the Canned Cycle Menu: option #3) If you press F1 - Drill from the Canned Cycle Menu you will gain access to three types of drilling operations: Drilling, Chip Breaking, and Deep Hole drilling. The current drilling operation in use is reflected in the field Cycle Type, and pressing F3 - Toggle or SPACE toggles between all three.
Page 102: Boring
Position: Specifies the X and Y coordinates where the drilling will take place. If either the X or Y coordinate is an incremental value, you will have the option to drill multiple holes in a linear pattern (See Canned Cycle Introduction #2).
Page 103 The numbers in the fields on the screen correspond to the following example, shown here graphically: Where: Position: Specifies the X and Y coordinates where the boring will take place. If either the X or Y coordinate is an incremental value, you will have the option to bore multiple holes in a linear pattern. (See Canned Cycle Introduction Surface Height: Absolute Z-axis position from where each incremental depth is measured.
Page 104: Tapping
Tapping (F2 in the Canned Cycle Menu) If you press F2 - Tap from the Canned Cycle Menu you will gain access to the tapping operations: The numbers in the fields on the screen correspond to the following example, shown here graphically: Where: Tap Head Type: Without rigid tapping, this selects either Floating tap head or Reversing tap head (where the special tapping head reverses for you).
Page 105 Spindle Direction: Shows the current spindle direction. The spindle direction should be CW for right-hand tapping, and CCW for left-hand tapping. The spindle speed and direction appropriate for the tapping tool should be set in the tool change in which the tapping tool was loaded. This field will be hidden if a reversing tap head is used. * WARNING: The tap must be rotating in the correct direction before performing this operation.
Page 106: Facing
Facing (F4 in the Canned Cycle Menu) If you press F4 - Face at the Canned Cycle Selection Menu, the following screen is displayed: The parameters in the previous screen correspond to the following dimensions: Start: X and Y coordinates of the starting corner of the area to be faced. Surface Height: Z coordinate of the top of the area to be faced.
Page 107: Rectangular Pocket
Width: Y-axis dimension of the area to be faced. If a negative value is entered for the width, the facing will occur in the negative Y-axis direction from the Y-axis start position; otherwise, facing will occur in the positive Y-axis direction from the Y-axis start position.
Page 108 The parameters on the screen correspond to the following dimensions: Where: Center or Corner: Center - X and Y coordinates of the center of the Rectangular Pocket. Corner – X and Y coordinates of the corner of the rectangular pocket. A positive or negative value in the length and width fields will determine the location of the rectangular pocket from the corner position.
Page 109: Circular Pocket
Circular Pocket (F6 in the Canned Cycle Menu) When you press F6 - Circ. Pocket from the Canned Cycle Selection Menu, this screen is displayed: The parameters on the screen correspond to the following dimensions: Where: Center: X and Y coordinates of the center of the circular Pocket. Surface Height: Z-axis position from which each incremental depth is measured.
Page 110 Depth: Total: Total depth of the circular pocket. Depth: Per Pass: Depth of each individual pass. Depth: Plunge Rate: Z-axis speed of descent. Depth: Plunge Type: Straight or Ramped. Straight plunge does a vertical Z plunge with no X, Y movement. Ramped plunge does a zigzag plunge limited by the Plunge Angle entered below.
Page 111 Rectangular or Circular Frame Milling (F7 in the Canned Cycle Menu) When you press F7 - Frame from the Canned Cycle Selection Menu, the following screen is displayed: The parameters on the screen correspond to the following dimensions (rectangular frame): Where: Frame Type: Selects Inside Rectangle, Outside Rectangle, Inside Circle, and Outside Circle.
Page 112 Length: X-axis dimension of the frame mill. (Rectangular frame only.) Width: Y-axis dimension of the frame mill. (Rectangular frame only.) Corner Radius: Radius of curvature of the corners. On an Inside frame, corner radius must be greater than the current cutter radius.
Page 113: Thread Milling
Thread Milling (F8 in the Canned Cycle Menu) When you press F8 - Thread from the canned cycle menu, the following screen is displayed: Multiple Thread Mill Single Thread Mill The parameters on the screen correspond to the following: Where: Center: X and Y coordinates of the center of the thread mill operation.
Page 114 Thread / Unit: Number of threads per inch or mm. Used to calculate thread pitch. Thread Pitch: Thread pitch calculated from threads/unit field. This field cannot be modified. Thread Type: Specifies right or left hand threads. Thread Direction: Specifies whether to start at the bottom of the hole and work up or start at the top of the hole and work down.
Page 115: Cleanout
Cleanout (F9 in the Canned Cycle Menu) The cleanout cycle performs a horizontal zigzag pocket cleanout of a profile composed of lines and arcs. When you press F9 - Cleanout from the canned cycle menu, the following screen is displayed: Where: Rough Cuts: Selects type of rough cut.
Page 116 per Pass: The depth amount of cut to be taken to reach the total depth. This value must be greater than 0.0 and cannot exceed the total depth. Plunge Rate: The feedrate at which the Z axis is moved when plunging to a lower depth. After the cleanout parameters are accepted, a screen similar to the following appears: Key points about the Cleanout cycle: •...
Page 117 F1-Island (Island Avoidance) Once you have defined a pocket in the cleanout cycle. There may be areas or islands that you don’t want cleaned out. To create an island press F1-Island, enter the starting point of the island and then use F2-Linear and F3-Arc to create the island. See an example of a completed cleanout backplot below.
Page 118: Subprograms
F7 - Cutter Compensation Pressing F7 - Cutter Comp from the Insert Operation screen, will insert a cutter compensation command. Press F3 - Toggle or SPACE to select cutter compensation Left, Right, or Off. Cutter compensation may be used with Linear Mill, Frame Mill, and Rapid Traverse operations. For details on using cutter compensation, see the section “G40, G41, G42 –Cutter Compensation”...
Page 119 A typical subprogram screen appears as follows: All subprogram operations contain the following fields: Start Block: Selects the first operation in the block of operations to repeat. This operation must lie before the place in your program where you are trying to repeat operations. End Block: Selects the last operation in the block of operations to repeat.
Page 120: Repeat To Depth
Repeat to Depth (F1 in the Insert Subprogram Menu) The Repeat to Depth feature is useful for repeating a part contour when the material being machined is too thick to cut in just one pass. The contour formed by these operations may either be a closed contour or an open one. If a non- vertical plunge to the start of the contour is desired, it must be programmed into the contour (a vertical plunge between passes will be provided if one is not programmed).
Page 121: Repeat
Repeat (F2 in the Insert Subprogram Menu) The Repeat feature is useful for repeating a part contour one or more times along a straight line in the XY plane. The contour formed by these operations may either be closed or open. If a rotary axis is enabled, this operation can also be used for repeating such a contour one or more times over a specified rotary increment.
Page 122: Mirror
Mirror (F3 in the Insert Subprogram Menu) The Mirror feature is useful for reflecting a part contour over a line. The contour formed by these operations may either be closed or open. Mirror Line: Specifies the type of mirror line to use. Choices are Horizontal, Vertical and Other (user-defined). X Offset: Specifies the X coordinate on the Mirror Line.
Page 123: Rotate
Rotate (F4 in the Insert Subprogram Menu) The Rotate feature is useful for rotating a part contour multiple times around a given point. The contour formed by these operations may either be closed or open. Center: The XY location of the center of rotation. Start Angle: The angle from the original copy at which the first copy will be placed.
Page 124: Graphics
Graphics Intercon features three-dimensional previews of the tool path to be followed when milling the part. You may choose to display your project in one of two formats: a three-plane display, where the project is shown in each of the XY-, ZX-, and YZ-planes;...
Page 125 F2 – View/Rotate In three-plane (2D) view, F2 - View switches the point of view to a different plane. In isometric, (3D) view, F2 - Rotate enables the arrow keys to rotate the figure. The arrow keys actually rotate a larger version of the YZX axes figure that shows the orientation in which the part will be redrawn.
Page 126 F4 - Dimension Menu Press this key to access a sub-menu of options: F1 – Prev Line: Press this to walk forward to the next G-code line and graphically highlight it. If this G-code line contains movement, the Start and End points will be displayed at the bottom of the screen.
Page 127: Math Help
Math Help Intercon provides a math assistance function to solve the trigonometric problems common in part drawings. To enter Math Help, press F6 - Math Help from any Edit Operation screen. The first time that you invoke Math Help, the following screen appears which shows all available solvers: The figures on the right are a graphical representation of the highlighted solver on the left.
Page 128 F1 – Prev Soln (Previous Solution) F2 – Next Soln (Next Solution) The Prev Soln and Next Soln options will cycle backward and forward, respectively, through the available solution sets for math solvers that may have multiple solutions. A status line near the bottom left of the screen appears once a valid solution has been found. The solution status line indicates the total number of solutions and the solution number that is currently represented by the graphic display on the right.
Page 129 F1 –Triangle: Right F2 –Triangle: Other The screen will show UNKNOWN if the value of each parameter is not known. Math Help waits for known values to be entered, where: Point a, b, or c is the coordinate value for each corner of the triangle. Angle A, B, or C is the angle at each point of the triangle.
Page 130 F3 – Tangent: Line Arc Given the center (C1) the radius of an arc, and 1 point (LP) on a line, find the lines tangent to the arc (defined by the tangent point (T1)). You must enter the X and Y coordinates for the circle's center point, the circle's radius, and the X and Y coordinates for a point on the line.
Page 131 F5 – Tangent: Line Arc Arc Given the center points (C1 and C2) and radii (R1 and R2) of two arcs, find the lines (defined by T1 – T2) tangent to both arcs. You must enter the X and Y coordinates for the first circle's center point, the radius of the first circle, the X and Y coordinates for the second circle's center point, and the second circle's radius.
Page 132 You must enter the radius of the tangent arc, the X and Y coordinates for the first circle's center point, the radius of the first circle, the X and Y coordinates for the second circle's center point, and the second circle's radius. F7 –...
Page 133 Given the center (C1) and radius (R) of an arc, 1 point (P1) and either a second point (P2) or one coordinate (P2 X or Y) and the angle from horizontal, find the intersection point(s) (I1 and I2). You must enter the X and Y coordinates for the circle's center point, the circle's radius, the X and Y coordinates for one point on the line, and one of the following: * the X and Y coordinates of a second point on the line * the X coordinate of a second point and the angle from horizontal...
Page 134: Importing Dxf Files
Importing DXF files (Optional) Intercon allows you to convert geometry in DXF files to Intercon operations. To insert operations from a DXF file press F6 – Other then F8 - Import DXF. If no DXF files have been loaded yet, the Intercon load file menu will appear.
Page 135 After the zero reference is set the Select Intercon operation menu appears. This menu allows you to select the type of Intercon operation you wish to create using geometry from the DXF file. F1 – Contour Convert one or more connected lines and/or arcs to linear and arc operations. F2 –...
Page 136 Selecting DXF geometry After selecting an operation to from the Select Intercon operation menu, one of two menus appears. Contour, pocket and frame operations display the Select Chain menu and Drill, Bore, Tap and Thread operations display the Select Point menu. These menus allow you to select the geometry you wish to use to create the specified Intercon operation(s).
Page 137 F7, F8 & F9 - Zoom In, Zoom Out & Zoom All F7 - Zoom In and F8 - Zoom Out, set the center of the plot to the center of the crosshairs and Zoom In and Zoom Out respectively. F9 - Zoom All redraws the part with its original scale.
Page 138 (Arrow Keys) – Move crosshairs Press the arrow keys to move the crosshairs. F1 – Window This key allows you to select all points within a specified box. Press F1 - Window once to set the first corner of the box. Move the crosshairs to the desired location for the opposite corner of the box and press F1 - Window.
Page 139 The key F2 - Single only appears when a point is highlighted. The keys F5 - Undo and F10 - Done only appear when one or more points have been selected with F1 - Window or F2 - Single. Using a mouse In addition to the arrow keys, a mouse may be used to position the crosshairs in the DXF selection menus.
Page 140 M-Series Operator’s Manual 4/9/15 10-58...
Page 141: Intercon Tutorials
Intercon Tutorial #1 This is a step-by-step instructional example of going from blueprint to part with Intercon. The tool path to be created is for the part shown in Figure 1. For instructional purposes, this part will be programmed to cut into stock held in 3 fixtures, 6 inches apart along the X-axis.
Page 142 Part Creation Each feature of the part will become an operation in your program. Before beginning, decide where you want the X0 and Y0 reference. For this particular part, the center of the bolt hole pattern was selected. Now start the Intercon program (from the CNC software main screen, press F5 - CAM).
Page 143 N0030 Circular pocket Center: : 0.0000 : 0.0000 Surface Height : 0.0000 Diameter : 1.0000 Cleanout : Yes Depth: Total : 0.5000 Per Pass : 0.2500 Plunge Rate : 2.0000 Plunge Type : Ramped Plunge Angle : 0.00° Rough Cuts : Conventional Stepover : 0.2250...
Page 144 FIG. 2 - Graphics screen showing bolt holes and circular pocket ESC/CANCEL Return to the editing screen. F10 - Accept Keep selected values. F5 -Cycles Access the list of available Canned Cycles. F7 - Frame Now add an outside frame to cut the flange out of the material. The flange is 3.0000 inches long by 3.0000 inches wide, and has rounded corners with 0.2500-inch radii.
Page 145 FIG. 3 - Graphics screen showing part with bolt holes and outer frame ESC/CANCEL Return to the editing screen. F10 - Accept Keep selected values. F9 - Subpgm Access the Insert Subprogram screen. F2 - Repeat We programmed the part to cut one copy only. We now want to repeat the part 2 more times at an incremental distance of 6 inches along the X-axis.
Page 146 ESC/CANCEL Creation of the part is complete. Intercon programs automatically turn the spindle and coolant off at the end. F1 - File Press F3 - Save to save the part under its current name. Press F4 - Save As to save it under a new name. F10 - Post The CNC file needed to run this part on your mill will be generated at this time.
Page 147 Milling the Part Now that the part has been programmed, it is time to mill it. Take your material and clamp it to the table. Remember that the clamps must be positioned such that they do not interfere with the tool as it cuts. You may choose either to place the clamps around the edges of the material for the entire process and let the part drop through upon completion, or you may wish to pause after milling the circular pockets and place clamps through the holes to prevent the part from moving.
Page 148 F2 - Tool Lib. Now you need to make sure that each tool uses the correct diameter and height offset values. Inspect the values for T001. T1 should use H001 and D001. If any of these values are incorrect, use the arrow keys to select the incorrect values. Enter the new values in their places and press ENTER to accept them.
Page 149 Intercon Tutorial #2 This demonstration will show you how to create a tool path for a part from a blueprint using the Math Help function of Intercon. The tool path to be created is for the part shown in Figure 1 below. 4.0000"...
Page 150 PRESS COMMENTS F1 - New Create a new program by filling in the appropriate program name (we recommend c_rod) and your name. Press Enter or F10 - Accept to accept the new name. Enter “Intercon Tutorial #2” for the description. Press F10 - Accept to accept. F4 - Tool Describe the tool below.
Page 151 FIG. 2 - Bolt Hole Circle N0003 Drill bolt holes Cycle Type : Drilling Center: : 0.0000 : 0.0000 Surface Height : 0.0000 Clearance Height : 0.5000 'Rapid To' Depth : 0.1000 Depth: Total : 0.5100 Plunge Rate : 2.0000[M] Dwell Time : 0.0000 Number of holes...
Page 152 N0004 Tool change Tool Number Description : 0.250 Dia End Mill Position: X : 0.0000 Y : 0.0000 Tool H Offset (Tool Height) : (Your tool) Tool D Offset Tool Diameter : 0.2500 Spindle Speed : 1000 Spindle Direction : CW (M3) Coolant Type : Flood (M8)
Page 153 N0060 Circular pocket Center: : 4.0000 : 0.0000 Surface Height : 0.0000 Diameter : 0.7500 Cleanout : Yes Depth: Total : 0.5100 INC Per Pass : 0.2500 Plunge Rate : 2.0000 Plunge Type : Ramped ° Plunge Angle : 0.00 Rough Cuts : Conventional Stepover...
Page 154 N0080 Rectangular pocket Center: X : 3.0000 Y : 0.0000 Surface Height : 0.0000 Length (X) : 0.7500 Width (Y) : 0.4250 Corner Radius : 0.1875 Depth: Total : 0.2500 Per Pass : 0.2500 Plunge Rate : 2.0000 Plunge Type : Ramped °...
Page 155 F7 - Cutter Comp Hit Space until Left cutter compensation is selected. The tool must move outside of the part outline at a distance at least equal to its radius so the part outline is the correct size. N00011 Comp left F10 - Accept Keep selected values.
Page 156 FIG 3. - Tangent point and arc reference. 4.0000" 2.0000" 1.0000" Arc 4 Arc 5 3.15” R 45º .1875 .3750 .6000 .6250 .9250 Arc1 0.7500" x 0.4250" 1.2500" R 3.1500" R Arc 3 Arc 2 N0013 Arc Arc type : EP&R End: X : 4.6250 Y : 0.0000...
Page 157 F6 - Tangent Arc Arc Arc This scenario will generate tangent points P2 - P5 of Figure 3. Enter the values as shown below: Arc Tangent Arcs: Circle 1: X : 4.0000 Y : 0.0000 Radius : 0.6250 Circle 2: X : 0.0000 Y : 0.0000 Radius : 1.2500...
Page 158 rectangle and the solid block will appear in the arc operation on the right. ARROWS Move the block cursor to the End X field of the arc operation. As before, use only <↑> and <↓>. F8 - Copy >>> Transfer the tangent point T1 value for X into the end point X coordinate.
Page 159 FIG. 5 - Draw screen showing Bolt Holes, Pockets and first arc of part ESC/CANCEL Return to the editing screen. F10 - Accept Keep selected values. The other arc values were calculated for you. F3 - Arc The next arc to be cut is labeled as ARC 2 in Figure 3. The start point is labeled P2, the end point of the last arc.
Page 160 FIG. 6 – New arc 2 entry screen shown with solution for arcs 1 and 2 of Figure 3. ↑ ↑ ↑ ↑ ↓ ↓ ↓ ↓ (UP/DOWN) If necessary, move the block cursor to the Tangent 2 X field as shown above.
Page 161 Arc type : EP&R End: X : 0.7496 Y : -1.0003 Z : -0.0500 Center: Angle Radius : 3.1500 Plane : XY Direction : CCW Feedrate : 10.0000 Angle <= 180° : Yes F10 - Accept Keep selected values. F3 - Arc The third arc to be cut is labeled as ARC 3 in Figure 3.
Page 162 FIG. 7 - Math Help solution for arcs 3 and 4. ↑ ↑ ↑ ↑ ↓ ↓ ↓ ↓ ( ARROWS) Press to highlight the needed tangent point X coordinate in Math Help. Tangent point T2 is the one you want this time. →...
Page 163 Arc type : EP&R Mid: End: X : 0.7496 Y : 1.0003 Z : -0.0500 Center: Angle Radius : 1.2500 Plane : XY Direction : CW Feedrate : 10.0000 Angle <= 180° : No F10 - Accept Keep selected values. F3 - Arc The fourth arc to be cut is labeled as ARC 4 in Figure 3.
Page 164 ↑ ↑ ↑ ↑ ↓ ↓ ↓ ↓ (UP/DOWN) Highlight the needed tangent point X. Tangent point T1 is the one you want this time. ARROWS If necessary, move the cursor to the arc operation and select the End X field. F8 - Copy >>>...
Page 165 N0017 Arc mill Operation type : EP&R Mid: End: X : 4.6250 Y : 0.0000 Z : -0.0500 Center: Angle Radius : 0.6250 Plane : XY Direction : CW Feedrate : 10.0000 Angle <= 180° : Yes F10 - Accept Keep selected values.
Page 166 F1 - Rapid Move the tool away from the part. This is called a lead-out move. When cutter compensation is turned off, the compensation is removed during the next move. This must be done to allow the CNC software to correct its position. N0020 Rapid traverse End: 5.0000...
Page 167 ESC/CANCEL Creation of the part is complete. Intercon programs automatically turn the spindle and coolant off at the end. F8 - Graph Display a preview of the finished part. Just make sure that the finished part is going to look the way you want it to. The display shown in Figure 7 has rulers placed around the various view windows that are scaled to the same size as the part displayed to allow visual inspection of the part.
Page 168 As it processes each operation, it checks for values that, if used, will cause incorrect code to be produced. If such a value is found, a message will appear on the screen alerting you of the problem. For example, a problem with a rectangular pocket may produce this message: Changes to the part would then be required to allow proper code generation to proceed.
Page 169 Milling the Part Now that the part has been programmed, it is time to mill it. Take your material and clamp it to the table. Remember that the clamps must be positioned such that they do not interfere with the tool as it cuts. You may choose to place the clamps around the edges of the material for the entire process and let the part drop through upon completion, or you may wish to pause after milling the circular pockets and place clamps through the holes to prevent the part from moving.
Page 170 F10 - Save Keep the updated tool offset library values. F2 - Tools Now you need to make sure that each tool uses the correct diameter and height offset values. Inspect the values for T001 and T002. T1 should use H001 and D001, while T002 should use H002 and D002.
Page 171 Measuring Tool Heights The following is a brief description of the method used to measure tool height values (offsets). You will need to insert a reference tool into the quill before beginning. For more information also see chapter 5. PRESS ACTION COMMENTS F1 - Setup...
Page 172 M-Series Operator’s Manual 4/9/15 10-90...
Page 173: Cnc Program Codes
Chapter 11 CNC Program Codes General The next three chapters contain a description of the CNC program codes and parameters supported by the M-Series Control. The M-Series Control has some G codes and parameters that are modal, and some that are "one shots." The G codes and parameters that are modal will stay in effect until a new G code or parameter is issued.
Page 174 H - Tool Length Offset Number H is used to select the Tool Length Offset Number. The H code offset amounts are stored in the file Offset Library. Tool Length Offsets can be specified anytime before a G43 or G44 is issued. Once specified the offset amount is stored and will only be changed when another H code is entered therefore, H is modal.
Page 175 Q - Parameter Q is used as a depth parameter in canned drilling cycles. Example: G73 X1.5 Y2.0 Z-.75 R.25 Q.25 F5 ; Q Sets the depth cut at .25 R - Radius, Return Point, Parameter R can represent the radius, a return point, or a general parameter. This is used as a variable for any of those values in the NC file.
Page 176: User And System Variables
; - Internal Comment Identifier The semicolon (;) is used to indicate the start of an internal comment within a CNC program line. All characters after the semicolon are ignored when the program is run. Internal comments are used to document NC programs or temporarily omit the remainder of a line.
Page 177 #, = - User or System Variable reference The ‘#’ character is used to reference a macro or a user or system variable. For variables that can be written, the ‘=’ is used to assign to them. General purpose user variables are #100 to #149 and #29000 to #31999. Index Description Returns...
Page 178 Index Description Returns 10001-10200 Mill: Height offset amount, H001 – H200 Floating point value 11000 Mill: Diameter offset amount, active D Floating point value 11001-11200 Mill: Diameter offset amount, D001 – D200 Floating point value 12000 Mill: Tool H number, active tool (T) 0 - 200 12001-12200 Mill: Tool H number, tools 1 - 200...
Page 179 Index Description Returns 23301-23308 min_error (PID) for axes 1-8 23401-23408 at_index_pulse for axes 1-8 23501-23508 travel_minus for axes 1-8 23601-23608 travel_plus for axes 1-8 23701-23708 axis_home_set for axes 1-8 23801-23808 abs_position (in encoder counts) for axes 1-8 23901-23908 PID_out for axes 1-8 24001-24008 reference set for axes 1-8 24101-24108...
Page 180: Advanced Macro Statements
Index Description Returns 27201-27208 ACDC drive estimated brake wattage for axes 1-8 27301-27308 Real motor encoder positions for axes 1-8 Motor encoder positions that accounts for lash, MPG, and scale offsets. (Note that these can be different from what is displayed as Abs Pos in the PID menu.) 27401-27408 Scale encoder positions for axes 1-8...
Page 181 GOTO - Branch Execution To branch to another line within the same program or subprogram, use the statement: GOTO <expression> where <expression> is any expression that evaluates to a valid block number in the program. GOTO causes an immediate branch to the specified destination. Program codes preceding a GOTO on the same line will be executed normally.
Page 182 INPUT – Prompt Operator for Input The INPUT macro prompts the operator for numeric input. The general form of the INPUT statement is: INPUT “<prompt>” <variable> Where <prompt> is the message prompt for the operator and <variable> is the variable in which to store the input. The CNC software will display a dialog with the given prompt and space for the operator response.
Page 183 Chapter 12 CNC Program Codes: G-codes G-code Group Description Rapid Positioning Linear Interpolation Circular or Helical Interpolation CW Circular or Helical Interpolation CCW Dwell Decelerate and Stop (formerly known as Exact Stop) Parameter Setting Circular Interpolation Plane Selection XY Circular Interpolation Plane Selection ZX Circular Interpolation Plane Selection YZ Select Inch Units Select Metric Units...
Page 184 Drilling and Spot Drilling Drill with Dwell Deep Hole Drilling Tapping Boring Boring with Dwell Absolute Positioning Mode Incremental positioning Mode Set Absolute position Inverse Time On G93.1 Velocity Scrubber for Smoothed Inverse Time Data Inverse Time Off Initial Point Return R Point Return G117 Rotation of Plane Selection XY...
Page 185 When the Z axis is commanded to move in the + direction, the Z axis will move up to its new position first, then the other axes will move to their new position along a straight line. When the Z axis is commanded to move in the - direction, all axes but the Z axis will move to their new position along a straight line, then the Z axis will move down to its new position.
Page 186 Helical and circular motion can be programmed in two different ways: specifying the final point and the radius of the arc, or specifying the final point and the parameters I, J, K (center point of the arc as incremental values from the start position).
Page 187 METHOD 2: USING FINAL POINT AND PARAMETERS I, J, K Another way to specify a helical or circular operation is using the parameters I, J, K instead of the radius R. The parameters I, J, and K are the incremental distances from the start point to the center of the arc. For absolute positioning on I, J, and K, parameter 2 bit 0 will need set.
Page 188 Dwell G4 causes motion to stop for the specified time. The P parameter is used to specify the time in seconds to delay. G4 causes the block to decelerate to a full stop. The minimum delay is 0.01 seconds and the maximum is 327.67 seconds. The dwell time is performed after all motion is stopped and M functions on the line are completed.
Page 189 G21 - Select Metric Units G21 selects metric units, affecting the interpretation of all subsequent dimensions and feedrates in the job file. G21 does not change the native machine units, as set on the control setup menu. G22/G23 – Work Envelope On/Off G22 turns on programmable work envelope in machine coordinates.
Page 190 G29 - Return from Reference Point G29 moves all axes to the intermediate point stored in a preceding G28 or G30 command. It may be used to return to the work piece. If a position is specified, the machine will move to that position (in local coordinates) after reaching the intermediate point.
Page 191 Whenever cutter compensation is applied, the following factors must be taken into account in order to obtain proper results. 1. The cutter diameter compensation function (G41, G42) must be implemented before the cutter tool reaches the starting cutting point. Example 1: G0X0Y0 ;...
Page 192 Example 2: G0 X0Y0 ; Rapid tool to X0, Y0 G42 D5 ; Turn cutter compensation on, with a diameter of D5 G1 X.75Y-1 F5 ; Linear move to X0.75, Y-1. (Notice this damages the ; corner of the work piece) X3.6 ;...
Page 193 G0X0Y0 ; Rapid tool to X0, Y0 G42D5 ; Turn cutter compensation on, with a diameter of D5 G0X0Y-1 ; Rapid tool to X0, Y-1 G1X.75Y-1 ; Linear cut to X0.75, Y-1. X3.6 ; move X to 3.6 ; Turn cutter compensation off. 3.
Page 194 Example, Scaling: G51 X0.0 Y0.0 Z0.0 I3.0 J2 K1 ; turn scaling on G00 X0.0 Y0.0 Z1.0 ; rapid to X0, Y0, Z1 G01 X1.0 Y0.0 Z1.0 ; line to X1, Y0, Z1 G01 X1.0 Y1.0 Z1.0 ; line to X1, Y1, Z1 G01 X0.0 Y1.0 Z1.0 ;...
Page 195 G52 - Offset Local Coordinate System G52 shifts the local coordinate system origin by a specified distance. Multiple G52 codes are not cumulative; subsequent shifts replace earlier ones. The G52 shift may therefore be canceled by specifying a shift of zero. If you are using multiple coordinate systems, the G52 shift amount will affect all coordinate systems.
Page 196 G61 - Modal Decelerate and Stop (formerly known as Exact Stop Mode) G61 activates Decelerate and Stop mode for every block processed. This forces motion to decelerate to a stop and invokes a brief dwell (1/100 seconds) at the end of each block (equivalent to G9 in each block).
Page 197 G65 - Call Macro G65 calls a macro with user-specified values. A macro is a subprogram that executes a certain operation (e.g. drill pattern, contours, etc.) with values assigned to variable parameters within the operation. Calling methods: G65 Pxxxx Lrrrr Arguments G65 "program.cnc"...
Page 198 The macro variables would handle the length in the Y direction and depth in the Z direction: O0002 G90 G1 Z0 F30 ; Linear move to Z0 Z#Z F5 ; Cut to variable depth G91Y#Y F10 ; Cut variable length G90 G0 Z0.1 ;...
Page 199 Example: G68 R45 X4 Y2 ; Rotate 45 degrees centered on X4 Y2 G0 X3.0 Y1.0 ; Rapid to position G1 X5.0 Y1.0 F20 ; Start part profile X5.0 Y3.0 X4.125 Y3.0 G3 X4.0 Y2.875 J-0.125 G1 X4.0 Y2.125 G2 X3.875 Y2.0 I-0.125 G1 X3.125 Y2.0 G3 X3.0 Y1.875 J-0.125 G1 X3.0 Y1.0...
Page 200 Feed Spindle CCW, then Dwell Feed Tapping (Right-hand (Set with the P parameter) thread) Feed ---------- Feed Boring cycle Feed Dwell (Set with the P Feed Boring cycle parameter) Table 1. Canned drilling, boring and tapping cycles Canned Cycle Operation Operation 1: Position the X, Y axes.
Page 201 Z ____ Specifies point Z in figure 1. In incremental mode Z is measured from point R. In absolute mode Z is the position of the hole bottom. R ____ Specifies the distance to point R (figure 1) with an absolute or incremental value. Q ____ Determines the cut-in depth for the G73 and G83 cycles.
Page 202 Example: (Part surface height is Z = 0, initial tool position is X.50 Y1.0 Z.625. Drill 0.50 deep hole at X1.0 Y1.0; clearance height (R) is 0.10 above surface.) Absolute Incremental G81 X1 Y1 R.1 Z-.5 G81 X.5 Y0 R-.525 Z-.6 * NOTE for Articulated Head machines configured with the TWCS feature enabled via Parameter 166: If the currently selected WCS is non-TWCS (TWCS = No) and the B axis is at an angle other than 0, then you cannot use the regular Canned Cycle G-codes G73, G74, G76, G81, G82, G83, G84, G85, G89.
Page 203 G74 - Counter Tapping G74 performs left-hand tapping. The spindle speed (and feedrate, if you are doing floating tapping) should be set and the spindle started in the CCW direction before issuing G74. G74 will normally use the default M3 to select spindle CW (at the bottom of the hole) and M4 to re-select spindle CCW (after backing out of the hole) depending on the settings of parameters 74 and 84.
Page 204 G76 – Fine Bore Cycle WARNING!!! G76 requires that the machine be capable of orienting the spindle and that a custom M19 macro is present in order to command the inverter to orient the spindle. Please contact your dealer to confirm that your machine meets these requirements before attempting to use this cycle.
Page 205 G81 - Drill Cycle Transformation to G81 Air Drill Cycle G81 may be modified to execute an M function instead of moving the Z-axis by setting parameter #81 to the desired M function. Example use is for air-actuated drills. Example: Execute M39 each time a new G81 position is given: G10 P81 R39 ;...
Page 206 G82 is a general purpose drilling cycle similar to G81. However, G82 includes an optional dwell at the bottom of the hole before retracting the tool. This can make the depth of blind holes more accurate. Example: G82 X1 Y1 R.1 Z-.5 P.5 ;...
Page 207 G83 is a deep hole drilling cycle. It periodically retracts the tool to the surface to clear accumulated chips, then returns to resume drilling where it left off. The retract and return are performed at the rapid rate. Because there may be chips in the bottom of the hole, the tool does not return all the way to the bottom at the rapid rate.
Page 208 Example: M3 S500 F27.78 ; start spindle CW, set up for 18 pitch tap G84 X1 Y1 R.1 Z-.5 ; tap a 0.5 deep hole at X1 Y1 Y1.5 ; ... and another one at X1 Y1.5 ; cancel canned cycle …...
Page 209 List of Rigid tapping setup parameters – see Chapter 14 for more details Parameter Function Spindle Encoder Counts/Rev Spindle Encoder Axis Number Rigid Tapping Enable/Disable Spindle Deceleration Time Minimum Rigid Tapping Spindle Speed Duration For Minimum Spindle Speed M-Function executed at bottom of tapping cycle M-Function executed at return to initial point of tapping cycle Spindle Drift Adjustment Graphic representation of test results for precision...
Page 210 Summary Rigid tapping parameters will vary from machine to machine. Not all machines are built the same (i.e. Spindle hp, inverter type, rigidity, etc.), and tooling will play a roll in performance also. It was found through our testing, if we changed one physical parameter, (i.e. using a tapping oil instead of water base coolant), it improved the off target values by 1.5%.
Page 211 G89 - Boring cycle with dwell G89 is similar to G85, except that it includes an optional dwell at the bottom of the hole before retracting the tool. Example: G89 X1 Y1 R.1 Z-.5 P.1 ; bore 0.5" hole at X1 Y1, dwell .1 seconds ;...
Page 212 G93 - Inverse Time Rather than using a conventional federate in Inch per Minute or MM per Minute, F in inverse time mode specifies the movement frequency for subsequent moves. Specifically, the inverse time feedrate is the inverse of the amount of time that a move is allowed to take.
Page 213 G98 - Initial Point Return G98 sets the +Z return level to point I as pictured in Figure 1 in the Canned Cycle Section. (G98 is the default setting) G99 - R Point Return G99 sets the +Z return level to point R as pictured in Figure 1 in the Canned Cycle Section. G117, G118, G119 - Rotation of Pre-set Arc Planes G117, G118 and G119 have the same functionality as G17, G18 and G19, respectively, except that they include 2 optional parameters P and Q to specify the arc plane rotation away from the pre-set arc plane: P specifies the arc...
Page 214 G173, G174, G176, G181, G182, G183, G184, G185, G189 – Compound Canned Cycles On a machine configured as an Articulated Head machine with the TWCS feature enabled, the Compound Canned Cycle G-codes are used to perform tilted-head Drill/Bore/Tap operations when the currently selected WCS is not transformed (TWCS=No).
Page 215 Chapter 13 CNC Program Codes: M functions M functions are used to perform specialized actions in CNC programs. Most of the M-series Control M functions have default actions, but can be customized with the use of macro files. Summary of M functions M00 Stop for Operator M80 (macro) Carousel In * M01 Optional Stop for Operator...
Page 216 Macro M functions (custom M functions) Most M-Series CNC M functions from 0 through 90 can be fully customized. Exceptions are M2, M6, and M25 that can be customized, but will always move the 3rd (Z) axis to the home position before executing the macro M function commands.
Page 217 M00 - Stop for Operator Motion stops, and the operator is prompted to press the CYCLE START button to continue. M01 - Optional Stop for Operator M1 is an optional pause, whose action can be selected by the operator. When optional stops are turned on, M1 will pause the currently running job until CYCLE START is pressed. However, if optional stops are turned off, M1 will not pause the program.
Page 218 Default action (tool changer installed): ; always does M25 first M95/1/2/3/5 ; turn off spindle & coolant M95/16 ; turn off tool changer strobe M107 ; send tool number to tool changer M94/16 ; turn on tool changer strobe M101/32 ;...
Page 219 M17 – Prepare for Tool Change (Macro) M17 has no default action, therefore a custom M17 macro must be defined for this feature to work. If defined, the M17 macro turns off spindle and coolant and starts the spindle orientation process in preparation for M6 (Tool Change).
Page 220 Example: ; PLC program fragment CNC_program_running is SV_PROGRAM_RUNNING ;program running indicator M15 is SV_M94_M95_15 ; M function 15 indicator drill_out is OUT5 ; air drill output relay if M15 && CNC_program running then (drill_out) ; Drill On if M94/15 and the ;...
Page 221 Example M60 use in a program: M121 "m60test.dig5" ; Open text file to record data too #29100 = -8.7999 ; X-Axis Start Position #29101 = .3747 ; Y-Axis Start Position #29102 = -1.1832 ; Z-Axis Start Position #29103 = 85.957 ;...
Page 222 M94/M95 - Output On/Off There are 128 user definable system variable bits that can be used to communicate with the PLC. M94 and M95 are used to request those system variable bits to turn on or off respectively. Requests 1-128 are mapped to the PLC as system variables SV_M94_M95_1 through SV_M94_M95_128 as shown in the following table: PLC bit M94/1...
Page 223 Suppose that a drilling pattern of 4 holes is needed in 3 different locations. This subprogram would handle the drilling and incremental moves between the holes: O9101 ;Program O9101.cnc G91 F10 ;Incremental positioning G81 X0 Y0 R -.4 Z-.6 ;Drill lower left hole Y1.5 R -.4 Z-.6 ;Drill upper left hole X1 R -.4 Z-.6...
Page 224 M99 - Return from Macro or Subprogram M99 designates the end of a subprogram or macro and transfers control back to the calling program when executed. M99 may be specified on a line with other G codes. M99 will be the last action executed on a line. If M99 is not specified in a subprogram file, M99 is assumed at the end of the file: Example: G1 X3 M99...
Page 225 M102 - Restart Program M102 performs any movement requested, and restarts the program from the first line. The Z-axis is NOT moved to the home position, and the operator is NOT prompted to press the CYCLE START button to continue. M103 - Programmed Action Timer M103 is used to set up the time limit for a timed operation.
Page 226 M108 - Enable Override Controls M108 re-enables the feedrate override and/or spindle speed override controls if they were disabled with M109. A parameter of “1” indicates the feedrate override; “2” indicates the spindle speed override. Example: M109/1/2 ; disables feedrate and spindle speed overrides M108/1 ;...
Page 227 Example: Finding the center of a vertical slot. In this example, it is assumed that there is a probe connected to INP15 and that the probe tip is positioned somewhere in the slot, such that movement along the X-axis will cause a probe trigger.
Page 228 M120 - Open data file (overwrite existing file) This M function will open the requested data file for writing. If no drive or directory is specified with the file name, then the file will be opened in the same directory as the CNC program. If the file cannot be successfully opened, then an error will be returned, ultimately terminating the job.
Page 229 M123 - Record value and/or comment in data file This M function will write the specified parameter value (if any) to the data file, followed by any comment that appeared on the line with M123. If a P value is specified, M123 will record the numeric value (4 decimal places in inches, 3 in millimeters).
Page 230 M130 - Run system command This allows shell commands to be called from a CNC program or MDI. M130 takes one string argument which contains the system command to execute. For example: M130 "mycommand.bat" will run the batch file mycommand.bat. Normally, the command will run asynchronously, meaning that the G-code program will not wait for the command to finish before continuing.
Page 231 *The above method of representing an axis label should be used only when writing to an external file or for display in a message box. It is not valid if you are attempting to “build” a motion command in real-time from within the currently running g code program.
Page 232 M225 – Display Formatted String for A Period of Time The M225 command displays a formatted-string for a specified period of time. The syntax is: M225 time_expr formatted-string [user_var] ... where time_expr is a user_var_expr that evaluates to a floating point variable specifying the number of seconds to display the output, with a value of zero interpreted as indefinitely.
Page 233 M1000-M1015 – Graphing Color for Feedrate movement When a CNC program is graphed (F8 from the Main Screen), feedrate movements are normally plotted using the color yellow. This color setting can be changed to another color as stated in the chart below. M Code Feedrate M Code...
Page 234 M-Series Operator’s Manual 4/9/15 13-20...
Page 235: Configuration
Chapter 14 Configuration General The first four options, F1 through F4, will display a set of parameters. Each option is explained in detail below. The ESC key will return you to the previous screen (Setup). The configuration option provides you with a means for modifying the machine and controller configuration. The majority of information in this section should not be changed without contacting your dealer.
Page 236: Control Configuration
Control Configuration Pressing F1 - Contrl from the configuration screen will display the Control Configuration screen. The Control Configuration screen provides you with a method of changing controller dependent data. Each of the fields is discussed in detail below. If you wish to change a field, use the up and down arrow keys to move the cursor to the desired field. Type the new value and press ENTER, or press the SPACE bar to toggle.
Page 237: User Specified Paths
Maximum Spindle Speed (High Range) This field sets the high range maximum spindle speed for those machines that have a variable frequency spindle drive controller (VFD). All spindle speeds entered in a CNC program are sent to the PLC as percentages of this maximum value.
Page 238: Machine Configuration
Path tag Purpose of path INTERCON_PATH Main directory containing *.icn files ICN_POST_PATH Directory INTERCON places *.cnc files created when posting *.icn files. DIGITIZE_PATH Directory digitize files are saved to. Directory used by F4 key in Load Job menu when parameter 4 is set to 2. CAD_PATH Default directory used by the Import DXF file menu in Intercon.
Page 239 Max Rate: Determines the maximum feedrate of each individual axis. The feedrate on each axis can never exceed Max Rate, even if the feedrate override knob on the front panel is turned up above 100%. (See also the Machine Parameters section for the "Multi-Axis Max Feedrate" parameter that limits the feedrate along move vectors, not just each individual axis.) * NOTE: The maximum rate may be set to a smaller value if you wish to run your machine at a slower rate.
Page 240 Label: The letter you want to use to identify the axis. The first three axes should normally be X, Y, and Z. If a fourth axis is installed, it is usually named W or B. If you change a label, for example from X to A, the controller will then accept G-codes for axis A instead of X.
Page 241 F7 – Scales This menu lets you set up scale encoders for the purpose of applying scale encoder correction to one or more axes. The Scale Settings should not be changed without contacting your dealer. Corrupt or NOTICE incorrect values could adversely affect the accuracy of the positioning of your machine. Axis and Label are for informational purposes to indicate on which axis the scales will be applied.
Page 242: Machine Parameters
Machine Parameters (F3 - Parms from Configuration) This screen provides you with a method of changing various parameters that are used by the control. Altogether, you have access to 500 parameters spread across 5 tables. Each table gives you access to 100 parameters at a time. You can navigate between tables using the following keys: F7-Previous Table and F8-Next Table.
Page 243 Bit-mapped parameters Certain control parameters are defined by bit-mapped values. In order to change these parameters you must understand how bit mapping works. A bit-mapped parameter is stored as a number, representing a 16-bit value in the control. If a certain bit needs to be turned on, that bit’s binary value must be added to the parameter value, if the bit needs turned off, its binary value must be subtracted from the parameter value.
Page 244 Parameter Definition Default setting MPG modes Ambient Temperature 72°F / 22°C 21-24 Motor Heating Coefficients for axes 1,2,3,4 Refer to text 25-28 Motor Cooling Coefficients for axes 1,2,3,4 Refer to text Warning Temperature 150°F / 65.5°C Limit Temperature 180°F / 82°C Legacy SPIN232 Com Port Spindle Motor Gear Ratio Spindle Encoder Counts/Rev...
Page 245 Parameter Definition Default setting 91-94 Axis Properties for axes 1,2,3,4 95-98 Autotune / Auto Delay Move Distance for axes 1,2,3,4 2” / 50.8 mm Cutter Compensation Look-ahead Intercon comment generation Intercon clearance amount Intercon spindle coolant delay Intercon corner federate override 50.0 Intercon modal line parameters Intercon modal arc parameters...
Page 246 Parameter Definition Default setting Lube Pump Operation Probe Stuck retry disable Hard Stop Homing Power Limit 188-199 Aux key functions 200-207 OPTIC4 Tach Volts Per RPM 208-215 MPU Lash/Screw Comp Acceleration Coefficient 0.125 PC Based Lash Compensation on/off PC Based Screw Compensation on/off 220-231 Smoothing Parameters Refer to text...
Page 247 Parameter 0 – E-Stop PLC Bit This parameter specifies the PLC bit to which the physical Emergency Stop switch is connected. It is mainly used for ATC applications that use custom PLC messages. See table below for examples. PLC Type ESTOP Input on PLC Parameter Value GPIO4D...
Page 248 Parameter 4 - Remote File Loading Flag & Advanced File Ops This parameter controls the action of the Load Job menu when CNC job files are selected from drives letters higher than C. These drives (i.e. drives D, E, F, etc.) are presumed to be network drives or extra hard drives. Value Meaning Job files are not copied or cached.
Page 249 Parameter 8 - Available Coolant Systems This parameter is used by Intercon to determine what coolant systems are available on the machine. It should be set as follows: Value Meaning Mist Coolant (M7) only Both coolant systems Flood Coolant (M8) only Parameter 9 - Display Language This parameter determines what language will be used for menus, prompts and error messages.
Page 250 RTK3 M400 Servo3IO M400s PLCIO2 M15-10 15/15 M400 ATC (RTK3) RTK2 M400 ATC (PLCIO2) Koyo ATC MPU11 50769 Parameter 12 – Touch Probe Tool Number This parameter is the tool number of the DP4 probe. Allowable range is 0 through 200. By default the value is 10. This is used to look up the length offset and tip diameter of the probe in the Tool Offset Library.
Page 251 Parameter 17 – Detector Location Return Point A non-zero value specifies the number of the reference return point (entered into the WCS menu) directly above a permanently mounted TT-1 tool detector. When the Auto function is called up in the tool offset library, the control will position the table to the return point specified by this parameter, and touch the tool off the TT-1 Tool detector.
Page 252 Note: Temperature estimation only applies to controls operating in Torque mode (i.e. DC brushed systems and Centroid AC systems). MPU11 systems running in Velocity mode (i.e. third party drive systems) do not use this feature, and thus should be disabled (by setting all heating and cooling coefficients to 0).
Page 253 Parameter 34 - Spindle Encoder Counts/Rev This parameter controls the counts/revolution for the spindle encoder. Input from the spindle encoder is required for the spindle-slaved movements used in the Rigid Tapping cycles. If the encoder counts up when running CW (M3), the value of this parameter must be positive.
Page 254 Parameter 39 - Feedrate Override Percentage Limit This parameter is used for limiting the upper end of the Feedrate Override Knob percentage to a value from 100% to 200%. This parameter can be used to restrict the Feedrate Override Knob effect on machines with maximum rates over 200 in/min.
Page 255 Parameter 48 – Grid Digitize Patch Playback Z rapid clearance amount This is the additional Z clearance amount higher than the Z surface level at which the original Grid Digitizing operation was begun. The purpose of this value is to set the recorded starting “rapid to” Z level of a Grid Digitize playback patch.
Page 256 If Parameter 51 = 11 and you program a G2 arc with a radius of 100 mm at a feedrate of 2500 mm/min, then the actual feedrate of the arc will remain unmodified at 2500 mm/min because the arc radius is outside both ranges specified by Parameters 49 and 50, and therefore this feature does not affect such arcs.
Page 257 Parameter 63 - High Power Idle PID Multiplier This parameter holds the value of a constant used for motor high power idle detection when an axis is not moving and no job is running, but there is power going into the motor to maintain its position. The default value is 1.5. This is intended for early detection of an axis if it’s stopped against some abnormal resistance or not tuned correctly, such that it will probably overheat later.
Page 258 Parameter 69 – Duration for Minimum Spindle Speed Mode (Rigid Tapping Parameter) This is the duration of time, in seconds, that the control will stay at minimum spindle speed. If the number is too small, overshoot will occur. If the number is too large, the user waits longer for the hole to be tapped at the slow speed specified by parameter 68.
Page 259 The “Summed Axis” is the axis that bears the position sum of itself with the “Axis to Sum with”. The DRO display of the “Summed Axis” will show this summed position. The DRO will display both labels when displaying a summed axis.
Page 260 Bit 2 (value = 4) will turn on the “Spindle up-to-speed” function. The active modal spindle speed S at the point where the most recent M3 or M4 is invoked sets the target spindle speed for this function. This function is invoked on the first feed-per-minute move (such as G1/G2/G3) following the aforementioned M3 or M4.
Page 261 Parameters 87-90 (and also 252-255) - Autotune Ka Performance parameters These parameters are used by autotune. Increasing the value will increase the Ka used by autotune which when used will increase the PID used during acceleration. The default value is 0. The maximum value is 50 and the minimum value is 0.
Page 262 Bit 10: In order for this setting to work, bit 8 must be turned on. This setting has meaning only for parameter 166 (5 axis). Setting this bit on will identify this axis as the controller of the angle of articulation on an Articulated Head machine.
Page 263 Parameter 121 – Grid digitize prediction minimum Z pullback This parameter specifies the minimum distance the Z-axis will move upward when pulling back from a surface. The digitizing function attempts to predict the slope of a part surface because time is saved when the Z-axis does not have to travel upward to the starting Z depth for every digitized point.
Page 264 Example 2: A value of 392 in parameter 130 will toggle the 3rd axis label between Z and M and power off all axes and receive its positions from the 4 axis encoder input. The 3 sets bits two and one to power off all axes and use the 4 encoder input as a scale input, the 9 enables the 3 axis to “Z”, and the 2 changes the axis label to “M”...
Page 265 Parameter 141 – Maximum message log lines This parameter is the number of lines that will be kept in the message log. If this parameter is set to 10,000, for example, the newest 10,000 messages will be retained. The CNC software will delete the oldest messages, trimming the log file to the given number of lines at startup and periodically while the CNC software is in an idle state.
Page 266 Parameter 146 – Feed Hold Threshold for Feed Rate Override This parameter sets the lowest value permitted as the feed rate override percentage before feed hold is engaged. Feed hold will be released when the override percentage is greater than this value. Parameter 147 –...
Page 267 Parameter 160 – Enhanced ATC This parameter controls enhanced automatic tool changer (ATC) options. A value of 1 indicates a nonrandom type of ATC (carousel ATC) and a value of 2 indicates a random type ATC. A value of 0 disables enhanced ATC features. A warning is displayed when attempting to enable enhanced ATC features as these features work in conjunction with specific PLC programs.
Page 268 Parameters 165 – Acceleration/Deceleration Options This is a bit field parameter which modifies certain details of axis acceleration and deceleration when an axis stops moving, changes direction, or starts moving. The Jog Parameters screen in the Machine Configuration set the original DeadStart values for each axis.
Page 269 179 – Lube Pump Operation This parameter can be configured to control a variety of lube pumps. The value is formatted as MMMSS, MMM for minutes and SS for seconds. Below is a table of some examples. Type of Pump Operation Mechanical/CAM 179=0 Power is on when machine is running a job or in MDI Mode...
Page 270 Parameters 200-207– OPTIC 4 Tach Volts Per 1000 RPM These parameters control the digital Tach output on the Optic4 boards. They are used on drives like old Fanuc velocity mode drives that require a tach input. The value put here is the volts/1000 RPM off of the motor. A negative value can be entered to invert the tach voltage compared to the encoder count derived velocity direction from the encoder.
Page 271 Parameters 256 – Drive Mode This parameter indicates to the control software what mode the drives are operating under. It also controls the availability and behavior of the F5 Tune key in the PID Menu based on the drive mode. Drive mode Value Torque mode.
Page 272 Parameter 270-271 – XY Skew Correction These parameters work together to correct XY position skew, which can occur if the X axis is not exactly perpendicular to the Y axis (or vice versa). To turn on XY skew correction, use the chart and follow the skew measurement procedure described below.
Page 273 Parameter 284-291 – Brake Resistor Wattage for ACDC Drives 1-8 These parameters specify the brake resistor wattage which default to the minimum internal resistor value. If CNC11 detects that the estimated brake wattage exceeds these parameter settings, then a "470 _ axis (drive _) brake wattage exceeded"...
Page 274 Parameter 323 – MPU11 Encoder Speed Filter This is an axis bitfield where setting a bit to ‘on’ selects the low speed filters for the corresponding axis. As a general guideline, an axis’s bit should be set unless that axis refers to a 3rd party drive. Bit 0 (value 1) refers to axis #1, bit 1 (value 2) refers to axis #2, bit 2 (value 4) refers to axis #3, bit 3 (value 8) refers to axis #4, and so forth.
Page 275 Parameter 349, 352, and 355 – MPG/Handwheel Detents per Revolution 1, 2, and 3 This value is the number of clicks (detents) per revolution. It is the number of divisions or markings on the mpg or handwheel. Moving the mpg or handwheel one detent or division will cause the motor to move one jog increment (depending on the multiplier x1, x10, x100, etc).
Page 276 Parameters 396 – Probing Setup Plunge Speed This sets the probing plunge feedrate for the macro-based probing cycles on engine block systems. Parameters 398 – Port/Block mode This determines the current mode of Port/Block systems and is set by the Port/Block menu. This parameter should not be manually modified.
Page 277: Pid Menu
PID Menu Pressing F4 - PID from the Configuration screen will bring up the PID Menu. The PID Menu provides qualified technicians with a method of changing the PID dependent data to test and configure your machine. The PID Parameters should not be changed without contacting your dealer. WARNING Corrupt or incorrect values could cause damage to the machine, personal injury, or both.
Page 278 Change the program that will run F1 – Edit Program when F2 is pressed F2 – Run Program Causes the machine to run a simple test program, while collecting data F3 – Ranges Can be used to specify the X and Y ranges for the Oscilloscope view F4 –...
Page 279 If the drives are in Precision mode, pressing this key will start the Auto Delay Calculation procedure. It is used by qualified technicians to automatically determine values for the Precision Mode delay parameters 340-347. The Auto Delay Calculation procedure will make a single move on each non-paired controlled axis, traveling a limited distance (configured via parameters 95-98 and 156-159) from the initial position.
Page 280: Dsp Probe Configuration
DSP Probe Configuration Pressing F7 – DSP Probe from the configuration screen will display the DSP Probe configuration. Note that this menu is available only for DSP probes (Parameter 155=1). Minimum Difference: Default - 0.001 inches. The minimum difference between mechanical and reported DSP position. Maximum difference: Default - 0.025 inches.
Page 281 Accept Mechanical Points in Digitizing Cycles Default –Yes. Used when any given point has failed window checking # times where # = the limit as specified in DSP Retry Limit. Setting this option to Yes records the last mechanical position rather than throw out the point entirely.
Page 282 M-Series Operator’s Manual 4/9/15 14-48...
Page 283: Smoothing
Smoothing Configuration Parameters Parameter Description Recommended values Turn the Smoothing feature ON or OFF . 1 = Smoothing (set to 0 to use Exact Stop mode) NBpts: The number of points in the Smoothing filter. The For Milling For Routers: higher this value, the more rounded corners will become (see Machines: 5 to 20...
Page 284 Note: STEP must be in the same units that the control is currently set to (Inches or MM). Once entered in, if you change units in the control from inches to mm or vice versa the Smoothing parameters will automatically be converted to the other units for you, so you don't have to re-enter them once you've type them in properly.
Page 285 2. P230 Curve Feedrate multiplier Arcs and Corners Low values produce lower feedrates in curves. Fig. 4a: P230 determines speed around curves and arcs Tighter arcs produce lower feedrates 3. P231 Acceleration Multiplier Fig. 4b: Lower values produce lower accelerations. P231 Velocity Time...
Page 286 5. Feature width W (P226) W and Min_Angle work together to determine which angles will be "sharp" (not be smoothed). For example a Gcode file may contain small spikes, double backs or zig zags of less 1mm that may be causing unwanted slowdowns in an otherwise high speed stretch of toolpath.
Page 287 Smoothing Setup Menu Pressing F8 – Smoothing Setup from the Setup menu will bring up the Smoothing Setup Menu. The Smoothing Setup Menu provides a simplified way of choosing parameters for the Smoothing module. Smoothing is especially useful in controlling and minimizing the amount of banging a machine experiences as it proceeds along the toolpath. Smoothing is also able to (optionally) round part geometry, allowing for faster feedrates around corners.
Page 288 Custom Smoothing Presets Menu Pressing F9 – Customize Presets from the Smoothing Setup menu will bring up the screen that allows you to customize the Quick Setups keys that appear in the Smoothing Setup menu. There are a total of 99 Smoothing presets. Each Smoothing preset consists of a customizable label and a customizable set of parameter values that will be copied to the actual parameters P221 through P231 (excluding P229) when such a preset is selected in the Smoothing Setup Menu or when activated by the “G64 ON”...
Page 289: Cnc Software Messages
Chapter 15 CNC Software Messages CNC software startup errors and messages Error Message Cause & Effect Action Error initializing Error while sending .hex file. Cannot Inspect MPU11 connection, or fix CPU...cannot communicate with MPU11 or it is not plugged missing or corrupted hex file. continue.
Page 290 Error Message Cause & Effect Action Operator abort: job ESC or CYCLE CANCEL pressed. Job is canceled cancelled. Waiting for input #NN M100 or M101 executing. Program will continue once specified input opens or closes. Waiting for CYCLE M0, M1, M100/75, or Block Mode is executed. Press Cycle Start START button Waiting for output...
Page 291 Error Message Cause & Effect Action Jogging... An axis jog key is pressed and machine is moving the corresponding axis Limit (#__) cleared A previously tripped limit switch is now in the “untripped” position Probing Cycle A probing cycle ran to completion Finished Waiting for motion to PC is waiting for the MPU11 to complete motion...
Page 292 Number Message Cause & Effect Action _ axis lag Lag Distance (Allowable Following 1. If the problem is occasional heavy Error) is detected on any axis for more cuts, slowing down the cutting feedrate than 1.5 seconds. can solve the problem. 2.
Page 293 Number Message Cause & Effect Action _ axis full power 90% Power (PID Output > 115) is 1. If the axis has run into a physical without motion applied to any axis and no motion stop, use the slow jog mode to move >0.0005 inches is detected, for more the axis away from the stop.
Page 294 Number Message Cause & Effect Action _ axis runaway: Motor was in a runaway fault condition. Check motor wiring Check motor Power to motor will automatically be wiring shut off. Servo drive This error message is produced by On DC systems check status of the shutdown hardware detection of a physical error.
Page 295 Number Message Cause & Effect Action _ axis Drive overtemp sensor tripped. No The drive is being run at over capacity overtemperature motor power. or the cooling fan is either not detected functioning or its air flow is blocked. _ axis Overcurrent detected on an axis.
Page 296 Number Message Cause & Effect Action axis scale The scale encoder skipped a transition Reconnect/replace scale encoder or encoder state on its count-up/count-down scale encoder cable. quadrature error sequence. May indicate a bad encoder or a loose or severed encoder cable. This will stop all motion and cancel the job.
Page 297 Number Message Cause & Effect Action Missing parameter A parameter is required or expected but not Correct program. found. Job cancelled. Expected “=” Error in expression to left of “=”, missing Correct equation. “=”, or orphaned parameter. Job cancelled. Empty expression The expression contains no operands.
Page 298 Number Message Cause & Effect Action M22x missing format The format code was missing the its Correct program. specifier specifier M22x Missing A format code was specified in the format Correct program. Argument string, but its corresponding #variable argument was missing M22x argument parse A format code was specified in the format Correct program.
Page 299 Number Message Cause & Effect Action Canned cycle not allowed on Canned cycle attempted during Do not use cutter comp. line NNNNN compensation. Job cancelled. with canned cycles. G53 not allowed on line G53 attempted during compensation. Job Choose a different work NNNNN cancelled.
Page 300 Miscellaneous errors / messages Number Message Cause & Effect Action Ref. point invalid on G30 with invalid P value (must be 1 or 2). Change P-value to a 1 or 2. line NNNNN Job cancelled. No prior G28 or G30 G29 with no preceding G28 or G30.
Page 301 Number Message Cause & Effect Action File read error Problem reading the job file, this error occurs if the file was opened successfully but there was an error while reading the file. Error reading job file same as above at a different place in the code Failed to locate job Job continuation from the Run Menu...
Page 302 Number Message Cause & Effect Action PC resending The PC is resending Status Message PC received data out The PC needed to reorder data received Status Message of order from the MPU PC packet error The PC received bad data from the MPU Status Message and will try to recover by requesting a resend.

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M39

Centroid M400 Operator's Manual

CHAPTER 1 - Introduction

CHAPTER 2 Operators Panel

CHAPTER 3 - CNC Software Main Screen

CHAPTER 4 - Part Setup

CHAPTER 5 - Tool Setup

CHAPTER 6 - Running a Job

CHAPTER 7 - the Utility Menu

CHAPTER 8 - Digitize

CHAPTER 9 - Probing

CHAPTER 15 - CNC Software Messages

CHAPTER 11 - CNC Program Codes

CHAPTER 12 - G-Codes

CHAPTER 13 - M Functions

CHAPTER 14 - Configuration

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