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OmniTurn GT-75 Operator And Maintenance Manual

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OmniTurn Safety
Read and heed all "DANGER " and "CAUTION" labels on the
machine.
MOVING PARTS CAN CAUSE INJURIES! Keep hands and clothing
!
clear of spindle and tooling plate at all times.
DO NOT OPERATE WITH DOOR or SPLASH SHIELD OPEN!
DO NOT OPEN DOOR DURING OPERATION!
DO NOT operate machine without guards, doors and covers in place.
DO NOT operated while under the influence of alcohol or drugs,
including prescription drugs.
DO NOT wear loose clothing or gloves while operating machine.
DO NOT wear jewelry (necklaces, bracelets, watches, rings) while
operating machine.
DO NOT allow unsupported bar-stock to extend past drawtube end.
Keep long hair tied up and out of the way.
Wear eye and face protection.
Report any malfunction to your supervisor.
OmniTurn Operator and Maintenance Manual
i
www.OmniTurn.com (541)332-7004

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Summary of Contents for OmniTurn GT-75

  • Page 1 DO NOT allow unsupported bar-stock to extend past drawtube end. Keep long hair tied up and out of the way. Wear eye and face protection. Report any malfunction to your supervisor. OmniTurn Operator and Maintenance Manual www.OmniTurn.com (541)332-7004...
  • Page 2 DO NOT modify or alter this equipment in any way. If modifications are necessary, all such re- quests must be handled by NC Electronics, Inc. Any modification or alteration of any OmniTurn Lathe could lead to personal injury and/or mechanical damage and will void your warranty.
  • Page 3 Windows must be replaced if damaged or severely scratched -Replace damaged win- dows immediately. z Do not process toxic or fl ammable material. Deadly fumes can be present. Consult material manufacturer for safe handling of material by-products before processing. OmniTurn Operator and Maintenance Manual www.OmniTurn.com (541)332-7004...
  • Page 4 DO NOT modify or alter this equipment in any way. If modifications are necessary, all such requests must be handled by the OmniTurn factory. Any modification or alteration of any OmniTurn lathe could lead to personal injury and/or mechanical damage and will void your warranty.
  • Page 5 OmniTurn Safety Safety Labels on OmniTurn Machines This label is found on front of machine by the sliding door or splash guard. Do not put your hands into the cutting area without setting CNC E-Stop first. This label is found on front of machine by removable hatch, and on the left side removable panel.
  • Page 6 OmniTurn Safety OmniTurn Factory 42820 Port Orford Loop Port Orford, Oregon 97465 Phone: 541.332.7004 Fax: 541.332.1018 Email: sales@omniturn.com Website: www.OmniTurn.com OmniTurn Operator and Maintenance Manual www.OmniTurn.com (541)332-7004...

  • Page 7: Table Of Contents

    GT-75 Initial Setup Instructions ....1.3 GT-75 Major Components ..... . . 1.4 GT-Jr Major Components .

  • Page 8: Technical Specifications

    OmniTurn - Startup: GT-75 Technical Specifications GENERAL SPECIFICATIONS: Travel in X:12” Travel in Z:9” Tooling Height:1/2” (2” optional) Tooling Plate Size:Gang type (quick change) Repeatability of Slide Travel:.00005” (50 millionths) Resolution of Slide Travel:.00005” (50 millionths) Accuracy of Slide Travel:.0001” (one tenth)
  • Page 9 OmniTurn - Startup:GT-75 Initial Setup REMOVE CHIP PAN The chip pan is usually shipped in the cutting area of the GT-75. It holds the coolant pump, leveling feet, and any special tooling or accessories. REMOVE 4x4’s Replace the 4x4’s with the leveling feet (or optional bolt-down feet). Absolute leveling is not necessary;...

  • Page 10: Major Components

    Sliding door must be closed before pressing Cycle Start. If door is opened while program is running, spindle will stop and Feed Hold will be active (slides will stop). To continue machining, close the door and press Cycle Start. OmniTurn Operator and Maintenance Manual Sep 2017 www.OmniTurn.com (541)332-7004...

  • Page 11: Gt-Jr Major Components

    If hatch or splash-guard is opened while program is running, spindle will stop and Leveling Feed Hold will be active (slides will stop). To continue machining, close the hatch or Mounts splash-guard and press Cycle Start. OmniTurn Operator and Maintenance Manual Sep 2017 www.OmniTurn.com (541)332-7004...
  • Page 12 ( slow, NOTE ALSO: Use M84 to lock Feedrate Override at 100%. Use medium, fast or .01° to 90° M85 to re-enable. M30, M02 and Tool call will also re-enable. per step). OmniTurn Operator and Maintenance Manual Sep 2017 www.OmniTurn.com (541)332-7004...
  • Page 13 Insert Key Set coolant ON/OFF (PgDn) Set / Reset M25 Auxilliary function (Must hold Ctrl key) Backslash Key Alt Key Enter Key Ctrl Key (Press & hold to enable M25/M26 key) OmniTurn Operator and Maintenance Manual Sep 2017 www.OmniTurn.com (541)332-7004...
  • Page 14 Cycle start from Front Panel or from Operator’s station Must press both buttons at once. Open Close E-Stop Collet Collet Operator’s Station (also called “Palm Box”) OmniTurn Operator and Maintenance Manual Sep 2017 www.OmniTurn.com (541)332-7004...
  • Page 15 Carries signals to and from Spindle Cabinet. Z-Axis Servo Motor (MTE) X-Axis Servo Motor (MTE) Spindle Encoder for standard 5hp: Enables threading and IPR feeds. Also Optional C-Axis Connector (1 of 2) OmniTurn Operator and Maintenance Manual Sep 2017 www.OmniTurn.com (541)332-7004...
  • Page 16 After the OmniTurn has been installed and all of the cables are connected set Main Power disconnect ON. The Main Power disconnect is located on the Spindle Drive Cabinet at left-hand side of the GT-75 or GT-Jr, as illustrated below.

  • Page 17: Startup: Turn On Servos

    Press the blue “Servos On” pushbutton. It should illuminate and you should hear a slight hum as the axis motors engage. Press any key to clear the ‘Servos off’ prompt. The OmniTurn is now in “Jog” mode. The only other mode is “Automatic”. Manual Data Input (MDI) is part of Jog mode; a dialog box opens to allow program commands to be manually entered.

  • Page 18: Startup: Establish Home

    Cycle Start to start the homing procedure. The slide will move slowly in +Z, then in -X, seeking the home marks on the motor encoders. When homing is complete, X & Z position indicators will read 0.00000. The following three pages describe the homing procedure in detail. OmniTurn Operator and Maintenance Manual Sep 2017 1.12 www.OmniTurn.com (541)332-7004...

  • Page 19: Establish Home, Detail

    “9” then Cycle Start again. Verify that the position display at the top of the screen now reads zero for both axes. See following page for the screens which display the process. OmniTurn Operator and Maintenance Manual Sep 2017 1.13 www.OmniTurn.com (541)332-7004...

  • Page 20: Establish Home, Screens

    100% Tool 0 It’s a good practice to send the slide “home” before shutting down the OmniTurn. (To do this, press “H”, then “Z”, then “X”) This makes “Establish Home” very quick when machne is turned on: set Servos ON, then press any key, then press “2” for Medium Jog, then move the slide off the zeros with a quick “left”...

  • Page 21: Establish Home, Explanation

    The outside line is used to find a definite location. The encoder will ”see” this line once every revolution of the ball screw used to position the slide. The ball screw used on the OmniTurn moves the slide .200” / revolution. So if the slide is positioned within .200” of what we want to call HOME and then tell the control to slowly rotate the screw while looking for the single pulse we can establish this as an eas- ily repeatable location.

  • Page 22: Jog Mode

    The slide can be manually positioned with the ”Jog stick” actuator on the operator’s panel. Deflecting this actuator in the four directions available produces the following motions: X axis minus = up on GT-75 & Jr; away from you on attachment Down X axis plus = down on GT-75 &...
  • Page 23 5. 0.00100”/.1° Feed 6. 0.01000”/1° 0.0000 IPM 7. 0.10000”/10° 100% 8. 1.00000”/90° 9.Establish H.Go Home Tool Number:_ T.Set Tool Press Esc to cancel tool setting M.Manual Data I A.Automatic Tool 0 OmniTurn Operator and Maintenance Manual Sep 2017 1.17 www.OmniTurn.com (541)332-7004...

  • Page 24: Mdi Mode

    T.Set Tool Speed M.Manual Data Input 1000 RPM A.Automatic 100% Cycle Start pressed Tool 0 Command:_ Pending: Press Cycle start to Execute or Esc to cancel command or exit MDI OmniTurn Operator and Maintenance Manual Sep 2017 1.18 www.OmniTurn.com (541)332-7004...

  • Page 25: File Handler, Introduction

    File Handler Automatic Mode Pressing the ”A” key switches the OmniTurn to Automatic mode. If no program has been selected, a file handler screen will come up and you must select an existing program or create a new program to con- tinue.

  • Page 26: File Handler, Copy Programs

    R - Rs232 operations after boot-up, memory stick may be removed and ESC - Exit arrows move cursor replaced without issue. Copying d:\programs\newprog2 to c:\programs\newprog2 Current machine file; null Current directory; d:\programs\ OmniTurn Operator and Maintenance Manual Sep 2017 1.20 www.OmniTurn.com (541)332-7004...

  • Page 27: Copy Programs From Floppy

    To copy all programs from old-style CNC hard drive to floppy: 1. On the G3 OmniTurn, drop to DOS. (If the machine is already on, press and hold the left-shift key, then press Esc key; if you’re just starting up, press and hold Ctrl key, then press C key (Ctrl-c) at the “Do you want to backup...”...

  • Page 28: File Handler, Delete Programs

    1. On your desktop computer, create a new folder named “PROGRAMS” on the USB stick. 2. On the OmniTurn, drop to DOS. (If the machine is already on, select Jog, press and hold the Ctrl key, then press Q key (Ctrl-Q); if you’re just starting up, press and hold Ctrl key, then press C key (Ctrl-C) at the “Please backup your program files”...
  • Page 29 File Handler: Create Program Alt-N: To create a new program: Selecting “Create new file” (Alt-N) opens the OmniTurn program editor. The editor is described in Section Five, Automatic Mode. The following steps describe entering and exiting the editor. 1. Press Alt-N. You will be prompted “Name of file to create?”...
  • Page 30 G71 is not necessary. TO CHANGE THE PARAMETER FILE: 1. Drop to DOS (Ctrl-Q from Jog screen or Ctrl-C from “OmniTurn CNC” screen). 2. At K:\CNC> prompt, type C: then press enter. 3. At C:\RUNFILES> prompt, type edit filepath.cfg then press Enter to start OmniTurn editor.
  • Page 31 M05 M05 Spindle off, stop ..............62,66 M08 M08 Coolant on ............... 16,62,66 M09 M09 Coolant off ................. 62 M12 M12 Collet clamp ................62 M13 M13 Collet unclamp ................62 OmniTurn Operator and Maintenance Manual Jan '16 www.OmniTurn.com (541)332-7004...
  • Page 32 Plane Switching on OD (optional: C-Axis only) ........77 Custom M-Functions Writing Custom M-Functions for use with Optional PLC ..... 64 Spindle Control Manual Control of the Spindle ............65 Tapping Tapping with the OmniTurn ..............66 OmniTurn Operator and Maintenance Manual Jan '16 www.OmniTurn.com (541)332-7004...
  • Page 33 Maximum spindle speed for constant surface feet ......60 Metric mode ..................44 G76Sn Minimum spindle speed for constant surface feet ....... 60 Locks feedrate & spindle speed override pots at 100% ... Section 1: 1.4 OmniTurn Operator and Maintenance Manual Jan '16 www.OmniTurn.com (541)332-7004...
  • Page 34 G10XnZn Work Shift ................6,26-28,73 Custom M-Functions Writing Custom M-Functions for use with Optional PLC ....64 Spindle Control Manual Control of the Spindle............65 Tapping Tapping with the OmniTurn ............66 OmniTurn Operator and Maintenance Manual Jan '16 www.OmniTurn.com (541)332-7004...
  • Page 35 MOVE BRINGS YOU TO THE SAME POINT NO MATTER WHERE YOU START X-3 Z-4 INCREMENTAL - G91 IN INCREMENTAL (G91) THE FOLLOWING MOVES YOU THE SAME AMOUNT FROM EVERY START. X-3 Z-4 OmniTurn Operator and Maintenance Manual Jan '16 www.OmniTurn.com (541)332-7004...
  • Page 36 There can be more than one nonconflicting modal G code per line The S and F commands can be with any other command • N sequence are not allowed. They can cause intermittent problems. OmniTurn Operator and Maintenance Manual Jan '16 www.OmniTurn.com (541)332-7004...
  • Page 37 Comment is displayed here F10-Spec. Functions J-Jog Mode M-Manual Data Input • Secondary offsets: These are activated by the letter D. See the section of secondary offsets. X.2Z-.35D2 Calls secondary tool offset number two OmniTurn Operator and Maintenance Manual Jan '16 www.OmniTurn.com (541)332-7004...
  • Page 38 A new program can be created at the OmniTurn, or ‘off-line’ at a computer. When the program is cre- ated at the OmniTurn, it is automatically saved to the hard drive. To save a backup to the USB stick, use the File Handler (Section 1.17). You also have opportunity to backup programs when the Omni- Turn is first turned on: selecting ‘Y’...
  • Page 39 Later you can call the tool closer in Z to shorten the cycle time. G00..........Rapid move T1...........Tool call for tool#1 X.25Z1 ...........move the tool to a location of X=.25 and Z=1 Z.1 ..........move the tool closer to the work, still in rapid mode OmniTurn Operator and Maintenance Manual Jan '16 www.OmniTurn.com (541)332-7004...
  • Page 40 The code is shown in the; diameter mode: radius mode: G90G94F300G72 G90G94F300G73 M03S2000 M03S2000 X0 Z1 X0 Z1 Z0 G95f.003 Z0G95f.003 X.25 Z-.5 Z-.5 X.35 Z-1.1 Z-1.1 X .5 Z1G00 Z1G00 OmniTurn Operator and Maintenance Manual Jan '16 2.10 www.OmniTurn.com (541)332-7004...
  • Page 41 See page 2.36 for mult-pass thread-milling example. Rapid travel (G00): Rapid travel is 300 inches per minute, which is also the fastest feed rate also. OmniTurn accelerates quickly to 300 ipm, and tool-to-tool distances are generally an inch or two, so transit time between tools is very quick, typically 1/4 - 1/2 second.
  • Page 42 This way the program knows what feedrate to use. Here is an example showing establishing the rapid and feedrate modes and making some moves, then changing to rapid, and then back to the feedrate with G01: G94F300X0Z1 Z. l G95F.003Z.005 X.5 G00Z.05 G01Z0 G00Z1 OmniTurn Operator and Maintenance Manual Jan '16 2.12 www.OmniTurn.com (541)332-7004...
  • Page 43 In the example below we will be ‘finish turning’ a sample part with a left hand tool. The part dimen- sions are given in diameters: put G72 in the first block of your program to set OmniTurn to Diameter Mode.
  • Page 44 This page intentionally blank OmniTurn Operator and Maintenance Manual Jan '16 2.14 www.OmniTurn.com (541)332-7004...
  • Page 45 Running programs using C or R When you use the automatic corner radius or chamfer commands the OmniTurn creates a number of moves to generate what you want. If you look at the command line while you run a program you will notice lines of code that you did not write.
  • Page 46 Use the radius value found in D1 for compensation X.27C.03 Set chamfer amount Z-.35C.03 Set chamfer amount X.5R.025 Set radius amount Z-.45 X.54 Move off the part more than the compensation value G00Z1 Turn cutter compensation off OmniTurn Operator and Maintenance Manual Jan '16 2.16 www.OmniTurn.com (541)332-7004...
  • Page 47 .00005 the arc statement will not work. If the version with R is used there is a more tolerance for error: the arc used will be the one that best fits the end points and arc length. OmniTurn Operator and Maintenance Manual Jan '16 2.17...
  • Page 48 .100 .15r .635r .4Ø .3Ø .250 .75r .6Ø g90g94f300g73 g90g94f300g73 g90g94f300g73 m03s2500 m03s2500 m03s2500 x0z1 x0z1 x0z1 g95f.003z0 g95f.003z0 g95f.003x.2 x.15 z-.2 g02x.25z-.15r.15 g02x.3z-.1r.75 g02x.2z-.5r.635 z-.3 z-.3 z-.7 x.275 x.275 OmniTurn Operator and Maintenance Manual Jan '16 2.18 www.OmniTurn.com (541)332-7004...
  • Page 49 Center of arc T1F300 Start of arc X0 Z.1 X.1 Z0 G02 X.25 Z-.15 I.1 K-.15 Z-.5 or the arc statment could be: G02 X.25 Z-.15 R.15 End of arc OmniTurn Operator and Maintenance Manual Jan '16 2.19 www.OmniTurn.com (541)332-7004...
  • Page 50 G90 G94 G73 T1F300 X0 Z.1 X.1 Z0 G03 X.25 Z-.15 I.1 K-.15 Z-.5 Start of arc or the arc statment could be: Center of arc G03 X.25 Z-.15 R.15 .15r OmniTurn Operator and Maintenance Manual Jan '16 2.20 www.OmniTurn.com (541)332-7004...
  • Page 51 .100 .15r .635r .3Ø .4Ø .250 .75r .6Ø g90g94f300g72 g90g94f300g72 g90g94f300g72 m03s2500 m03s2500 m03s2500 x0z1 x0z1 x0z1 g95f.003z0 g95f.003z0 g95f.003 g02x.5z-.15r.15 z-.3 z-.2 x.55 g02x.6z-.1r.75 g02x.4z-.5r.635 g00z1 z-.3 z-.7 x.65 OmniTurn Operator and Maintenance Manual Jan '16 2.21 www.OmniTurn.com (541)332-7004...
  • Page 52 Arc center (In Kn): This is different. With diameter programming the arc center is defined as the incremental distance from the arc start to the center. Values of I and K Incremental from start (K=Z value) OmniTurn Operator and Maintenance Manual Jan '16 2.22 www.OmniTurn.com (541)332-7004...
  • Page 53 X are at the same diameter value so the distance between them is zero (IO). In the Z axis the distance is -.15. Note: the value of this is minus because of the direc- tion, not the end location. OmniTurn Operator and Maintenance Manual Jan '16 2.23 www.OmniTurn.com (541)332-7004...
  • Page 54 Start of arc üüüüüü -.15 So the program lines could be: XOZO G02X.5Z-. 1SIOK-.15 For the next example we will show a G03: .2Ø .1 R .5Ø X0Z0 Z-.3 G03X.4Z-.4I.1K0 Z-.5 OmniTurn Operator and Maintenance Manual Jan '16 2.24 www.OmniTurn.com (541)332-7004...
  • Page 55 • There is no limit to the length of the dwell. However we suggest you only use it for machin- dwells. DO NOT use it for loading and unloading operations in the program. This would be unsafe! Example G04F.5 This statement will dwell the slide .5 seconds. OmniTurn Operator and Maintenance Manual Jan '16 2.25 www.OmniTurn.com (541)332-7004...
  • Page 56 M03S2000 G04F2 G10XOZ3 Shifts program 3” to the right T 1(LH TURN TOOL) XOZ.2 ZOG95F.01 X.1 Z-.05F.002 Z-.15 G94F300Z1 T2(PART OFF TOOL) X0Z1 X-.4 Z-.35 G96S150 G76S500 G95F.001 X.005 G94F300Z1 OmniTurn Operator and Maintenance Manual Jan '16 2.26 www.OmniTurn.com (541)332-7004...
  • Page 57 Z0G95F.01 X.1 Z-.05F.002 Z-.15 G94F300Z1 T2(PART OFF TOOL) X0Z 1 X-.4 Z-.35 G96SI50 G76S500 G95F.001 X.005 G94F300Z1 G10XOZ-.35 Here is the work shift, shifting the next loop End of loop OmniTurn Operator and Maintenance Manual Jan '16 2.27 www.OmniTurn.com (541)332-7004...
  • Page 58 A digital indicator with serial data output is used to locate the face of the part and to transmit the location to the OmniTurn CNC. The CNC uses this information to offset the tools correctly to accommo- date the part-to-part differences in overall length.
  • Page 59 Because the depth of cut reduces with each pass to keep the amount of material constant, the number of passes is not simply total depth of cut divided by “I”. OmniTurn Operator and Maintenance Manual Jan '16 2.29...
  • Page 60 This option can be used with all variations of the threading command. End of cycle position: At the end of the threading cycle the tool will return to the starting point. OmniTurn Operator and Maintenance Manual Jan '16 2.30 www.OmniTurn.com (541)332-7004...
  • Page 61 (The offset puts the tool at the part center, .2” from the face in Z) X.237 (Positions the tool at the starting radius to cut the thread) G33X.212Z-.5I.012K.05PC (Cut thread) OmniTurn Operator and Maintenance Manual Jan '16 2.31 www.OmniTurn.com (541)332-7004...
  • Page 62 Then reposition the threading tool and take a clean up pass. Control: The single pass technique can be used to have greater control over the amount to be removed with each pass. OmniTurn Operator and Maintenance Manual Jan '16 2.32 www.OmniTurn.com (541)332-7004...
  • Page 63 The offset puts the tool at the part center, .2” from the face in Z X.237 Positions the tool at the starting radius to cut the thread G33X.212Z-.5I.008K.05PCO Cut a single pass thread OmniTurn Operator and Maintenance Manual Jan '16 2.33 www.OmniTurn.com (541)332-7004...
  • Page 64 .2” from the face of the material. The second start is offset by .2” + (.15/3) .25. The third start is offset by .25 + (.15/3) .3 Code for the above example: G90G94 F300 X0Z.2 X.247 G33X.212Z-.5I.01K.15P Z.25 G33X.212Z-.5I.01K.15P G33X.212Z-.5I.01K.15P OmniTurn Operator and Maintenance Manual Jan '16 2.34 www.OmniTurn.com (541)332-7004...
  • Page 65 .035" Example diameter .5" .45" diameter 0769" g90g94f300g72 x0z.2 x.415 Move to start corrected for taper (remember .2 in Z) g33 x.365z-.5i.005k.0769a.035 Taper thread OmniTurn Operator and Maintenance Manual Jan '16 2.35 www.OmniTurn.com (541)332-7004...
  • Page 66 OmniTurn Operator and Maintenance Manual Jan '16 2.36 www.OmniTurn.com (541)332-7004...
  • Page 67 The value of the R in the secondary offsets must be (+). It is the incremental value of the tool nose radius. ie: a .007” radius tool has a compensation value of .007 OmniTurn Operator and Maintenance Manual Jan '16 2.37...
  • Page 68 In the following example you would want to apply G42 -right handed compensation: OmniTurn Operator and Maintenance Manual Jan '16 2.38...
  • Page 69 FINISHED PART IS THE WRONG SIZE DESIRED PART TOOL PATH WITH Notice the following table for the direction of the corrections to be added to the same secondary offset as the tool nose radius. OmniTurn Operator and Maintenance Manual Jan '16 2.39 www.OmniTurn.com (541)332-7004...
  • Page 70 TOOL NOSE RADIUS COMPENSATION G41,G42, G40 (+) X (+)Z (+) X (-)Z Correction needed in secondary offsets: (-) X (+)Z (-) X (-)Z OmniTurn Operator and Maintenance Manual Jan '16 2.40 www.OmniTurn.com (541)332-7004...
  • Page 71 You do not have to clear the register first. If you want to correct a value slightly, you must enter in the final value needed. ie: if you have .007 and want to increase it by .001 you must enter .008. Do not enter -.001 OmniTurn Operator and Maintenance Manual Jan '16 2.41 www.OmniTurn.com (541)332-7004...
  • Page 72 If the values are not correct, then clear them and enter new ones. Remember when entering the X value you must enter twice the TNR value, i.e. -.03 for the above example. OmniTurn Operator and Maintenance Manual Jan '16 2.42...
  • Page 73 Also every time you leave the secondary offset table the program will be rewritten to compensate for the new tool nose radius values given. OmniTurn Operator and Maintenance Manual Jan '16 2.43 www.OmniTurn.com (541)332-7004...
  • Page 74 1. Drop to DOS (Ctrl-Q from Jog screen). 2. At K:\CNC> prompt, type C: then press enter. 3. At C:\RUNFILES> prompt, type edit filepath.cfg then press Enter to start OmniTurn editor. NOTE: on older OmniTurns, you may have to type ew filepath.cfg.
  • Page 75 The X, Z coordinate may be absolute or incremental, based on the current mode of the control. The return passes are at a fixed clearance distance (.02”) from the last cutting pass. OmniTurn Operator and Maintenance Manual Jan '16 2.45...
  • Page 76 An In value of .05 would take .1 off the diameter of the part with each pass. Tool nose radius compensation cannot be active when using this box roughing cycle. OmniTurn Operator and Maintenance Manual Jan '16 2.46 www.OmniTurn.com (541)332-7004...
  • Page 77 Z axis must be done with the end location value in the G74 code. The finish pass is not shown on this example. 1.000" .375" .750" G90G94F30OG72 M03S2000 T1(LH Turn tool for roughing) X1.05Z.5 G74X.375Z-.747I.075U.005F.003 programmed to leave .005 on X and Z for finish cut G00Z 1 OmniTurn Operator and Maintenance Manual Jan '16 2.47 www.OmniTurn.com (541)332-7004...
  • Page 78 If the P code is present, the contour is defined in a subroutine n. • If the P code is not present, the contour is defined in the following blocks until a block with an ”RF” code is encountered OmniTurn Operator and Maintenance Manual Jan '16 2.48 www.OmniTurn.com (541)332-7004...
  • Page 79 This is not allowed. The A point is not in the same quadrant as B relative to the start point. If the start point is moved over to include both A and B the cycle will work. OmniTurn Operator and Maintenance Manual Jan '16 2.49 www.OmniTurn.com (541)332-7004...
  • Page 80 X.343C.125 Z-.5 X.406 G02X.406Z-.687R.0935 X.375 X.75 The first example has the finished contour to be roughed immediatly after the G75 command. This program would just rough the part and stop. OmniTurn Operator and Maintenance Manual Jan '16 2.50 www.OmniTurn.com (541)332-7004...
  • Page 81 If you want to use the compensation then you must leave the finish pass out of the subrou- tine since they will not accept the compensation. G90G94F300G72 M03S2500 T 1(LH TURN TOOL) X0Z 1 X.4Z.1 G95F.003 G75i.05u.02f.003P1 G00Z1 X0Z0 X.343C.125 Z-.5 X.406 G02X.406Z-.687R.0935 X.375 X.75 OmniTurn Operator and Maintenance Manual Jan '16 2.51 www.OmniTurn.com (541)332-7004...
  • Page 82 .03” chamfer. If this were needed in this box cycle you could add a facing move and chamfer to the contour pass. Start G90G94F300G72 M03S2000 X.4Z.1 G95F.003 G75i.05u.02f.003 X 1.2Z0 X1.06 X 1 Z-.03 Z-.5 X.75C.062 Z-.704 G03X.658Z-.75R.046 Z-1. G00Z 1 OmniTurn Operator and Maintenance Manual Jan '16 2.52 www.OmniTurn.com (541)332-7004...
  • Page 83 So if you need to use TNR compensation for the finish pass you will have to copy the contour pass into the program for the last pass. OmniTurn Operator and Maintenance Manual Jan '16 2.53 www.OmniTurn.com (541)332-7004...
  • Page 84 Box rough cycle G00Z1 T2(LH FINISH TURN TOOL) Call finish tool X0Z1 X0 Z.1 G95F.003 G 78 U.01 F.003 P1 Rough contour cycle G00Z.1 G95F.002 ..continued on next page ..OmniTurn Operator and Maintenance Manual Jan '16 2.54 www.OmniTurn.com (541)332-7004...
  • Page 85 G78 - Rough Contour Cycle continued Finish pass to depth with same tool G00Z1 X0Z0 X. 343C.125 Z-. 5 X.406 G02X.406Z-. 687R. 0935 X.375 X.75 OmniTurn Operator and Maintenance Manual Jan '16 2.55 www.OmniTurn.com (541)332-7004...
  • Page 86 G90 G94F300 Puts the control into absolute mode Calls tool #1 offset X0Z.01 Positions tool at x=0, Z=.01 Sets ipr mode G81Z-.1F.005 Drills the hole .1” deep at .005 ipr. OmniTurn Operator and Maintenance Manual Jan '16 2.56 www.OmniTurn.com (541)332-7004...
  • Page 87 L is the rapid travel feedrate for the retraction move, noted in IPM. Default is 200ipm C is the clearance distance left when the drill returns to the cut. Default is .02” OmniTurn Operator and Maintenance Manual Jan '16 2.57...
  • Page 88 Z = .8" Z = .5" Starting point G90 G94F300 First drill (large one) X0Z.01 G83Z-.5K.2F.003R.5C.05L300 G00Z1 Second drill (small one) X0Z 1 Z-.4 G83Z-.8K. 1 F.002R.5C.05L300 OmniTurn Operator and Maintenance Manual Jan '16 2.58 www.OmniTurn.com (541)332-7004...
  • Page 89 Slowest: .00005” per revolution Fastest: depends on spindle speed, the limit has to be calculated to 300 ipm As an example, the fastest feedrate at 3000 rpm is. l ”/rev OmniTurn Operator and Maintenance Manual Jan '16 2.59 www.OmniTurn.com (541)332-7004...
  • Page 90 Constant Surface feet spindle speeds - G96,G97,G77,G76 To use the following codes the OmniTurn must be equipped with a spindle control package. There are two types of spindle speed control modes that the OmniTurn control can use: Spindle speed in RPM -(G97). In this mode the S value will set the spindle speed in turns per minute, ”RPM”.
  • Page 91 F3-Edit F4-Verify F5-New File F6-Program Search F8-File Ops F9-Sec. Offsets F10-Spec. Functions J-Jog Mode M-Manual Data Input See Section Five, Automatic Mode, page 5.6 for more detail about these switches OmniTurn Operator and Maintenance Manual Jan '16 2.61 www.OmniTurn.com (541)332-7004...
  • Page 92 M19 - Spindle Positioning: Stop the spindle and lock it at repeatable home position. M25, M26 -User assigned spare M functions (parts catcher on GT-75) A 3 pole double throw relay in the spindle cabinet is controlled by these M-codes. You can wire to this relay for optional live tools or air blast or any other on/off device.
  • Page 93 M91, M92, M93, M94 - Wait for input These M-codes stop the program until an input is “on” or “off”. This is useful for coordinating activity for an auto-loader. The OmniTurn ‘waits’ (the program stops, like M00 or M01) until the input is in the correct state.
  • Page 94 3. At C:\RUNFILES> prompt, type edit m??.usr (where m?? is the number of the M-function) then press enter to start OmniTurn editor. NOTE: on older OmniTurns, you may have to type ew m??.usr. Edit the program as usual, save and exit, then restart the OmniTurn.
  • Page 95 Dial for spindle speed override Switch to turn spindle off/on manually To review the functions of all the front panel controls, refer to pages 1.4, 1.5 and 1.6 in Section 1. OmniTurn Operator and Maintenance Manual Jan '16 2.65 www.OmniTurn.com (541)332-7004...
  • Page 96 Spindle off automatically at the end of the program: Spindle off by command in the program: Manual override: There is a switch on the face of the OmniTurn control that will turn the spindle off. Leaving the spindle on at the end of the program: If you are running a job automatically (bar work or automatic loaders) and want to leave the spindle running at the end of the program use M02 for end of program.
  • Page 97 Before you run a program that uses secondary offsets be sure that you have reset the secondary offsets that you are using to zero! This can be done by pressing C when asked to make a correction to the offset table (See F9 in the Automatic section) OmniTurn Operator and Maintenance Manual Jan '16 2.67 www.OmniTurn.com (541)332-7004...
  • Page 98 Look at the following example: ØA ØB With this shaft, 0A diameter = 0B diameter. In order to do this, put an offset command at the end of the turn. OmniTurn Operator and Maintenance Manual Jan '16 2.68 www.OmniTurn.com (541)332-7004...
  • Page 99 • There is a tool change. This cancels an offset • Calling up secondary offset DO will turn off the offset. • Calling up another offset will cancel the original offset and set the new offset OmniTurn Operator and Maintenance Manual Jan '16 2.69 www.OmniTurn.com (541)332-7004...
  • Page 100 • The diameter at the end of the taper -D5 X value • The location in Z of the taper. -D5 Z value Neither, either, or both values can be entered. Each will effect the angle generated. OmniTurn Operator and Maintenance Manual Jan '16 2.70 www.OmniTurn.com (541)332-7004...
  • Page 101 The next move to .4” diameter and .3” diameter will not be corrected. When the next tool is called, the D3 offset will be canceled. OmniTurn Operator and Maintenance Manual Jan '16 2.71 www.OmniTurn.com (541)332-7004...
  • Page 102 For this example the could be: G90G94F300 T 1 (notch tool 045 wide) X.25Z.2 Z-.035 G91-----------------------NOTE THIS LOOP IS DONE IN INCREMENTAL LS16 G95F.001 X-.1 G04F.05 G00X.1 Z-.085 G90-----------------------BACK TO ABSOLUTE MODE OmniTurn Operator and Maintenance Manual Jan '16 2.72 www.OmniTurn.com (541)332-7004...
  • Page 103 T 1 (DRILL) X0Z.5 Z. 1 G95F.003 G83Z-1 K.3L300C.200 G00Z1 T2 (TURN TOOL) X.3Z.5 Z. 1 G95F.003Z0 X.35Z-.025 Z-.15 G00X.36 T3 (PART OFF TOOL) X.4Z.5 Z-.15 G95F.001 X.25 G00Z 1 G10X0Z-.15 OmniTurn Operator and Maintenance Manual Jan '16 2.73 www.OmniTurn.com (541)332-7004...
  • Page 104 To set a custom C-Axis home, position the spindle as desired, then press Alt-H; the spindle will orient to this posisition ±.02° whenever C-Axis is enabled, manually or by M19. OmniTurn Operator and Maintenance Manual Jan '16 2.74 www.OmniTurn.com (541)332-7004...
  • Page 105 The four holes will be at 90° relative to each x.75f10 f300 (position spindle at max feedrate) other, but independent of any other features. ci90 (rotate 90° incrementally) lf (end of loop) OmniTurn Operator and Maintenance Manual Jan '16 2.75 www.OmniTurn.com (541)332-7004...
  • Page 106 (Feed mill into part at 3ipm) ca-90z-1.5f5 (Rotate spindle m04 direction 1/8 turn and move 1.000 in Z at 5ipm) f100x.75 (Clear tool) m28 (Turn mill off) g00z0 (Clear tool) m30 (End program) OmniTurn Operator and Maintenance Manual Jan '16 2.76 www.OmniTurn.com (541)332-7004...
  • Page 107 There are two plane-switched modes: XC and ZC: XC Plane In the XC plane, the Omniturn’s X and C axes work together to trace an X-Y tool path on the face of a part. In this mode the live tool is oriented par- allel to the Z axis.
  • Page 108 All dimensions in the plane-switched mode are in absolute coordinates. The commands are as follows: (~PLXC): Start XC mode. The tilde character “~” in a (comment) alerts the Omniturn’s parsing program to scan for a plane switching command. (~PLZC): Start ZC mode.
  • Page 109 (~PLXC) start XC mode (x.340y-.255) safe near corner (x.313y-.250) at first corner (x.313y.250) next corner (x-.313y.250) third corner (x-.313y-.250) fourth (x.313y-.250) back at first Tool Path (end) end plane-switch mode f200Z1.5 OmniTurn Operator and Maintenance Manual Jan '16 2.79 www.OmniTurn.com (541)332-7004...
  • Page 110 (~PLXC) (x.38465y0) (x.19235y.33315) (end) x-.8 f200Z1.5 OmniTurn Operator and Maintenance Manual Jan '16 2.80 www.OmniTurn.com (541)332-7004...
  • Page 111 (~plzc) plane switch mill position is x0,y0,z1 (f5z.85) tool tip moves in to cut at a diameter of .85 Note that the z.85 command moves the tool tip in toward the center of the part. OmniTurn Operator and Maintenance Manual Jan '16 2.81 www.OmniTurn.com (541)332-7004...
  • Page 112 (y.0313) start point for circle (g02x.1313y.1625i.1313j.0313) do a cw circle in 4 segments centered at x.1313,y.0313 (g02x.2625y.0313i.1313j.0313) (g02x.1313y-.1i.1313j.0313) (g02x0y.0313i.1313j.0313) (z1) withdraw tool (end) cancel plane-switch mode Part Dimensions Tool Path OmniTurn Operator and Maintenance Manual Jan '16 2.82 www.OmniTurn.com (541)332-7004...
  • Page 113 (g03x.4y.15i.5j.15) ccw arc back to start of right oval (g02x.3y.05i.3j.15) cw arc to bottom straightaway of left oval (x.2) bottom straight (g02x.1y.15i.2j.15) cw arc back to start point (z1) withdraw cutter (end) cancel plane-switch OmniTurn Operator and Maintenance Manual Jan '16 2.83 www.OmniTurn.com (541)332-7004...
  • Page 114 (x.475) cut straight side of J (g02x.675y-.2i.475j-.2) right turn at end of long side (y-.3) short straight segment (x.375) move back in x to create detent notch (z1) withdraw tool (end) cancel plane switch OmniTurn Operator and Maintenance Manual Jan '16 2.84 www.OmniTurn.com (541)332-7004...
  • Page 115 7RRO 2IIVHWV 7RRO 2IIVHWV $IWHU D SURJUDP LV ZULWWHQ WKH FRQWURO KDV WR EH WROG ZKHUH WKH WRROV DUH RQ WKH VOLGH 7RRO RIIVHWV DUH XVHG E\ WKH FRQWURO WR SRVLWLRQ WKH WRRO DQG NQRZ ZKHUH LW LV 7KHUH DUH WKUHH VWHSV ZKHQ XVLQJ WKH RIIVHWV  (VWDEOLVKLQJ WKH RIIVHWV 7KLV LV GRQH LQ WKH -RJ PRGH EHIRUH WKH SURJUDP LV UXQ  &DOO WKH WRRO RIIVHW DQG HVWDEOLVK ZKDW WKH ORFDWLRQ LV 7KLV LV GRQH LQ WKH SURJUDP \RX...
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  • Page 127 OmniTurn Sample Part Welcome to the OmniTum. This document is a tutorial used to run a first program with the OmniTurn. It is suggested before you try to work with this tutorial that you spend some time reading the manual and gain a basic understanding of the programming and operations of the system.
  • Page 128 We will take two passes to rough the part. After we rough the OD and remove most of the material we change tools and center (spot) drill. Then we change tools again and peck drill the hole to finish depth. OmniTurn Operator and Maintenance Manual www.OmniTurn.com (541)332-7004...
  • Page 129 Also note that we have all the tools starting 1 inch away, you can vary this. We made them all the same so that setup will be a little easier at first. OmniTurn Operator and Maintenance Manual www.OmniTurn.com (541)332-7004...
  • Page 130 In order to enter the part into the OmniTurn you will have to enter a new program: Refer to pages 1.10 - 1.12 for startup and establish home procedure.
  • Page 131 • The tool is moved at rapid to clear the face of the part S2500 • Change the spindle rpm to a higher speed for the next smaller diameter pass. G95F .003Z-.195 • Change to feed mode, and make the second pass OmniTurn Operator and Maintenance Manual www.OmniTurn.com (541)332-7004...
  • Page 132 • Spindle back to RPM mode and set speed to 2000 G94F300Z1 • This clears the tool in Z to 1 at rapid feed rate • Turn tool nose radius compensation off with move off the part OmniTurn Operator and Maintenance Manual www.OmniTurn.com (541)332-7004...
  • Page 133 • this is a clearance move • End of the program, the control will now be ready to run another part OmniTurn Operator and Maintenance Manual www.OmniTurn.com (541)332-7004...
  • Page 134 This will be enough to machine the part and not hit the collet or spindle. 1.0" Then put the turning tool on the slide. For this example put it on the near side. OmniTurn Operator and Maintenance Manual www.OmniTurn.com (541)332-7004...
  • Page 135 Then move the slide in Z only to clear the material, do not move in X! Turn the spindle off. If you have the spindle control use the switch on the OmniTurn panel. Then measure the diameter with a micrometer Measure diameter Now press T -”SET TOOL ”...
  • Page 136 For this example the tools should be positioned so there are no collisions and the amount of wasted moves is limited. OmniTurn Operator and Maintenance Manual 4.10 www.OmniTurn.com (541)332-7004...
  • Page 137 -When asked for the tool number, enter 2 and return -Press Z for the axis to be set. -Enter 0 for the current location, and return. -The Z is set, press the ”Esc” key to return to the jog menu. OmniTurn Operator and Maintenance Manual 4.11 www.OmniTurn.com (541)332-7004...
  • Page 138 ”T” from the jog menu to enter the X tool offset for tool #4. Then when the control asks what the turned diameter was enter the value given for this turn from tool #1. Then press RETURN. Tool #4 Tool #2 Tool #1 Tool #3 OmniTurn Operator and Maintenance Manual 4.12 www.OmniTurn.com (541)332-7004...
  • Page 139 Possible collision Tool #4 Tool #2 Tool #1 Tool #3 If we move the slide back and over a little there will be no problem. Tool #4 Tool #2 Tool #1 Tool #3 OmniTurn Operator and Maintenance Manual 4.13 www.OmniTurn.com (541)332-7004...
  • Page 140 TNR, and the direction is (-). • Then enter the size of the TNR into R. .007 and press RETURN. • Then press ESC to get out of the secondary offset entry page., OmniTurn Operator and Maintenance Manual 4.14 www.OmniTurn.com (541)332-7004...
  • Page 141 ESC and then go to set the tool again. If the tool is in the expected location, then press cycle start and the program will continue. To activate the Optional stop mode press the letter O when in the automatic mode before you start the program. OmniTurn Operator and Maintenance Manual 4.15 www.OmniTurn.com (541)332-7004...
  • Page 142 F9-Sec. Offsets Three blocks of the program are displayed: F10-Spec. Functions Current block is highlighted with reverse text J-Jog Mode Previous block is above it M-Manual Data Input Next block is below it OmniTurn Operator and Maintenance Manual 4.16 www.OmniTurn.com (541)332-7004...
  • Page 143 X: +0.00000 Z: +0.00000 X: +0.00000 Z: +0.00000 X: +0.00000 Z: +0.00000 X: +0.00000 Z: +0.00000 X: +0.00000 Z: +0.00000 X: +0.00000 Z: +0.00000 OFFSET NUMBER: Press Esc to exit offset adjustment screen OmniTurn Operator and Maintenance Manual 4.17 www.OmniTurn.com (541)332-7004...
  • Page 144 After you correct the X adjustment then just press return to get past the Z input. Then press Esc to go back to the Automatic mode to run the next part. Now you are ready to run parts. OmniTurn Operator and Maintenance Manual 4.18 www.OmniTurn.com (541)332-7004...
  • Page 145 Thread the part, Tool #2 Contour to follow Now, the tools can be selected for the operations listed above. See below the tool selections that will be used: Tool #2 Threading tool Tool #1 turning tool OmniTurn Operator and Maintenance Manual 4.19 www.OmniTurn.com (541)332-7004...
  • Page 146 Reference zero for the part. The location of this Zero is established by the G92statement after the Tool change. G94 or G95: This part will be programmed in G94, Inches per Minute. OmniTurn Operator and Maintenance Manual 4.20 www.OmniTurn.com (541)332-7004...
  • Page 147 Tool #1 turning tool Z-.79F3 X.27F200 X.21 Tool #2 Threading tool Tool #1 turning tool (10) Z-.29F3 (11) X.22 (12) Z.1 F200 (13) Tool #2 (14) Z0F3 Threading tool Tool #1 turning tool OmniTurn Operator and Maintenance Manual 4.21 www.OmniTurn.com (541)332-7004...
  • Page 148 (21) (22) X.32 Tool #1 turning tool 18 17 (23) Z.5F200 Tool #2 Threading tool Tool #1 turning tool (24) G92X.245 Z.2 (25) g33x.22z-.8i.005k.0769p Tool #2 Threading tool Tool #1 turning tool OmniTurn Operator and Maintenance Manual 4.22 www.OmniTurn.com (541)332-7004...
  • Page 149 Tool #2 Finishing boring bar The blank has been predrilled and is a little longer than the finished part. G90 G94 F200 G92 X0 Z.2 M03S2000 X.28 Z.01 Tool in location after T1 OmniTurn Operator and Maintenance Manual 4.23 www.OmniTurn.com (541)332-7004...
  • Page 150 Bore second diameter with correction for back of bore (16) X.29 (17) Z.5 G94 F200 Position the tools away from the part for loading, it also Turns off the secondary offsets Finish face and bore OmniTurn Operator and Maintenance Manual 4.24 www.OmniTurn.com (541)332-7004...
  • Page 151 Search To Tool in Program .......... 5.14 Save Offsets with Program ........... 5.17 Cycle Repeat Counter ..........5.17 Parts Counter .............. 5.17 M-Functions on Keyboard..........5.18 New Editor ..............5.19 Original Editor ............. 5.22 OmniTurn Operator and Maintenance Manual Jun 2015 www.OmniTurn.com (541)332-7004...
  • Page 152 NOTE: After ten hours prompt will appear mid-screen and Cycle-start will be inhibited until oil level is veri- fied and Alt-L is pressed (Press and hold “Alt” key, then press “L ” key). OmniTurn Operator and Maintenance Manual Jun 2015 www.OmniTurn.com (541)332-7004...
  • Page 153 The speed is NOT written to your program. You must edit your program to include spindle speed and direction. OmniTurn program verification Enter spindle speed for time calculation: 4000_ Press ENTER to complete entry OmniTurn Operator and Maintenance Manual Jun 2015 www.OmniTurn.com (541)332-7004...
  • Page 154 Press Enter to accept the default (Yes). If you choose not to save the program, use the down arrow to select No, then press Enter. Pressing ESC key will save and exit. If there are no more errors OmniTurn Operator and Maintenance Manual Jun 2015 www.OmniTurn.com (541)332-7004...
  • Page 155 Pg Dn Parts catcher Out/In (M25/26). Press to turn M25 on, press again to turn M26 off. Note that M25 is an auxiliary output on all OmniTurn machines; if a parts catcher is not installed, this M-function is available for any auxiliary function you need. See page 5.19 for keyboard.
  • Page 156 To run the program over and over without pressing Cycle Start, select Cycle Repeat by pressing the C key. This is the preferred mode for bar jobs and loaders, which automatically supply material for machining. To cancel the Cycle Repeat mode, press C again, or press A. OmniTurn Operator and Maintenance Manual Jun 2015 www.OmniTurn.com (541)332-7004...
  • Page 157 Press S to initiate Single Block mode. Cycle Start must be pressed to execute each line. Press S again to return to normal automatic mode. OmniTurn Operator and Maintenance Manual Jun 2015 www.OmniTurn.com (541)332-7004...
  • Page 158 X: +0.00000 Z: +0.00000 X: +0.00000 Z: +0.00000 X: +0.00000 Z: +0.00000 X: +0.00000 Z: +0.00000 X: +0.00000 Z: +0.00000 X: +0.00000 Z: +0.00000 OFFSET NUMBER: Press Esc to exit offset adjustment screen OmniTurn Operator and Maintenance Manual Jun 2015 www.OmniTurn.com (541)332-7004...
  • Page 159 To correct another tool, enter the tool number now and press Return. To exit the tool offset correc- tion screen press ESC and press return. This will tell the control that you are done and bring you back to the Automatic mode. OmniTurn Operator and Maintenance Manual Jun 2015 www.OmniTurn.com (541)332-7004...
  • Page 160 Automatic Mode, F3, Program Editing F3 Program Editing This function starts the text editor, used to change existing programs, or to create new ones. The editor is described starting on page 5.19. OmniTurn Operator and Maintenance Manual Jun 2015 5.10 www.OmniTurn.com (541)332-7004...
  • Page 161 The default is ALL tools; pressing enter willl display tool pats for all the tools. OmniTurn program verification Select tool for verification T1 TURNING THREADING TOOL Use Cursor keys; Press Enter to make a selection. ESC to Exit OmniTurn Operator and Maintenance Manual Jun 2015 5.11 www.OmniTurn.com (541)332-7004...
  • Page 162 (T1) is a left-hand tool, which cuts on the plus side of the part, and the threading tool (T2) is a right-hand tool, which cuts on the minus side of the part. OmniTurn Operator and Maintenance Manual Jun 2015 5.12...
  • Page 163 When the window covers the desired area, press Z again (or press Enter) to fill the screen with that sec- tion of the tool path, as shown below. If you want to get closer, press Z again to obtain window. Press Esc to return to Automatic screen OmniTurn Operator and Maintenance Manual Jun 2015 5.13 www.OmniTurn.com (541)332-7004...
  • Page 164 Note that no collision avoidance calculation is done, so be sure that the tool can move safely to the part before pressing Cycle Start. OmniTurn Operator and Maintenance Manual Jun 2015 5.14...
  • Page 165 Alt-N = Create New file: You will be prompted “Name of file to create?” Type the name then press En- ter. The OmniTurn editor will start. When you leave the editor, you will have opportunity to load this program into memory (make it the current machine file). The editor is described in Section Five.
  • Page 166 It is possible to clear all of the secondary offsets by pressing C when asked for a secondary offset num- ber. This will set the entire table to Individual offsets can be set to zero by pressing C when asked to enter a correction amount. OmniTurn Operator and Maintenance Manual Jun 2015 5.16 www.OmniTurn.com (541)332-7004...
  • Page 167 Auto screen to enable Cycle Repeat. This is good for use with a barfeed. As an example you could set the machine up and tell it you need 20 pieces. The OmniTurn will count down to zero and then stop.
  • Page 168 (Parts Catcher Out/In) (PgDn key) *Must press Ctrl key to activate To review the functions of all the front panel controls, refer to pages 1.4, 1.5 and 1.6 in Section 1. OmniTurn Operator and Maintenance Manual Jun 2015 5.18 www.OmniTurn.com (541)332-7004...
  • Page 169 Do not move the cursor before Alt-Backspace; if you do, you cannot recover.) To move selected text: Press Shift-Del, move cursor to where you want text to begin, then press Shift-Ins OmniTurn Operator and Maintenance Manual Jun 2015 5.19 www.OmniTurn.com (541)332-7004...
  • Page 170 Backspace: erases the character to the left of the cursor; use with Alt to recov- er deletions (before moving cursor) Ctrl: use with Ins to copy text Shift: use with Ins to past text OmniTurn Operator and Maintenance Manual Jun 2015 5.20 www.OmniTurn.com (541)332-7004...
  • Page 171 NOTE: If you want to run the new program when you return to automatic mode, you must press F5 (new program) and select the new, renamed program to get it into memeory. OmniTurn Operator and Maintenance Manual Jun 2015 5.21...
  • Page 172 You will be prompted to press Esc for no backup, or F1 to make a backup copy with “.&” extension. The backup is unnecessary if you have consistently answered “Y” to backup your program files when OmniTurn is first turned on. (See page 1.8). After pressing Esc or F1 the editor will open with your program.
  • Page 173 Back Space: erases the character to the left of the cursor Fn: use to access Page Up & Page Down keys Fn-PgUp: moves the cursor one screen back per hit Fn-PgDn: moves the cursor one screen forward per hit OmniTurn Operator and Maintenance Manual Jun 2015 5.23 www.OmniTurn.com (541)332-7004...
  • Page 174 • when you are done working with the program, save and exit the editor as you normally would, press Fl, then F2. Now you will still have the old program, and a new one. OmniTurn Operator and Maintenance Manual Jun 2015 5.24...
  • Page 175 Spindle Drive Schematic (C-Axis) ........ 6.37 Collet Closser General Information ......6.38 Collet Closer Bearing Replacement ......6.43 Lubricator Operation & Service ........6.45 Lubrication & Maintenance Schedule ......6.46 OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 www.OmniTurn.com (541)332-7004...
  • Page 176 • Check that the Spindle Drive is not faulted; press the reset button on the the spindle drive cabinet located at the left side of GT-75 and GT-Jr. • Check the hatch on GT-Jr, or any interlocked doors on your system. To jog the ma- chine with door open during setup, get the interlock bypass key from your supervisor.
  • Page 177 • Noise from coolant pump or other contacts • Acceleration or deacceleration are to short (standard 5hp drive). Parameters can be set to change these: see “AC Spindle Drive” pg 6.18 OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 www.OmniTurn.com (541)332-7004...
  • Page 178 4000, then start over at zero. If the numbers don’t reset, the encoder is faulty. To alert you to this, the color of the numbers will reverse at about 4100 counts. OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 www.OmniTurn.com (541)332-7004...
  • Page 179 Also, when door interlock switch is open (1), the Spindle Off/Auto switch is shown as off (1) regardless of its actual condition, and Motion Stop is shown as on (0) regard- less of its actual condition. To cancel Alt-I press Alt-I again. OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 www.OmniTurn.com (541)332-7004...
  • Page 180 4000, the problem is on the motion card. If that axis reads 4000, but the other axis is now not reading 4000, the problem is in the motor encoder. OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 www.OmniTurn.com (541)332-7004...
  • Page 181 Only personnel spe- cially trained by your company should have access to the interlock by-pass key. OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 www.OmniTurn.com (541)332-7004...
  • Page 182 CAUTION - YOUR TOOL OFFSETS HAVE CHANGED. The slide will not home exactly where used to: f you are set up on a job you must re-set all offsets. OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 www.OmniTurn.com (541)332-7004...
  • Page 183 Z-Axis Support Unit This document describes removal and replacement of the servo motors, fl exible couplers and support units (thrust bearings) on the OmniTurn slides. The illustration above shows the location of the components. Sheet metal removal is illustrated on pages 2 and 3...
  • Page 184 OmniTurn - Trouble shooting guide, G4 CNC To remove Z-Axis Sheet Metal: (Current) To remove Z-Axis Sheet Metal: (Old Style) OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.10 www.OmniTurn.com (541)332-7004...
  • Page 185 Two 6-32 cap screws secure the cylinder to the saddle. To remove Servo Motor: If only replacing coupler, install new coupler, then skip to Page 6.13 for motor re-installation instructions. OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.11 www.OmniTurn.com (541)332-7004...
  • Page 186 3. Tighten nut using1/2”and 19mm wrenches. NOTE: ground fl at on nut goes against ring 4. Install small brass cushion 5. Secure nut with setscrew (not too tight) OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.12 www.OmniTurn.com (541)332-7004...
  • Page 187 If the pointer is not at ”0”, loosen it and move it as required. 2. Before tightening coupler, verify alignment by sliding 3. Re-set all tools before running! coupler on both shafts. Tighten coupler clamps to 40lb/in. OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.13 www.OmniTurn.com (541)332-7004...
  • Page 188 Remove plugs here and at power supply on opposite side to remove computer. Wing-nuts clear these notches to lift chassis over front lip of case. OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.14 www.OmniTurn.com (541)332-7004...
  • Page 189 It is mounted vertically adjacent to the connect card. The servo amps and cooling fan have been rearranged to provide better cooling. OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.15 www.OmniTurn.com (541)332-7004...
  • Page 190 Y-AXIS JOG SPIN OFF/AUTO C-AXIS JOG JOG STICK E-STOP SERVOS ON CONTROL ON CNFP1 RT CYCLE START CNFP1 LFT CYCLE START CNFP3 MOTION STOP CNFP6 COL CLSR CN403 OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.16 www.OmniTurn.com (541)332-7004...
  • Page 191 M93 ....CAX-7 ..CN402-25 M95 ....CAX-12 ..CN402-28 OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.17...
  • Page 192 USB PORT ( USB MEM STICK) POWER SUPPLY POWER SUPPLY PCI SLOT CONNECTOR (ETHERNET CARD) cnc_disassembly-M830.cdr KEYBOARD MONITOR 110VAC IN (FROM CONNECT CARD) ETHERNET cnc_disassembly-M830.cdr (TO MOTION CARD) OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.18 www.OmniTurn.com (541)332-7004...
  • Page 193 TB1-23 E-Stop ..HDR104-1 TB1-25 Inhibit ..HDR101-8 TB1-30 Guards ..HDR101-13 revised 0812 OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.19 www.OmniTurn.com (541)332-7004...
  • Page 194 Adjust BALANCE pot for Zero Volts between pins 4 & 5 with Servos On. Put DVM probes on 4 & 5 adjust_pots2.cdr Brown & Black wires on both axes OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.20 www.OmniTurn.com (541)332-7004...
  • Page 195 Set X and Z to 70 at Medium jog 100% 9.Establish Home H.Go Home T.Set Tool Speed adjust_pots2.cdr MOTION CARD ZERO ADJUSTMENT X-Axis Adjust for Zero Following Error (Ctrl-E in Jog) Z-Axis adjust_pots2.cdr OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.21 www.OmniTurn.com (541)332-7004...
  • Page 196 After re-adjusting the balance, be sure to jog back & forth at Jog 2 and re-adjust the Tach pot for 70 ± 2 counts. Ctrl-E again to close the Following Error box. This concludes the Servo Amplifier setup procedure. OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.22 www.OmniTurn.com (541)332-7004...
  • Page 197 OmniTurn - Trouble shooting guide, G4 CNC X AXIS AMP Z AXIS AMP OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.23 www.OmniTurn.com (541)332-7004...
  • Page 198 OmniTurn - Trouble shooting guide, G4 CNC OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.24 www.OmniTurn.com (541)332-7004...
  • Page 199 OmniTurn - Trouble shooting guide, G4 CNC OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.25 www.OmniTurn.com (541)332-7004...

  • Page 200: M03

    OPERATORS STATION (PALM BOX) OP STA CONNECTOR AT REAR PANEL OF CNC OmniTurn INVERTER DRIVE MISCELLANEOUS CABLE G4 CNC AND OPERATORS STATION misc_cb_inv-G4_pwb.dcd feb 2015 (re-routed encoder wiring) OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.26 www.OmniTurn.com (541)332-7004...
  • Page 201 SPINDLE CONNECTOR CONN SPINDLE ENCODER SHLD PART OF PART OF MOTION CARD CONNECT CARD REAR PANEL OmniTurn INVERTER DRIVE SERVO DRIVE INTERFACE srvo_sch-G4.dcd 8/2010 (chgd sp.encoder wire colors) OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.27 www.OmniTurn.com (541)332-7004...

  • Page 202: M08

    ZIP PLC 0V ZIP PLC X14 (INTERLOCK) P302 (Bar Loader Standard) (Sp.Cab Door) HDR104 Triple Air BF EXT FLT End of Bar G4 CNC OmniTurn INVERTER SPINDLE DRIVE PANEL OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.28 www.OmniTurn.com (541)332-7004...

  • Page 203: M27

    (Sp.Cab Door) ZIP PLC Y7 (FAULT) SPNDL FLT LAMP ZIP PLC Y4 (CLS COL) ZIP PLC Y5 (OPEN COL) ZIP PLC 0V ZIP PLC X14 (INTERLOCK) OmniTurn spindle_cab_pwb_lbl.dcd may2013 OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.29 www.OmniTurn.com (541)332-7004...

  • Page 204: Inhibit

    M23 (OUT4) M27 (OUT11) HDR306 12V SO (Servos On) HDR111 M91/M92 (IN24) HDR110 M93/M94 (IN26) M95 (IN25) HDR112 OmniTurn CIRCUIT CARD SPINDLE DRIVE CONTROL LOGIC (CCA) spindle_cab_pwb_sch.dcd oct 2017 OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.30 www.OmniTurn.com (541)332-7004...
  • Page 205 SP FLT LAMP SpinRst HDR113 Fault Ext Inhibit OPEN = FLT SPNDL RST PB CIRCUIT CARD OmniTurn v1000_sc-G4_pwb.dcd feb 2015 INVERTER SPINDLE DRIVE w/CCA added 220vac wire colors OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.31 www.OmniTurn.com (541)332-7004...
  • Page 206 MA MB HC SC H1 T1-T3 Motor Out v1000_wiring.cdr B2: RED Braking Rsisistor B1: RED Braking Resistor L3: BLK Line In L2: RED Line In L1: RED Line In OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.32 www.OmniTurn.com (541)332-7004...
  • Page 207 Three Way To Spindle Bearings Flow Control (6psi back pressure) To Slide Brake To Collet Closer Lube Flow Control (15psi back pressure) OmniTurn GT AIR PACK gt_air5.dcd Sep 2010 OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.33 www.OmniTurn.com (541)332-7004...
  • Page 208 OmniTurn - Trouble shooting guide, G4 CNC X AXIS AMP Z AXIS AMP OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.34 www.OmniTurn.com (541)332-7004...
  • Page 209 CONNECTORS AT LEFT-HAND EXTENSION CABLE MOTION CARD BRACKET OPERATORS STATION (PALM BOX) OmniTurn C-AXIS DRIVE MISCELLANEOUS CABLE G4 CNC misc_cb_cax-G4_pwb.dcd oct 2017 AND OPERATORS STATION (added 12SO definition) OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.35 www.OmniTurn.com (541)332-7004...
  • Page 210 Pins 9-5, 10-6, 12-8 = Normally Open (NO Pin14 = +12V (from HDR303-1,304-1,305-1,306-1) G4 CNC Pin13 = Signal (from HDR303-2,304-2,305-2,306-2) OmniTurn C-AXIS SPINDLE DRIVE PANEL spindle_cab_pwb_cax.dcd feb 2012 OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.36 www.OmniTurn.com (541)332-7004...
  • Page 211 SP FLT LAMP SpinRst DRVCOM HDR113 OPEN = FLT Ext Inhibit SPNDL RST PB OmniTurn CIRCUIT CARD acs_sch2_PWB.dcd feb 2015 C-AXIS SPINDLE DRIVE w/CCA added 220vac wire colors OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.37 www.OmniTurn.com (541)332-7004...
  • Page 212 OmniTurn - Trouble shooting guide, G4 CNC Dunham Collet Closer OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.38 www.OmniTurn.com (541)332-7004...
  • Page 213 3) Verify lubricator provides four drops of oil per minute. 8 Parklawn Drive· Bethel· CT· 06801 • USA· 203-739-0415· FAX: 203-739-0461 www.dunhamtool.com preferred@dunhamtool.com OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.39 www.OmniTurn.com (541)332-7004...
  • Page 214 OmniTurn - Trouble shooting guide, G4 CNC OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.40 www.OmniTurn.com (541)332-7004...
  • Page 215 1 drop every 15 seconds. The reservoir should be replenished with Mobil “DTE” light (or equivalent) as required. FAILURE TO USE THIS LUBRICATION MAY RESULT IN UNIT FAILURE OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.41 www.OmniTurn.com (541)332-7004...
  • Page 216 OmniTurn - Trouble shooting guide, G4 CNC This page intentionally blank OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.42 www.OmniTurn.com (541)332-7004...
  • Page 217 OmniTurn - Trouble shooting guide, G4 CNC Collet Closer Bearing Replacement OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.43 www.OmniTurn.com (541)332-7004...
  • Page 218 OmniTurn - Trouble shooting guide, G4 CNC Collet Closer Bearing Replacement OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.44 www.OmniTurn.com (541)332-7004...
  • Page 219 F use the polycarbonate kit, and for C or G use the nylon kit. Leaner — Clockwise Richer — Counterclockwise By counting the number of drops per minute in the sight dome, you can adjust to your requirements. OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.45 www.OmniTurn.com (541)332-7004...
  • Page 220 A “needle tip” is required to fit the fitting on the blocks. Tips are available from Napa (pn 715-1215) or MSC (pn 48527378). The ball screws should be lubricated with a drizzle of Slick-50 over the entire exposed length. OmniTurn Operator & Maintenance Manual (G4 ) Oct 2017 6.46 www.OmniTurn.com (541)332-7004...

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