OPERATING MANUAL FOR eWinCNC V1.12 -------------------------------------------------------------------
------------------------------------------------------------------REGD. OFFICE :
WORKS :
MARKETED BY
ELECTRONICA MACHINE TOOLS LTD. ELEKTRA ELEKT RA HOUSE, 691/1 A, PUNE SATARA ROAD,
ELECTRONICA ELECTRO NICA MACHINE MACHI NE TOOLS LTD., SASWAD, TAL. : PURANDHAR
PUNE - 411037 (INDIA)
DIST. : PUNE - 412301 (INDIA)
ELECTRONICA ELECTRONIC A MAC HINE HIN E TOOLS LTD., ELEKTRA CHAMBERS,44, MUKUND NAGAR, PUNE -411037. (INDIA.)
D:01:278:05:08 INDEX
eWinCNC Help Index Menu
Page No
1. Operations
1.1
2. Manual Operation Modes
2.1- 2.7
3. Automatic Operation Modes
3.1-3.5
4. Programming Instructions
4.1-4.7
5. List Of Messages
5.1-5.10
6. Short Keys
6.1- 6.3
7. Terms Term s
7.1
8. Installation Procedure
8.1- 8.5
9. Machine ID generation procedure
9.1-9.6
Annexture 10. Annexture
This Manual provides guidance guidance in brief for for the operations of eWinCNC. It should be used in conjuction with eWinCNC Help. For detailed operational instructions please refer to ON-line ON-lin e or OffOff-line line eWinCNC Help.
D:01:278:05:08 INDEX
eWinCNC Help Index Menu
Page No
1. Operations
1.1
2. Manual Operation Modes
2.1- 2.7
3. Automatic Operation Modes
3.1-3.5
4. Programming Instructions
4.1-4.7
5. List Of Messages
5.1-5.10
6. Short Keys
6.1- 6.3
7. Terms Term s
7.1
8. Installation Procedure
8.1- 8.5
9. Machine ID generation procedure
9.1-9.6
Annexture 10. Annexture
This Manual provides guidance guidance in brief for for the operations of eWinCNC. It should be used in conjuction with eWinCNC Help. For detailed operational instructions please refer to ON-line ON-lin e or OffOff-line line eWinCNC Help.
CHAPTER 1 Operations This chapter introduces you to the controller of ELEKTRA Wire EDM machine. You can interact with the machine either through the Machine Control Panel or through keyboard & mouse attached with the controller. The machine will interact with you with the help of the display. The display is situated at the top of the interface panel. It shows the status of all the operations taking place on the Machine tool.
It Contains topics such as 1. Getting Started 2. Screen Layout The entire screen sc reen is divided into following areas. Ø
Menu & Toolbar
Many operations can be performed using them.
Ø
Status Display Area
Displays status parameters, position & flags.
Ø
Profile Display Area
Profile display is the area where user can get the profile profil e of currently currently downloaded program to controller.
Ø
Block display (Optional) Display executing block while running the program
Ø
Message & alarm
Here controller will display the messages, warnings, and errors
Ø
Function key panel
To perform function on cnc operations.
Ø
Status Bar
Status bar is the bottommost area of the screen.
Ø
Display
few status information & tool tips
PAGE : 1 - 1
CHAPTER 2 Manual Operation Modes operation modes are the first available modes after loading the application. operations give you the functions required to perform machine commands of jogging, machine referencing, switching ON/OFF conditions, etc. Following modes come under manual operations:
Ø
2-1
Main mode
Ø
2-2
JobSet mode
Ø
2-3
DrySpk mode
Ø
2-4
Coord mode
2.1
Main mode: (Alt + F1)
Main mode includes function key set as as follows Function Key Set : Ø
Buzzer (F1): This key is used to toggle togg le [Buzzer] flag ON/OFF.
Ø
Contact (F2): This This key is used to toggle toggle [Contact] option option ON/OFF.
Ø
Cut (F3):
Ø
Thread (F4): This key key is used to thread the wire.
Ø
S-AWT (F5): This key is used to thread the wire manually manually through workpiece
This key is used to cut the wire.
and lower wire sense position. Ø
AWT (F6):
This key is used to enable/disable the Auto Wire Threading operation .
Ø
FillTnk (F7): This key key is applicable only only for Submerge M/c to fill the tank with coolant.
Ø
DrnTnk (F8): This key is applicable only for M/c with submerge facility to remove the coolant from tank.
Ø
Flush (F9):
This key is used to switch the flushing system ON/OFF.
Ø
WFWT (F10): This key is used to switch the Wire Wire feed and Wire tension ON/OFF.
ELECTRONICA MACHINE TOOLS
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Ø
Halt (F11):
This key halts the current operation.
In Main mode, Jog Mode dialog is displayed as shown below.
From this dialog user can do the Jogging, Machine referencing, Jog Zero & Prejog operations.
2.2
JobSet Mode ( Alt + F4 )
Workpiece used in manufacturing has to be referred either from an edge or from center of a hole. Function of mode is to find the edge of the workpiece or the center of the hole. stands for EDGE FIND and CENTER FIND Operation Before machining, one also needs to make the Wire exactly vertical. Auto Wire Verticality facility (abbreviated as [AWV]) is also pr ovided in the same mode. This mode also provides Workpiece Rotation angle calculation mode.(as AlignEF, AlignCF)
Ø
2.2.1 EF Mode
Ø 2.2.2 CF Mode ELECTRONICA MACHINE TOOLS
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Ø
2.2.3 3PtCF Mode
Ø
2.2.4. Align §
2.2.4.1
AlignEF Mode
§
2.2.4.2
AlignCF Mode
Ø
2.2.5 AWV Mode
Ø
2.2.6 EFVolt
Ø
2.2.7 SLimit
2.2.1 EF Mode(F1)
EF Function Key Set: Ø
EF (F1)
To find Edge along the path in the direction of selected angle.
Ø
SetHalf (F7) This function key is used for HALF FUNCTION. This key is used to make axis coordinates half of their current value.
Ø
Set (F8)
To set the coordinates of current WCS to any value.
Ø
Zero (F9)
To set the coordinates of current WCS to zero.
Ø
Prmtr (F10) This key pops up a dialog that lets you to set the edge find Mode (Fast / Slow).
Ø
Halt (F11)
To stop the Edge Find (EF) operation.
Ø
Prev (F12)
This key is used to switch to the JobSet mode key set.
2.2.2 CF Mode(F2)
CF Function Key Set: Ø
CF (F1)
To find center along the direction and angle selected in Center Find Angle selection dialog.
Ø
Set (F8)
To set the coordinates of current WCS to any value.
Ø
Zero (F9)
To set the coordinates of current WCS to zero.
Ø Prmtr (F10) This key ELECTRONICA MACHINE TOOLS
pops up a dialog that lets you to set the edge find Mode PAGE:
(Fast / Slow). Ø
Halt (F11)
To stop the Edge Find (CF) operation.
Ø
Prev (F12)
This key is used to switch to the JobSet mode key set.
2.2.3 3 PTCF Mode(F3)
3 Pt.Center Find Function Key Set: Ø
EF1 (F1)
To find Edge-1 along the path in the direction of selected angle.
Ø
EF2 (F2)
To find Edge-2 along the path in the direction of selected angle.
Ø
EF3 (F3)
To find Edge-3 along the path in the direction of selected angle.
Ø
GoCntr (F4) Jog to the calculated center find position.
Ø
Set (F8)
To set the coordinates of current WCS to any value.
Ø
Zero (F9)
To set the coordinates of current WCS to zero.
Ø
Prmtr (F10) This key pops up a dialog that lets you to set the edge find Mode (Fast / Slow).
Ø
Halt (F11)
To stop the 3Point Center Find (CF) operation.
Ø
Prev (F12)
This key is used to switch to the JobSet mode key set.
2.2.4 Align Mode This mode is used to calculate work piece rotation angle. Screen shows Align point 1, Align point 2, Calc. WCS Align angle, distance between two points (Align point 1 & Align point 2) & Set Align angle. When you are out of this mode (Align mode) after carrying out Align point 1 or Align point 2 or both operation earlier, then while entering in to this mode again it will ask you whether to clear previous readings. Align Mode is divided in two parts
Ø
2.2.4.1
AlignEF Mode
Ø
2.2.4.2
AlignCF Mode
ELECTRONICA MACHINE TOOLS
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2.2.4.1
AlignEF Mode(F4)
AlignEF Function Key Set: Ø
EF1 (F1)
To find Edge-1 along the path in the direction of selected angle.
Ø
EF2 (F2)
To find Edge-2 along the path in the direction of selected angle.
Ø
ALIGN (F4) To make the Align ON / OFF.
Ø
DIAL (F6)
Use to find the Align angle by using Dial without doing edge find operation.
Ø
Set (F8)
To set the coordinates of current WCS to any value.
Ø
Zero (F9)
To set the coordinates of current WCS to zero.
Ø
Prmtr (F10) This key pops up a dialog that lets you to set the Align Angle & Mode Parameters.
Ø
Halt (F11)
To stop the AlignEF operation.
Ø
Prev (F12)
This key is used to switch to the JobSet mode key set.
2.2.4.2
AlignCF Mode(F5)
AlignCF Function Key Set: Ø
CF1 (F1)
To find Center-1 a long the path in the direction of selected angle.
Ø
CF2 (F2)
To find Center-2 along the path in the direction of selected angle.
Ø
ALIGN (F4) To make the Align ON / OFF.
Ø
DIAL (F6)
Use to find the Align angle by using Dial without doing edge find operation.
Ø
Set (F8)
To set the coordinates of current WCS to any value.
Ø
Zero (F9)
To set the coordinates of current WCS to zero.
Ø
Prmtr (F10) This key pops up a dialog that lets you to set the Align Angle &
ELECTRONICA MACHINE TOOLS
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Mode Parameters. Ø
Halt (F11)
To stop the AlignCF operation.
Ø
Prev (F12)
This key is used to switch to the JobSet mode key set.
2.2.5 AWV Mode (F6) A dialog has been displayed for AWV mode, which contains mode selection for following three operations Ø
AWV Mode: To make the wire vertical
Ø
AWV-Jig:
Ø
Guide Span and Worktable Height CalculationTo calculate the Guide
To make the wire vertical
span & Worktable height. 2.2.6 EFVolt (F7) EFVOLT key is used to select high or low voltage for spark during JobSet & Dryspark Operation.
2.2.7 SLimit (Soft Limit) (F9) SLIMIT is used to set software over travel limits for X & Y axis.
2.3
Dry Spk mode: (Alt + F5)
This mode is used for making the wire vertical with the help of verticality block so that during cutting the sparking will be uniform along the workpiece height. If req uired you can also make wire parallel to workpiece surface. Dry spark mode includes function key set as follows Function Key Set: Ø
X+ (F1)
To find edge on X -axis in positive direction.
Ø
X- (F2)
To find edge on X -axis in negative direction.
Ø
Y+ (F3)
To find edge on Y -axis in positive direction.
Ø
Y- (F4)
To find edge on Y -axis in negative direction.
Ø
U+ (F5)
To move U-axis in positive direction.
ELECTRONICA MACHINE TOOLS
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Ø
U- (F6)
To move U-axis in negative direction.
Ø
V+ (F7)
To move V-axis in positive direction.
Ø
V- (F8)
To move V-axis in negative direction.
Ø
Prmtr (F9)
This key pops up a dialog that lets you to set the WF, WT & Jstep parameters.
Ø
EFVolt (F10) EFVOLT key is used to select high or low voltage for spark during JobSet & Dryspark Operation.
Ø
2.4
Halt (F11)
To stop the Dry spark operation.
Coord Mode ( Alt + F6 )
Coord mode includes function key set as follows Function Key Set: Ø
G54 (F1)
Ø
G55 (F2)
Ø
G56 (F3)
Ø
G57 (F4)
Ø
G58 (F5)
Ø
G59 (F6) To select one of the six WCS (Work Co-ordinate Systems).
Ø
G92 (F7)
To set global offset, so that ORIGIN Point for all WCS can be shifted from its current position by that offset.
Ø
SET (F8)
To set the coordinates of current position to any value for selected WCS.
Ø
ZERO (F9)
To set the coordinates of current position as Zero position for selected WCS.
Ø
Halt (F11)
To Halt operation.
ELECTRONICA MACHINE TOOLS
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CHAPTER 3 Automatic Operation Modes Ø
3.1
Set M/c mode
Ø
3.2
Run mode
Ø
3.3
Status mode
Ø
3.4
Setup mode
3.1
Set M/c Mode (Alt + F7)
Set M/c mode includes following options as follows Ø
TON Pulse ON time setting
Ø
TOFF Pulse OFF time setting.
Ø
IP
Fine Pulse & Power Pulse setting
Ø
VP
To set Pulse peak voltage.
Ø
WP
To set Programmable Submerge mode & Dielectric pressure.
Ø
WF
To set Wire Feed Rate
Ø
WT
To set Wire tension
Ø
SV
To set Spark gap reference voltage.
Ø
SF
To set Servo Feed Rate.
Ø
CS % To set cutting speed override.
Ø
CC% To set Corner control
Ø
CDwell To set Corner dwell
Ø
SC
To set the Conductivity value.
3.2
Run Mode (Alt + F8).
Run mode is used to check the loaded profile by Dry run facility and to cut the profile. Run mode includes two-function key set as follows Function Key Set 1: Ø
Start (F1)
: To start the cutting or Dry run of the programmed job.
Ø
Dry (F2)
: To switch the Dry run facility ON/OFF.
Ø
Step (F3)
: To switch the STEP Mode ON/OFF.
Ø
Hold (F4)
: To hold all the axes that are moving.
Ø
MidStart (F5)
: To switch the Midstart mode ON/OFF.
Ø
PreSpk (F6)
: To switch the PreSpk mode ON/OFF.
Ø
MDI (F7)
: To execute single line program.
Ø
Abort (F8)
: To stop the sparking & execution of program.
Ø
Noman (F9)
: To switch on Noman level.
Ø
Goto Start Point (F10): Move to the start point of cavity.
Ø
Halt (F11)
: To halt running program.
Ø
More (F12)
: To go to function key set 2.
Function Key Set 2 :
Ø
Skip / (F1)
: To switch the Skip facility ON/OFF.
Ø
OStop (F2)
: To switch the program stop functionality ON/OFF at M01.
Ø
F% (F3)
: To override the Dry run feed in terms of percentage.
Ø
Set (F4)
: To set the origin of active WCS.
Ø
Zero (F5)
: To set the selected WCS to ZERO & switch OFF all transformations.
Ø
Timerst (F6)
: To reset the timer which counts the machining time.
Ø
Align (F7)
: To switch Align Mode ON/OFF
Ø
Halt (F11)
: To halt running program.
Ø
Prev (F12)
: To go to function key set 1.
3.3
Status Mode (Alt + F9)
This mode displays the current status that includes various flags, G and M codes that are active while the program is running. Status mode includes function key set as follows Function Key Set: Ø
GMCODE (F1)
This screen displays all the G and M codes. Currently active or executing codes are highlighted and all others ar e displayed in normal intensity. This helps user to note the status of various codes at a glance.
Ø
FLAGS (F2)
The flag status screen displays ON/OFF state & values of various controls, functions & parameters
Ø
IOSTAT (F3)
The Input and Output line status is displayed portwise in this screen. This is used mainly for the diagnostic and troubleshooting purpose.
Ø
DIAG (F4)
DIAG screen describes the current position in terms of ABSOLUTE MACHINE coordinates. It displays the Global (G92) offset and origin of currently active WCS. It also displays the actual coordinates of all axes and commanded and goto coordinates of X, Y, U, V and Z-axes. In addition it shows Following Error and Velocities of X, Y, U, V, Z and W axes.
Ø
Maintain (F5)
Maintain screen displays routine maintenance required for P.F.Unit.
Ø
CONSUM (F6)
CONSUMABLES screen shows Total & Remaining life of consumable components of the M/c.
3.4
Setup mode (Alt+F10)
The Setup mode allows you to set various machine related parameters. Setup mode includes function key set as follows Function Key Set: Ø
USER (F1)
Ø
Fact. (F2)
Ø
PERR (F5)
This is the table provided for setting the values, which can be used for Pitch Error compensation.
Ø
Pass. (F6)
To set the password. (Refer chapter “Machine ID generation procedure” while setting password)
Ø
Default (F7)
Load the default parameter given from Factory. After pressing this key all user parameter gets overwrite.
Factory setup contains the parameters, which are set in Factory. User is not allowed to change these parameters. User Setup and factory setup contains following key set : Ø
MOTOR (F1)
Motor setup values are factory set, and they should not be changed unless there is a change in hardware or any other major modifications. User is not supposed to change these values.
Ø
MCH (F2)
This mode is to set the values concerned with machine tool.
Ø
FLAGS (F3)
This mode is used to set the Flag in machine.
Ø
AWT (F4)
This mode is used to AWT related parameters.
CHAPTER 4 Programming Instructions
1] G Code Programming Instructions Ø
G0---G9
Ø
G20---G29
Ø
G40---G49
Ø
G50---G59
Ø
G70---G79
Ø
G90---G99
Ø
G100---G103
2] M Code Programming Instructions Ø
M0---M9
Ø
M20---M29
Ø
M90---M99
ELECTRONICA MACHINE TOOLS
PAGE
PROGRAMMING INSTRUCTIONS This chapter explains the CODES (or COMMANDS) used in creating the NC Program with their applications and examples. It explains all the necessary terms and definitions that are frequently used in connection with a NC program. MOTION PROGRAM FOR A CNC MACHINE Computerized Numerical Control
(abbreviated as CNC) machine understands a
group of commands, which are called motion codes or simply G-Cod es and MCodes. The sequence of these commands in a particular syntax is called NC PROGRAM. This NC PROGRAM changes with the size and shape of a Part to be cut. Hence it is also called PART PROGRAM. The codes and commands of the NC PROGRAM are converted into machine movements and/or
settings inside the
controller, which in turn produces the component according to the NC PROGRAM. As the major function of this NC Program is to maneuver the machine table movements it is also called MOTION PROGRAM. In this manual the terms NC PROGRAM, PART PROGRAM and MOTION PROGRAM are used interchangeably. This Manual explains all the G, M and E codes used in ELPULS-50 controller Mastering these codes and formats will help you to exploit the power of the machine to the fullest extent. Structure of a NC Program Any NC Program is divided into number of Blocks. A BLOCK is further divided into number of Words. A WORD is an ADDRESS (an ALPHABET from A to Z) followed by a EXPRESSION or a VALUE (positive or negative) associated with it. A WORD can be classified as CODE (or COMMAND) and PARAMETER. Any WORD with ADDRESS 'G' or 'M' or 'E' is treated specially as CODE. All other Words are treated as Parameters and are used along with the Codes. Codes with similar functions are associated to form a GROUP. A block cannot have two Codes from a same GROUP. In such a condition Group Clash occurs and Error is generated. Some codes are STAND ALONE type of codes. Any Block can Contain one and only one Stand Alone code in it. Two characters are treated very specially by the controller. They are '/' and ';'. Block beginning with '/'will be skipped by the controller if the SKIP b lock feature is turned ON. Any Text after ';' in a Block is always ignored by the controller, so that you can write your own notes, comments after this. Part of a NC Program is shown below as ELECTRONICA MACHINE TOOLS
PAGE
an Example: Program for cutting Die plate G54 G0 X0 Y0 G1 Y5 X5 Y10 X-5 Table 4.1 : List of valid addresses. ADDRES S A
USED IN
RANGE
REMARKS
G51,G52
0-360
Taper Angle
G26
0-360
Rotation angle
B
G74
0-Top height
D
Expr,G41,G42
0-9
Height where Bottom Profile is defined. Wire comp. Offset value
E
ECodes
1-9999
Machining Cond,ECode
G
GCodes
0-103
Preparatory Code
H
Expressions
0-99
Scratch Pad variable
I
G2,G3
-99999.9999
Offset of centerpoint from current position
J
G2,G3
+99999.9999
Offset of center point from current position
L
M98
1-99
Subroutine Loop count
M
Motion Prog
0-99
Machine Codes
N
All Blocks
1-9999
Block number
P P
M98 G102,G103
1-999 -99999.9999
Q
G102,G103
+99999.9999
R
G48,G1,G2,G3
0.005-99999.9 0.005-99999.9
T
G4
0-99
Subroutine Program number Offset of center point from current position. Offset of center point from current position. MODALCorner radius rounding Corner radius for rounding at the end of the block Dwell in seconds
G74
Not Applicable
ELECTRONICA MACHINE TOOLS
Height where Top profile is defined. PAGE
ADDRESS
U V
USED IN
X Y
-99999.9999 +99999.9999
Coordinates of the end point to be reached.
G29
-99999.9999 +99999.9999 -99999.9999 +99999.9999 -99999.9999 +99999.9999 0-Z Position
Coordinates of Ref. point
-99999.9999 +99999.9999 -99999.9999 +99999.9999 -99999.9999 +99999.9999 -99999.9999 +99999.9999 -99999.9999 +99999.9999 0 - 99999.99
Coordinates of the end point to be reached. Coordinates of the point about which to rotate Coordinates of Ref. point
G92-G54to G92-G59 G51,G52 G0, G1, G2, G3 G26 G29 G92
Z
REMARKS
G0, G100, G101, G102,G103
G92
W
RANGE
G92-G54 to G92-G59 G51, G52, G74
ELECTRONICA MACHINE TOOLS
Global offset Change the WCS Origin so that current point has specified coord. Programmed height
Global offset Change the WCS Origin so that current point has specified coord. Z Height
PAGE
Table 4.2 : List of G Codes, Short Summary GCODE PARAMETERS
EFFECT, STAND ALONE?
GROU P
0
XYUV
1
XYR
2
XYIJR
3
XYIJR
5
NONE
Modal, NOT STAND ALONE Modal, NOT STAND ALONE NonModal, NOT STAND ALONE NonModal, NOT STAND ALONE Modal, STAND ALONE
6
NONE
Modal, STAND ALONE
Y Mirror
8
NONE
Modal, STAND ALONE
X-Y Exchange
9
NONE
Modal, STAND ALONE
95
NONE
Modal, STAND ALONE
Cancel all Mirror or Exchanges Simultaneous X-Y Mirror
96
NONE
Modal, STAND ALONE
13
NONE
Modal, STAND ALONE
14
NONE
Modal, STAND ALONE
Ref. return OFF
22
NONE
Modal, STAND ALONE
Stored stroke Limits ON.
23
NONE
Modal, STAND ALONE
Stored stroke Limits OFF.
26
XYA
Modal, STAND ALONE
27
NONE
Modal, STAND ALONE
28
NONE
Modal, STAND ALONE
29
XYUV
Modal, STAND ALONE
40
NONE
Modal, STAND ALONE
41
D
Modal, STAND ALONE
W.D.Comp. LEFT
42
D
Modal, STAND ALONE
W.D.Comp. RIGHT
48
R
Modal, STAND ALONE
ELECTRONICA MACHINE TOOLS
A
APPLICATION Rapid Traverse Linear interpolation CW circular interpolation CCW circular interpolation
B
C
D
X Mirror
Cancel all Mirror or Exchanges Ref. return ON
Pattern rotation ON Pattern rotation OFF
E
Reference point return Remember Ref. point
F
G
W.D.Comp. OFF
Const. Corner radius ON
PAGE
GCODE PARAMETERS 49
NONE
EFFECT, STAND ALONE? Modal, STAND ALONE
50
NONE
Modal, STAND ALONE
51
AWZ
Modal, STAND ALONE
52
AWZ
Modal, STAND ALONE
53
G
54
G
55
G
Modal, NOT STAND ALONE
Activate WCS or Define WCS origin
56
G
Modal, NOT STAND ALONE
Activate WCS or Define WCS origin
57
G
Modal, NOT STAND ALONE
Activate WCS or Define WCS origin
58
G
Modal, NOT STAND ALONE
Activate WCS or Define WCS origin
59
G
Modal,NOT STAND ALONE
Activate WCS or Define WCS origin
70
NONE
Modal,STAND ALONE
71
NONE
Modal, STAND ALONE
74
BTZ
Modal, STAND ALONE
75
NONE
Modal, STAND ALONE
90
NONE
Modal, STAND ALONE
91
NONE
Modal, STAND ALONE
92
XYUV
100
UV
Modal, NOT STAND ALONE Modal, NOT STAND ALONE
Modal, NOT STAND ALONE Modal, STAND ALONE
ELECTRONICA MACHINE TOOLS
GROUP G
Const. Corner radius OFF
H
Taper cutting mode OFF
I
APPLICATION
Taper cutting mode (LEFT) ON Taper cutting mode (RIGHT) ON Absolute M/c Ref. Activate WCS or Define WCS origin
J
Dimensions in mm Dimensions in Inch
K
Complex machining mode ON Complex machining mode OFF
L
Absolute program mode
M
Incremental program mode Def.Global offset Rapid traverse for UV table, Complex cutting mode
PAGE
101
UV
Modal,STAND ALONE
N
102
UVPQ
Modal, STAND ALONE
N
103
UVPQ
Modal, STAND ALONE
4
T
46
NONE
MODAL , STAND ALONE
47
NONE
MODAL , STAND ALONE
NonModal, STAND ALONE
Linear interpolation for UV table, Complex cut. Mode CW Circular interpolation for UV table,Complex cutting mode CCW Circular interpolation for UV table,Complex cutting mode
O
Dwell in seconds
P
CRK Enable CRK Disable
Table 4.3 : List of M Codes, short summary MCODE
PARAMETERS
0
None
Program stop
1
None
Optional stop
2
None
Program end
6
None
Index the Rotary Table
20
None
Cut the Wire
21
None
Thread the wire
98
P,L
Call subprogram
99
None
End sub-program
ELECTRONICA MACHINE TOOLS
APPLICATION
PAGE
CHAPTER 5 List of messages
LIST OF CONTROLLER MESSAGES : List of Simulator's Messages. Ø
McCond Table Not Found. The specified machining condition given by E code does not exist .It has to be set, saved and then can be used.
Ø
Const.R in arc-invalid.
Ø
Code not allowed in MDI.
Ø
Error in Z / W / B / T.
Ø
Error Start Corner Rad.
Ø
Error End Corner Radius.
Ø
Error (CT xxxx).
Ø
Corner Rad. too Small.
Ø
Complex Not Intersect.
Ø
Addnl.Block Insert Fail.
Ø
Error!!! This error displays in following cases. 1. If stroke limit error occurs. 2. If Guide Span + Z height is less than or equal to worktable height for complex & taper programs.
Ø
Lxxx : CRK distorted original profile Where Lxxx specifies the line number in which the error has occurred.
List of Controller's General Messages Ø
Controller SYSTEM Software Checksum Failed.
Ø
Switch off the Machine and Download System again using key 2/3.
Ø
Controller PROM 1.15E version required. Switch off machine, Change PROM Chip. Download System again Using 2/3
Ø
Controller not Found ! Controller hardware problem, Contact EMTL.
Ø
Communication Link Failure (mode latter)..
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Internal system communication error. Ø
Controller Software version old.
Ø
Controller FIRMWARE checksum failed. Contact ELECTRONICA
Ø
Missing GLib and/or MLib at PMAC.
Ø
Terminating CNC...
Ø
Pitch error table MISSING, press key to Download....
Ø
1000 Sparking hours! It's Time for Preventive maintenance. This is a warning that 1000 sparking hours completed. Time for preventive maintenance. 1. Cleaning of filter housed in panel cooler. 2. Check that all Fan’s are working. 3. All fuses, connectors are tight enough. 4. Clean head of floppy disk drive by head cleaning diskette. 5. Greasing of all L-M guides.
Ø
Can't do. Program is running.
Ø
CRK has distorted original profile, Press key. This message appears when selected Program is downloaded to the controller in which, because of application of Radius correction (CRK) factor profile distortion is occurred.
Ø
Reading Downloaded Program ... After power up the previously downloaded NC program is being read in the controller's memory
Ø
Wire Break...Press any Key. Wire break encountered at the M/c tool. Acknowledge the same with a key press at the controller keyboard.
Ø
Servo overload, RESET Drive. Servo Drive Fault has encountered, cannot continue unless the RESET operation is done.
Ø
X Positive Software Limit Reached..
Ø
X Negative Software Limit Reached..
Ø
Y Positive Software Limit Reached..
Ø
Y Negative Software Limit Reached..
Ø
U Positive Software Limit Reached..
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Ø
U Negative Software Limit Reached..
Ø
V Positive Software Limit Reached..
Ø
V Negative Software Limit Reached.. The axis has crossed the Software Stroke Limit set in the SETUP mode; Software stroke limits can be disabled giving G23 code from MDI
Ø
Program aborted and rewound.. Running program halted, spark off, and program rewound so program will start from the beginning.
Ø
M/c Referencing in progress... Selected axis Homing is in progress
Ø
Program Halted. Program stopped and can be continued from the same position.
Ø
Program Ho ld. System is in hold condition; the operation can be continued wit h “Start” key
Ø
Step Mode - Program Halted.. Program halted in single step mode, can be continued with “Start” key
Ø
Electrode Workpiece Short! Press Key. EW short detected when contact sensing enabled.
Ø
Running.. Currently loaded program is running at the machine
Ø
Program End .. Program end has encountered and Program is automatically rewound and actions like spark off, flushing off, wire feed/tension off, table movements stop are taken. “Start” key restarts the operation from beginning of program.
Ø
X Axis Negative Travel Limit Reached..
Ø
X Axis Positive Travel Limit Reached..
Ø
Y Axis Negative Travel Limit Reached..
Ø
Y Axis Positive Travel Limit Reached..
Ø
U Axis Negative Travel Limit Reached..
Ø
U Axis Positive Travel Limit Reached..
Ø
V Axis Negative Travel Limit Reached..
Ø
V Axis Positive Travel Limit Reached..
Ø
Z Axis Positive Travel Limit Reached..
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Axis travel limit is reached, move the axis in opposite direction to get out of this. Ø
DWELL in Progress...... The system is in dwell status for specified time
Ø
Downloading program, Please wait !!! Selected program is downloading to the controller, please wait
Ø
No Program Downloaded! Press Key. “Start” key is pressed without downloading the NC program; no start operation can be done.
Ø
Running program is going to be KILLED.
Ø
Please download running program again. Due to some changes made in the machine parameters the downloaded program becomes invalid and it is being erased from the system.
Ø
AL723SYS.PMC File Not Found..
Ø
AL723FLX.PMC File Not Found.. Very important system software file is corrupted, install software and then operation should be continued.
Ø
Unable to open pitch error file. Pitch error compensation file corrupted.
Ø
Can not PreSpark. Prespark is allowed only after program halt due to M0.
Ø
PreSpark Mode can NOT be turned OFF. Once machine is forced in prespark mode by user, prespark cannot be turned off. The only way to turn prespark off is to abort program.
Ø
Restoring conditions This message indicates 'E' code execution is over.
Ø
Power Disturbance ...Program Hold. It is an indication of a power supply fluctuation. Machine momentarily waits and resumes if normal power conditions are restored.
Ø
Program Buffer Full...Press Key Controller is out of memory because program is too lar ge.
Ø
PMACRSET.DAT File NOT Found..
Ø
PMACIFLX.DAT File NOT Found..
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Ø
PMACINIT.DAT File NOT Found.. Very important system file is corrupted.
Ø
M/c Reference related messages: 1. Message “Do M/c Ref for ... ... Axes, Press Key” as specific axis related message, eg. “Do M/c Ref for X, Y, Z Press key...” depending on which axes require referencing. 2. Message “...axis M/c Ref Fail, set Limit-ABS dist, Press key...” as specific axis related message, eg. “X axis M/c Ref Fail, set Limit-ABS dist...”. In reference, table sense limit & try to find ABS, if it gets ABS between 1 mm.to 4mm. from limit then only M/C reference is successful.
Ø
PROGRAM NUMBER LOST...
Ø
PROGRAM ABSENT, (Err595)... Program number internally stored is lost or misreported. Re-cycle power supply and recheck, if the condition persists, report EMTL.
Ø
WARNING : Negative radius The taper cut in the circular block is causing XY table and UV table to move in opposite direction. This is due to higher taper angle. You may use constant radius to solve this problem if it is allowed in the application.
Ø
MCP Not Found If ELC-304 card is not present or faulty.
Ø
WCS Origin inconsistent, Press key... If stored data of WCS is corrupted.
Ø
Table NOT In-Pos. Set/Zero failed. If table is moving & operator tries to set co-ordinates. It is not all owed.
Ø Ø
Program will be aborted, if exists. Servo Trip, RESET Drive... Due to over speed, servo trips, reset it.
Ø
Prejog all axes before START, Press key. If operator halts a program & moves the table from it's programmed path and presses “Start” key.
Ø
Z Axis Position incorrect, Press Key. In case of tapered and complex profiles if difference between Z axis position and Z axis GOTO position is greater than Z tolerance specified in SETUP.
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Ø
Reseting NOMAN mode... On selecting NOMAN mode if a program is running and wire breaks or limit is sensed, key sense for 3 minutes, if within these three minutes operator press a key NOMAN mode gets reset.
Ø
M/cRef aborted, Lift Quill, press key. In 7** series M/C, it is a software interlock to
prevent quill accident. When
this limit operates then only referencing is possible. Ø
NOMAN active, Press key to continue.. It is an indication of activated NOMAN mode & after 3 minutes M/C will be turned OFF.
Ø Enable
pitch error table?
This indicates the operator that the pitch error table is disabled. It also asks whether it should be enabled. It should normally be enabled. It can be enabled or disabled from the SETUP. Ø
Exprn. evaluation error. The entered expression is not proper or is evaluated to a wrong value that is not allowed.
Ø
Run Time Error, Halt! Press Key. Program is halted due to some runtime error.
Ø
Please wait, Confirming program absence
Ø
Save pitch error table?
Ø
Download pitch error table?
Ø
Start M/C Ref ?
Ø
PERR downloading FAILED, press key.
Ø
Downloading pitch error compensation.
Ø
Battery voltage low !!!!
Ø
Filter life over , change it and reset life in status
Ø
Resin life over, change it and reset life in status
Ø
Wire guides life over , change it and reset life in status
Ø
E-W Short, Operation Aborted ! Press Key.
Ø
Safety Cover Open, press key.
Ø
Program Halt, Wire Brake in Outlet, Press Key.
Ø
Program halt by Flush Off, Press Key.
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Ø
Program Halted due to Gap Short.
Ø
NIR Temp. High.
Ø
Filter Pressure Crossed Limit, Replace It.
Ø
Entering deadlock.
Ø
Power recovered.
Ø
Bringing axes in closed loop.
Ø
All PLCs enabled.
Ø
Bringing all axes in closed loop.
Ø
All axes are in closed loop.
Ø
Start command issued.
Ø
Do M/cRef for Axes.
Ø
Is Wire Normally vertical?
Ø
Axes at PreSpark target position?
Ø
Kill program?
Ø
Abort Current Run Program?
Ø
Reset time?
Ø
Program not downloaded.
Ø
Switching OFF Machine.
Ø
Currentpickup life over, change it and reset life in status
Ø
Installation completed successfully !!!
Ø
Power fail position not saved.
Ø
Initializing System Transformation..Wait
Ø
WCS Orgin inconsistent.
Ø
Machine Stop.
Ø
Clear previous 3pt center find settings?
Ø
Set calculated WCS angle ?
Ø
Angle Calculation Error ! Aln Pt1 & Aln Pt2 angles are different.
Ø
Edge find failed,clean workpiece, press key.
Ø
Clear Previous Settings ?
Messages related to AWT operation: Ø
Clamp miss Error This message is displayed if the wire clamp fails to hold the wire properly
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before cutting the wire. Ø
Failed to cut the wire. If cutter failed to cut the wire, this message gets displayed
Ø
Cutting over. Indicates the wire cutting operation is over.
Ø
Retracing sparking path. After threading the wire through wireguides and work-piece after wire break condition, wire traces the path upto the position where wire had broken. During this operation this message is displayed.
Ø
Failed to thread upto upper guide. Wire failed to reach upto upper wire guide within specified time (First insertion time) due to some obstacle.
Ø
Failed to thread upto lower sense. Wire failed to reach upto lower assembly within specified time (Third insertion time) due to some obstacle.
Ø
Failed to thread upto workpiece. Wire failed to reach upto workpiece within specified time due to some obstacle.
Ø
Wire blocked in outlet. Wire stucked in between lower assembly and bin sense.
Ø
Threading Successful. Wire threading completed successfully.
Ø
Moving to jet vertical. Z axis is moving towards the jet so that Z-axis will be vertically aligned above the jet.
Ø
Wire spool empty, prog halt, press key. This message is displayed if the wire bobbin becomes empty.
Ø
Lower Sense, Wire blocked in o utlet. There is wire in the lower assembly.
Ø
Wire stucked in outlet OR Water conductivity high. Wire is blocked in the lower assembly or water conductivity is increased.
Ø
Wire idling in progress. After cutting the wire, the wire remained between lower assembly and bin
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sense is being pulled out of assembly. Ø
Wire Blocked at Cutter, Program Halted! Press Key. Wire is blocked in spring or near Cutter.
Ø
Program Halt, Threading Retries Over, Press Key. As Threading Reties are over & as Handling retry over is not selected from AWT Setup Program is halted.
Messages related to large program downloading : Ø
Loading program, please wait… While downloading program to controller.
Ø
Prog aborted due to previous load failure. While loading program, if power failure occurs, & loading is not completed.
Ø
Program downloading aborted. Program downloading canceled by user.
Ø
Reading program, please wait… While downloading program to controller.
Ø
Prespark disabled due to large cavity program Prespark will be disabled for single large cavity in program, which occupies PROG memory more than 60KB approximately
Ø
Aborting load, Memory insufficient at Block No. XXXXX . .If size of program in from “G0 to G0 for Non AWT“ or “M21 to M21for AWT” is greater than controller memory then program will not be downloaded. If program contains single G0 or single M21 & program size is grater than controller memory then program will not be downloaded. XXXXX – stands for cavity no.
Messages related to rotary axis: Ø
Rotary table program not rewound. This message is displayed if referencing (Home Zero Position) of rotary axis is not done.
Ø
Rotary table indexing error. This message is displayed if there is any error while indexing rotary axis. Messages related with floppy and floppy drive faults
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Messages related to Submerge: Ø
Tank door open, Prog halt, Press key.
Ø
Backwash / Clean filter / PF unit fault, Prog halt, Press key.
Ø
Tank door open, Fill disabled.
Ø
Work tank water level low.
Ø
Quill level high.
Ø
Water level low not reached.
Ø
PF unit fault, Prog halt, Press key.
Ø
Filter pressure high, Prog halt, Press key.
Ø
Float switch fault, Prog halt, Press key.
Ø
MCP WFWT/ Flush Off Program halt, Press Key.
Messages related to password during password setting: Ø
Password successfully set. This message indicates password is set successfully.
Ø
Invalid password This message is displayed whenever there is mismatch in Machine ID of machine & that of password.
Ø
Invalid password, Mismatch in expiry dates. This message occurs due to the mismatch in password expiry date and CNC expiry date.
Ø
Invalid password, Mismatch in dates. This message occurs due to the mismatch in password generation date and current date of machine.
Ø
Same Password already present.
Messages related to password at the time of initi alization: Ø
Unable to run eWinCNC application, Contact Service Engineer. This message occurs due to the mismatch in machine date.
Ø
Password expired, Contact Service Engineer The validity period for Password expired, Contact service engineer to get the new password or to activate the machine.
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CHAPTER 6 Short Keys
The list of keyboard commands available in eWinCNC is as follows Command
Short key
Open
Ctrl + O
XY layer
Alt + X
UV layer
Alt + U
Top layer
Alt + T
ProgHeight layer
Alt + P
DrawHeight layer
Alt + D
Wirepath layer
Alt + W
ReDraw
Alt + R
FullGraphics
Alt + G
Pan
Alt + N
3D profile view
Alt + 3
AutoPan
Alt + A
Main Mode
Alt + F1
Jog Mode
Alt + F2
M/cReference Mode
Alt + F3
JobSet Mode
Alt + F4
DrySpark Mode
Alt + F5
Coord Mode
Alt + F6
Set Machine Mode
Alt + F7
Run Mode
Alt + F8
Status Mode
Alt + F9
Setup Mode
Alt + F10
Reset
Alt + F12
File Menu
Alt + F
View Menu
Alt + V
Parameter Menu
Alt + M
Serial Menu
Alt + S
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Install Menu
Alt + I
Help Menu
Alt + H
The list of keyboard commands available in MidStart mode is as f ollows –
Previous Block
Up Arrow
Next Block
Down Arrow
Goto Start Block
Ctrl+PgUp
Goto End Block
Ctrl+PgDn
Previous G0 Block
PgUp
Next G0 Block
PgDn
Mark Start Block
Ctrl+S
Mark End Block
Ctrl+E
Find Text
Ctrl+F
Clear Settings
Ctrl+L
OK
Ctrl+Y
Cancel
Ctrl+N
The list of Symbols used in eWinCNC is as follows – Main Mode JobSet Mode Coordinate Mode Set Machine Mode Run Mode Setup Mode Start DryRun Step Hold ELECTRONICA MACHINE TOOLS LTD.
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Manual Data Input (MDI) Abort Noman Goto start point Halt Skip Ostop TimeReset Goto next key set Goto previous key set Buzzer Cut the Wire Thread the wire Semi Auto wire threading Fill tank Drain tank Flush WFWT Motor Reset
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CHAPTER 7 Terms
XY layer : Layer drawn at XY guide level. UV layer : Layer drawn at UV guide level. Top layer : Layer drawn at the height of workpiece from worktable height. ProgHeight layer : Height at which profile is programmed. DrawHeight layer : Height at which user wishes to view the profile. It is user settable parameter. Wirepath layer : Connecting lines between XY and UV layers. Ecode : Technology used for cutting workpiece. Guide Span : Distance between UV and XY guides. When Z = 0. WorkTable Height : Distance between top surface of worktable & lower(XY) guide.
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CHAPTER 8 Installation Procedure Installing FirstTime On System Following steps to be followed to install a eWinCNC Software first time on your system from CD-Rom -
Insert CD into CD drive
-
Explore the contents of CD
-
Double click on “Setup.exe” file
-
Follow the instructions displayed by application.
Install from CD-Rom Following steps to be followed to install a eWinCNC from CD-Rom -
Insert CD into CD drive
-
Select “Install from CD” option from Install menu
-
Follow the instructions displayed by application.
Install from System Following steps to be followed to install a eWinCNC from System -
Select “Install from PC” option from Install menu
-
Follow the instructions displayed by application.
Above given both procedures will ask for “Insert disk to drive & press OK to take backup of setup.cnc & perr.dat file”. After that it will ask for Model, Drive/Motor, Feedback, Technology & Language selection. Select the appropriate option. Now eWinCNC will get installed on your system at path C:\eWinCNC.
Installation Steps 1. From list of machine models select the current machine model. The selection dialog looks like
2. From list of drives select the appropriate drive. The selection dialog looks l ike
3.From list of feedback select the appropriate option. The selection dialog l ooks like
4.Select the appropriate option for technology. The selection dialog looks like
5. From list of languages select the language in which software to be installed. The selection dialog looks like
6. In above 5 steps as you go on selecting the previous selected options is displayed at the top of dialog. If your selection is correct then at last setup shows following message.
CHAPTER 9
How to get and send Machine ID and Machine number Ø
Method 1: Get Machine ID from Command Prompt
During Initialization of eWinCNC application Press F4 ( Function Key), So that application closes and brings Desktop. Now go to the command prompt using “command” as shown in Figure 1 Or “cmd” as shown in Figure 2 Figure 1
Figure 2
DOS command prompt is displayed as shown in Figure 3 Figure 3
Now Type command “D:\>ipconfig/all” in command prompt as shown in Figure 4 Encircled in yellow. Note: If physical address is not displayed then check the network configuration. After executing above command following Information is displayed on screen as Shown in Figure 4 Look for “Physical Address” encircled in Blue and note down the number (Address) Displayed in front of it encircled in Red e.g. 00-01-53-82-43-96 Send this Address with the Machine No. Figure 4
Ø
Method 2: Machine ID from eWinCNC application
Step1: Install eWinCNC V 1.08 s/w or higher ver in the machine. Step2:
How to Save Machine No in Machine Setup
After installing eWinCNC V1.08, enter the Machine No in Machine Setup and save it. Figure1
Step3:
How to send Machine ID and Machine number
Press Password key in SETUP mode, Password dialog will be displayed Send “Machine Number” and “Machine ID” displayed on the Password Dialog Machine Number: 010607 Machine ID: 00-01-53-82-43-96 Note: First check that the Machine number & Machine ID is displayed on the screen. If Machine number is not displayed fill machine number in setup. If Machine ID is not displayed then check the network configuration.
Figure2
OR Send Password Site ID file generated from Backup option. (Parameter-> Backup -> SAVE -> Password file.) Figure3
Select drive to store generated Site ID file. Name of Generated (site ID) file is “IMID-xx-xx-xx-xx-xx-xx.dat” IMID followed by Machine ID No
e.g IMID-00-01-53-82-43-96.dat
Figure4
Figure5
Step3:
How to Set Password to eWinCNC
After sending the site ID file or Machine ID, password or password file for that Machine ID will be provided. Load this file from Password dialog using “LoadFromFile” button (by specifying path of the file) or enter the key / Password in “New password:” box & press set password button. Name of Password file is “OMID-xx-xx-xx-xx-xx-xx.dat” IMID followed by Machine ID
e.g OMID-00-01-53-82-43-96.dat
Figure6
SiteID and Password File description: Generated (Site ID) file is
“IMID-xx-xx-xx-xx-xx-xx.dat” :
Password file is
“OMID-xx-xx-xx-xx-xx-xx.dat” :
Example: For Machine ID: 00-01-53-82-43-96 Files will be Generated (site ID) file is: “IMID-00-01-53-82-43-96.dat” Password file is:
“OMID-00-01-53-82-43-96.dat”
