Mill Operator’s Manual JUNE 2008 HAAS AUTOMATION INC. • 2800 STURGIS ROAD • OXNARD, CA 93030 TEL. 888-817-4227 FAX. 805-278-8561 www.HaasCNC.
Warranty Certificate Covering Haas Automation, Inc.
Warranty Registration Certificate LIMITED WARRANTY COVERAGE All new Haas mills are warranted exclusively by the Haas Automation’s (“Manufacturer”) limited warranty as follows: Each Haas CNC machine (“Machine”) and its components (“Components”) (except those listed below under limits and exclusions) is warranted against defects in material and workmanship for a period of one (1) year (except Tooroom Mills and Mini-Mills, which are six (6) months) from the date of purchase, which is the date that a machine is
Buyer has accepted this restriction on its right to recover incidental or consequential damages as part of its bargain with Seller. Buyer realizes and acknowledges that the price of the equipment would be higher if Seller or Manufacturer were required to be responsible for incidental or consequential damages, or punitive damages.
Customer Satisfaction Procedure Dear Haas customer, Your complete satisfaction and goodwill are of the utmost importance to both Haas Automation, Inc., and the Haas distributor where you purchased your equipment. Normally, any concerns you may have about the sales transaction or the operation of your equipment will be rapidly resolved by your distributor.
The Information contained in this manual is constantly being updated. The latest updates, and other helpful information is available online as a free download in .pdf format (go to www.HaasCNC.com and click on “Manual Updates” under the “Customer Services” drop-down menu in the navigation bar). Table of Contents USES AND GUIDELINES FOR PROPER MACHINE OPERATION ........................................................................ 4 MODIFICATIONS TO THE MACHINE ............................................
TOOLING.................................................................................................................................................... 47 TOOL CHANGER.......................................................................................................................................... 48 JOG MODE ................................................................................................................................................ 57 PALLET CHANGER (EC-SERIES AND MDC-500) ...
HAAS SAFETY PROCEDURES THINK SAFETY! DON’T GET CAUGHT UP IN YOUR WORK All milling machines contain hazards from rotating parts, belts and pulleys, high voltage electricity, noise, and compressed air. When using CNC machines and their components, basic safety precautions must always be followed to reduce the risk of personal injury and mechanical damage.
READ BEFORE OPERATING THIS MACHINE: ♦ Only authorized personnel should work on this machine. Untrained personnel present a hazard to themselves and the machine, and improper operation will void the warranty. ♦ Check for damaged parts and tools before operating the machine. Any part or tool that is damaged should be properly repaired or replaced by authorized personnel. Do not operate the machine if any component does not appear to be functioning correctly. Contact your shop supervisor.
OBSERVE ALL OF THE WARNINGS AND CAUTIONS BELOW: ♦ Do not operate without proper training. ♦ Always wear safety goggles. ♦ Never place your hand on the tool in the spindle and press ATC FWD, ATC REV, NEXT TOOL, or cause a tool change cycle. The tool changer will move in and crush your hand. ♦ To avoid tool changer damage, ensure that tools are properly aligned with the spindle drive lugs when loading tools. ♦ The electrical power must meet the specifications in this manual.
USES AND GUIDELINES FOR PROPER MACHINE OPERATION All milling machines contain hazards from rotating cutting tools, belts and pulleys, high voltage electricity, noise, and compressed air. When using milling machines and their components, basic safety precautions should always be followed to reduce the risk of personal injury and mechanical damage. READ ALL APPROPRIATE WARNINGS, CAUTIONS, AND INSTRUCTIONS BEFORE OPERATING THIS MACHINE.
! DANGER ! 96-8000 rev U June 2008 Safety 5
MILL WARNING DECALS 6 Safety 96-8000 rev U June 2008
LATHE WARNING DECALS 96-8000 rev U June 2008 Safety 7
OTHER SAFETY DECALS Other decals may be found on your machine, depending on the model and options installed: 8 Safety 96-8000 rev U June 2008
DECLARATION OF WARNINGS, CAUTIONS, AND NOTES Throughout this manual, important and critical information is prefaced with the word “Warning”, “Caution” and “Note” Warnings are used when there is an extreme danger to the operator and/or to the machine. Take all steps necessary to heed the warning given. Do not continue if you cannot follow the warning instructions. An example warning is: WARNING! Never put hands between tool changer and spindle head.
10 Safety 96-8000 rev U June 2008
INTRODUCTION The following is a visual introduction to a HAAS mill. Some of the features shown will be highlighted in their appropriate sections.
Data Plate Model Serial Number Date of Manufacture Voltage Phase Hertz Full Load Largest Load Short Circuit Interrupting Capacity Wiring Diagram Over current protection provided at machine supply terminals) Warning Lethal voltages inside cabinet! Disconnect from power source before opening cabinet! Trained service personnel only! Made in USA Main Circuit Breaker Switch Control Box Fan (runs intermittently) Control Box Lube Panel Assembly Tramp Oil Container Coolant Tank Assembly Air Filter/Regulator Hos
CONTROL DISPLAY AND MODES The control display is organized into panes that vary depending on the current control mode, and on what display keys are used. The following illustration shows the basic display layout: Interaction with data can be carried out only within the currently active pane. Only one pane is active at any given time, and it is indicated with a white background.
PENDANT KEYBOARD INTRODUCTION The keyboard is broken up into eight sections: Function Keys, Jog Keys, Override Keys, Display Keys, Cursor Keys, Alpha Keys, Mode Keys and Number Keys. In addition there are miscellaneous keys and features located on the pendant and keyboard which are described briefly.
Memory Lock Key Switch - This switch prevents the operator from editing programs and from altering settings when turned to the locked position, and the below-listed settings are turned on. The following describes the hierarchy of locks: Key switch locks Settings and all programs. Setting 7 locks parameters. Setting 8 locks all programs. Setting 23 locks 9xxx programs. Setting 119 locks offsets. Setting 120 locks macro variables.
OVERRIDE KEYS These keys give the user the ability to override the speed of non-cutting (rapid) axes motion, programmed feeds and spindle speeds. -10 - Decreases current feedrate by 10%. 100% - Sets overridden feedrate to programmed feedrate. +10 - Increases current feedrate by 10%. -10 - Decreases current spindle speed by 10%. 100% - Sets overridden spindle speed to programmed speed. +10 - Increases current spindle speed by 10%.
DISPLAY KEYS Display keys provide access to the machine displays, operational information and help pages. They are often used to switch active panes within a function mode. Some of these keys will display additional screens when pressed more than once. Prgrm/Convrs - Selects the active program pane in most modes. In MDI/DNC mode, press to access VQC and IPS/WIPS (if installed). Posit (Position) - Selects the positions pane, located in the lower center of most screens. Displays the current axis positions.
CURSOR KEYS Use Cursor Keys to move to various screens and fields in the control, and for editing CNC programs. Home - This button will move the cursor to the top-most item on the screen; in editing, this is the top left block of the program. Up / Down Arrows - moves up/down one item, block or field. Page Up / Down - Used to change displays or move up/down one page when viewing a program. Left Arrow - Used to select individually editable items when viewing a program; moves cursor to the left.
Alter - Pressing this button will change the highlighted command or text to the newly entered commands or text. This button will also change the highlighted variables to the text stored in the clipboard, or move a selected block to another location. Delete - Deletes the item that the cursor is on, or deletes a selected program block. Undo - Undoes up to the last 9 edit changes, and deselects a highlighted block. MEM (Memory) - Selects the memory mode.
Origin - Sets selected displays and timers to zero. Singl (Single) - Returns one axis to machine zero. Press the desired axis letter and then press the Singl Axis button. This can be used to move a single axis to the initial axis zero position. HOME G28 - Returns all axes to machine zero in rapid motion. Home G28 will also home a single axis in the same manner if you enter an axis letter and press the home G28 button. CAUTION! There is no warning message to alert the operator of any possible collision.
Distance To Go This display shows the distance remaining before the axes reach their commanded position. When in hand jog mode, this position display can be used to show a distance moved. You can zero this display by changing modes (EDIT, MEM, MDI) and then switching back to hand jog. OFFSETS DISPLAY There are two offsets tables. The first is the Tool Geometry/Wear table. The second is the Work Zero offset table.
Active Codes Lists active program codes. It is an expanded display of the program code display described above. Positions Display Provides a larger view of current machine positions, with all reference points (operator, machine, work, distance to go) displayed at once. You can also handle jog axes from this screen.
SETTING / GRAPHIC DISPLAY FUNCTION Press the SETNG/GRAPH key to access Settings. There are some special functions in the settings which change the way the mill behaves; refer to the “Settings” section for a more detailed description. The Graphics function is selected by pressing the Setng/Graph button twice. Graphics is a visual dry run of your part program without the need to move the axes and risk tool or part damage from programming errors.
DATE AND TIME The control contains a clock and date function. To view the time and date, press the CRNT COMDS key, then Page Up or Page Down until the date and time appears. To make adjustments, press Emergency Stop, type the current date (in MM-DD-YYYY format) or current time (in HH:MM format), and press WRITE/ENTER. Reset Emergency Stop when finished. TABBED HELP / CALCULATOR FUNCTION Press the HELP/CALC key to display the tabbed help menu.
Trigonometry Help Function The Trigonometry calculator page will help solve a triangular problem. Enter the lengths and the angles of a triangle and when given enough data the control will solve for the triangle and display the rest of the values. Use the Cursor Up/Down buttons to select the value to be entered with WRITE. For inputs that have more than one solution, entering the last data value a second time will cause the next possible solution to be displayed. HELP (MEM) O00000 N00000000 CALCULATOR 0.
CIRCLE-CIRCLE TANGENT CIRCLE1 X CIRCLE1 Y RADIUS 1 CIRCLE2 X CIRCLE2 Y RADIUS 2 5.0000 6.0000 4.0000 0.0000 0.0000 2.0000 CIRCLE-LINE TANGENT a TANGT A X 1.3738 Y 7.6885 TANGT B X 7.3147 Y 2.7378 TANGT C X -1.8131 Y 0.8442 TANGT D X 1.1573 Y -1.6311 b c d Type: STRAIGHT Use F and T to form G-code. F1 for alternate solution POINT A X Y POINT B X Y POINT C X Y 5.0000 3.0000 1.0000 4.0000 0.0000 0.0000 RADIUS TANGT PT X TANGT PT Y 4.1231 1.0000 4.
Materials The Milling calculator includes a field called MATERIAL, which, when highlighted, allows the operator to select a type of material from the list using the left and right arrow keys. A recommended surface speed and chip load will be displayed based on the material chosen, as shown. SURFACE SPEED *.*** FT/MIN RECOMMENDED **** TO ***** CHIP LOAD *.*** IN RECOMMENDED *.*** TO *.*** Also, the required horsepower will be calculated and displayed as shown below on the right. CUT DEPTH *.
OPTIONS 200 Hour Control Option Try-Out Options that normally require a unlock code to activate (Rigid Tap, Macros, etc.) are activated and deactivated as desired by entering the number "1" instead of the unlock code to turn it on. Enter a "0" to turn off the option. An option activated in this manner is automatically deactivated after a total of 200 power-on hours. Note that the deactivation only occurs when power to the machine is turned off, not while it is running.
Programmable Coolant Spigot The optional programmable coolant spigot allows the user to direct the coolant stream to the most optimum location in order to flush out chips from the cutting area. The direction of the coolant can be changed by the CNC program. Automatic Chip Auger The automatic chip auger assists the user in removal of chips for jobs with heavy material removal.
High Speed Tooling – The tool holders should be an AT-3 or better with a nylon back-up screw. The tolerances maintained in the AT-3 design are the minimum that would be recommended for a high speed process. The nylon back-up screw increases collet grip on the tool and creates a better seal to aid in coolant transfer. Use single angle collet chucks and collets for best grip and concentricity. These collet systems are made up of a long single angle located in the holder.
Axis Select: Used to select any of the available axes for jogging. The selected axis is displayed at the bottom of the screen. RJH-C: The far right position of this selector accesses the auxiliary menu. Removing the unit from the cradle/holster powers it on and turns over jogging control from the pendant to the Remote Jog Handle (The hand wheel on the pendant is disabled). NOTE: For the RJH-C to take over jogging control, the pendant must be in Hand Jog mode (Setup).
RJH-E Menus The RJH-E uses four program menus to control manual jogging, set tool length offsets, set work coordinates, and display the current program. The four screens display information differently, but navigating and changing options are always controlled in the same way, as noted in the following illustration.
Manual Jogging (Remote Jog Handle) RJH-E: This menu contains a large display of the current machine position. The currently selected axis is highlighted and will move if the shuttle jog or pulse jog knobs are turned. Select another axis by using the thumb knob. The jog increment for the pulse knob is displayed on the second line and can be adjusted with the left and right arrow keys. Press ZERO to origin the operator coordinates only.
Work Offsets (Remote Jog Handle) RJH-E: Select "G code" with the up/down arrow keys and change the value with the pulse jog knob. Manually jog the selected axis with the shuttle or pulse knob when the bottom axis field is highlighted. Press SET to set the current position of the current axis into the work offset table. Press JOG to advance to the Jogging screen. RJH-C: Press WK CS to change the work offset G code.
Program Display (Run Mode) RJH-E and RJH-C: This mode displays the currently running program. Enter run mode by pressing MEM or MDI on the control pendant. The tab options at the bottom of the screen provide controls for coolant on/off, single block, optional stop, and block delete. Toggled commands such as COOL will appear highlighted when turned on. The CYCLE START and FEED HOLD buttons function just as the buttons on the pendant.
OPERATION MACHINE POWER-UP Turn the machine on by pressing the Power-On button on the pendant. The machine will go through a self test and then display either the Messages screen, if a message was left, or the Alarms screen. In either case the mill will have one alarm present (102 SERVOS OFF). Pressing the Reset button a couple times will clear the alarms. If an alarm cannot be cleared the machine may need servicing, if this is the case call your dealer.
Numbered Programs To create a new program, press LIST PROG to enter the program display and the list of programs mode. Enter a program number (Onnnnn) and press Select Prog key or Enter. If the program exists, it will be selected. If it does not yet exist, it will be created. Press Edit to show the new program. A new program will consist of only the program name and an End of Block (;). Numbered programs are retained when the machine is turned off.
Converting an MDI program to a numbered program An MDI program can be converted to a numbered program and added to the list of programs. To do so, cursor to the beginning of the program (or press Home), enter a program name (programs need to be named using the format Onnnnn; the letter “O” followed by up to 5 numbers) and press Alter. This will add the program to the list of programs and clear MDI. To re-access the program, press List Prog and select it.
Loading Programs to the CNC Control Numbered programs can be copied from the CNC control to a personal computer (PC) and back again. It is best if the programs are saved to a file that ends in “.txt”. That way, they will be recognized by any PC as a simple text file. Programs can be transferred by many different methods such as USB, RS-232 and floppy disk. Settings, offsets and macro variables can be transferred between the CNC and a PC in a similar manner.
Copying Files Highlight a file and press “Enter” to select it. A check mark appears next to the file name. Navigate to the destination directory with the arrow keys, press “Enter”, and press F2 to copy the file. Note that files copied from the control’s memory to a device will have the extension “.NC” appended to the file name. However the name can be changed by navigating to the destination directory, entering a new name, and then pressing F2.
RS-232 RS-232 is one way of connecting the Haas CNC control to another computer. This feature enables the programmer to upload and download programs, settings and tool offsets from a PC. Programs are sent or received through the RS-232 port (Serial Port 1) located on side of the control box (Not the operator’s pendant). A cable (not included) is necessary to link the CNC control with the PC. There are two styles of RS-232 connections: the 25-pin connector and the 9-pin connector.
To receive a program from the PC, push the LIST PROG key. Move the cursor to the word ALL and push the RECV RS-232 key and the control will receive all main and sub programs until it receives a “%” indicating end of input. All programs sent to the control from the PC must begin with a line containing a single “%” and must end with a line containing a single “%”. Note that when using “ALL”, your programs must have a Haas formatted program number (Onnnnn).
DIRECT NUMERIC CONTROL (DNC) Direct Numeric Control (DNC) is another method of loading a program into the control. It is the ability to run a program as it is received through the RS-232 port. This feature differs from a program loaded through the RS232 port in that there is no limit to the size of the CNC program. The program is run by the control as it is sent to the control; the program is not stored in the control.
MACHINE DATA COLLECTION Machine Data Collection is enabled by Setting 143, which allows the user to extract data from the control using a Q command sent through the RS-232 port (or by using an optional hardware package). This feature is softwarebased and requires an additional computer to request, interpret and store data from the control. Certain Macro variables can also be set by the remote computer. Data Collection Using the RS-232 Port The control only responds to a Q command when Setting 143 is ON.
Data Collection Using Optional Hardware This method is used to provide machine status to a remote computer, and is enabled with the installation of an 8 Spare M-code relay board (all 8 become dedicated to below functions and cannot be used for normal M-code operation), a power-on relay, an extra set of Emergency Stop contacts, and a set of special cables. Contact your dealer for pricing information on these parts.
ALPHABETICAL ADDRESS CODES The following is a list of the address codes used in programming the CNC. A, B, C, U, V, W, X,Y, Z Axis motion – Specifies axis motion (distance or angle). D Tool diameter selection – Selects the tool diameter or radius used for cutter compensation. See the Cutter Compensation section. E Contouring accuracy – Used, with G187, to select the accuracy required when cutting a corner during high-speed machining operations.
TOOLING Tool Functions (Tnn) The Tnn code is used to select the next tool to be placed in the spindle from the tool changer. The T address does not start the tool change operation; it only selects which tool will be used next. M06 and will start a tool change operation, for example T1M06 will put tool 1 in the spindle.
Tool Holder Assembly Tool holders and pull studs must be in good condition and tightened together with wrenches or they may stick in the spindle. Clean the tool holder body (the part that goes into the spindle) with a lightly oiled rag to leave a film, which will prevent rusting. 40 Taper CT Tool Holder Tool (Center Drill) Pull Stud Install a tool into the tool holder as instructed by the tool manufacturer.
Tools are always loaded into the tool changer by first installing the tool into the spindle. Never load a tool directly into the tool changer. Note: Tools that make a loud bang when being released indicate a problem and should be checked before serious damage to the tool changer occurs. Tool Loading for a Side Mount Tool Changer NOTE: A normal size tool has a diameter of less than 3” for 40-taper machines, or less than 4” for 50-taper machines.
6. Organize the tools to match to the CNC program. Determine the numerical positions of large tools and designate those pockets as Large in the Tool Pocket Table. To designate a tool pocket as “Large”, scroll to that pocket, press L, then Write/Enter. NOTE: When setting up tooling for the CNC program, large tools must have the surrounding pockets empty to prevent a tool changer crash. However, large tools can share adjoining empty pockets.
change operations a normal size tool can be taken from one pocket and put back into another. Tool pockets designated as large size are dedicated only to large tools; large tools will not migrate to an empty normal pocket during a tool change. Tool Loading Flowchart Using 0 for a Tool Designation A 0 (number zero) can be inserted in the tool table in place of a tool number.
To designate a pocket as an “always empty” pocket: Use the arrow keys to move to and highlight the pocket to be empty, press the 0 button on the numeric keypad and then press Enter. Moving Tools in the Carousel Should tools need moving in the carousel, follow the steps below. CAUTION! Plan the reorganization of the tools in the carousel ahead of time. To reduce the potential for tool changer crashes, keep tool movement to a minimum.
4. Take tool 1 in hand and insert the tool (pull stud first) into the spindle. Turn the tool so that the two cutouts in the tool holder line up with the tabs of the spindle. Push the tool upward while pressing the Tool Release button. When the tool is fitted into the spindle, release the Tool Release button. 5. Press the “ATC FWD” key. 6. Repeat Steps 4 and 5 with the remaining tools until all the tools are loaded.
Side Mount Tool Changer Recovery Flow Chart Press Recover Button Alarms exist? Alarms exist, they must be cleared. Press ‘Y’ to continue, then ‘Reset’ to clear alarms, then retry. Y N Tool in arm or spindle (Y/N)? N Arm at origin? N Y N Y At origin, continue to Pkt Restore (Y)? “ATC Fwd/Rev” still moves arm. Cnc waits for ‘Y’ before continuing Will arm prevent tool in spindle or pocket from being removed (Y/N)? Y Tool may fall during tool recovery. Place something soft under tool to catch it.
Hydraulic Tool Changer Tool Pocket Setup The Tool pocket table is accessed by pressing the Offset key and then press the right cursor arrow key until you reach the tool pocket column. Enter the pocket values for each tool used. This table must be properly setup by the operator to avoid the possibility of damaging tools, the spindle or the tool changer. Creating a New Tool Table During the course of operating the machining center it will be necessary to completely reprogram the tool table.
To remove an ‘L’ designation, highlight the ‘L’ pocket and press the ‘SPACE’ button and then the ‘WRITE/ENTER’ button. NOTE: Large tools cannot be bigger than 9.8” (250mm). Heavy tools Designating a tool as “Heavy” will have no affect on tool changer speed or actions.
JOG MODE Jog Mode allows you to jog each of the axes to a desired location. Before jogging the axes it is necessary to home (beginning axes reference point) the axes (See the Machine Power-up Section). To enter jog mode press the hand jog button, then press one of the desired axes (e.g. X, Y, Z, A or B etc.) and either use the handle jog buttons or the jog handle to move the axes. There are different increment speeds that can be used while in jog mode; they are .0001, .001, .01 and .1.
12. Press Part Zero Set (J) to load the value into the X-axis column. The second press of Part Zero Set (J) will load the value into the Y-axis column. CAUTION! Do Not Press Part Zero Set a third time; doing so will load a value into the Z-axis. This will cause a crash or Z-axis alarm when the program is run. C D G J F I H A B E Spindle at top left of the front Setting the Tool Offset The next step is to touch off the tools.
This will take the Z position located in the bottom left of the screen and put it at the tool number position. CAUTION! The next step will cause the spindle to move rapidly in the Z axis. J K E G H A B Tool Length is measured from the tip of the tool to the top of the part with the Z axis at its home position. D C I Tip of Tool Top of Part F 13. Press Next Tool (K). Additional Tooling Set-up There are other tool set-up pages within the Current Commands.
Advanced Tool Management Operation • Tool Group - In the Tool Group Window the operator defines the tool groups used in the programs. • Previous – Highlighting and pressing Enter changes the display to the previous group. • Next – Highlighting and pressing Enter changes the display to next group. • Add – Highlight , enter a number between 1000 and 2999, and press Enter to add a tool group. • Delete – Use or to scroll to the group to delete.
• • • • Life – The percentage of life left in a tool. This is calculated by the CNC control, using actual tool data and the limits the operator entered for the group. CRNT PKT – The tool changer pocket the highlighted tool is in. H-Code – The H-code (tool length) that will be used for the tool. H-code cannot be edited unless Setting 15 H & T Code Agreement is set to Off. The operator can change the H-code by entering a number and pressing Enter.
Example: #8001 = 1 (this will expire tool 1 and it will no longer be used ) #8001 = 0 (if tool 1 was expired manually or with a macro, then setting macro 8001 to 0 will make tool 1 available again for use) See the variables 8500-8515, in the Macros chapter for further information. Save and Restore Advanced Tool Management tables The control can save and restore the variables associated with the Advanced Tool Management (ATM) feature to floppy disk and RS-232.
Programmable Coolant (P-Cool) Set-up 1. Press the OFFSET button to enter the offsets table, press the CLNT UP or CLNT DOWN button to move the P-cool nozzle into the desired position. Press the COOLNT button to turn on the coolant in order to check the P-cool position. Note: The P-cool position is displayed at the bottom left corner of the screen. 2. Enter the coolant position number for the tool in the Coolant Position column and press F1. 3. Repeat steps 1 and 2 for each tool. 4.
None Ignore Canned Cycle Manual Squirt On Time Canned Cycle (M101 Ix.xxx): Squirt On Time MOM (M102 Ix.xxx): Time Between Squirts MOM (M102 Jx.xxx): MOM Override: Use M-Codes to operate MOM. Ignore MOM M-Codes. Act as if M101 is always active (squirt per G-Code). Turns MOM Mode on (squirt every time between squirts) 0.100 sec (Tapping) 0.050 sec 2.
Graphics mode can be run from Memory, MDI, DNC or Edit modes. To run a program press the SETNG/ GRAPH button until the Graphics page is displayed. You can also press Cycle Start from the active program pane in Edit mode to enter Graphics mode. To run DNC in graphics, you must select DNC first, then go to graphics display and send your program to the machines control (See the DNC section).
Items Beyond the Maximum Radius and Height Limits Will Damage the Machine When the Pallet Rotates Plane3 EC-300 Shown Maximum Pallet Loads EC-300 MDC EC-400 Full 4th Axis 550lb (249kg) per station, balanced within 20% 700lb (318kg) per station, balanced within 20% 1 and 45 degree indexer – 1000 lb per pallet 660 lb per pallet Pallet Changer Operation The Pallet Changer is commanded using M Codes. M50 determines if a pallet has been scheduled.
NOTE: The EC-400 must have the pallet in the load station at home to do a pallet change. Sub-Panel Controls Emergency Stop: The button behaves just like the one on the operator’s pendant. Rotary Index (EC-300 only): Rotates the load station pallet (see Setting 164). Part Ready: Used to indicate the pallet is ready. It also contains a light that 1) blinks when the control is waiting for the operator or 2) is on when the operator is ready for a pallet change.
Pallet Usage This feature gives the number of times the specific pallet has been loaded into the machining area. The counter will turn over to 0 after 32767 pallet changes. Program Number This detail shows which program number has been assigned to the pallet. Program Comment This area displays the comments that are written in the part program. There are 30 different pallet status values to use. The first four: Unscheduled, Scheduled, Loaded, and Completed, are fixed and cannot be changed.
Important: Verify that the rotary table on pallet one is plugged into “Connector 1”, and that the rotary table on pallet two is plugged into “Connector 2”. Sample Programs Example #1 A basic pallet change program that loads the next scheduled pallet and runs the parts program. The following is a sample of the PST, which indicates that pallet #1 is loaded and pallet #2 is scheduled.
Oxxxxx M50 M46 Q1 Pxx1 Program number (Perform pallet change after the Part Ready button is pressed or PST is updated) This line will check to see if pallet #1 is on the machine. If it is then it will jump to line xx1. If the pallet is not on the machine, then it will continue to the next line. (See description of M46.
EC-400 The control has a pallet changer recovery mode to assist the operator if the pallet changer fails to complete a pallet change. To enter the pallet changer recovery mode press the Recover button and then press the specific function key (F2) for pallet changer recovery mode. Note that is the pallet is in the proper position, the pallet changer recover function is not available. The most convenient way to recover from a failed pallet change attempt is to press “Y” and follow the onscreen help text.
3. Lift the pallet approximately .25” (6.35mm) to position it above the load station pins, but below the load station lock plate. Pull the pallet towards you until it has cleared the load station. Pallet Storage When removing the pallet, be sure to set it on a soft surface such as a wooden pallet. The bottom side of the pallet has machined surfaces that must be protected.
TIPS AND TRICKS General Tips Cursor Searching for a Program. When in EDIT or MEM mode, you can select and display another program quickly by entering the program number (Onnnnn) and pressing the Up/Down arrow. Searching for a Program Command. Searching for a specific command in a program can be done in either MEM or EDIT mode. Enter the address letter code (A, B, C, etc.) or address letter code and value (A1.23), and press the Up/Down arrow.
Duplicating a Program in LIST PROG. In the List Prog mode, a program can be duplicated by selecting the program number, typing in a new program number (Onnnnn), and pressing F1. Select “duplicate program/file” from the popup list and press Enter. Communications Receiving Program Files from a Floppy Disk. Program files can be loaded from a floppy disc via a USB Floppy Drive. Use the LIST PROG menu to transfer the files. Sending Multiple Programs Using Program Numbers.
MANUAL SETUP FACE DRILL POCKET MILLING ENGRAVING SYSTEM END MILL TOOL 1 WRK ZERO OFST 54 R PLANE 1.5000 X DIMENSION 0.0000 in DEPTH OF FACE 0.0000 in Y DIMENSION 0.0000 in TOOL CLEARANCE 0.0000 in Sample IPS Screen SYSTEM MODE The System Mode screens are set up to show the user current alarms, an alarm history, an alarm viewer and write display messages. Turning the Option On and Off The IPS option is toggled off and on using parameter 315 bit 31 (Intuitive Prog Sys).
SUBROUTINES Subroutines (subprograms) are usually a series of commands that are repeated several times in a program. Instead of repeating the commands many times in the main program, subroutines are written in a separate program. The main program then has a single command that “calls” the subroutine program. A subroutine is called using an M97 and a P address. The P code is the same as the sequence number (Onnnnn) of the subroutine to be called, that is located after an M30.
SUBROUTINE CANNED CYCLE EXAMPLE
EDIT MODE Edit gives the user the ability to edit programs using popup menus. Press the EDIT key to enter edit mode. Two editing panes are available; an active program pane and an inactive program pane. Switch between the two by pressing the EDIT key. To edit a program, enter the program name (Onnnnn) from the active program pane and press SELECT PROG; the program will open in the active window.
Delete Program From List This menu item will delete a program from the program memory. Hot Key - Erase Prog Swap Editor Programs Puts the active program in the inactive program pane and the inactive program in the active program pane. Hot Key-F4 Switch To Left Or Right Side This will switch between the active and inactive program for editing. Inactive and active programs remain in their respective panes.
THE SEARCH MENU Find Text This menu item will search for text or program code in the current program. Find Again This menu item will search again for the same program code or text. Find And Replace Text This menu item will search the current program for specific text or program and optionally replace each (or all) with another G-Code item. THE MODIFY MENU Remove All Line Numbers This menu item will automatically remove all unreferenced N-Codes (line numbers) from the edited program.
OTHER KEYS INSERT INSERT can be used to copy selected text in a program to the line after where you place the cursor arrow point. ALTER ALTER can be used move selected text in a program to the line after where you place the cursor arrow point. DELETE UNDO 96-8000 rev U June 2008 DELETE can be used to delete selected text in a program. If a block has been selected, pressing undo will simply exit a block definition.
VISUAL QUICK CODE To start Visual Quick Code (VQC), press MDI/DNC, then press the PRGRM/CONVRS key. Select VQC from the tabbed menu. Selecting a Category Use the arrow keys to select the parts category whose description closely matches the desired part and press Write. A set of illustrations of the parts in that category will appear.
CUTTER COMPENSATION Cutter compensation shifts the programmed tool path so that the centerline of the tool is moved to the left or right of the programmed path. The OFFSET (Length and Radius) page is used to enter the amount that the tool is shifted. The offset is entered as either a diameter/radius value (see setting 40) for both the geometry and wear values. Note that If diameter is specified, the cutter compensation shift amount is half of the value entered.
ENTRY AND EXIT FROM CUTTER COMPENSATION Cutting should not be performed when entering and exiting cutter compensation or when changing from left side to right side compensation. When cutter compensation is turned on, the starting position of the move is the same as the programmed position, but the ending position will be offset, to either the left or right of the programmed path, by the amount entered in the, radius/diameter offset column.
FEED ADJUSTMENTS IN CUTTER COMPENSATION When using cutter compensation in circular moves, there is the possibility of speed adjustments to what has been programmed. If the intended finish cut is on the inside of a circular motion, the tool should be slowed down to ensure that the surface feed does not exceed what was intended. There are problems when the speed is slowed by too much, therefore, setting 44 is used to limit the amount of feed adjustment. It can be set between 1% and 100%.
G02 & G03 Circular Interpolation Note: Tool is a .250” diameter end mill. R .3437 R .500 R .375 R .375 R .5625 X0, Y0 Offset Tool Path X1., Y1. Start Position X0, Y0 Programmed Path Center of Tool % O6100 T1 M06 G00 G90 G54 X-1. Y-1. S5000 M03 G43 H01 Z.1 M08 G01 Z-1.0 F50. G41 G01 X0 Y0 D1. F50. Y4.125 G02 X.250 Y4.375 R.375 G01 X1.6562 G02 X2.0 Y4.0313 R.3437 G01 Y3.125 G03 X2.375 Y2.750 R.375 G01 X3.5 G02 X4.0 Y2.25 R.5 G01 Y.4375 G02 X3.4375 Y-.125 R.5625 G01 X-.125 G40 X-1. Y-1. G00 Z1.
MACROS INTRODUCTION This control feature is optional; call your dealer for information. Macros add capabilities and flexibly to the control that are not possible with standard G-code. Some possible uses are, families of parts, custom canned cycles, complex motions, and driving optional devices. The possibilities are almost endless. A Macro is any routine/subprogram that may be run multiple times.
Useful G and M Codes M00, M01, M30 - Stop Program G04 - Dwell G65 Pxx - Macro subprogram call. Allows passing of variables. M96 Pxx Qxx - Conditional Local Branch when Discrete Input Signal is 0 M97 Pxx - Local Sub Routine Call M98 Pxx - Sub Program Call M99 - Sub Program Return or Loop G103 - Block Lookahead Limit.
Entering the macro variable number and pressing the up/down arrow will search for that variable. The variables displayed represent values of the variables during running of the program. At times, this may be up to 15 blocks ahead of actual machine actions. Debugging programs is easier when inserting a G103 at the beginning of a program to limit block buffering and then removing the G103 after debugging is completed.
Macro Variables There are three categories of macro variables: system variables, global variables, and local variables. Macro Constants are floating point values placed in a macro expression. They can be combined with addresses A-Z or they can stand alone when used within an expression. Examples of constants are .0001, 5.3 or -10. Local Variables Local variables range between #1 and #33. A set of local variables is available at all times.
VARIABLES #0 #1-#33 #100-#199 #500-#699 #700-#749 #800-#999 #1000-#1063 #1064-#1068 #1080-#1087 #1090-#1098 #1094 #1098 #1100-#1139 #1140-#1155 #1264-#1268 #1601-#1800 #1801-#2000 #2001-#2200 #2201-#2400 #2401-#2600 #2601-#2800 #3000 #3001 #3002 #3003 #3004 #3006 #3011 #3012 #3020 #3021 #3022 #3023 #3024 #3025 #3026 #3027 #3028 #3030 #3031 #3032 #3033 #3201-#3400 #3401-#3600 #3901 #3902 #4000-#4021 #4101-#4126 USAGE Not a number (read only) Macro call arguments General-purpose variables saved on power off
#5001-#5005 #5021-#5025 #5041-#5045 #5061-#5069 #5081-#5085 #5201-#5205 #5221-#5225 #5241-#5245 #5261-#5265 #5281-#5285 #5301-#5305 #5321-#5325 #5401-#5500 #5501-#5600 #5601-#5699 #5701-#5800 #5801-#5900 #5901-#6000 #6001-#6277 #6501-#6999 Previous block end position Present machine coordinate position Present work coordinate position Present skip signal position - X, Y, Z, A, B, C, U, V, W Present tool offset G52 Work Offsets G54 Work Offsets G55 Work Offsets G56 Work Offsets G57 Work Offsets G58 Work Off
#8511 #8512 #8513 #8514 #8515 #14401-#14406 #14421-#14426 #14441-#14446 #14461-#14466 #14481-#14486 #14501-#14506 #14521-#14526 #14541-#14546 #14561-#14566 #14581-#14586 ATM. Percent of available tool life of the next tool. ATM. Available usage count of the next tool. ATM. Available hole count of the next tool. ATM. Available feed time of the next tool (in seconds). ATM. Available total time of the next tool (in seconds).
CAUTION! Do not use outputs that are reserved by the system. Using these outputs may result in injury or damage to your equipment. The user can change the state of these outputs by writing to variables designated as “spare”. If the outputs are connected to relays, then an assignment of “1” sets the relay. An assignment of “0” clears the relay.
#3002 Hour Timer - The hour timer is similar to the millisecond timer except that the number returned after accessing #3002 is in hours. The hour and millisecond timers are independent of each other and can be set separately. System Overrides #3003 Variable 3003 is the Single Block Suppression parameter. It overrides the Single Block function in Gcode. In the following example Single Block is ignored when #3003 is set equal to 1.
#4101-#4126 Last Block (Modal) Address Data Address codes A-Z (excluding G) are maintained as modal values. The information represented by the last line of code interpreted by the lookahead process is contained in variables 4101 through 4126. The numeric mapping of variable numbers to alphabetic addresses corresponds to the mapping under alphabetic addresses. For example, the value of the previously interpreted D address is found in #4107 and the last interpreted I value is #4104.
NOTE: Parameter bits are numbered 0 through 31. 32-bit parameters are formatted, onscreen, with bit 0 at the top-left, and bit 31 at the bottom-right.
The previous statement can be replaced by the following code: #1=1; #2=.5; #3=3.7; #4=20; G#1 X[#1+#2] Y#3 F#4 ; The permissible syntax on addresses A-Z (exclude N or O) is as follows:
<-> A-#101 [] Y[#5041+3.5] <->[] Z-[SIN[#1]] If the variable value does not agree with the address range, the control will generate an alarm. For example, the following code would result in a range error alarm because tool diameter numbers range from 0-50.Notes on Functions The function “Round” works differently depending on the context that it is used. When used in arithmetic expressions, any number with a fractional part greater than or equal to .5 is rounded up to the next whole integer; otherwise, the fractional part is truncated from the number. #1= 1.714 ; #2= ROUND[#1] ; (#2 is set to 2.0) #1= 3.1416 ; #2= ROUND[#1] ; (#2 is set to 3.0) When round is used in an address expression, “Round” is rounded to the significant precision.
Boolean Operators Boolean operators always evaluate to 1.0 (TRUE) or 0.0 (FALSE). There are six Boolean operators. These operators are not restricted to conditional expressions, but they most often are used in conditional expressions. They are: EQ - Equal to NE - Not Equal to GT - Greater Than LT - Less Than GE - Greater than or Equal to LE - Less Than or Equal to The following are four examples of how Boolean and Logical operators can be used: Example IF [#1 EQ 0.0] GOTO100; WHILE [#101 LT 10] DO1; #1=[1.
Assignment Statements Assignment statements allow the programmer to modify variables. The format of the assignment statement is: = The expression on the left of the equal sign must always refer to a macro variable, whether directly or indirectly. The following macro initializes a sequence of variables to any value. Here both direct and indirect assignments are used.
The following code skeleton could be developed to make a program that adds serial numbers to parts: With the above subroutine, you would engrave digit five with the following call:
In this statement, if the variable #1 contains anything but 0.0, or the undefined value #0, then branching to block 5 will occur; otherwise, the next block will be executed. In the Haas control, a conditional expression can also be used with the M99 Pnnnn format. For example: G0 X0 Y0 [#1EQ#2] M99 P5; Here, the conditional is for the M99 portion of the statement only. The machine tool is instructed to X0, Y0 whether or not the expression evaluates to True or False.
#101= 3; #102= 4; G0 X#101 Y4. ; F2.5; WH [#101 GT 0] DO1; #102= 4; WH [#102 GT 0] DO2; G81 X#101 Y#102 Z-0.5; #102= #102 - 1; END2; #101= #101 - 1; END1; ; M30; This program drills a 3 x 4 matrix hole pattern. Although nesting of WHILE statements can only be up to three levels, there really is no limit since each subroutine can have up to three levels of nesting.
G65 P1000; M30; O1000; ... M99; Example 1: (Call subroutine 1000 as a macro) (Program stop) (Macro Subroutine) (Return from Macro Subroutine) In Example 2, subroutine 9010 is designed to drill a sequence of holes along a line whose slope is determined by the X and Y arguments that are passed to it in the G65 command line. The Z drill depth is passed as Z, the feed rate is passed as F, and the number of holes to be drilled is passed as T.
COMMUNICATION WITH EXTERNAL DEVICES - DPRNT[ ] Macros allow additional capabilities to communicate with peripheral devices. One can do digitizing of parts, provide runtime inspection reports, or synchronize controls with user provided devices. The commands provided for this are POPEN, DPRNT[ ] and PCLOS. Communication preparatory commands POPEN and PCLOS are not required on the Haas mill. It has been included so that programs from different controls can be sent to the Haas control.
Editing Improperly structured or improperly placed macro statements will generate an alarm. Be careful when editing expressions; brackets must be balanced. The DPRNT[ ] function can be edited much like a comment. It can be deleted, moved as a whole item, or individual items within the bracket can be edited. Variable references and format expressions must be altered as a whole entity. If you wanted to change [24] to [44], place the cursor so that [24] is highlighted, enter [44] and press the write key.
4TH AND 5TH AXIS PROGRAMMING A-AXIS B-AXIS B-Axis 360º A-Axis ±120º +32° -32° FRONT -32° +32° SIDE Axis motion on the VR-11 Mill and the Haas TRT 210 CREATING FIVE-AXIS PROGRAMS Most five-axis programs are rather complex and should be written using a CAD/CAM package. It is necessary to determine the pivot length and gauge length of the machine, and input them into these programs. Each machine has a specific pivot length.
Work coordinate numbers are usually entered as positive numbers. Work coordinates are entered into the table as a number only. To enter an X value of X2.00 into G54, cursor to the X column and enter 2.0. Five-axis Programming Notes Use a tight synchronization cut across resolution of geometry in the CAD/CAM system will allow smooth flowing contours and a more accurate part. Positioning the machine to an approach vector should only be done at a safe distance above or to the side of the workpiece.
When programming simultaneous 5-axis motion, less material allowance is required and higher feedrates may be permitted. Depending on finish allowance, length of cutter and type of profile being cut, higher feed rates may be possible. For example, when cutting mold lines or long flowing contours, feedrates may exceed 100 IPM. Jogging the 4th and 5th Axis All aspects of handle jogging for the fifth axis work as they do for the other axes.
INSTALLING AN OPTIONAL FOURTH AXIS When adding a rotary table to the Haas mill change settings 30 and 34 to the specific rotary table and part diameter currently used. Warning: Failure to match the correct brush or brushless rotary setting to the actual product being installed on the mill may cause motor damage. “B” in the settings denotes a brushless rotary product. Brushless indexers have two cables from table and two connectors at the mill control.
Parameters When interfacing to an auxiliary axis the Haas single axis servo control must have Parameter 21 set according to the following table. Name in CNC: C U V W Parameter 21: 6 1 2 3 Axis select: Z U V W Multiple auxiliary axes must be daisy chained through the second RS-232 port as described in the auxiliary axis operator’s manual. Auxiliary axes can be jogged from the CNC front panel using the jog handle.
G CODES (PREPARATORY FUNCTIONS) G codes are used to command specific actions for the machine, for example simple machine moves or drilling functions. They will also command more complex features from bolt hole circles to non-vertical machining. G-codes are divided into groups. Each group of codes is commands for a specific subject. For example, Group 1 G-codes command point-to point moves of the machine axes, Group 7 are specific to the Cutter Compensation feature.
G-CODE TABLE OF CONTENTS G00 Rapid Motion Positioning (Group 01) ........................................................................................116 G01 Linear Interpolation Motion (Group 01) .....................................................................................116 G02 CW / G03 CCW Circular Interpolation Motion (Group 01) .......................................................117 G04 Dwell (Group 00) ..................................................................................
G91 Incremental Position Commands (Group 03)........................................................................... 149 G92 Set Work Coordinate Systems Shift Value (Group 00) ............................................................ 150 G93 Inverse Time Feed Mode (Group 05) ......................................................................................... 150 G94 Feed Per Minute Mode (Group 05) ............................................................................................
G00 Rapid Motion Positioning (Group 01) G00 is used to move the machines axis at the maximum speed. It is primarily used to quickly position the machine to a given point before each feed (cutting) command (All moves are done at full rapid speed). This G code is modal, so a block with G00 causes all following blocks to be rapid motion until another Group 01 code is specified.
These two linear interpolation blocks specify a corner of intersection. If the beginning block specifies a C, the value following the C is the distance from the intersection to where the chamfer begins, and also the distance from the intersection to where the chamfer ends. If the beginning block specifies an R, the value following the R is the radius of a circle tangent to the corner at two points: the beginning of the corner-rounding arc and the endpoint of that arc.
Corner Rounding and Chamfering example: G00 X1. Y1. G01 X5. F10. ,C0.75 Y2.5 ,R0.4 G03 X8. Y5. R3. ,R0.8 G01 X5. ,C0.8 Y7. ,R1. X1. ,R1. Y1. G00 X0 Y0 M30 Thread Milling Thread milling uses a standard G02 or G03 move to create the circular move in X-Y, then adds a Z move on the same block to create the thread pitch. This generates one turn of the thread; the multiple teeth of the cutter generate the rest. Typical line of code: N100 G02 I-1.0 Z-.05 F5.
Single-Point Thread Milling Example The program is for a 2.500 diameter hole, with a cutter diameter of .750” a radial value of .875 and a thread pitch of .0833 (12 TPI) and a part thickness of 1.0.
Programming Examples
Circular Pocket Milling (G12-Clockwise Shown) I I Q K I Only I, K, and Q Only These G codes assume the use of cutter compensation, so a G41 or G42 is not required in the program line. However, a D offset number, for cutter radius or diameter, is required to adjust the circle diameter. The following programming examples show the G12 and G13 format, as well as the different ways these programs can be written. Single Pass: Use I only.
G17 XY / G18 XZ / G19 YZ plane selection (Group 02) The face of the workpiece to have a circular milling operation (G02, G03, G12, G13) done to it must have two of the three main axes (X, Y and Z) selected. One of three G codes is used to select the plane, G17 for XY, G18 for XZ, and G19 for YZ. Each is modal and applies to all subsequent circular motions. The default plane selection is G17, which means that a circular motion in the XY plane can be programmed without selecting G17.
Example 1 Work Offset G54: Z = 2.0 Tool 2 Length: 12.0 Program segment: G90 G54; G43 H02; G28 Z0.; G00 Z1. The G28 block will move to machine coordinate Z = 14.0 before moving to Z = 0. The following block (G00 Z1.) will move to machine coordinate Z = 1. Example 2 (same work and tool offsets as Example 1) Program segment: G54; G43 H02; G00 G91G28 Z0 The G28 block will move directly to machine coordinate Z = 0 since incremental positioning is in effect.
G35 Automatic Tool Diameter Measurement (Group 00) (This G-code is optional and requires a probe) F D X Y Feedrate in inches (mm) per minute Tool diameter offset number Optional X-axis command Optional Y-axis command Automatic Tool Diameter Offset Measurement function (G35) is used to set the tool diameter (or radius) using two passes of the probe; one on each side of the tool. The first point is set with a G31 block using an M75, and the second point is set with the G35 block.
Tool offsets (G41, G42, G43, or G44) must not be active this function is preformed. The currently active work coordinate system is set for each axis programmed. The point where the skip signal is received becomes the zero position. If an I, J, or K is specified, the appropriate axis work offset is shifted by the amount in the I, J, or K command. This allows the work offset to be shifted away from where the probe actually contacts the part.
G40 Cutter Comp Cancel (Group 07) G40 will cancel G41 or G42 cutter compensation. G41 2D Cutter Compensation Left / G42 2D Cutter Comp. Right (Group 07) G41 will select cutter compensation left; that is, the tool is moved to the left of the programmed path to compensate for the size of the tool. A D address must be programmed to select the correct tool radius or diameter offset.
The initial serial number can also be set manually into a macro variable. The Macros option does not have to be enabled to do this. Macro variable #599 is used to hold the initial serial number to be engraved. For example, when macro variable #599 is set to “1234,” will produce: See the Macros section for more information. Literal String Engraving This method is used to engrave desired text on a part. The text should be in the form of a comment on the same line as the P0 statement.
P values to engrave specific characters: 32 33 34 35 36 37 38 39 40 Example blank ! “ # $ % & ‘ ( 41 42 43 44 45 46 47 48-57 58 ) * + , . / 0-9 : 59 60 61 62 63 64 65-90 91 92 ; < = > ? @ A-Z [ \ 93 94 95 96 97-122 123 124 125 126 ] ^ _ ‘ a-z { | } ~ To engrave “$2.00” two lines of code are necessary. The first will be using a P36 to engrave the dollar sign ($), and the second will use P0 (2.00).
N1 (!) G00 X0.2692 G01 Z - #702 F#8 G03 J0.0297 F#9 G00 Z#702 G00 Y0.2079 G01 Z - #702 F#8 G01 X0.0495 Y0.6732 F#9 G03 X-0.099 R0.0495 G01 X0.0495 Y-0.6732 G00 Z#702 G00 X0.2692 Y-0.2079 M99 N2 («) G00 X0.2345 Y0.792 G01 Z - #702 F#8 G01 X0.0148 Y0.198 F#9 G01 X-0.0297 G01 X0.0148 Y-0.198 G00 Z#702 G00 X0.1485 G01 Z - #702 F#8 G01 X0.0148 Y0.198 F#9 G01 X-0.0297 G01 X0.0148 Y-0.198 G00 Z#702 G00 X0.2346 Y-0.792 M99 N3 (#) G00 X0.4082 Y0.1666 G01 Z - #702 F#8 G01 X0.0433 Y0.8086 F#9 G00 Z#702 G00 X0.2627 Y0.
For the creation of each character, there is a different label to start the code. Each section terminates with an M99. Label Character N126 space ! N1 “ N2 # N3 $ N4 % N5 & N6 ‘ N7 ( N8 ) N9 Label Character * N10 + N11 , N12 - N13 .
Z Y 0001 (GOTHIC WINDOW) ; F20. S500 ; G00 X1. Y1. ; G01 X2. ; Y2. ; G03 X1. R0.5; G01 Y1. ; G00 X0 Y0 ; M99 ; X = Work coordinate origin No Scaling G51 The first example illustrates how the control uses the current work coordinate location as a scaling center. Here, it is X0 Y0 Z0. Z Y 00010 ; G59 ; G00 G90 X0 Y0 Z0 ; G51 P2.
Z Y 00011 ; G59 ; G00 G90 X0 Y0 Z0 ; G51 X1.0 Y1.0 P2 ; M98 P1 ; M30 ; X = Work coordinate origin = Center of scaling G51 Scaling Programming notes: Tool offsets and cutter compensation values are not affected by scaling. Scaling does not affect canned cycle Z-axis movements such as clearance planes and incremental values. The final results of scaling are rounded to the lowest fractional value of the variable being scaled.
G61 Exact Stop Mode (Group 15) The G61 code is used to specify an exact stop. It is modal; therefore, it affects the blocks that follow it. The machine axes will come to an exact stop at the end of each commanded move. G64 G61 Cancel (Group 15) The G64 code is used to cancel exact stop (G61). G68 Rotation (Group 16) (This G-code is optional and requires Rotation and Scaling.
The first example illustrates how the control uses the current work coordinate location as a rotation center (X0 Y0 Z0). Z 00002 ; G59 ; G00 G90 X0 Y0 Z0 ; M98 P1 ; G90 G00 X0 Y0 ; (Last Commanded Position) G68 R60. ; M98 P1 ; G69 G90 G00 X0 Y0 ; M30 ; X Y = Work coordinate origin = Center of rotation G68 Rotation The next example specifies the center of the window as the rotation center. Z Y 00003 ; G59 ; G00 G90 X0 Y0 Z0 ; M98 P1 ; G00 G90 X0 Y0 Z0 ; G68 X1.5 Y1.5 R60.
Rotation with Scaling If scaling and rotation are used simultaneously, it is recommended that scaling be turned on prior to rotation, and that separate blocks be used. Use the following template when doing this. Rotation with Cutter Compensation Cutter compensation should be turned on after the rotation command is issued.
G72 Bolt Holes Along an Angle (Group 00) +CCW / -CW This non-modal G code drills “L” number of holes in a straight line at the specified angle. It operates similarly to G70. For a G72 to work correctly, a canned cycle must be active so that at each position, a drill or tap function is performed.
Program Example Description Modifying Canned Cycles In this section we will cover canned cycles that have to be c
X, Y Plane Obstacle Avoidance In A Canned Cycle: There is also a way to avoid an obstacle in the X, Y plane during a canned cycle by placing an L0 in a canned cycle line, we can tell the control to make an X, Y move without executing the Z-axis canned operation. For example, we have a six-inch square aluminum block, with a one-inch by one-inch deep flange on each side. The print calls for two holes centered on each side of the flange. We need to write a program to avoid each of the corners on the block.
CANNED CYCLES Introduction Canned cycles are used to simplify programming. They are used for repetitive operations, such as drilling, tapping, and boring. The canned cycle is executed every time an X and/or Y-axis motion is programmed. Using Canned Cycles The positioning of a canned cycle in the X and/or Y-axes can be done in either absolute (G90) or incremental (G91).
G73 High-Speed Peck Drilling Canned Cycle (Group 09) F I J K L P Q R X Y Z Feedrate in inches (mm) per minute First cut depth Amount to reduce cutting depth for pass Minimum depth of cut (The control will calculate the number of pecks) Number of repeats (Number of holes to drill) if G91 (Incremental Mode) is used Pause at the bottom of the hole (in seconds) Cut Depth (always incremental) Position of the R plane (Distance above part surface) X-axis location of hole Y-axis location of hole Position of the Z-
G74 Reverse Tap Canned Cycle (Group 09) F J L R X Y Z Feedrate in inches (or mm) per minute (use the formula, described in the canned cycle introduction, to calculate feed rate and spindle speed) Retract Multiple (How fast to retract - see Setting 130) Number of repeats (How many holes to tap) if G91 (Incremental Mode) is used Position of the R plane (position above the part) where tapping starts X-axis location of hole Y-axis location of hole Position of the Z-axis at the bottom of hole G74 Tapping Canne
G77 Back Bore Canned Cycle (Group 09) F I J L Q R X Y Z Feedrate in inches (or mm) per minute Shift value along the X-axis before retracting, if Q is not specified Shift value along the Y-axis before retracting, if Q is not specified Number of holes to bore if G91 (Incremental Mode) is used The shift value, always incremental Position of the R plane (position above the part) X-axis location of hole Y-axis location of hole Position of the Z-axis at the bottom of hole In addition to boring the hole, this cy
G81 Drill Canned Cycle Feed Rapid Move Begin or end of stroke ne g Pla tar tin S l ia it 98 In ing Star t nitial G I G99 Y ne R Pla Plane ne R Pla Z Plane Rapid Y Z X th Z Dep X ne Z Pla Program Example The following is a program to drill through an aluminum plate: G82 Spot Drill Canned Cycle (Group 09) F L P R X Y Z Feedrate in inches (or mm) p
G82 Spot Drill Canned Cycle tar itial S 98 In Feed Rapid Move Begin or end of stroke lane ting P lane ing P Star t G Y ne R Pla Plane Rapid 9 9 G Y ne R Pla Z Z X X ne Z Pla ne Z Pla G82 Spot drilling example G83 Normal Peck Drilling Canned Cycle (Group 09) F I J K L P Q R X Y Z Feedrate in inches (or mm) per minute Size of first cutting depth Amount to reduce cutting depth each pass Minimum depth of cut Number of holes if G91 (Incremental Mode) is used Pause at end of last peck, in second
Setting 52 changes the way G83 works when it returns to the R plane. Usually the R plane is set well above the cut to ensure that the peck motion allows the chips to get out of the hole. This wastes time as the drill starts by drilling “empty” space. If Setting 52 is set to the distance required to clear chips, the R plane can be put much closer to the part being drilled. When the chip-clearing move to R occurs, the Z axis distance above R is determined by this setting.
Program Example Helpful notes are listed in parentheses ( ).
G86 Bore and Stop Canned Cycle (Group 09) F L R X Y Z Feedrate in inches (or mm) per minute Number of holes if G91 (Incremental Mode) is used Position of the R plane (position above the part) X-axis location of hole Y-axis location of hole Position of the Z-axis at the bottom of hole G86 Bore and Stop Canned Cycle g tar tin itialS 98 In Feed Rapid Move Begin or end of stroke Plane ne g Pla tar tin S l ia Init Plane Rapid G99 G Y Y ne R Pla Z nene lala R R PP Z X X th Z Dep th Z Dep G87 Bore
G88 Bore In, Dwell, Manual Retract Canned Cycle (Group 09) F L P R X Y Z Feedrate in inches (or mm) per minute Number of holes if G91 (Incremental Mode) is used The dwell time at the bottom of the hole Position of the R plane (position above the part) X-axis location of hole Y-axis location of hole Position of the Z-axis at the bottom of hole This G code will stop once the hole is bored. At this point the tool is manually jogged out of the hole. The program will continue when Cycle Start is pressed.
G91 is not compatible with G143 (5-Axis Tool Length Compensation). G91 Canned Cycle (Incremental) G90 Canned Cycle (Absolute) Feed Rapid Move Begin or end of stroke Z=0 R Z R Y ane R Pl Z ane R Pl Y Z X pth Z De Z X pth Z De G92 Set Work Coordinate Systems Shift Value (Group 00) This G-code does not move any of the axes; it only changes the values stored as user work offsets. G92 works differently depending on Setting 33, which selects a FANUC, HAAS, or YASNAC coordinate system.
G95 Feed per Revolution (Group 05) When G95 is active; a spindle revolution will result in a travel distance specified by the Feed value. If the Setting 9 Dimensioning is set to Inch, then the feed value F will be taken as inches/rev (set to MM, then the feed will be taken as mm/Rev). Feed Override and Spindle override will affect the behavior of the machine while G95 is active.
Mirror Image and Cutter Compensation When using cutter compensation with mirror imaging, follow this guideline: After turning mirror imaging on or off with G100 or G101, the next motion block should be to a different work coordinate position than the first one.
Program Code for Mirror Imaging in the X-Axis: Program Example Description
G103 Limit Block Buffering (Group 00) Maximum number of blocks the control will look ahead (Range 0-15), for example: This is commonly referred to, as “Block Look-ahead” which is a term used to describe what the control is doing in the background during machine motions. The control prepares future blocks (lines of code) ahead of time. While the current block is executing, the next block has already been interpreted and prepared for continuous motion.
Cylindrical mapping will also be turned off automatically whenever the G-code program ends, but only if Setting 56 is ON. Pressing the RESET key will turn off any cylindrical mapping that is currently in effect, regardless of the status of Setting 56. R .50" 4X 2.00 4.
G136 Automatic Work Offset Center Measurement (Group 00) (This G-code is optional and requires a probe) F I J K X Y Z Feedrate in inches (mm) per minute Optional offset distance along X-axis Optional offset distance along Y-axis Optional offset distance along Z-axis Optional X-axis motion command Optional Y-axis motion command Optional Z-axis motion command Automatic Work Offset Center Measurement (G136) is used to command a probe to set work offsets.
Programming example to probe the center of a part: G141 3D+ Cutter Compensation (Group 07) X Y Z A B D I J K F X-axis command Y-axis command Z-axis command A-axis command (optional) B-axis command (optional) Cutter Size Selection (modal) Size of first cutting depth Amount to reduce cutting depth each pass
Only the end-point of the commanded block is compensated in the direction of I, J, and K. For this reason this compensation is recommended only for surface tool paths having a tight tolerance (small motion between blocks of code). For best results program from the tool center using a ball nose end mill.
G150 General Purpose Pocket Milling (Group 00) D F I J K P Q R S X Y Z Tool radius/diameter offset selection Feedrate X-axis cut increment (positive value) Y-axis cut increment (positive value) Finishing pass amount (positive value) Subprogram number that defines pocket geometry Incremental Z-axis cut depth per pass (positive value) Position of the rapid R-plane location Optional spindle speed X start position Y start position Final depth of pocket The G150 starts by positioning the cutter to a start poin
G150 General Pocket Milling Y Start Point Z X J Start Point Q Z (Final Depth) I Example
Square Pocket G150 General Purpose Pocket Milling 2 1, 6 5 Start Point X0, Y1.5 5 X0, Y0 4 3 5 Tool #1 is a .500 diameter end mill Pocket milling for G150 operation.
Square Island G150 Pocket Milling (Square Island) 3 4 5 12 11 5 6 7 8 10 9 Start Point 13 X0, Y0 2 1, 14 Tool #1 is a .500 diameter end mill 5 G150 Pocket milling program with a Square island.
Round Island G150 Pocket Milling (Round Island) 9 4, 10 5 5 3 8 6, 7 Start Point 11 X0, Y0 2 1, 12 Tool #1 is a .500 diameter end mill 5 G150 Pocket milling program with a Round island.
G153 5-Axis High Speed Peck Drilling With I, J & K Options G153 5-Axis High Speed Peck Drilling With K & Q Options Setting #22 Setting #22 E E I1=I Q I2= I1- J Q I3=I2 -J Q This is a high-speed peck cycle where the retract distance is set by Setting 22. If I, J, and K are specified, a different operating mode is selected. The first pass will cut in by amount I, each succeeding cut will be reduced by amount J, and the minimum cutting depth is K.
#14781-#14786 G154 P40 #14981-#14986 G154 P50 #15181-#15186 G154 P60 #15381-#15386 G154 P70 #15581-#15586 G154 P80 #15781-#15786 G154 P90 #15881-#15886 G154 P95 #15901-#15906 G154 P96 #15921-#15926 G154 P97 #15941-#15946 G154 P98 #15961-#15966 G154 P99 G155 5-Axis Reverse Tap Canned Cycle (Group 09) G155 only performs floating taps. G174 is available for 5-axis reverse rigid tapping.
G161 5-Axis Drill Canned Cycle E E G98 Start Position Start Position G99 Rapid Position G98 / G99 Z Axis position between holes Feed Rapid Move Begin or end of Stroke A specific X, Y, Z, A, B position must be programmed before the canned cycle is commanded. This position is used as the “Initial Start position”.
G163 5-Axis Normal Peck Drilling Canned Cycle (Group 09) E F I J K L P Q A B X Y Z Specifies the distance from the start position to the bottom of the hole Feedrate in inches (mm) per minute Optional size of first cutting depth Optional amount to reduce cutting depth each pass Optional minimum depth of cut Number of repeats Optional pause at end of last peck, in seconds The cut-in value, always incremental A-axis tool starting position B-axis tool starting position X-axis tool starting position Y-axis tool
G164 5-Axis Tapping Canned Cycle E E G98 Start Position Start Position G99 Rapid Plane G98 / G99 Z Axis position between holes Feed Rapid Move Begin or end of Stroke A specific X, Y, Z, A, B position must be programmed before the canned cycle is commanded. This position is used as the “Initial Start position”. You do not need to start the spindle CW before this canned cycle. The control does this automatically.
G166 5-Axis Bore and Stop Canned Cycle (Group 09) E F L A B X Y Z Specifies the distance from the start position to the bottom of the hole Feedrate in inches (mm) per minute Number of repeats A-axis tool starting position B-axis tool starting position X-axis tool starting position Y-axis tool starting position Z-axis tool starting position G166 5-Axis Bore Stop Canned Cycle E E G98 Start Position Start Position G99 Rapid Plane G98 / G99 Z Axis position between holes Feed Rapid Move Begin or end of Str
G174 CCW Non-Vertical Rigid Tap (Group 00) G184 CW Non-Vertical Rigid Tap (Group 00) F X Y Z S Feedrate in inches per minute X position at bottom of hole Y position at bottom of hole Z position at bottom of hole Spindle Speed A specific X, Y, Z, A, B position must be programmed before the canned cycle is commanded. This position is used as the “Start position”. This G code is used to perform rigid tapping for non-vertical holes.
M CODES (MISCELLANEOUS FUNCTIONS) M Code Introduction M-Codes are non axes moving commands for the machine. The format for an M code is the letter “M” followed by two numbers, for example M03. Only one M code may be programmed per line of code. All M codes take effect at the end of the block. M00 Stop Program The M00 code is used to stop a program. It stops the axes, spindle, turns off the coolant (including Through Spindle Coolant).
M17 Unclamp APC Pallet and Open APC Door/ M18 Clamp Pallet and Close Door This M-code is used on vertical machining centers with pallet changers. It is used as a maintenance/test function only. Pallet changes should be commanded with an M50 command only. M19 Orient Spindle (P and R values are an optional feature) The M19 code is used to adjust the spindle to a fixed position.
M31 Chip Conveyor Forward / M33 Chip Conveyor Stop M31 starts the optional chip conveyor motor in the forward direction; the direction that moves the chips out of the machine. The conveyor will not turn if the door is open. It is recommended that the chip auger be used intermittently. Continuous operation will cause the motor to overheat. Starting and stopping the chip conveyor will also run the optional conveyor washdown. M33 Stops Conveyor motion.
M48 Check Validity of Current Program This M code generates alarm 909 if the current program is not listed in the Pallet Schedule Table. It generates alarm 910 if the pallet that is currently loaded is not listed in the Pallet Schedule Table for the current program. M49 Set Status of Pallet This M code sets that status of the pallet specified by the P code to the value specified by the Q code. The possible Q codes are 0-Unscheduled 1-Scheduled 2-Loaded 3-Completed 4 through 29 are user definable.
M79 Alarm if Skip Signal Not Found This M-code is used with a probe. An M79 will generate an alarm if a programmed skip function (G31, G36, or G37) did not receive a signal from the probe. This is used when the lack of the skip signal means a probe positioning error. This code can be placed on the same line as the skip G-code or in any block after. M80 / M81 Auto Door Open / Close The M80 opens the Auto Door and the M81 closes the close the Auto Door.
The comment immediately following the M95 must contain the hours and minutes that the machine is to sleep for. For example, if the current time were 6 p.m. and the user wanted the machine to sleep until 6:30 a.m. the next day, the following command would be used: M95 (12:30) The line(s) following the M95 should be axis moves and spindle warm-up commands.
O0001 M98 P100 L4; M30 (Main Program number) (Call Sub-program, Sub-program Number, Loop 4 Times) (End of program) O0100 (SUB-PROGAM NUMBER) G00 G90 G55 X0 Y0 S500 M03 G43 H01 Z1. Z-.5 G01 G41 X.5 F100. G03 YI-.5 G01 X0 G40 Z1. F50. G91 G28 Z0 G90 M99 M99 Sub-Program Return or Loop This code is used to return to the main program from a subroutine or macro, the format is M99 Pnnnn (Pnnnn is the line in the main program to return to).
M109 Interactive User Input This M code allows a G-code program to place a short prompt (message) on the screen. A macro variable in the range 500 through 599 must be specified by a P code. The program can check for any character that can be entered from the keyboard by comparing with the decimal equivalent of the ASCII character (G47, Text Engraving, has a list of ASCII characters). The following sample program will ask the user a Yes or No question, then wait for either a “Y” or an “N” to be entered.
N40 (If 4 was entered run this sub routine) (Run sub program 22) #3006= 25 (Cycle start program 22 will be run) M98 P22 (Call sub program 22) GOTO100 N50 (If 5 was entered run this sub-routine) (Programmed message) #3006= 25 (Reset or cycle start will turn power off) #1106= 1 N100 M30 % 96-8000 rev U June 2008 M Codes 179
180 M Codes 96-8000 rev U June 2008
SETTINGS The setting pages contain values that control machine operation and that the user may need to change. Most settings can be changed by the operator. They are preceded by a short description on the left and the value on the right. In general, settings allow the operator or setup person to lock out or turn on specific functions. The settings are organized into pages of functionally similar groupings.
7 - Parameter Lock Turning this setting On will stop the parameters from being changed, except for parameters 81-100. Note that when the control is powered up, this setting is on. 8 - Prog Memory Lock This setting locks out the memory editing functions (Alter, Insert, etc.) when it is set to On. 9 - Dimensioning This setting selects between inch and metric mode. When it is set to Inch, the programmed units for X, Y, and Z are inches, to 0.0001”.
When set to RTS/CTS, the signal wires in the serial data cable are used to tell the sender to temporarily stop sending data while the receiver catches up. When set to XON/XOFF, the most common setting, ASCII character codes are used by the receiver to tell the sender to temporarily stop. The selection DC Codes is like XON/XOFF, except that paper tape punch or reader start/stop codes are sent. XMODEM is a receiver-driven communications protocol that sends data in blocks of 128 bytes.
28 - Can Cycle Act w/o X/Z Turning this setting On will cause the commanded canned cycle to complete without an X or Z command. The preferred method of operation is with this setting On. When this setting is Off, the control will stop if a canned cycle is programmed without an X or Z axis move. 29 - G91 Non-modal Turning this setting On will use the G91 command only in the program block it is in (non-modal).
36 - Program Restart When this setting is On, restarting a program from a point other than the beginning will direct the control to scan the entire program to ensure that the tools, offsets, G and M codes, and axis positions are set correctly before the program starts at the block where the cursor is positioned.
XY MIRROR Y MIRROR X MIRROR OFF 49 - Skip Same Tool Change In some program, the same tool may be called in the next section of a program or a subroutine. The control will do two changes and finish with the same tool in the spindle. Turning this setting ON will skip same tool, tool changes; a tool change will only occur if a different tool will be placed in the spindle. 50 - Aux Axis Sync This changes the synchronization between sender and receiver for the second serial port.
53 - Jog w/o Zero Return Turning this setting On allows the axes to be jogged without zero returning the machine (finding machine home). This is a dangerous condition as the axis can be run into the mechanical stops and the possibly damage the machine. When the control is powered up, this setting automatically returns to Off. 54 - Aux Axis Baud Rate This setting allows the operator to change the data rate for the second serial port (Auxiliary axis).
67 - Graphics Y Offset This setting locates the top of the zoom window relative to the machine Y zero position (see the Graphics section). Its default is zero. Graphics Mode Setting 66 & 67 set to Ø Setting 66 & 67 set to 2.0 69 - DPRNT Leading Spaces This is an On/Off setting. When set to Off, the control will not use leading spaces generated by a macro DPRNT format statement.
When Setting 74 and Setting 75 are both Off, the control will execute 9000 series programs without displaying the program code. If the control is in Single Block mode, no single-block pause will occur during the running of the 9000 series program. When Setting 75 is On and Setting 74 is Off, then 9000 series programs are displayed as they are executed. 76 - Tool Release Lock Out When this setting is ON, the tool release key on the keyboard is disabled.
83 - M30/Resets Overrides When this setting is On, an M30 restores any overrides (feedrate, spindle, rapid) to their default values (100%). 84 - Tool Overload Action This setting causes the specified action (Alarm, Feedhold, Beep, Autofeed) to occur anytime a tool becomes overloaded (see the Tooling section). Choosing “Alarm” will cause the machine to stop when the tool is overloaded.
100 - Screen Saver Delay When the setting is zero, the scren saver is disabled. If setting is set to some number of minutes, then after that time with no keyboard activity the IPS screen will be displayed. After the second screen saver delay, the Haas logo will be displayed that will change position every 2 seconds (deactivate with any key press, handle jog or alarm). The screen saver will not activate if the control is in Sleep, Jog, Edit, or Graphics mode.
110 - Warmup X Distance 111 - Warmup Y Distance 112 - Warmup Z Distance Settings 110, 111 and 112 specify the amount of compensation (max = ± 0.0020” or ± 0.051 mm) applied to the axes. Setting 109 must have a value entered for settings 110-112 to have an affect. 114 - Conveyor Cycle (minutes) 115 - Conveyor On-time (minutes) These two settings control the optional chip conveyor. Setting 114 (Conveyor Cycle Time) is the interval that the conveyor will turn on automatically.
Entering a value of 2, is the equivalent of using a J code of 2 for G84 (Tapping canned cycle). However, specifying a J code for a rigid tap will override setting 130. NOTE: If the machine does not have the Rigid Tap option, this setting has no effect. 131 - Auto Door This setting supports the Auto Door option. It should be set to On for machines with an autodoor. Also see M85/86 (Autodoor Open/Close M-codes).
157 - Offset Format Type This setting controls the format in which offsets are saved with programs. When it is set to A the format looks like what is displayed on the control, and contains decimal points and column headings. Offsets saved in this format can be more easily edited on a PC and later reloaded. When it is set to B, each offset is saved on a separate line with an N value and a V value.
175 Air Supply Filter Check default in power-on hours 176 Hydraulic Oil Level Check default in power-on hours 177 Hydraulic Filter Replacement default in motion-time hours 178 Grease Fittings default in motion-time hours 179 Grease Chuck default in motion-time hours 180 Grease Tool Changer Cams default in tool-changes 181 Spare Maintenance Setting #1 default in power-on hours 182 Spare Maintenance Setting #2 default in power-on hours 183 Spare Maintenance Setting #3 default in motion-time hours 184 Spare Ma
196 Settings 96-8000 rev U June 2008
MAINTENANCE GENERAL REQUIREMENTS Operating Temperature Range: 41°F to 104°F (5 to 40°C) Storage Temperature Range: -4°F to 158°F (-20 to 70°C) Ambient Humidity: 20% – 95% relative humidity, non-condensing Altitude: 0-7000 ft. ELECTRICITY REQUIREMENTS All Machines Require: AC input power is three phase Delta or Wye power, except that the power source must be grounded (e.g.
The rated horsepower of the machine may not be achieved if the imbalance of the incoming voltage is beyond an acceptable limit. The machine may function properly, yet may not deliver the advertised power. This is noticed more often when using phase converters. A phase converter should only be used if all other methods cannot be used. The maximum leg-to-leg or leg-to-ground voltage should not exceed 260 volts, or 504 volts for high-voltage machines with the Internal High Voltage Option.
MAINTENANCE SCHEDULE The following is a list of required regular maintenance for the machining center. These required specifications must be followed in order to keep your machine in good working order and protect your warranty. Interval Maintenance Performed Daily • Check coolant level each eight-hour shift (especially during heavy TSC usage). • Check way lube lubrication tank level. • Clean chips from way covers and bottom pan. • Clean chips from tool changer.
PERIODIC MAINTENANCE A periodic maintenance page is found within the Current Commands screens titled “Maintenance”. Access the screen by pressing CURNT COMDS and using Page Up or Page Down to scroll to the page. An item on the list can be selected by pressing the up and down arrow keys. The selected item is then activated or deactivated by pressing Origin. If an item is active, the remaining hours will be displayed, a deactivated item will display, “—” instead.
SPINDLE AIR PRESSURE Verify Spindle air pressure using the gauge located behind the main air regulator. VF, VR, and VS mills should be set to 17 psi. EC-series and HS Series should be set to 25psi. Adjust if necessary. 12K & 15K Spindle The air pressure for 12K &15K Spindles is 20 psi. The 12K &15K Spindles require higher pressure to slightly reduce the delivery speed and amount of oil on the bearings.
COOLANT SYSTEM MAINTENANCE Chip Tray Cleaning The most frequent interaction with the coolant tank will be with the chip tray. Depending upon the type of material being milled, the chip tray may need to be removed and cleaned a few times each day. If the level sensor reads full, but the pumps begin to cavitate, the gate filter needs to be cleaned. Pull the gate filter from the tank and tap it in the chip barrel or use an air hose to remove excess chips.
Level Sensor Lid Gate Filter Single Lid Chip Tray Tank Component Removal (55 Gallon Tank shown) The tank may be cleaned by using a standard shop-vac. If excessive chip build-up is present, you may need to use a scoop to remove the chips. Coolant and Coolant Tank Considerations As the machine runs the water will evaporate which will change the concentration of the coolant. Coolant is also carried out with the parts. A proper coolant mixture is between 6% and 7%.
TSC1000 Maintenance Before doing any maintenance to the 1000psi system, disconnect the power source; unplug it from the power supply. Handle TSC Pump Auxiliary Filter Double Standard Pump Lid Level Sensor Lid Gate Filter Replacement Bag Filter Holder Check the oil level on a daily basis. If the oil is low, add oil through the fill cap on the reservoir. Fill the reservoir about 25% full with 5-30W synthetic oil.
To change the filter element follow these steps: 1. Remove the screws that hold the oil reservoir to the pump body, carefully lower the reservoir and set aside. 2. Use a strap wrench, pipe wrench or adjustable pliers to unscrew the end cap (see the figure). Caution: Use a screwdriver or similar tool to stop the filter from turning while the end cap is removed. 3. Remove the oil filter element from the filter body once the end cap is removed. 4.
HS 3/4/6/7 38-TOOL TOOL CHANGER MAINTENANCE Six Months • Lubricate the Magazine Drive Gear, Tool Pot and Changer Slide Rack using red grease: • Lubricate the Arm Shaft using Moly grease. Annually • Lubricate the Changer Slide Linear Guide with red grease. Tool Pot Chain Tension The tool pot chain tension should be checked regularly as a preventive maintenance procedure. Chain tension adjustment is performed in the lower left area of the magazine.
EC-1600 AND HS 3/4/6/7 TRANSMISSION OIL Oil Fill Port Oil Fill Oil Drain Oil Sight Glass Oil Drain Plug Oil Level View EC-1600 HS-3/4/6/7 Oil Check Remove the sheet metal necessary to gain access to the transmission. View the sight glass on the side of the transmission box as shown. The oil level should be half way on the sight glass. Fill as needed. Oil Change 1. Remove the sheet metal from the spindle head. 2. Remove the drain plug as shown.
EC-400 Full Fourth Axis Rotary Table (Perform Every 2 years) Oil In Pre-Fill Pallet Side Oil Fill Sight Glass Solenoid Plunger Air Vent (pressure relief) Spindle Side Oil Reservoir Oil Fill Connection Oil Drain 1. Remove the fourteen (14) BHCS on the right Z-axis way cover at the receiver end and slide it toward the column. 2. Remove the left Z-axis way cover: Jog the Z-axis all the way toward the column and rotate the H-frame 45° counter clockwise.
HYDRAULIC BRAKE (EC-1600-3000, HS3-7R) Check the brake fluid level by viewing the fluid level in the booster. To check the EC 1600-3000 remove the brake booster cover. The cover/booster is located at the right, front of the machine. The HS 3-7R brake booster is located on the operator pendant side of the machine. Remove the way cover from the table and slide the way cover away from the table.
VR-SERIES AIR FILTER The VR mills are equipped with an air filter (P/N 59-9088) for the motor housing. The recommended replacement interval is monthly, or sooner depending on your machining environment. The air filter is located on the rear of the head cover. To remove the air filter, simply pull up on the filter; the filter will slide upward out of its bracket. To replace the filter, slide in the new air filter, oriented properly to filter air into the motor housing.
Index Symbols 4th and 5th Axis Programming 108 4th-axis Operation 110 A Air Requirements 198 Alarms 17 Auto Air Gun 175 Auto Door 191 AUTOFEED 190 B Background Edit 65 Block Delete 19 C Calculator 17, 24 Canned Cycles 113, 140 Chip Auger 15, 173 Chip Conveyor 173 Coolant 171 Coolant Up/Down 15 Current Commands 17 Cutter compensation 154 D Date 24 Deleting Programs 38 Direct Numeric Control 42 DIRECTORY LISTING 43 DNC 43 E Electricity Requirements 197 Emergency Stop 14 End-Of-Block 18 ENGRAVING 20 F Fi
G65 Macro Call 104, 115 G65 Macro Subroutine Call 104, 115 General Requirements 197 Guarding 200 H Handle Control Feedrate 16 Handle Control Spindle 16 Hard Drive 39 Help 17 High Speed Machining (Optional) 30 High-Speed Side Mount Tool Changer 50 Hydraulic Tool Changer 55 I Introduction 11 Intuitive Programming System 74 IPS 74 J Jog Handle 14 Jog Keys 15 Jog Lock 15 Jog Mode 57 K Keyboard 14 Key Switch 15 L Loading Programs 39 Lookahead, Macros 88 M Machine Data Collect 193 Machine Power-Up 104 Macro
Operation Timers 22 Operator Load Station, Pallet Changer 66 Optional Stop 19 Option Try-Out 28 Orient Spindle 172 Override 16 Override Keys 16 P Pallet changer 110 Pallet Changer 65 Pallet Changer Programming 67 Pallet Changer Recovery 70 Pallet Loads, Maximum 66 Pallet Replacement 71 Pallet Schedule Table 67 Pallet Storage 72 Parameters 17 Parentheses ( ) 18 P-Cool 173 R Renaming Programs 38 RS-232 30, 185, 193 S Searching the program 38 Serial Number Engraving 127 Service 197 Settings 17 Settings, Mac
TOOL OFSET MESUR 187 transmission 173 U Umbrella Tool Changer 52 USB 39 W Warm-up Compensation 191 Worklight 200 Z Zero Return 19 214 Index 96-8000 rev T January 2008
