Prima Electro OPENcontrol User Manual

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OPEN

control

End User Manual

DOCUMENT NUMBER: 4602H RELEASE REF.: EDITION: 00 AUTHOR: Prima Electro S.p.A. DATE: June 2013

PRIMA ELECTRO reserves the right to modify and improve the product described in this manual at any time and without prior notice. The application of this manual is under customer responsibility. No further guarantees will be given by PRIMA ELECTRO, in particular for any possible faults, incompleteness and/or difficulties in the operation. In no event will PRIMA ELECTRO be responsible or liable for indirect or consequential damages that may result from the use of such documentation.

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Edition

Date

Notes

Author

14/06/2013

First DRAFT

Prima Electro S.p.A.

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Contents

1. Features and specifications ............................................................................................................ 7

Reading keys and security instructions ................................................................................................................................. 7 1.1

General .......................................................................................................................................................................................... 7 1.2

Hardware structure ................................................................................................................................................................... 8 1.3

1.3.1 Operator Panel ............................................................................................................................................ 9

1.3.2 OPENconsole and OPENconsole COMPACT ................................................................................................ 9

WinNBI Interface Software.................................................................................................................................................... 10 1.4

1.4.1 Connection between the WinNBI and the CNC ........................................................................................ 11

1.4.2 Common features of the WinNBI applications ......................................................................................... 12

2. System Start-up ............................................................................................................................. 14

System Power Up ..................................................................................................................................................................... 14 2.1

System Shut Down ................................................................................................................................................................... 14 2.2

Diagnostic Screens ................................................................................................................................................................... 16 2.3

Switching the System in Special Operating Modes........................................................................................................... 17 2.4

Selection of the Operating Mode ......................................................................................................................................... 18 2.5

3. User Interface ................................................................................................................................ 21

The Screen ................................................................................................................................................................................. 21 3.1

The Keyboard ............................................................................................................................................................................ 21 3.2

The Control Panel .................................................................................................................................................................... 21 3.3

The ProcessController ........................................................................................................................................................... 22 3.4

3.4.1 Title bar ..................................................................................................................................................... 23

3.4.2 Menu bar .................................................................................................................................................. 23

3.4.3 Tool bar ..................................................................................................................................................... 23

3.4.4 Operator Panel bar ................................................................................................................................... 24

3.4.5 OEM Operator Panel ................................................................................................................................. 25

3.4.6 Screen layouts ........................................................................................................................................... 26

3.4.7 SoftKey bar ................................................................................................................................................ 26

3.4.8 Main video screen osai_p6a.qv ................................................................................................................ 27

CNC Status Area ...................................................................................................................................................................... 28 3.5

Flags Area ................................................................................................................................................................................... 30 3.6

3.6.1 Axes positions and origin area .................................................................................................................. 31

3.6.2 Feed and overrides Area ........................................................................................................................... 32

3.6.3 Selected Tools Area ................................................................................................................................... 33

3.6.4 G and M functions Area ............................................................................................................................ 34

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3.6.5 Part program data area ............................................................................................................................. 34

Keyboard Commands .............................................................................................................................................................. 35 3.7

3.7.1 Additional information windows .............................................................................................................. 35

Panels for Command and data input.................................................................................................................................... 36 3.8

3.8.1 General rules on the input windows ......................................................................................................... 36

3.8.2 The ProcessController soft-keys ............................................................................................................... 37

3.8.3 Multiple connection, CNC selection .......................................................................................................... 40

3.8.4 MDI Panel functions .................................................................................................................................. 54

Operator Consoles .................................................................................................................................................................. 55 3.9

3.9.1 Keys and functions of the OPENconsole COMPACT Operator Panel ........................................................ 55

3.9.2 Keys and functions of the OPENconsole COMPACT Operator Panel ........................................................ 57

4. Establishing origins and homing the axes .................................................................................... 58

General ........................................................................................................................................................................................ 58

4.1

Axis homing procedure ........................................................................................................................................................... 58 4.2

Definition of the origins .......................................................................................................................................................... 59 4.3

4.3.1 Manual setting of the absolute origin....................................................................................................... 60

4.3.2 Automatic set of the absolute origin ........................................................................................................ 61

Axes and part origins ............................................................................................................................................................... 64 4.4

5. Axes jogging and Stop functions .................................................................................................. 66

JOG .............................................................................................................................................................................................. 66 5.1

5.1.1 Continuous jog .......................................................................................................................................... 67

5.1.2 Incremental JOG ....................................................................................................................................... 68

Manual Feedrate change .......................................................................................................................................................... 68 5.2

Hold entry and JOG return on the profile ........................................................................................................................ 68 5.3

Spindle Speed Override .......................................................................................................................................................... 70 5.4

Stop functions ............................................................................................................................................................................ 70 5.5

5.5.1 Reset ......................................................................................................................................................... 70

5.5.2 Hold ........................................................................................................................................................... 71

Emergency Stop ........................................................................................................................................................................ 71 5.6

Active reset ................................................................................................................................................................................ 71 5.7

Removing the tool after an Emergency ............................................................................................................................... 74 5.8

6. Part Program Management .......................................................................................................... 77

Main Video Screen .................................................................................................................................................................... 77 6.1

Selection of an item .................................................................................................................................................................. 78 6.2

Multiple selection ...................................................................................................................................................................... 78 6.3

Creation of a new Part Program .......................................................................................................................................... 79 6.4

Creation of a new Directory ................................................................................................................................................. 79 6.5

File copy and directory............................................................................................................................................................ 80 6.6

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Delete a directory or a file..................................................................................................................................................... 80 6.7

Change the name of a file or a directory ........................................................................................................................... 81 6.8

Writing and editing a Part program ..................................................................................................................................... 81 6.9

Enabling a Part-Program for the execution ........................................................................................................................ 82 6.10

Disabling the Part-Program selected ................................................................................................................................... 82 6.11

Program Management Configuration ................................................................................................................................... 83 6.12

Logical drive configuration ..................................................................................................................................................... 83 6.13

6.13.1 Adding a logical drive ................................................................................................................................ 84

6.13.2 Removing a logical drive ........................................................................................................................... 84

6.13.3 Showing logical drive path ........................................................................................................................ 84

Four Windows Display (Quad View) .................................................................................................................................. 85 6.14

7. Part Program execution ............................................................................................................... 86

Part program execution .......................................................................................................................................................... 87 7.1

7.1.1 Selecting and activating a part program ................................................................................................... 87

7.1.2 Automatic execution ................................................................................................................................. 87

7.1.3 Block-by-block execution .......................................................................................................................... 87

7.1.4 Multiblock retrace..................................................................................................................................... 88

Executing blocks from the keyboard ................................................................................................................................... 89 7.2

7.2.1 MDI execution without an active part program ....................................................................................... 89

7.2.2 MDI execution with an active part program ............................................................................................. 89

7.2.3 Executing part of a part program .............................................................................................................. 90

Modifying blocks in BLK/BLK mode..................................................................................................................................... 90 7.3

Strings search ............................................................................................................................................................................. 91

7.4

Feedrate Override .................................................................................................................................................................... 91 7.5

Spindle feedrate override ....................................................................................................................................................... 91 7.6

Rapid Feedrate Override ........................................................................................................................................................ 92 7.7

Execution in Dry Run mode .................................................................................................................................................... 92 7.8

Memory Search ......................................................................................................................................................................... 92 7.9

7.9.1 Automatic Search ...................................................................................................................................... 93

7.9.2 Search for a pre-set block ......................................................................................................................... 93

Restart a working cycle ........................................................................................................................................................... 94 7.10

Searching Mode ......................................................................................................................................................................... 94 7.11

8. Using Tables .................................................................................................................................. 96

Enabling Table Editor ............................................................................................................................................................... 96 8.1

Origin Table ............................................................................................................................................................................. 102 8.2

Tool Table ................................................................................................................................................................................ 104 8.3

Tool Offset Table ................................................................................................................................................................... 106 8.4

User Table ................................................................................................................................................................................ 110 8.5

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9. The Table Builder ....................................................................................................................... 111

General ...................................................................................................................................................................................... 111 9.1

Origin table customization ................................................................................................................................................... 114 9.2

Tool Table customization ..................................................................................................................................................... 119 9.3

Table Offset Customization ................................................................................................................................................. 124 9.4

User Table customization ..................................................................................................................................................... 129 9.5

Translation of the variable names....................................................................................................................................... 136 9.6

Configuration file .................................................................................................................................................................... 137 9.7

10. Tool Management ...................................................................................................................... 138

General ...................................................................................................................................................................................... 138 10.1

Tool Pre-setting ...................................................................................................................................................................... 138

10.2

10.2.1 Manual Tool pre-setting ......................................................................................................................... 138

10.2.2 Manual pre-setting of the tool length mounted on the spindle ............................................................. 141

10.2.3 Automatic pre-setting of the tool mounted in the spindle ..................................................................... 142

11. Machine Plot ............................................................................................................................... 143

General ...................................................................................................................................................................................... 143 11.1

Machine Plot Interface ........................................................................................................................................................... 143 11.2

Machine Plot Configuration ................................................................................................................................................. 147 11.3

Profile Drawing ....................................................................................................................................................................... 151 11.4

Drawing a 3D Profile ............................................................................................................................................................. 153 11.5

Checking the Profile ............................................................................................................................................................... 154 11.6

Drawing the disconnected axes profile (DRY RUN) .................................................................................................... 157 11.7

12. System History ............................................................................................................................ 158

General ...................................................................................................................................................................................... 158 12.1

System History Interface ...................................................................................................................................................... 158 12.2

13. Appendix A .................................................................................................................................. 164

Error Messages ........................................................................................................................................................................ 164 13.1

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WARNING! Dangerous Voltage: This symbol is associated with dangerous high voltages that could damage the system, the equipment and the operators.

WARNING! Danger: This symbol is associated with facts and circumstances that could damage the system, the equipment and the operators.

NOTES: This symbol is used for operations that have to be executed with great care in order to ensure their successful completion.

1. Features and specifications

Reading keys and security instructions 1.1

ATTENTION! To use the system in a correct manner, follow the instructions provided in this manual and

pay special attention to the symbols below:

General 1.2

OPENcontrol is a family of state-of-the-art numerical controls, designed to meet a vast range of standard and non-standard application requirements. The most powerful model can manage up to 64 digital axes. The OPENcontrol systems can be installed on many types of machine: milling machines, grinding machines, wood-, glass- and marble-working machines, oxygen cutters, etc. Thanks to the “open” Hardware and Software architecture, the systems are particularly suitable for both standard and for those applications requiring special functions. OPENcontrol allows the manufacturer to customize the system to integrate with their specific application requirements.

The OPENcontrol systems are based on the most advanced technologies; from the hardware components to the powerful Operating System (multitasking, real time, event driven) complete with either a local or networked graphic interface, that makes the OPENcontrol system one of the most important CNCs. The powerful and sophisticated functions typical of numerical control, can be combined with a user friendly

interface, configurable according to the MTB’s requirements. This interface is named “WinNBI”

(Windows Network Based Interface) and is displayed on the operator panel connected to the CNC.

There are several HMI types to match with the OPENcontrol, from the simple industrial monitor up to the more advanced Operator Panel. This manual describes the user interface provided by the OPENconsole Operator panel and the WinNBI application graphical software. In the following pages, there is an overview of the configuration to which this manual refers.

For any additional information and a complete evaluation of all the OPENcontrol hardware configuration, refer to the manuals below:

“OPENcontrol – Software Installation Manual” code 45006692G. “OPENcontrol – Installation Guide” code 45006652F.

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Hardware structure 1.3

The OPENcontrol systems are made up of a number of modules that can be combined in different ways according to the requirements. Usually, the system has an operator panel used to display the data and to handle commands to be sent to the CNC.

Only skilled operators together with the MTB can open the operator panel and the basic unit for “service” reasons.

This manual explains how to use the OPENcontrol CNCs combined with the OPENconsole operator panel as shown below.

In this configuration the OPENcontrol Control Unit is connected on the network to an industrial PC dedicated to the graphical user interface. The control unit is therefore dedicated to the real-time software, while the data is displayed on the industrial PC on the OPENconsole Operator Panel. The other devices, such drives and I/Os, are connected to the Control Unit.

In other configurations, the user interface software runs on the control unit without using an industrial PC between the control unit and the operator panel.

This manual describes the use of standard video screen layouts provided by Prima Electro with the product software release. The structure of the video screen layouts can be changed by the MTB, and may therefore appear to the end user in a different way. In this case, the MTB will describe the functionality of the customized screen layouts.

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1.3.1 Operator Panel

The Operator Panel (or front panel) is the interface device between the system and the operator. In all versions, the Operator Panel is equipped with a LCD monitor, a standard USA-ASCII keyboard with function buttons that work as softkeys. It offers the most up to date Man-Machine interface techniques together with ease of use, its main functions are:

introduction of operating commands. introduction of start, stop and reset commands. the data input using the keyboard software and data entry (part program, software options, etc.), using USB connected devices. display of the data and all the system operating conditions. control of the CNC and PC ambient.

This manual deals with the OPENconsole operator panel use and the WinNBI graphical user interface by Prima Electro.

1.3.2 OPENconsole and OPENconsole COMPACT

The OPENconsole operator panel offers great modularity and an innovative design. The panel consists of independent modules that can be assembled together to obtain the ideal configuration match the specific application requirement. The Control Panel exchanges data using an EtherCAT fieldbus. The panel is equipped with a silicon rubber keyboard, Windows standard, that is supplemented by a Touch Pad or Track-Ball unit. The 17” or 19” Monitor, has a resistive integrated Touch Screen. Both the monitor and the keyboard can be connected directly to the CNC or to the interface PC (if this is provided in the system configuration).

Figure 1: OPENconsole configuration with Monitor, Control Panel, Control Panel Extension

and Keyboard with TouchPad

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Figure 2: OPENconsole COMPACT - all HMI elements in one module

WinNBI Interface Software 1.4

The WinNBI graphics suite (Windows Network Based Interface) consists of several different applications or independent HMI utilities, each dedicated to a specific function. These applications allow the complete management of the machine tool. The applications (standard or optional) are for users having different requirements (end user, MTB, service engineer). This manual describes the WinNBI utilities used by the end user:

ProcessController Data display and commands for the CNC.

This is the main WinNBI application which displays all the CNC data: axes position, speed, active functions, program lines etc. and also allows the sending of commands and parameters to the CNC. The Process Controller is supplied with some standard video screens to manage the machine in manual and automatic mode. In addition the optional Layout Builder ambient allows the screen content to be adapted to suit the exact requirements of the application

Therefore, the ProcessController can present a graphic interface completely different from the standard one supplied and documented by Prima Electro.

BootController Numerical Control boot controller.

It displays the messages from the CNC during the boot stage. It also allows the system software restart and setting of the operating state that the CNC must be in for machining, tuning and service.

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TableEditor Data table editor It allows display, entry and modification of some parameters, in particular:

origins tools tool offsets user tables tool magazines tool data base

The TableBuilder is part of the TableEditor allowing customisation of the data and the data display within the same tables. For details see chapters 8 and 9.

System History This is a standard feature that stores in a file all the diagnostic messages produced

by the system in case of malfunction or incorrect operation, together with time and date. It is a useful tool for fault diagnosis.

1.4.1 Connection between the WinNBI and the CNC

As described in the previous paragraphs, the WinNBI applications can be installed on both the PC dedicated to the HMI and the control unit. In both cases, the applications connect to a data server in the control unit. The connection between the WinNBI Application and the NC, is always done via the network. The network will be virtual for the WinNBI locally installed on the CNC and real in case of the PC installation on the network. In all the WinNBI applications, the user can select the numerical control to which the application has to connect. The connection status is displayed in a dedicated status bar.

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1.4.2 Common features of the WinNBI applications

Even if activated separately, the WinNBI applications are designed to offer the same graphic structure and common elements for ease of use. The basic graphic structure of a WinNBI application is as follows:

Title bar: Shows the name of the application and in some cases the name of the document

(typically the file name) to which the application refers for the data display.

Menu Bar: Contains the main menu commands. These commands open a scroll-down menu

listing a group of commands or a data insertion panel. The menu bar always contains all the entries in the Softkey bar together with other entries less used by the operator.

Tool Bar: Contains the buttons enabling the most used application functions. These can be

direct or indirect commands. Every WinNBI application can have several or nontoolbars.

Status Bar: Displays the name of the Numerical Control to which the application is connected

and the connection status via the virtual or real network.

Data view area: This is the area where the application displays the information and the graphic

objects dedicated to the specific functions required by the application. Each WinNBI application has data and control elements of different types in this area.

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Softkey bar: It is a bar that, in all applications, has 5 buttons that can be enabled using the

mouse or touch Screen. For quicker activation, the buttons are associated with the function buttons F6 and F10 of the operator panel keyboard. These 5 buttons open the scroll-down menus containing the most used commands (see also Menu bar description).

In some application, the display of the field described can be customized. Their presence on the video depends on the settings made by the OEM and by the final user.

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2. System Start-up

To turn the system on and off, comply with the machine manufacturer’s instructions. To

turn off the Numerical Control, follow the shut-down procedure described below.

System Power Up 2.1

The system is powered up when power is supplied to the central unit and the front panel, typically this is

done by operating the machine’s main power switch. Since most of the system software is stored on the

hard disk, all the software that remains resident for the numerical control operation is automatically uploaded from the hard disk at system boot.

The BootController is a utility of the WinNBI graphic interface that checks and manages the CNC power up. Using this application, it is possible to choose the CNC operating mode and to check the messages

generated by the CNC when powering up. The main working modes of the CNC are “Normal”, “Emergency”, “Setup” and “Service” are defined as “stable”. Each mode has a specific function (for details see the paragraph “Switching the system on in special operation modes”. The other modes, e.g., “HW boot” and “SW boot”, are transitory and lead to one of the stable modes. The BootController utility

displayed by the OPENconsole Operator Panel, in the Windows ambient, can be manually enabled or automatically launched at power up. This behaviour depends on the choices made by the OEM when installing WinNBI.

By default, the BootController, after connecting to the CNC and verifying that a stable mode has been established, automatically launches the ProcessController application for the system management.

System Shut Down 2.2

The CNC must always be shut down using the “Controlled shut down” procedure that closes all open

sessions. This ensures the integrity of the data contained in the user, OEM or system files that, when shutting down, could still be open for writing. Controlled shut down can be initiated during all working stable modes of the CNC. It is done using the BootController application.

The procedure is:

With the system on in one of the four stable operating modes:

If disabled, enable the BootController application

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and select the “Shut Down” command from the “Boot” menu.

In the window, select the “Shut Down” command and confirm with the “OK” button

when shut-down is completed, the following message appears, indicating that the CNC can be turned off.

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Diagnostic Screens 2.3

The control starts the diagnostic phase at boot up during which the hardware and software modules of the system are checked. The modules are tested in the following order:

basic hardware (CPU, ROM, RAM, keyboard and disk) modules and additional devices numerical control software

The messages generated from the CNC diagnostics are displayed in the main window of the BootController application (Data Logger Display). If the system is powering up, the messages are displayed as they are generated, but the same messages are recorded by the CNC and are visible in the Data Logger Display at any time, even when the boot phase of the CNC is finished.

The messages generated by the diagnostics are listed according to the test results and change according to the hardware and software system configuration, both in quantity and meaning.

Usually the messages are divided in several parts as the example below:

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From left to right, the message contains the following elements:

Date and Time Are the date and time of the message generation, with mill-second precision.

Ambient Indicates what part of the CNC generates it (e.g., “Log”).

Message Code Two numbers separated by a slash. The numbers identify the message (in this

example "31/34"). The first number is the "Class" of the message, identifying a group or category of messages. The second number is the message "Code". Codes within a class are consecutive numbers starting from 1. The whole Class+Code group uniquely identifies a message or an error code of the OPENcontrol.

Message Text This column contains a brief description of the type of operation performed, the

test passed by a device or the software section initialized. The message may be an error message if the operation has failed. The message in this example is "Loading field protocols."

Appendix A describes all the messages in detail and possible corrective actions.

When the CNC detects a non-critical error, it indicates it through the message in the Data

Logger and continues powering up the system. These errors are recorded in the “SW0”

variable, accessible to the machine logic. The subsequent behaviour of the system depends on the machine logic defined by the OEM. For additional details on the non-critical errors, see the documentation of the SW0 variable in the “OPENcontrol – Application Manual” code 45006962W.

Switching the System in Special Operating Modes 2.4

With the OPENcontrol system, it is possible to execute power on sequences different to the default. These power up sequences put the CNC into special operating modes, activating only parts of the software system, allowing execution of such basic operations as:

software installation or update calibration system configuration

Some of these modes are essential, for example, to remove user errors in the characterisation that prevents the CNC from starting properly.

The four OPENcontrol operating modes are:

Normal Mode: it is the standard boot mode of the CNC, for the Part Program management and execution, axes movement etc.

Emergency Mode: the CNC works as a Server and only certain operations can be done, the main ones are:

changing the AMP characterization using the ODM utility reset, save and restore the retentive memory via BootController reset of the CNC message history via the CNC System History utility CNC file management

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Setup Mode: the CNC works as a File Server. In this mode, using the Security application, it is possible to upload the basic software, fixup or options to the CNC. It is also possible to save the CNC mass memory, to manage the security levels and option enabling (PAK) and to manage surface checks of the CNC disks, etc.

Service Mode: the CNC executes only the first boot stage of the CNC to initialize the axes control software. This mode is used for the calibration of the digital drives via the ODM utility. The Emergency, Setup and Service modes can be set only via the BootController utility. If nothing is done with the BootController, the CNC will automatically select Normal mode. All the WinNBI application indicate the operating mode of the CNC via a status bar that displays the name of the numerical control connected:

The background of the field containing the CNC name changes according to the status of the connection between the WinNBI and the CNC. The colours used and their meanings are:

RED CNC not connected. Connection in progress.

GREEN CNC connected. CNC in “Normal” mode

ORANGE CNC connected. CNC in “emergency” mode

BLUE CNC connected. CNC in “Setup” mode

CYAN CNC connected. CNC in “Service” mode

At the end of the CNC boot phase, in the working mode Normal or Emergency, if the option A03 is enabled on the system (see Application Security WinNBI), the BootController automatically starts the ProcessController application.

The ProcessController is the main application for numerical control management. The automatic start-up of ProcessController can be disabled via the "NBIconfig" configurator of the WinNBI.

Selection of the Operating Mode 2.5

To select the boot-up operating mode of the CNC, the BootController is used. The procedure is the same for all the operating modes described in the previous paragraph.

Selection of the operating mode with system on

To enable an operating mode, i.e., Emergency, select “Emergency” using the “Mode” menu

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or with the dedicated button in the BootController toolbar.

After selection, reboot the CNC using the “Shut Down” command from the “Boot” menu entry.

The system re-executes the boot phase, as if it had been turned off and on, and enters the EMERGENCY boot mode identified by the orange colour in the status bar.

Selection of the operating mode with the system off

Turn the system on. After the first hardware boot stage, the CNC waits for 30 seconds, for the selection of the operating mode from the Boot Controller. During this time it is possible, to select the desired mode using the buttons on the tool-bar. The CNC will continue the boot with the selected mode. If no selection is made, the CNC, continues to the Normal mode.

When the BootController is connected to a CNC waiting for the selection of the operating mode, the following page is displayed:

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In emergency status the following WinNBI applications can be used:

SECURITY

Manages the security levels of the system for different user and installation levels. More information about this utility can be found later in this manual.

SYSTEM HISTORY

Utility for viewing / printing / deleting of the archived errors and system messages displayed during the machine operation.

FILEBROWSER

Management of the CNC’s and the PCs OSAI file system.

ODM

Definition and change of the system configuration.

TABLE EDITOR

Management of the system’s data tables (Tools, Offset, Origins and User). In Emergency mode, it is possible to work only on the tables file, not on the retentive memory files.

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The RESET button interrupts both the part program being executed and any active function.

The CYCLE START button initiates axes movements and other commands in both manual and automatic mode.

The CYCLE STOP button temporarily stops the active functions. For instance it stops the part program execution with a controlled deceleration of the axes. After a CYCLE STOP the operation can be restarted.

3. User Interface

The system displays data and information on the screen to start the communication, then the operator introduces commands and data. All these operations take place on the operator panel. The keyboard, video and the softkeys of the panels " OPENconsole " and "OPENconsole COMPACT" are described here. The user interface is the means by which the operator communicates with the system.

The Screen 3.1

The screen is the means by which the system communicates with the operator, sharing all information concerning the functioning, the data associated with the operations carried out, the data entry requests, etc. The screen can have a Touch functions to select field and graphic areas, to enable commands, etc. With the OPENconsole Operator Panel the information is displayed on a 17” or 19” colour screen with the Touch Screen option and 1280x1024 resolution. The COMPACT OPENconsole Operator Panel is equipped with a 15’’ monitor with 1280x1024 resolution and Touch Screen option.

The Keyboard 3.2

The OPENconsole and OPENconsole COMPACT Operator Panels have a 101-key U.S. keyboard. The function buttons from F5 to F10 have a special function when the panel is used with the Prima Electro HMI software. The WinNBI, uses the function buttons for softkey activation. The F4 button is used for the selection of the video screen to display.

The Control Panel 3.3

The two Operator Panels have a section (Control Panel) used to send the operating instructions to the numerical control. The buttons provide the following functions:

More detailed information on each button will be provided later in this manual.

The functions of the buttons described here those provided as standard by the system. However, they may be changed through the machine logic written by the machine tool builder. Refer to the MTB documentation.

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The ProcessController 3.4

The ProcessController utility of the WinNBI displays and manages both axes movements and part programming of the CNC. For general features of the WinNBI applications, refer to Ch.1-“Features and specifications”.

For proper use of the ProcessController, it is important to understand the concept of “process”. “Process” (or “channel”) means the management of a machine tool, i.e., the control of the axes, the

part program execution, the enabling and disabling of the machine logic control, etc. More generally, process can also refer to a support activity for the machine tool, such as the tool change, management of part loading and unloading, calculations, statistics, reports, etc. The term multiprocess represents one of the most important features of the OPENcontrol numerical controls. A single CNC can manage un to 24 different processes. The processes work simultaneously, each executing a part program independent of the others. If the systems controlled by the individual processes must be synchronized, they can be controlled more quickly and with greater flexibility than with separate control systems. The standard screens provided by Prima Electro with the ProcessController, display the data of only one process, so that they can be used on any machine. The standard screen can be used for multiprocess/mono-process systems. For the multiprocess systems, it is enough to select the desired process to ensure that the data on the screens are automatically updated with the selected process.

This manual describes the use of the standard screens provided by Prima Electro the software product release. The layout of the screens can be changed by the OEM and can then appear in a very different way to the end user. In this case the OEM describes the functionality of the customised screens.

Even if the content of the screen changes, the commands and the data-entry enabled with the data entry menu or with the softkeys remains unchanged.

The picture below identifies the main part of the ProcessController screen

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3.4.1 Title bar

Shows the name of the application and the name of the selected screen. The title bar can be hidden or

restored with the menu command “Display”-“Toolbar”.

3.4.2 Menu bar

Contains the main menu items, each item includes a set of commands displayed in a drop-down menu. The items in the drop-down menu typically open a panel for the introduction of commands and parameters. The most frequently used menu items are repeated in the Softkey task bar. The menu bar can be hidden with the menu command "Display" - "Menu". To re-display the menu, press the keys "Ctrl" and "P" on the keyboard.

3.4.3 Tool bar

Contains buttons to activate all the WinNBI applications:

The buttons enable the other WinNBI applications:

BootController

MachinePlot

TableEditor

SystemHistory

Digicad

PathView

ODM

Tool Calibration.

I/O config

TimeMonitor

Security

O-Scope

O-Scope.NET

The button opens a panel that displays information referred to the software version of the ProcessController.

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Code

Mode

Use

MDI

Opens the MDI (Manual Data Input) data entry to allow keyboard entry of a program block.

AUTO

Selects the continuous execution mode of the selected part program.

BLK/BLK

Selects the block to block execution mode for the selected part program

MANJOG

Enables continuous manual movements. Pressing the [CYCLE START] button, starts the movement of the selected axis, The movement stops when the Cycle Star button is released. For details, see Ch. 5 “Axes jogging and Stop functions”.

JOG INCR

Enables incremental manual movements. Pressing the [CYCLE START] button, the incremental movement defined for the selected axis starts. For details, see Ch. 5 “Axes jogging and Stop functions”.

PROFILE

Enables the return to the profile after a manual movement. For details, see Ch. 5 “Axes jogging and Stop functions”.

HOME

Enables axes homing

HANDWHEEL

Enables management of the handwheel

3.4.4 Operator Panel bar

It is a bar with buttons to select the CNC operating mode and the feedrate and spindle override values.

Mode selection

The CNC has different modes of operation, to move the axes in both manual and programmed mode. The operator panel allows the mode selection.

All the buttons select only the desired mode, without starting any machine movement. The machine movements must be confirmed with a dedicated command, usually the Cycle Start button.

The selected mode is displayed on the screen in the “CNC status” area. See the description of the main video screen in following pages.

Selector and switches to change the override values

In the toolbar, are the override selector (percentage increase/decrease) and the buttons “+” and “-“ to change the value of the selected override. Using the override selector it is possible to select the type of override that will be changed with the “+” and “-“ buttons.

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Code

Definition

Use

FRO

Feed Rate Override

Percentage change in the cutting feed defined by Part Program with the "F" function.

FMO

Feed Manual Override

Percentage change in the feed defined in the AMP configuration for manual operations.

SSO

Spindle Speed Override

Percentage change in the rotational feed of the spindle programmed by Part Program with the "S" function.

RAP

RAPid override

Percentage change in the feed defined in the AMP configuration for rapid movements.

The codes listed in the selector override values have following meanings.

The current values of the override are displayed on the screen in the area “Feed and Overrides”. See

description of the main video screen in the following pages.

Button “+”

Adjusts the feedrate, spindle speed or the rapid feed, depending on the function selected by the override selector. Each time the button is pressed, the percentage of the selected feed/speed is increased by a pre-set amount.

Button “-”

3.4.5 OEM Operator Panel

It is a password-protected button bar, for starting and stopping the movement. This bar is provided for the OEM only to allow initial machine tests which do not involve movement of the axes. The bar contains the Cycle Start, Hold and Reset commands.

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File name

Screen description

osai_p6a.qv

Screen to manage program execution. Displays a maximum of 6 process axes.

osai_p9a.qv

Screen to manage the program execution Displays a maximum of 9 process axes.

osai_a5a.qv

Screen to manage the programs in automatic. Displays a maximum of 5 process axes.

osai_a9a.qv

Screen to manage the programs in automatic. Displays a maximum of 9 process axes.

osai_m9a.qv

Screen to manage up to 9 axes in manual mode

osai_aux.qv

Screen to manage the auxiliary axes of the machine logic

3.4.6 Screen layouts

These may be the standard screen layouts provided by Prima Electro or one of the customised screens defined by the OEM. Remember that the video screen structure can be changed by the OEM and therefore the screens displayed to the end user may be different to those described in this manual. Usually, the screens contain data of the process under control. The ProcessController can automatically resize all the objects and the texts to adapt to the main window dimensions and therefore to the dimensions of the monitor used.

The table below lists the standard screens provided by Prima Electro with the numerical control software and the WinNBI.

The default configuration of the ProcessController is set to display the sequence of screens osai_p6a, osai_a5a, osai_m9a and osai_aux. The selection of a screen with the sequence above, is managed by the F4 key or via the menu command “Select – Next page”. The standard screen of the ProcessController dedicated to process control is

described below. Remember that the screen setting depends on the OEM’s choices and may vary

significantly from those described in this manual.

This manual describes the “osai_p6a” screen containing all the display elements related to a

process.

The other screens show the same data as in the “osai_p6a” screen, but rearranged to facilitate the use of the machine in manual or automatic mode.

3.4.7 SoftKey bar

Like the main menu items, each softkey selects a group of commands that are displayed in a drop down menu. The items in the drop-down menu usually open a panel for the introduction of parameters and commands. All the softkeys are repeated in the main menu. The softkey bar can be hidden from and restored to view with the menu command “Display” –

“Softkey”. The softkeys can be activated, by using a mouse, touch screen or with the function keys F5

to F9.

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3.4.8 Main video screen osai_p6a.qv

This manual describes the “osai_p6a” screen that contains all the display elements related to a process.

“osai_p6a” is a complete screen for the display of up to 6 process axes, that can be used for machining

in all modes (automatic and manual). The screen may be overlaid by other windows with additional information, these windows may appear automatically or on demand or according to user commands from menus and softkeys.

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Field

Description

CNC

Name of the Numerical Control connected on the network. The data displayed on the screen are referred to this NC.

PROCESS

Displays the number of the process selected and being controlled.

MODE

Displays the current operating mode, which can be either Automatic or Manual. The following belong to the modes:

Automatic: AUTO, BLK/BLK, MDI Manual: JOG CONT, HOME, JOG INCR, JOG RETURN, HANDWHEEL

STATUS

Displays the status of the currently selected process. Some are valid for both Automatic and Manual modes, while others are possible in only one mode. The possible states are: INPUT, ERROR, EMERG.

UNIT

Indicates the current unit of measurement for the selected process. It can be mm (millimetres) or inches

The osai_p6a screen has been divided into several functional areas, as shown in the following figure.

CNC Status Area 3.5

The Status Area contains information referring to the operating status of the numerical control:

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STATUS

AUTO

MAN

MEANING

IDLE



The process is stopped waiting for a command.

IN CYCLE



The process is executing a part program or a command entered from the keyboard in MDI mode.

RUN



The process is performing a manual movement.

CYCLE STOP



The execution of a part program or a command provided in MDI was stopped and the process is in a wait state.

HOLD



The execution of a manual movement was interrupted with CYCLE STOP button and the process is in a wait state.

RUNH



The process has been stopped during the execution of a part program with CYCLE STOP. Switching the process in MANUAL, the status changes from STOP to HOLD CYCLE. If one or more axes are manually moved, during these movements the message becomes RUNH and buttons CYCLE START and CYCLE STOP are both turned on. RUNH informs the user that there is an on-going movement.

HRUN



With the process in the HOLD or CYCLE STOP state and CYCLE STOP is pressed, the status switches to HRUN which means that the process is ready to continue the interrupted machining. The CYCLE STOP button will turn off and the process waits for CYCLE START to be pressed.

RESET



Indicates that the process is still managing the reset command following pressing of the RESET button.

WAIT 

The process is waiting to be synchronized with another process.

INPUT 

Indicates that the process is waiting for a data input from the keyboard (a data entry window is on the screen).

ERROR



Indicates that the process has detected an error during operation. The error can stop the process or be managed by the part program.

EMERG



The system detected an anomaly, and operator intervention is required. The type of fault is indicated on the screen with an explanatory message explained in the Appendix A ("Emergency Messages").

Each of the aforementioned states is briefly described in the table. More detailed information will be provided in the explanations of operator actions in which they are involved.

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Flag

Description

OSTOP

Optional Stop (Ready to stop when M01 occurs in the program)

BLK DEL

Block Delete (blocks preceded by / are omitted

DRY R

Dry Run Program executed without axis movement

RAP O

Rapid Override

Auto J

F Byp

Feed rate Bypass

Retr

Retrace

MemS

Search Memory

Mode

Sub-mode

Status

Flag

AUTO

BLK/BLK MDI

IDLE RUN HOLD HRUN RUNH WAIT INPUT EMERG ERROR RESET

OPTIONAL STOP BLOCK DELETE FEED BYPASS RETRACE RCM O N

MANUAL

HOME JOG INCR JOG RETURN HANDWHEEL

IDLE RUN HOLD HRUN RUNH EMERG ERROR RESET

RETRACE JOG+ JOGRCM ON

Flags Area 3.6

The active options referred to the current mode, are displayed in reverse in the flag area

The table below lists (for Automatic and Manual mode) the sub-modes available, the possible process status and the flags used.

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3.6.1 Axes positions and origin area

This area of the main screen displays the position data the origins of the process axes. The figure below indicates the elements contained in the area. The data are arranged as a matrix where each line belongs to the axis whose name is shown in the first column.

Axes name

The axis name is a letter identifying an axis within a process. Unlike a physical axis identifier, that is a unique number in the system, the axis name can be repeated in another process. The axis name in reverse indicates the axis selected for manual movements. The selection can be made in different ways:

Clicking with the mouse on the axis name Sequentially, via the command menu or softkey “Select” – “Next Axis” By the Cursor Up/Down Keys Sequentially, by pressing “Ctrl” and “A” simultaneously.

Axes position

The label of this column indicates the type of positions displayed in the fields below. The content of this field changes according to the selection made by:

the softkey or menu command “Select” – “Positions” Sequentially, from the keyboard by pressing the keys “Ctrl” and “B”.

The position types that can be displayed for the process axes are:

Work position calculated with respect to the current origin Machine actual position calculated with respect to the current origin To go distance to go (difference between current and commanded position) Error following error, i.e. the difference between the positions Work and Machine. Absolute absolute position referred to the home position ignoring offsets & origins

The positions of the axes are displayed with 10 digits in the formats 7.3, 6.4 or 5.5 (where the first digit represents the integers, the second the decimals) according to what has been configured in AMP for each axis.

Programmed position

This is the last position programmed from part program or MDI command. It is 10-digits long, displayed in the same format as the “Axis position” fields.

Selected Origin

Number and type of the origin selected for the axis. In this field are also displayed characters:

- “T” for temporary origins

- “I” for incremental origins

If only the origin is displayed, then the origin is absolute, not temporary or incremental.

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3.6.2 Feed and overrides Area

This area contains the information related to the machining speed and movement of the machine. The values in this area are expressed in current units of the process (mm / inches), which is also displayed on the screen. The information in this area is arranged in a matrix where the lines refer to the type of speed indicated by the labels in the first column.

Feed line Contains the information referred to the machining feedrate. From left to right, the data indicates:

The feedrate set by program the selected feedrate override actual feedrate (programmed * feed override)

Feed M line Contains the information referred to the manual feedrate. From left to right, the data indicates:

the configured feed for manual movements the selected manual feedrate override the actual manual feedrate (configured * override)

SPEED line Contains the information referred to the spindle speed. From left to right, the data indicates:

the programmed revolutions. If the Constant Surface Speed (CSS) is active, the field indicates

the calculated speed based on the programmed one which varies as the work diameter changes

the selected speed override the override speed of the spindle (rpm or CSS) * override.

RAPID line Contains the information referred to the axes rapid feedrate. From left to right, the data indicates:

rapid feedrate configured in AMP the selected rapid feedrate override the actual rapid rate (configured * override)

Jog field

It’s the incremental distance set for the execution of manual movements (incremental Jog).

Jog Dir. field Indicates the direction of movement set for manual movements (Jog and incremental Jog).

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3.6.3 Selected Tools Area

The area is dedicated to the display of the programmed tools.

Tool Number of the tool mounted on the spindle and its active offset. The field contains 2 groups of digits divided by a point. The group on the left of the point represents the tool number, the one on the right the offset.

Next T

Number of the next tool and its associated offset that will be mounted in the spindle. This is the tool already set by the program, but not yet mounted in the spindle. The field contains 2 groups of digits divided by a point. The group on the left of the point represents the tool number, the one on the right the offset.

Diam

Diameter of the tool mounted in the spindle.

Offs 1

Length 1 offset of the tool. The machine axis to which the tool compensation refers to in this field is configured in AMP via the ODM application.

Offs 2

Length 2 offset of the tool. The machine axis to which the tool compensation refers to in this field is configured in AMP via the ODM application.

Offs 3

Length 3 offset of the tool. The machine axis to which the tool compensation refers to in this field is configured in AMP via the ODM application.

Offs 4

Length 4 offset of the tool. The machine axis to which the tool compensation refers to in this field is configured in AMP via the ODM application.

Offs 5

Length 5 offset of the tool. The machine axis to which the tool compensation refers to in this field is configured in AMP via the ODM application.

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3.6.4 G and M functions Area

Area that displays the active G codes and M functions.

G codes

Active G codes. The codes are divided into display groups. Each field displays the active G code for one of the modal groups defined in AMP.

M functions

Active M functions. Usually each field displays an M code for every modal group configured in AMP.

3.6.5 Part program data area

This is the area dedicated to the display of the lines of the part program being executed. The area is read-only, at this point you cannot edit the program. In order you will find, the block already executed, the block being in execution highlighted in reverse and the blocks still to be executed. The part program lines automatically scroll upward as they are executed by the CNC. The figure below shows an example of the lines of a program in execution:

SELECTED PP

It’s the name of the main program selected.

SUBPROGRAM

Contains the name of the sub-program selected. The name is displayed only when the sub-program is enabled. A sub-program can call another sub-program. The sub-program displayed is always the one with the lower nesting level, i.e. the last called and still in execution.

PROGRAM MESSAGE

Messages defined in the part program with the DIS, command.

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Flag

Description

Sequential selection of the screens to be displayed from a list of active screens

F5, F6, F7, F8 F9

Activation of the corresponding softkey

Ctrl + A, key ↑, key ↓

Sequential selection of the axis to be moved in manual mode Ctrl + B

Sequential selection of the axes position type

Ctrl + P

Sequential selection of the selected process

Ctrl + T

Sequential selection of the selected target (CNC)

Keyboard Commands 3.7

The following tables summarizes the keyboard commands used as “accelerators” to enable the commands associated with the menu items.

3.7.1 Additional information windows

In addition to the information normally provided by the main video screen, additional information in specific windows can be displayed as required. These windows overlay the current screen and appear only upon request or when the system has to inform the user (for instance, via a message). The possible additional windows are:

MDI Command Panel

It is the panel for the MDI commands entry, i.e., for the execution of single command lines using the same syntax as used for the part program lines. For additional details, see the paragraph “MDI Panel Functions ”

Messages from System

Information messages from the system or process displayed in four lines (see figure)

Messages from PLC Program

Signalling messages generated by the machine logic program. (see figure)

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Panels for Command and data input 3.8

The ProcessController has several data entry windows used to enter commands, working parameters, configuration, parameter setting for the movements in manual and automatic. Usually the data entries are enabled by the commands associated with the softkeys described in the previous paragraphs. This chapter explains the function of all the process Controller data entries.

3.8.1 General rules on the input windows

With the standard screens, the data can be entered in the system only by using specific windows defined as “input windows” or “data-entry”. usually, the data-entries appear in the current screen after enabling an item in the main menu or with the softkey. For proper handling of input data it is necessary to apply some rules that are common to all input windows in the system. Below is an example of input window.

Each input window has fields that can contain parameters, file name, device names and so on. The values entered must comply with the type and the format of the field.

In the case of fields with parameters depending on the unit of measurement (mm / inches), the numerical values associated with them will be displayed in the unit of measure defined for the process with the default AMP configuration. The information is displayed in the title of the window.

The cursor is positioned on the selected input field. When the data-entry is opened the first input field is selected. With the operator panel touch-pad or with the touch-screen function, it is possible to select the desired field.

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KEY

FUNCTION

Moves the cursor to the right or to the left inside the field.

CANC or DEL

Deletes the character to the right of the cursor.

Deletes the character to the left of the cursor.

Toggles between overwrite and insert modes..

TAB

Moves the cursor on the following field

Aborts the current data entry window.

Confirms the current data entry window.

The characters inserted via the keyboard are displayed on the screen as the cursor is moved. Data entry can be managed using the following keys:

The input window can be exited at any time. If the data is not confirmed, the values inserted are not applied. To exit the input window, cancelling the data entered, press "Cancel". To exit the input window and validating the data entered, press "OK".

3.8.2 The ProcessController soft-keys

The ProcessController interface is controlled through the mouse or keyboard. To simplify access to all the CNC commands through the keyboard, some special keys have been added at the bottom of the application window, the soft-keys. The soft-keys are activated by pressing the OSAI Operator Panel F5, F6, F7, F8, and F9 function keys, the Touch-pad mouse or the Touch-screen function The soft-key activation opens a drop-down menu. To select the desired menu item from the keyboard use the arrow keys (cursor up, cursor down).

All the commands available with the soft-keys are also present in the main menu.

The ProcessController soft-keys are the following:

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The drop-down menus opened by the softkeys are shown below:

Select

Set Up

Origin/Tool

PartProgram

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Utility

The panels opened by the drop-down menu items are explained In the following pages.

“Select” – “CNC”

This command changes depending on the configuration of the type of connection (single or multiple). The configuration is set using the configuration panel reserved for MTB use. If the ProcessController has been configured for a single connection, the selection panel is as follows:

Permits selection of the CNC to be connected to the network.

When the WinNBI is connected to the CNC control unit, use the generic local address indicated by “IP.”

to address the local CNC. The remote CNCs are addressed by the prefix “IP.” followed by the TCP/IP address of the control unit (as shown in the picture). By using the Offline button or writing NULL instead of the CNC name it is possible to disconnect the CNC. This mode can be used by an offline PC in order to use the Layout Builder only.

When the offline mode is active the ProcessController displays an empty screen layout. In this condition ProcessController doesn’t try to connect to the selected CNC. The "Remove" button is used to remove an unused name from the history of the CNC previously connected. The key removes the selected name from the “CNC previously selected” list.

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3.8.3 Multiple connection, CNC selection

Multiple connection permits a list of CNCs to be specified to be connected contemporaneously. It is used and useful only when the screen layout has been designed to show the data of more than one CNC at the same time. If the ProcessController has been configured for multiple connections, the selection panel is as follows:

This panel is used to set the name of the selected list. The list contains the names of all the numerical controls to be connected simultaneously. To select the offline mode write “NULL” in the field “CNC list to select”.

The "Remove list" button may be used to delete an unused list (the button removes the selected name from the list).

To define the content of the list, press Edit. The list selected is the one shown in the "CNC list to be selected" box. If the list does not exist yet, a new empty list is created.

The Edit button opens (and closes upon being clicked again) the dialog window dedicated to the composition of the list. The dialog window can be edited as shown in the figure below:

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By means of the "Remove selected CNC" button you can remove the selected CNC from the list of CNC’s

to be connected. The "Add to list " button adds to the list the network name of the CNC specified in the "CNC name" field. The name is added to the list only if it not already present and if the list contains fewer than eight names.

The Up and Down arrow buttons next to the list of CNCs allows the position of the selected CNC name to be changed.

CAUTION:

The order of the names in the list is very important, since the information displayed in ProcessController screens depends on it. If a screen box has been configured to show a value of CNC # 1, the ProcessController will get the value from the first CNC in the list; if a box has been configured for CNC # 2, the value will be taken from the second CNC, and so on. When a multiple selection is active, the ProcessController enables selection of one of the CNCs from the status bar, or sequentially using the keyboard command CTRL+T. The selection from the status bar is made by selecting one of the items in the list by means of the "Arrow down" button next to the "CNC" field.

“Select – Process”

Allows selection of a process from those configured in AMP. The existing processes are listed in a drop-down menu.

If there is only one process, the command is disabled. If the screen is valid for the new process selected, the screen does not change, instead it will display the first screen of the sequence assigned to the process. The command can also be sent from the keyboard by simultaneously pressing the keys “CTRL” and “P”.

“Select” – “Next page”

Selects, sequentially, the screen following the sequence of the screens in use. The command can be sent from the keyboard (key “F4”).

“Select” – “Next axis”

Selects, sequentially, the axis for manual movements. the command can also be sent from the keyboard by simultaneously pressing the “Ctrl” and “A”.

“Select” – “Pos Display” Allows selection of the type of position display for the axes configured in the process.

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“Select” – “Next Pos Display”

Selects sequently the type of position display for the axes in the process. For each activation of the command the position type display can be selected in the order Work, Machine, Absolute, To Go, Error. The same command can be enabled from the keyboard by simultaneously pressing “Ctrl” and “B”.

“Set Up” - “Manual”

Opens a data entry window that allows the length of the axis movement to move with incremental manual movments and the type of return after a manual movement. It also enables the tool extraction procedure for some particular cases (see Chapter 6, " Manual Axes Movements and Stop Functions ").

Jog Value

Insert the incremental distance for incremental manual movement. The value inserted is displayed in the JOG field of the main video screen.

Jog Return/Jog Incr mode Selection

Specifies the JOG RETURN and the JOG INCR modes, that can be automatic or manual (See Chapter 4)

Skip

Specifies whether to return to the profile from HOLD, or to position along a straight line to the end point of the block in which the movement was suspended in HOLD. To skip a return on the profile, tick the Skip field.

For the fields related to the “Tool Direction”, refer to Ch. 5 “Axes jogging and Stop functions”.

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“Set Up” - “Dynamic Param”

Enables VFF

Enables/disables the VFF algorithm (velocity feed forvard) of the servo axes. When the algorithm is enabled, the following error will be reduced to a value close to zero, consistent with the gain of the servo configured in AMP, to minimize the shape error on the profile. When the algorithm VFF is disabled, the axes are controlled only with the following error. The value of the following error is displayed in the video area of the axis positions when selecting the “ERROR” display mode.

Dwell time G04

Defines the dwell time at the block end (G04). This time is used with G04 and in the following blocks of fixed cycles:

In G94 the dwell time is in seconds. in G95 the dwell time is in number of revolutions.

For detailed information on this parameter, see the Programming Manual.

SPEED limit (RPM)

Defines the maximum spindle speed. It is used in Constant Surface Speed (CSS), ie when the spindle feed depends on the master axis position.

Return feed % (G84)

Tapping return feed. It defines the percentage change in the feed rate applied during the return phase

of the tapping cycle. The range of values is 0-125%. The default value is 100%.

“Set Up” – “Dynamic Limits”

Enables Look-Ahead

Enables the automatic deceleration on the angles when executing a part program. If disabled, all the DLA instructions of the current part program will be ignored.

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Maximum Deviation Angle

MDA (Maximum Deviation Angle) is the maximum angular deviation from the axis in which G27 is active. The selected angle is the operational limit for G27. Angular deviation greater than this angle is done by G29 or point-by-point.

“Set Up” – “Program”

Opens a data entry that allows the configuration of some paraemters that influence the part programs execution modes.

Block Delete

Enables the block delete feature, the block preceded by a slash "/" is NOT executed (equal to the DSB = 1 programming). At system boot, this field is set to the condition established in the AMP characterization. System reset does not change the previous setting.

Optional Stop (M01)

Enables the optional program stop. At system boot, this field is set to the condition established in the AMP characterization. System reset does not change the previous setting.

Feedrate Bypass

It enables forcing of the rapid speed with G1, G2 or G3 active. At system boot, this field is disabled. System reset disables this field.

Rapid Override Control

Enables control of the rapid feed precentage with the Operator Panel. At system boot, this field is set to the condition established in the AMP characterization. System reset does not change the previous setting.

Disable program scroll

Disables part program scroll in the AUTO mode. If scroll is disabled, the block execution is faster. At system boot, this field is set to the condition established in the AMP characterization. System reset does not change the previous setting.

Stock allowance

Defines the machining allowance value added to the tool radius for the calculation of the trajectory in “tool offset” (G41 - G42) mode. It is the same as programming the MSA variable. At system boot and after a reset, this parameter =0.

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Rotation Angle

Defines, in degrees, the rotation of the active plane (positive value = CCW rotation). Unlike the triliteral code by programming (ROT, angle), system reset does not reset the rotation angle. If (ROT angle) is programmed after setting up a rotation angle with this input box, the value of the rotation of the plane will be the sum of the rotations. Entering the angle of rotation of the plane in this window after programming a value with the trilateral (ROT angle), the rotation of the plane will be equal to the value entered in the data entry. In this case, the rotation preset by (ROT, angle) will be lost.

Horizontal axis – Vertical Axis

Defines the working plane. Ii is equivalent to programming G16. When the system starts-up and after a reset, the work plane is defined by the value set in AMP (G17, G18, G19 or the alternative axis plane (G16).

“Set Up” – “Axes Setup”

Locked

Enables the movement of the axes. When selected, the system normally execute the part program, but the axes do not move physically. The reset does not disable this mode.

Mirror

Enable the reversal ("MIRROR") of the trajectory of the specified axis.It is equivalent to programming the

three-letter code (MIR, axis name).System reset disables this function.

Scale

Enables the scaling factor referred to the axis specified. System reset disables scaling..

Scale Factor

Defines the scale factor to be applied to the specified axis. Equivalent to programming the triliteral code (SCF axis name, scale factor). System reset reset set the scale factor to zero.

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Safety Tolerance

Approach Tolerance

“Setup” - “Probe Set Up”

Opens an input window for the entry of the probing parameters.

Approach tolerance. Represents the distance from the probing target. The probe moves this distance in rapid and then starts the probing cycle at the feedrate programmed in the entry Measuring Feed.

Safety Tolerance.

A value that prevents damage to the probe. If the probe does not find the target within this range, it stops.

Measuring Feed

The feed with the probe moves towards the target.

Horizontal Shift

The value for the abscissa axis of the probe requalification in millimetres.

Vertical Shift.

The value for the ordinate axis of the probe requalification in millimetres.

Probing Mode

The value of the probing mode:

0 for the standard probing (return to start point) 1 for the probe to remain at the probed position

“Setup” – “Set Accuracy”

Opens a data-entry to define the parameters related to circular interpolation.

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Circular Endpoint Tolerance (CET)

Defines the tolerance for the difference between the initial and final arc of a circle.

Full Circle Threshold (FCT)

Determines a tolerance for the distance between the first and the last point of the arc of the circle. If the distance is less than the value of FCT, the arc is to be considered a full circle.

Arc Modality (ARM)

Determines the mode applied by the system to normalize a programmed arc with center coordinates (I, J) and the end point, in order to make it geometrically congruent. The valid values are 0, 1, 2 and 3. 0 displaces centre within the CET tolerance (default mode) 1 displaces starting point within the CET tolerance 2 displaces centre independent of the CET tolerance 3 displaces centre beyond the CET tolerance range

“Set Up” – “Dry Run”

If Dry Run is selected it is possible to test the part program execution without any physical axis movement or command being sent to the machine logic.

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“Set Up” – “Search in Memory”

Search in memory: is the search for point in the program where it was interrupted and the subsequent recovery cycle or the search for a block where processing will begin. The parameters that uniquely identify a interrupt at run time are stored and continuously updated during the execution of the program. Based on these parameters, the control has the ability to perform an automatic search.

The strored search can be done in two ways:

Stored search of the interruption block (following a shutdown or reset). Stored search of to a specific block

“Set Up” – “Block Retrace”

This function allows blocks to be executed backwards with axis movements in reverse along the profile previously executed. The number of blocks that can be executed backwards may vary from 1 to 64, depending on the AMP configuration.

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The sequence of the operations to execute the commands backwards is:

Stop the running program by pressing Cycle Stop. Activate Block Retrace through the data-entry. Press the "Cycle Start" key: the system moves the axes backwards along the path stored during

the program execution..

The movements will be executed in selected mode (AUTO, BLK / BLK). Execution of Block Retrace can be interrupted by pressing the Cycle Stop command. To return to the standard conditions, disable Block Retrace, release Cycle Stop and press Cycle

Start.

MBR Length

This field defines the maximum distance that can be run backwards. By pressing Cycle Start, the control runs backward, along the profile, for a distance equal to the value set.

MBR Threshold

Allows the definition of a distance threshold from an edge. If the reverse displacement moves the tool along the profile close to one edge, the control recalculates the end point along the profile to keep (before or after the corner) the minimum distance defined with this field.

“Set Up” – “Ref”

Opens an input window allowing virtual referencing of the axes.

The box references the axes at the position where they are. Select the axes to refer and confirm by clicking “OK”.

The axes referenced in this way, unlike the HOME cycle, is only a logical operation for which the parameters NULL OFFSET and HOME POSITION, configured in AMP for each axis, are not considered and the operating limits are referred to the point where the axes are upon confirmation.

“Date” and “Time”

Opens a box that allows the CNC date and time to be changed.

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“Origin/Tool” – “Origin preset”

Opens an input window to define the origin values.

Origin Number

Number of the origin whose values are to be modified

Origin Values

Values of the axes to which the origin refers

”Origin/Tool” – Tool offset preset”

Opens a data-entry that allows the definition of an tool length offset

Offset Number

Offset number of the selected tool

Reference Axis

Name of the spindle axis (usually Z)

Tool Tip Position

Distance between the spindle "nose" and the fixed reference point

“Part Program” – “Activate Part Program”

Selects a part program for execution

“Part Program” – “Deactivate Part Program”

Disables the current part program.

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“Part Program” – “Part Program management”

This command enables the management of the part-programs stored on the selected CNC. The management of the programs includes the following commands:

Selecting a program for execution.

Deselect the active program Editing of a program. Changing the name of a program or a directory Erasing a program or a directory. Create a new directory or a new program. Copy / Paste of a program from a CNC directory to another. Copy / Paste of a program from PC to CNC and vice versa

For a full discussion of these commands see Ch. 6 "Part Program Management".

“Part Program” – “String Search”

Searches the current program for a string of characters. The command is enabled only if a part-program has been selected. The input window appears when the command is initiated.

After inserting the text string; each press of the <Up> or <Down> buttons will search for the occurrence of a string in the desired direction. Press the <OK> button to terminate the operation.

“Part Program” – “Exec From To”

This command allows the definition of the part-program block (start and end) for partial execution of the selected program. The command is active only if a part program has been selected.

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From

Mode

Specified

Executes the part program between the specified blocks

Specified

Absent

Executes the part program from the block specified to the end

Absent

Specified

Executes the part program from the current line to the specified block

Absent

Executes from the current line to the end

Allows setting of the partial execution modes of a part program; the number of parameters inserted determines the mode:

The starting block is defined using only one of the possible selections defined at point 3. The conditions, described at point 4, determining the end of the program execution, can be more than one at the same time. The field $BRK identifies the equivalent variable used in the part programs, for this field indicate the value that the variable must have in order to finish the program.

“Utility” – Application name The “Utility” soft-key opens a drop-down menu that allows thw launch of the other WinNBI applications listed below.

BootController, Machine Plot, TableEditor, SystemHistory, Digicad, PathView, ODM, Calibration Tool, TimeMonitor, Security, O-Scope, O-Scope..NET, FileBrovser

The OEM can disable these applications using the NBIconfig application.

Utility - Variables

The “Utility” soft-key also allows the opening of a data-entry for the display and change of program and system variables. The variables are divided by class and may be used for part-program writing, to obtain data from the system and from the machine logic developed by the OEM. The meaning of their content is therefore bound by the application developed for machine tool in use. For viewing and editing of the parameters through the windows of the standard ProcessController, the variables can be divided into two classes:

numerical variables alphanumeric variables (texts)

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For a numerical variable, the Process Controller displays a panel like the one below:

The variables displayed are shown in a preset or configured length array. To select the desired variable use the vertical scroll bar or the vertical direction keys (arrow up and down) on the keyboard. These operations move the display window through the array and allows the desired variable display to be selected. To change the value of the selected variable, press "Edit", and the data entry appears, change the value and confirm with the "OK" button.

Selecting an alphanumeric variable, the Process Controller displays a panel like the one below:

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The alphanumeric variables are displayed in the panel with both the numerical value and the text.

To select the desired variable,use the vertical scroll bar or the arrow keys as for numeric variables. To change the value of the selected variable, press "Edit", and in the box that appears, change the value and confirm with the "OK" button.

The change can be done via numerical values (using the “Numeric” column) or by characters, inserting the characters in the “ASCII” column.

Using the data-entry of the ProcessController dedicated to the variables, it is possible to view and if allowed, change the variables E, SN, SC, User, H, Plus, Input and Output. For additional details on the use of the variables and their format, refer to the Programming Manual.

3.8.4 MDI Panel functions

The MDI panel is used to set the command from keyboard that will be excuted by the CNC in MDI mode. The panel automatically appears when the “MDI” working mode is selected. Using the configuration panel, it is possible to choose how the MDI panel appears either as a basic data entry or it can be used to store the entered commands in order to re-execute them as a part program. There are two types of panel.

Basic MDI panel:

The "Confirm" button sends the command entered in the command editing window to the CNC. The "Change Block" button brings the current block of the selected part-program into the command editing window.The part-program block selection moves on to the next block.

Extended MDI panel:

When this panel is enabled, at each block “Confirm”, the command is stored in a local file (specific for the CNC and the selected Process). Using the controls in the panel, the list of commands can be run, edited, deleted and saved to a file of the CNC.

The "Start recording" button deletes the current storage file (of the CNC and the selected Process) enabling the storage of the MDI commands. When the storage is enabled, an image representing a camera is shown next to the “Confirm” button.

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The button "Continue recording" enables the storage of the MDI commands without erasing the previous ones. The new commands are appended after the existing ones. Note that the commands are stored in a file and therefore can be inherited from previous work sessions.

The button "End recording" stops the recording of commands and enables the buttons for execution, change and the saving of the stored commands.

The command "Delete" deletes the local storage file of the MDI commands (not the one saved on the CNC).

The command "Change" launches the program editor configured with the configuration panel for changing the stored command file.

The command "Save as…" saves the commands buffer to the CNC and gives them a name.

The command "Execute" starts the commands buffer execution as a pseudo-program. The buffer is executed as a sequence of MDI commands sent from the ProcessController to the CNC. The pseudoprogram. execution can be interrupted by RESET, MODE change, STATUS change (ie hold) or error during the execution of a block.

Operator Consoles 3.9

The Operator Console provides the operator with three control buttons for executing Cycle Start, Cycle Stop and Reset commands, plus a series of buttons and/or selectors for changing the speed of the axes and the mode.

3.9.1 Keys and functions of the OPENconsole COMPACT Operator Panel

As shown in the above figure, on the right side of the OPENconsole COMPACT operator panel there are the operator console keys and the pushbuttons START, HOLD and RESET, i.e. the three control buttons described in the section "Control Buttons" at the beginning of this chapter. The buttons on the operator console are described below. For their functionality, refer to Chapters 5 and 6.

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Enables continuous manual movements (JOG).

Enables incremental manual movements

Enables the axes homing cycle

Enables handwheel movements

Enables part-program execution in automatic mode

Enables block by block execution of the part program

Selects the MDI mode. The data entry input opens for keyboard entry of partprogram blocks.

Rotary switch for the percentage change of the movement feed of the axes in automatic (Feed Rate Override) and manual (Manual Feed Override) modes.

Rotary switch for the percentage change of the spindle speed (Spindle Speed Override)

The buttons from P1 to P6 can be customized with functions set by the OEM. The Cycle Start, Cycle Stop and Reset buttons are described at the beginning of the chapter.

The functions of the buttons described here, are the standard ones managed by the system. They can be changed through the machine tool builder’s machine logic. Refer to that documentations.

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Enable execution of programs in continuous automatic mode

Enables the continuous manual movments (JOG).

Moves the selected axis, in continuous manual mode, in the positive direction.

Moves the selected axis, in continuous manual mode, in the negative direction.

Drive ON.

Drive OFF.

Rotary switch for the percentage change of the feed movement of the axes in automatic (Feed Rate Override) and in manual (Feed Manual Override).

3.9.2 Keys and functions of the OPENconsole COMPACT Operator Panel

The OPENconsole is a modular Operator Panel, optimized for machine tools mainly used in Automatic and manual continuous. The control panel can be extended with the module below that can have buttons customized for the application. Below are described the keys of the standard operator console (for their functions refer to chapter 5 and

6).

The Cycle Start, Cycle Stop and Reset buttons are described at the beginning of the chapter.

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4. Establishing origins and homing the axes

General 4.1

On the machine tool you can define several reference points that allow the calculation of the axes homing positions. The following parameters are part of the machine configuration and are set by the MTB:

the ABSOLUTE ZERO is determined by the position of the micro switch which is placed on the

physical axis during each cycle reset

compared to the previous position, using the NULL OFFSET parameter, the MTB may require that

the zero position of each axis is moved as the quantity set: at the end of the homing cycle, on the micro switch, the axis executes an additional movement. At the end of this movement, it displays its position as 0.

compared to the previous position, using the HOME POSITION parameter, the MTB may require

that the zero position of each axis is moved as the quantity set: in this case, the axis does not move physically, but its position displayed is no more 0, as it coincides with the value set having th sign changed.

At the end of the reset cycle and the activation of the parameters previously described, it is defined what is seen by the end user as HOME POSITION i.e. the position in which all the axes have a displayed position equal to 0.

Axis homing procedure 4.2

Usually, after the machine boot, you can move the axes in manual mode (if allowed by the machine logic written by the MTB), but you cannot launch a program during the execution: this will be allowed only after following (at least once) an axes homing procedure.

If the axes have an absolute transducer, at the machine boot the axes already have a set position referred to their HOME POSITION, therefore you do not need to perform the homing procedure described below.

The standard procedure for axes homing follows the sequence below:

select the HOME mode select the axis you want to home press the CYCLE START button wait for the end of the axis homing cycle repeat the procedure for all the axes

If the MTB has set the mode MANUAL RESET, the operator must hold the CYCLE START button until the end of the loop otherwise this cuts off prematurely: to complete it will be necessary to press the CYCLE START. If you have set the mode AUTO ZERO, after pressing it you can release the CYCLE START button: to stop the cycle must eventually be pressed the RESET button.

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ABSOLUTE

These are the origins referred to the zero machine (HOME POSITION) and are stored in the Origin Table. During machining, the program can recall at any time a certain origin (via the command UAO, indicating number indicating the identification origin number) and from that moment all the positions will refer to this new origin. For each process can be defined up to 100 origins. For additional details, check the Programming Manual.

In some cases, the sequence to be used for the axes homing is determined by the machine

status: for instance, let’s suppose the machine has to restart after an emergency that left

the tool in the workpiece. In this case, the operator of the machine will decide which

sequence should be used or if it’s better to manually move the axes to retract the tool from

the workpiece.

Typically, the MTB includes a complete sequence of automatic homing for all the axes, that is launched in execution via specific commands: for this reason it is necessary to refer to the instructions of the MTB. The procedure previously described is still valid and can be used as an alternative to automatic one.

When the homing cycle of an axis finishes without errors, the message below appears:

22/6001 Axis homing complete Distance micro-marker…

The value displayed for each axis in the previous message, indicates the distance between the release position of the micro switch and the position of the market transducer: the MTB sets the axes homing parameters so that the value is equal to about half of the mechanical pitch. The message allows you to check this: if this value is too close to 0 or too close to the mechanical pitch, it could lead to a displacement error of the axis during the homing cycle equivalent to a mechanical pitch, with consequent errors in the manufacturing. Typically, the change of this parameter is due to mechanical causes such as the displacements of micro switch or a slip of the motor shaft.

Definition of the origins 4.3

Usually the MYB defines some reference positions different from the HOME POSITION, in various points of the machine (for instance, in the angles of the machining plane). In other cases, the final user needs to define additional positions referred to other machine points, according to his requirements. All these positions are defined as ORIGINS.

The OPENcontrol CNC allows the definition of up to 100 ORIGNIS for each process, identified by a number from 1 to 100. The number 0 identifies the HOME POSITION origin. Each origin includes a group of values (one for each machine axis) considered as the distance of the axis from his zero position: of course, this value can a positive or negative sign.

The user can use three different types of origin:

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TEMPORARY

These are active origins, enabled by part program via the UTO command, referred to an absolute origin of which you have to temporary modify the value of each axis, of the quantity indicated (without changing the values stored in the origin table). These remain active until the calling for a new temporary or absolute origin or until the control reset. For additional details, check the Programming Manual.

INCREMENTAL

These are origins referred to the active origin in that moment (absolute and/or temporary), defined and enabled directly from part-program using the UIO command. Unlike the temporary origins, where the following overwrites the previous one, the incremental origins programmed in sequence are summed. These remain active until the calling for a new temporary or absolute origin or until the control reset. For additional details, check the Programming Manual.

As aforementioned, the values to be inserted in the origin table for each axis, are considered as the distance of the axis from its HOME POSITION. If you want to move the axis origin towards its positive direction, the value to be inserted must have a positive sign, otherwise is negative. If the value is set =0, the axis origin coincides with its HOME POSITION.

To set an absolute origin in the table, the user can use one of the procedures below:

1) manual setting of the absolute origin

2) automatic setting of the absolute origin

4.3.1 Manual setting of the absolute origin

In this case, it is assumed that the user already knows the value to be set for each axis and that these values should only be stored in the CNC working area (Origin Table).

For example, you want to set the origin 1 moved of +200 in the X direction and -100 in the Y direction, compared to the home position (see figure below).

In order to get this, after opening the origin table and selecting the origin 1, you insert a +200 value in correspondence of the X axis and -100 in correspondence of Y axis. If you press APPLY, the values entered are stored in the origin 1.

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In this example, for the axes (ZCAB) a null origin remains set, i.e. their zero position coincides with the HOME POSITION.

4.3.2 Automatic set of the absolute origin

The same change made for origin 1 can be automatically obtained, i.e. without opening the origin tables editor. Without activating any origin (so that the axis positions are referred to the HOME POSITION), physically set the X and Y axes in the positions desired (X200 and Y-100 , in our example). Select ORIGIN/TOOL in the tool bar and then ORIGIN PRESET.

In the ORIGIN PRESET window displayed, you have to set:

ORIGIN NUMBER: the number of the origin you want to change (1, in our example) X..: indicated axis offset with respect to the present axis position

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If you set “0” as the quote desired for the XY axes and then press “OK” and confirm, the system takes

the present axes position (X+200 and Y-100, in our example) and writes it as the value of the origin 1 in the table. Therefore the origin 1 is physically updated with the value of the present position of the two axes: you can verify this opening the origin editor and checking the values of origin 1 for the X and Y axes.

For those axes where there is no value set (axis Z, C, A and B in our example) the corresponding values set in the origin 1 are not changed.

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If in the ORIGIN PRESET window you insert values different form zero, as the example in the figure below:

after confirming (“OK” button) the origin 1 is updated with the value (200+10.2) = 210.2 for the axis X and (-100-13.5) = -113.5 for the axis Y, as you can verify opening the origin table editor.

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Axes and part origins 4.4

The part program has programmed positions referred to a reference position name PART ZERO or PART ORIGIN. For a machining program execution, the axes origin must coincide with the origin of the part. A simple procedure is described below:

place the raw part in the desired working position on the working plane of the machine

enable the tool offset mounted on the spindle

disable any origin so that the axes positions are referred to the HOME POSITION

manually move the machine axes until the tool tip is on the point zero of the part (the positions

displayed on the screen represent the XYZ axes positions with respect to HOME POSITION)

on the tool bar, select ORIGIN/TOOL and then ORIGIN PRESET

set the required data in the ORIGIN PRESET window

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In our example, the origin 20 is set with 0 value for X and Y axes, while the Z axis has a -10 offset so that the machining is made with a -10 depth with respect to the upper surface of the raw part (present position of the tool tip).

after the confirmation, the axis positions are stored in the origin 20 of the origins table.

With this procedure, the origin 20 is correctly set and the part program can be sent to execution by putting it in the activation of the source using the command.

(UAO,20)

The previous procedure can be made also without having the tool mounted on the spindle. In this case, you will make the spindle nose coinciding with the zero position of the part. Obviously, no tool offset must be activated.

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5. Axes jogging and Stop functions

JOG 5.1

The manual movement (JOG) of an axis can be done in two ways:

continuous jog incremental jog

To select a jog move (continuous or incremental), press one of the two buttons in the software Operator Panel (bar selection of the operative mode) of the ProcessController.

The same selection can be done on the OPENconsole COMPACT Operator Panel using the selection buttons:

On the OPENconsole Operator Panel, enable the manual movements using the button and select the continuous or incremental mode via the ProcessController.

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To select manual mode the key-switch must be turned to the position indicated by the open lock.

The axis selected for the manual movement is the one shown in reverse on the screen:

As long as the axes are not homed, the machine software overtravels are disabled. Before doing any manual movement, it is necessary to carefully consider what movement will be done. The machine tool builder handles the management of any hardware overtravel.

5.1.1 Continuous jog

This mode permits the axes to be jogged continuously in the selected direction at the selected rate. The procedure is as follows: (for the execution of each command see Ch. 3):

1. Select continuous Jog mode

2. Select the axis to move

3. Select the direction of the manual movement

4. Select the manual feedrate change percentage as shown in the section "Feedrate change” of this

chapter.

5. Press the button “Cycle Start” and hold. As long as the “Cycle Start” button is pressed, the

axis moves in the direction and the speed defined.

Cycle Start button in the OPENconsole panel. The button could also be

white.

Cycle Start button in the OPENconsole COMPACT panel.

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5.1.2 Incremental JOG

This mode allows the jogging of the axes for a pre-set increment in the selected direction at the selected rate. To move an axis incrementally, use the procedure below: (for the execution of each command see Ch. 3):

1. Select the incremental Jog mode

2. Select the axis to move.

3. Select the jog direction

4. Select the manual feedrate increment as shown in the section "Speed change" of this chapter

.The jog increment is set with the data-entry enabled by the softkey command . “Setup”“Manual”.

5. Set the increment value. If this step is omitted, the system will apply the current increment, i.e.

the latest one selected and displayed on the screen.

6. Press “Cycle Start”.

There are two possible incremental jog modes which depend on the JOG INCR selection in the “Setup” “Manual data-entry window:

Manual: hold “Cycle Start” button until the move is completed. If “Cycle Start” is released

before the end of the move, the axis decelerates to a stop. To continue the move press and hold “Cycle Start”.

Automatic: in this mode if “Cycle Start” is released the move will be completed without the

axis stopping.

Manual Feedrate change 5.2

The default manual feedrate, defined by the configuration, can be changed with the following procedure (for the execution of each command see Ch. 3):

1. In the software operator panel, use the mouse to enable the button to select the override and

select FMO (Feed Manual Override).

2. Using the buttons “+” and “-“ to the right of the selector right, increase or decrease the current

override value. Every time one of the two buttons on the screen are pressed, the percentage increases or decreases by 1.25%. The manual feedrate change has a range between 0% and 125%.

Example:

If the value configured for the maximum manual feed is 2000 MMPM (millimetres per minute) and a 50% percentage change, the actual manual feed will be 1000 MMPM.

Hold entry and JOG return on the profile 5.3

During part program execution, it is possible to stop machining by using the “Cycle Stop” button that puts the system in HOLD status. In this status, the CNC allows the axes to be jogged to remove the tool from the profile.

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Cycle Stop button on the OPENconsole panel. The button could be black.

Cycle Stop button on the COMPACT OPENconsole panel.

In order to restart the part program execution, chose one of the following:

1. Repositioning of the axes to the point of interruption of the profile

Operating mode:

a) Select the axis to be returned to the profile. b) Select the desired feed percentage of the axis. c) Select Jog Return d) Press “Cycle Start”.

if JOG RETURN is in "Manual" mode, keep “Cycle Start” pressed until the "AXIS ON PROFILE"

message appears; this indicates that the axis return move has been completed.

if the JOG RETURN is in "AUTO" mode, just press “Cycle Start”. The system will

automatically move ALL the axes previously displaced by following the same trajectory in the reverse direction, so as to avoid obstructions. To abort automatic return to the profile press “Cycle Stop”.

2. Move the axes back to the final point of the interrupted block

Operating mode:

a) In the Data Entry activated by the Softkey command “Setup”-“Manual”, select the “Skip”

option and confirm with “OK”.

b) Quit the HOLD status by pressing “Cycle Stop”. c) Resume program execution by pressing “Cycle Start”. At this point, the axes will perform a

linear movement from their current position to the end point of the movement interrupted in HOLD. At the end of this positioning process, program execution will be resumed automatically.

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This procedure cannot be performed in the following conditions:

G61 active. Canned cycles and probe function on. TCP with mno/ijk programming or with rotary axes in "following" mode

(interpolation with following mode).

Program block in Hold without axis movements.

In such cases, the standard execution is forced and it is necessary to move the axes back to the profile interruption point according to procedure 1.

Spindle Speed Override 5.4

The value of the programmed spindle speed in execution can be changed with the following procedure (for the execution of each command see Ch. 3):

1. Click on the button to select the override in the software operator panel and select SSO (Spindle

Speed Override).

2. With the buttons “+” and “-“ to the right of the selector, increase or decrease the override

value. Each time one of these softkeys is depressed, a 12.5% increment or decrement will be applied to the programmed value. Spindle speed override percentages range from 75% to 125%.

Example: If the maximum programmed spindle speed is 1500 RPM (Revs Per Minute) and 80% speed override is applied, the actual spindle speed will be 1200 RPM.

Stop functions 5.5

There are various ways of stopping program execution and machine operation.

5.5.1 Reset

The reset function:

Stops axes moves. Clears the program execution buffer. Restores the absolute origin (Home Position). Restores the configured G codes. Positions the part program to the start of the file.

To perform a reset function press “Reset” on the operator panel.

Reset button in the OPENconsole panel. The button could be blue.

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Reset button in the OPENconsole COMPACT panel.

Press Cycle Start to resume execution. The execution restarts from the beginning of the part program.

Depending on how the machine logic has been programmed, it may give some typical stop commands (such as spindle stop, coolant off, etc.) when it receives the reset command. Check the MTB manual for details

5.5.2 Hold

The hold function:

Stops the axes with controlled deceleration. Temporarily stops program execution.

To put the axes into hold press “Cycle Stop”.

To resume execution press the Cycle Stop pushbutton again to exit from the hold condition and then press Cycle Start. Execution will restart from the point at which the Cycle Stop command was given. If manual moves have been performed after pressing Cycle Stop, it is necessary to re-position the axes on the profile before resuming automatic execution. To do this, use the procedure described above.

Emergency Stop 5.6

The “Emergency Stop” pushbutton stops power supply to the system. The “Emergency Stop”

pushbutton is not managed by the software system of the CNC and is controlled by the machine tool hardware. It is mounted on the Operator panel or in other parts of the machine tool.

Active reset 5.7

This command is available only in the WinPLUS logic program. It can be used after a cycle stop in order to cancel either the remaining portion of the current motion block or the subsequent part program blocks.

To allow automatic active reset, with WinPLUS the active reset function is available on an external pushbutton or on machine devices. For example, if a gap elimination device detects the contact between the tool and the part.

a) it resets the interrupted move. b) searches the subsequent program block for execution. This block will be calculated from the

current position.

c) executes assignment blocks, three-letter code instructions, branching instructions, etc. during

the search.

d) after the subsequent move has been terminated, the ACTIVE RESET function is reset and the

system does not re-launch the part program.

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If there is a part program selected, the active reset command is allowed if the system is in IDLE status and the procedure is the same as those described above apart from point a). If an active reset command is given when the system is neither on HOLD nor in IDLE status, the following error message will be displayed: "Command not congruent with the system status".

Active reset can be given in AUTO, MDI and BLK/BLK. If the control is in any other mode, the following message will appear: "Bad selected mode". If MDI (Manual Data Input) mode is active, active reset will only reset the interrupted move. All the instructions that have not been transferred to WinPLUS will be lost.

if active reset is allowed but the interrupted block is not a point to point move with linear or circular interpolation, the "active reset not permitted" message will be displayed. if the interrupted block has been stopped at the end of interpolation, the active reset command will be ignored.

The subsequent block must be a linear move (G1); if it is not, the "Active reset not permitted" error message will be displayed. If the subsequent block is a contouring move (G27/G28), the active reset function will be allowed but the new block will be executed as a point to point move.

All the M, T, S and logic functions that are programmed in the interrupted block or in subsequent blocks and have not been transferred to WinPLUS will be lost.

The new block calculated by the ACTIVE RESET command contains the coordinates of the axes programmed in the subsequent block. If the active reset command has been executed successfully, the system switches from HOLD to HOLD RUN (HRUN). The red LED turns off and the system awaits a “Cycle Start” command.

If an active reset function generates an error (for example, if the cycle start coordinate coincides with the subsequent motion block) the system remains in hold (red LED ON) but part program execution does

not resume when you give a “Cycle Start” command. All the subsequent active reset functions will be

allowed and the error will be removed.

Since during an active reset the system reads and executes part program blocks, some of the errors displayed may be numerical control errors. however, the "end of file" message is not an error but a

signal. When this message occurs, the system status does not change to HRUN and “Cycle Start” permits

execution of the block that has been restored after one or more active reset commands.

When the active reset function is not accepted by the system, further active request commands shall be taken to refer to the following blocks and, in the absence of errors, the active reset function for such blocks shall be accepted.

The block-end M functions programmed in the interrupted block will be "forgotten" after an active

reset. Execution of the subsequent block will start when the “Cycle Start” command is given. If other

active reset commands are given, the M codes programmed in these blocks will also be ignored.

G29 G01 X100 M05 Active reset at X=50 (M05 will be ignored) G01 Y100 M06 Active reset (M06 will be ignored) G01 M03 Y100 M05 Cycle start :

1. M03

2. Move to X50 Y100

3. M05

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100

HOLD, reset attivo

percorso nuovo

percorso originale

100

percorso nuovo

percorso programmato

HOLD, reset attivo

Any active reset function accepted by the system will enable the subsequent block. This can be observed on the display, where the enabled block will appear in reverse mode.

Example 1

X10 Y40 Y20 Active reset during execution of this block X100 Y30 X100 at the end of this block

Example 2

X10 Y40 X50 Y10 Active reset during execution of this block X100 Y30 Y30 X100 at the end of this block.

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Removing the tool after an Emergency 5.8

In some special applications (such as a 4- or 5-axis machines performing inclined machining in which the moves in the direction of the tool axes are the result of interpolations by other axes), execution may be interrupted by an emergency stop (voltage drop, general emergency, etc.) or by a programmed stop followed by manual moves.

An example of this is shown in the picture below.

This machine has three normal axes (X, Y and Z) and two rotary axes that incline the spindle carrier head.

When an emergency stop occurs, it sometimes happens that the tool remains inside the part. To remove the tool from the part after the machine has been re-powered up, the system must offer you the possibility to move the spindle in the tool direction. This can be useful in case the tool remains stuck in the part during machining. The system automatically defines the virtual axis whose name must be previously characterised in AMP. Movement of this virtual axis causes the linear axes to move, so that the tool moves in the linear axes direction, i.e. in the direction indicated by the position of the rotary axes.

The generation of the virtual axis along which the axes movement is required is set via the “Tool direction” field in the data-entry “Manual Setup” enabled by the softkey command “Setup” – “Manual”.

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The procedure is:

1. Open the data-entry “Manual Setup”:

2. Tick the field “Tool Direction”

3. If necessary, change the positions related to the (max) three rotary axes.

4. Check and if necessary correct the positions of the rotary axes and the selection of the Tool

Direction Mode

5. Confirm with “OK”. At this point, the system generates the virtual axis for the movement of the

axes along the tool direction or the axes of its plane (see below).

The three fields are editable, allowing e.g. to change the direction of tool output or input the correct positions of the axes that may have been moved between the time of the anomaly and when the "Tool direction " mode is activated.

Horizontal axis

Value in degrees of the position of the horizontal rotary axis (described as “Work rotary axis” in AMP)

Vertical axis

Value in degrees of the position of the vertical rotary axis (described as “Tool rotary axis”.in AMP)

Third axis

Value in degrees of the third rotary axis (described as “Middle rotary axis”.in AMP).

The values of the three fields can be changed only before the execution of the cycles reference axes.

Tool Direction Mode

Allows enabling of the axes movement along the tool direction and its reference plane. In AMP three virtual axes are configured (see Kinematics), one along the tool direction and two related to the plane fixed to the tool direction.

The value 1 only enables the tool direction axis. The value 2 enables both the axes. The value 3 enables all the axes, but the reference plane does not comply with the tool direction, but complies with the machine plane.

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NOTE:

If only one of the rotary axes is referred, the system displays the position corresponding to the one not referred: the previous considerations remain valid. See also the Tool Centre Point, mode 5, in the Programming Manual.

The functions described in this chapter are the system standard. They can be changed by the machine tool builder’s machine logic. Refer to the MTB documentation.

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6. Part Program Management

The OPENcontrol CNC has an ambient dedicated to the part program file management, that can be distributed in several directories. The program management ambient is therefore the file manager that activates the program and also allows the management of the files and system directories.

Main Video Screen 6.1

Pressing the “Part Program” softkey of the ProcessController and then selecting “Part Program Management”, the ambient screen video is displayed:

The video screen is divided in 4 functional areas:

Directory Tree Directory Contents Tool Bar Status bar

“Directory Tree” Area

As a reversed tree, in this area are displayed the devices and their content. Starting from the root, each branch represents a device (CNC/GMC/PC). The sub-branches are the directories contained in the device. This area displays the files contained in the directories. The content of the selected directory (file or other directories)is displayed in the “Directory contents” area. In this chapter, the area is also indicated as “left panel”.

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“Directory Contents” area This is the area displaying the content of the directory selected in the left panel. It lists the directories and the files. Selecting a directory in the left panel, the content of this read is automatically updated. In this chapter, the area is also indicated as “right panel”.

Toolbar

It contains the command to be applied on the directories and on the files. The commands available in the toolbar are also available selecting a directory or a file with touch-pad right-click.

Status Bar

It contains the data referred to the selected element. If a logic drive is selected in the Directory Tree area, the status bar below displays the capacity and the free space. If in the Directory Contents area is selected an element, the status bar below displays the time and date of creation for the directories; instead displays the date, time of creation and size for files.

Selection of an item 6.2

Usually, the several commands available in the Program Management, refer to the “selected element”. The selected element is the device, the file or the directory displayed in reverse in the “Directory Tree” or “Directory Contents” areas. To select an item, you can use touch-pad and selection keys, those from keyboard or those graphic in the Toolbar of the Program Management. If using the touch-pad, once the cursor is on the element, left-click.

Multiple selection 6.3

In the right panel it is possible to select several items. This allows the simultaneous application of a command to all the selected elements (for instance, the delete and drag&drop copy commands). A selected item is displayed in reverse.

The multiple selection, always done in the right panel, can be done is different ways:

Method 1, for close items, touch-pad selection:

Select the first element using the touch-pad Hold the “Shift” button of the keyboard and select with the touch-pad the last element All the items included between the first and the last are selected

Method 2, for close items, selection with the arrow keys “Up” and “Down” on the keyboard:

Select the first element using the touch-pad Press the “Shift” pushbutton and press several times the key “Up” or “Down”. each time you

press either button, a file form selection is added or removed (according to the selection of the movement with respect to the first element)

Method 3, for discontinuous elements:

Select the first element using the touch-pad Press the “Ctrl” key and select with the touch-pad another element, not necessarily close to the

previous one. If you select an element already selected, the element is removed from the selection.

All items selected individually, are added to the selection.

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Creation of a new Part Program 6.4

To create a new part program:

select in the left panel the directory in which you want to create a new file. right-click on the touch-pad in an empty area of the right panel. Select “Create File” from the

drop-down menu.

In the directory is created the “NewFil##” file. Where ## are two digits used to differentiate

one file from the other in case more than one file is created without renaming them. The first file will be NewFil01, the second NewFil02 etc.

The field containing the name of the file just created is opened for editing. Write the new name

and press “Return” on the keyboard, or select another element form the screen with the touchpad and confirm the new name; to exit the editing and restore the original name, press “ESC” on the keyboard.

To write the program in the file, see “Edit” command

Creation of a new Directory 6.5

The procedure is very similar to the one used for the creation of a new file. To create a new part program:

select in the left panel the directory in which you want to create a new file. right-click on the touch-pad in an empty area of the right panel. Select “Create Dir” from the

drop-down menu..

In the directory is created the “NewDir##” file. Where ## are two digits used to differentiate

one file from the other in case more than one file is created without renaming them. The first file will be NewDir01, the second NewDir02 etc.

The field containing the name of the file just created is opened for editing. Write the new name

To write the program in the file, see “Edit” command

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File copy and directory 6.6

To copy a file or a directory:

Search, via the left panel, the directory containing the element to copy and select it. right-click on the touch-pad in the right panel once the cursor is on the element name to be

copied.

Select “Copy” Using the left panel, select the destination directory. right-click on the touch-pad in an empty area of the right panel. Select “Paste” in the drop-

down menu. If the destination directory coincides with the one of the element to be copied, the element is copied and automatically renamed, adding in the end of the name a progressive number. To copy on e or more files or directories, it is also possible to “drag&drop”, i.e. using the touch-pad, drag the file name from the directory location to the destination one. The procedure is:

Open the destination directory in the left panel. In the left panel, search the directory containing the file and copy it. Left-click on the touch pad after placing the cursor on the file to be transferred, hold the

pushbutton (the multiple selection can be also used to move several elements at the same time –

see paragraph “Multiple selection”)

Using the touch-pad, drag the icon up to the destination directory in the left panel Release the touch-pad button.

This can be simplified by using the configuration screen in four quadrants. See the explanation of the “Quad View” command.

Delete a directory or a file 6.7

To delete a file or a directory:

Using the left panel, search the directory containing the file or the directory to delete. right-click on the touch-pad, in the left or right panel, after placing the cursor on the element

to delete.

Select “Delete” If the element to be deleted is a directory, an additional confirmation to delete the content is

required.

To delete a directory and several files at the same time:

Using the left panel, search the directory containing the file or the directory to delete. Multiple selection of file in the panel (see “Multiple selection” paragraph). Press “Delete” on the keyboard. Before deleting the selected elements, the systems requires a confirmation.

The file and the directory are permanently erased. When deleting a directory, all its content is erased (files and sub-directories).

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Change the name of a file or a directory 6.8

To change the name of a file or a directory:

Using the left panel, search the directory containing the file or the directory to rename. Right-click on the touch-pad in the right panel on the item to rename and select “Rename”.

Alternatively, select the item with the left button of the touch-pad, wait 2 seconds and select it

again.

The field containing the name of the item passes in “Editing” mode. Write the new name and

press the “Return” pushbutton on the keyboard or select another video item with the touch-pad

to confirm the new name; exit the editing and restore the original name, press “ESC” on the

keyboard.

Writing and editing a Part program 6.9

The part-programs are text files in ASCII format and can be edited with any Editor that does not change their format. The file can be defined or edited on the CNC or, offline, on a PC and then copied in the control. The Online Editor used by the CMC depends on the configuration set by the OEM using the WinNBI configuration application “NBIconfig” password-protected.

In the configuration released by Prima Electro the pre-set editor is Microsoft WordPad. For the Editor use, refer to the documentation provided by the application provider.

The edit of a par program is always done on a copy of the program. The file opened for editing is previously duplicated (the file is moved from the CNC to the PC in case the system hardware configuration has a PC dedicated to the HMI or is copied in a temporary directory in case the configuration has only one CNC module). This has two advantages:

it is possible to work on the PC HMI system in the same way as on the system having only the

CNC

allows the file editing even if it is selected for the execution (see further on)

The Program Management includes a panel for managing the temporary file in editing (see picture below).

The “Update” button applies the changes made. It is enabled only when the date/time of the file in editing are changed compared to the original, i.e. after saving the file changes done with the editor. Enabling the button, the original file is overwritten with the temporary one and the panel is closed. This command cannot be completed if the file is busy with other programs. Same thing for the program enabled for the execution. Before updating the program in execution, close it.

The button “Modify” re-opens in editing, Pressing this button the editor re-opens to edit the temporary file. The button “Clear” resets the changes made to the temporary file. Pressing this button, the temporary file is deleted and the panel closed.

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The program “Program Management” can be closed also if the panel to manage the program editing is opened. When re-opening the “Program Management”, the panel is displayed to complete the editing operations. In the panel, the button to be used by the user is blinking. Until the file has not been edited, the button “Modify” blinks, following the first edit, the button “Update” blinks. Therefore, when the “Update” button is blinking, it indicates the file has been edited form the original one.

Follow this procedure to edit a part-program:

If the file does not exist already, create it following the procedure “Creation of a new Part

Program”

In the right-panel, select the file to edit. Press “Edit” in the Toolbar. The part-program opens in editing using the configured editor. Edit the file, save it and close the editor. In the panel described above, overlapped to the Program Management, select “Update”. The file is edited and updated on the CNC.

To execute several editing sessions on the same file, i.e. to re-edit a file once closed and before the updated execution, use the “Modify” button in the panel to manage the temporary file instead of “Edit”.

Enabling a Part-Program for the execution 6.10

To execute a Part Program, it must be selected and enabled. The CNC reads the part-program from the file selected, that remains busy in reading until the command “Deactivate” is released.

To enable a part-program:

in the left panel, select the directory containing the file. in the right panel, select the file name press “Activate” in the Toolbar.

The name of the program activated and its firs lines, are displayed in the video screen of the ProcessController (if available in the selected video).

This procedure enables the program, but does not execute it. The procedure to execute the program is described in the Ch.7 “part Program Execution”.

Disabling the Part-Program selected 6.11

To disable the selected program for the execution, press “Deactivate” in the Toolbar. It is not necessary to select the file with the touch-pad to execute this operation. The CNC allows the deactivation of the program only in IDLE status.

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Program Management Configuration 6.12

The Program Management works on the configured devices. The Program Management displays in the left panel all the devices configured and allows the execution of the operations described in the previous paragraphs (also between devices). For example, it is possible to execute the copy drag&drop of a file from a CNC to another of from a PC to a CNC and vice versa. By "device" is meant an OSAI CNC or GMC, or even a PC or a Teach Pendant.

The "Add device" command is available in a drop-down menu that is displayed by clicking the “Configuration” button in the Toolbar. This command only requires the network name of the device that you want to connect. When a device has been connected, the Program Management is able to view all the relative drives configured.

NOTE:

In the panel opened by “Add Device” command the network name or the TCP/IP address of the device

must be specified adding the prefix "IP." For instance, if you want to connect an OPENcontrol CNC whose network name is "OPEN-XS_001" and whose network address is "192.168.1.26" in the device connection panel you may write either “IP.OPEN-XS_001” or “IP. 192.168.1.26”. To select a local device, i.e., the device where the Program Management is active is active you may use the prefix "IP." Please note that a device can be a PC (local or remote) making possible to use it a Part Program repository from where the programs are copied to the CNC executing them.

When the PC is the one running “Program Management” simply add to the configuration the “IP.” device

to access the configured PC logical drives (see below).

By default the Program Management connect the device selected by ProcessController. The user is not required to configure this device. The devices connected by the user with the “Add Device” command remain in the Program Management configuration on a permanent basis and are connected again each time the application is launched.

To remove a device from the configuration select the device name in the Directory Tree panel and press the “Configuration”. In the drop down menu select the “Remove Device” command. The visualization of device will be removed from the Directory Tree but the contents of the device will be unchanged.

Logical drive configuration 6.13

All drives shown for each device in the Directory Tree are directories that have been configured on the target device. The drives are simply a name assigned to a directory of the device. This is way they are called “logical drives”.

Enabling the configuration gives access to commands that make it possible to add or remove logic drives on all the devices configured. It is possible to create logical drives on each device connected by “Program Management”, also the remote one with the exception of the PC device. In the last case, for privacy reasons, to be able to create a logical drive, Program Management must run on the PC itself (see the warning below).

The “Enable Configuration” command is available in a drop-down menu that opens when you click “Configuration” button in the Toolbar.

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To access the configuration you must enter the OEM password. The predefined password of WinNBI is "OEM". The possibility to change the configuration remains active, without the need to re-enter the password, until the Program Management is closed.

6.13.1 Adding a logical drive

The command "Add logical drive” is available in the drop-down menu that is opened by clicking the “Configuration” button in the Toolbar, when a device is select in the Directory Tree.

In the panel that opens activating the command, you must enter the logic name of the drive (which users will see in the Directory Tree) and the absolute route of the directory to be associated with the drive. The route must be valid for the device referred to. For example, "\SSD\USER\PROGRAMS" could be a valid route for OPENcontrol while “C:\PartPrograms” could be the valid route for a PC. The specified directory must exist on the selected device.

The configuration resides in the (local or remote) selected device that is being configured, and is read by the Program Management when activated, and therefore the logical drives added to the configuration of a device are visible in the network by all the other admissible OSAI devices.

For data security purposes, it is NOT possible to configure a drive on a remote PC. The drives that you want to configure on a PC must be configured by launching the Program Management (or the “FileBrowser” WinNBI application) residing in the PC itself. In other words, only a user authorized to work on a PC may decide which directories, if any, will be visible to the other network devices.

6.13.2 Removing a logical drive

This "Remove logical drive” command becomes available only when the configuration has been enabled with the "Enable configuration" command. The command is in the drop-down menu that is opened by clicking the Configuration button in the Toolbar when a drive is selected. Upon being confirmed, this drive is removed from the Directory View and from the configuration. All drive contents on the target device will remain unchanged.

6.13.3 Showing logical drive path

The “Show logical drive path” command displays the physical path configured for a logical drive. This command becomes available only when the configuration has been enabled and when a drive is selected in the Directory View panel.

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Four Windows Display (Quad View) 6.14

Using the “Quad View” command available in the list that appears when clicking “Command” in the Toolbar, , you switch the display mode to the Quad View:

The two additional windows that appear have the same content of the previous windows. For instance, the windows simplify the files drag&drop operations from a directory to another. For example, to execute this operation select, in the upper panel, the origin directory and in the lower panel the destination directory.

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7. Part Program execution

Prior to executing a part program, it is possible to see a series of parameters that affect the execution mode and enable/disable controls, visualisations and special operations. These parameters are available in two data-entry windows, the “Program Setup” data-entry, enabled

by sending the softkey command “Setup”-“Program”

and the “Axes Setup” data-entry, enabled by sending the softkey command “Setup”-“Axes”.

For the data-entry description, refer to Ch. 3 “ User Interface”.

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Part program execution 7.1

There are two part program execution modes:

Auto Semi auto (block by block)

In order to execute a part program it is necessary to:

1. Select and activate the part program

2. Select the execution mode

3. Launch execution.

7.1.1 Selecting and activating a part program

These operations must be carried out before selecting the execution mode. The procedure is as follows:

Press the Part Program softkey and select the command “Activate Part Program” or “Part

Program Management”.

Select a part program for execution as described in Ch. 6. The name of the program selected and the first lines to follow are displayed on the screen.

7.1.2 Automatic execution

This mode permits to execute all the blocks in a program without interruptions. To execute the program in auto mode, use this procedure (for details on the operation see Ch. 3):

Select and activate the part program Select the AUTO mode. The selection is displayed on the screen. Press the Cycle Start pushbutton.

The selected part program will be executed from the first to the last block.

7.1.3 Block-by-block execution

This mode permits to execute one part program block (program line) at time. Usually this mode is used to check if a new program is correct as, at the end of each program block, the execution is interrupted.

In order to execute a part program in the block-by-block mode, proceed as follow:

Select and activate the part program. Select the “BLK/BLK” mode. The selection is displayed on the screen. Press “Cycle Start” each time you want to execute a block. Blocks will be executed in the same

sequence in which they are programmed. After executing a block the system stops until the

operator gives another Cycle Start command.

To alter the sequence of block execution or bypass one or several blocks, use the arrow keys to position the cursor to the desired block. To close block-by-block execution, select another operating mode.

If BLK/BLK is pressed during the part program automatic execution, the system executes all the blocks already analysed by the CNC and then stops. To resume part program execution in block-by-block mode, press “Cycle Start”.

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7.1.4 Multiblock retrace

This function permits to retrace a series of programmed blocks by moving the axes backwards along the executed profile. Depending on the parameter configured in AMP, the number of retraceable blocks varies from 1 through 64.

The procedure is as follows: Press the “Cycle Stop” pushbutton to stop the axes

1. Using the “Setup” – “Multi Block Retrace” softkey command, open the “Block Retrace” data-

entry window.

2. Enable the item “Enable Block Retrace” and confirm.

3. Press the “Cycle Start” pushbutton. The axes will move backwards in the selected mode In BLK/BLK mode the profile will be retraced one block at a time each time the “Cycle

Start” pushbutton is pressed.

In AUTO mode the system will retrace the last n blocks in the profile. n is the number of

blocks configured in AMP.

4. When the retrace move is completed the message “End of multi block retrace” appears.

In order to stop a backwards move, press “Cycle Stop” pushbutton. Now you can backwards move can be

restored or the movement direction can be inverted. In the first case, press “Cycle Start” pushbutton.

In the second case:

Using the softkey command “Setup” – “Multi Block Retrace”, open the “Block Retrace” data-

entry.

Enable “Emit Auxiliary Func.”, if during the Block Retrace execution the auxiliary functions

have to be released, stop it. If not, press “OK” and confirm.

Press the “Cycle Start” button. The axes will move in the mode selected at the previous step.

NOTE:

During part program execution in AUTO mode the “Block Retrace” function can be performed in

BLK/BLK mode. Part program execution will be resumed automatically when the profile has been retraced and the axes have returned to their stop point.

When the “Block Retrace” function is active the axes move in point-to-point mode (G29) in the

backwords retrace, while in the forwards trace they are executed according to the programmed modality (G27,G28,G29).

In “Block Retrace” mode, the control unit performs the motion blocks only and, on request, the

emission of auxiliary functions; assignment blocks are ignored.

The emission of auxiliary functions during the “Block Retrace” forward move can also be

enabled by assigning the MBA process variable.

 MBA = 1, emission is enabled  MBA = 0, emission is disabled

When the “Block Retrace” function is active the feedrate can be altered with the Feedrate

Override function (see later in this chapter).

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Executing blocks from the keyboard 7.2

The system permits to execute blocks entered from keyboard (MDI) both when a part program is active and when no part program is selected.

7.2.1 MDI execution without an active part program

The procedure is as follow:

1. Select the MDI mode. On the screen appears an input window to write the block to execute:

2. Write the block to be executed in the data entry window

3. Press “Confirm” to confirm the input block. As the block is confirmed, the MDI line displayed in

the data entry window will turn green. The list of the last commands previously confirmed can be displayed and reused pressing the right arrow of the input field.

4. Press “Cycle Start” to execute the inserted block.

For th introduction of another block, repeat steps 3 and 4. To reset the MDI mode, select another operative mode.

7.2.2 MDI execution with an active part program

While the system is executing a part program it is possible to execute blocks in MDI mode. The input block does not affect the active part program and is not retained in the system memory.

To execute a block in MDI mode use this procedure:

1. Select the MDI operative mode. This operation stops the part program execution after executing

all the pre-analysed blocks, if the program has not been stopped with the BLK/BLK softkey.

2. Write the block to be executed in the data entry window and press “Confirm” to confirm it.

3. Press “Cycle Start” to execute the confirmed block.

To input other blocks for execution repeat steps 2 and 3.

To restore part program execution select the “Automatic” operative mode or “BLK/BLK” and press the “Cycle Start” pushbutton. The program will restart from the interruption.

If MDI is pressed during automatic execution, the system executes all the pre-analysed blocks and then stops.

Execution of paramacros in MDI mode

This function makes it possible to run in MDI mode the paramacros called implicitly by the S,T,M, auxiliary functions, which must have been configured beforehand as paramacros. For information on how to program these functions as paramacros, see the Programming Manual.

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To run a paramacro in MDI mode, proceed as follows:

1. Activate the auxiliary function in MDI mode, as described in points 1 and 2 of the previous

paragraph. This displays the name of the corresponding paramacro in the list of active programs.

2. Deactivate the MDI mode by pressing the MDI softkey again.

3. Press the [CYCLE START] button to execute the paramacro.

At the end of the execution, the paramacro is closed and the system returns to MDI mode.

NOTE:

If you try to activate the same paramacro several times, the error message “programme already selected” (error 149) appears.

7.2.3 Executing part of a part program

The partial execution of a part program is the execution of the instructions between two defined blocks. When part program blocks are numbered the system can execute the part of program delimited by two block numbers.

The procedure is as follows:

1. Select and activate the part program.

2. Open the data-entry using the “Part Program” – “Exec From To” softkey command

3. Insert the starting block number, the label or the number of the file line where starting the

execution

4. Select and fill in the fields (block number, label, number of the file line or $BRK instruction) of

the conditions determining program stop execution.

5. Press “OK” to confirm data

6. Press “Cycle Start” to start executing the part of the program delimited by the specified blocks.

Modifying blocks in BLK/BLK mode 7.3

Part program blocks can be altered and executed from the keyboard. These alterations do not affect the original programmed block and are not saved in the active program. To modify a programmed block use this procedure:

1. Select the BLK/BLK operative mode

2. Execute the program up to the block to be edited.

3. Select the MDI mode.

4. In the input window, press the “Modify” pushbutton to move the program block on the data

entry window.

5. Edit the block displayed in the data entry window and press “Enter” to confirm the

modifications.

6. To execute the modified block press “Cycle Start”.

7. To quit the Block Modify select an operative mode different from MDI.

NOTE:

This procedure is not applicable when tool offset is active (G41, G42).

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Strings search 7.4

The following procedure permits to search for a string of characters in an active program.

1. Open the data-entry “Text Search” using the “Part Program” – “String Search” softkey

command

2. Insert in the input field the text to search

3. Press the “UP” button to start the search backwards. Press the “DOWN” button to start the

When the search is completed, if one block contains the text required, it is displayed backwards on the screen. If the string is not found after searching in a given direction, one of the following error messages appears: "End of File" or "Beginning of File".

Feedrate Override 7.5

The feedrate value to be used in the program is specified by the F value parameter. To alter this value without modifying the program use this procedure:

1. Use the mouse to activate on the screen the button to select the overrides and select FRO (Feed

Rate Override).

2. Using the buttons “+” and “-“ on the right, increase or decrease the present override value.

Each time one of the two button is pressed, the override percentage has a 1,25% increase/decrease. The allowed override has a range from 0% to 125% of the value configured, unless it has been programmed the maximum feed configures. In this case, the override has a range from 0% to 100%.

Example:

If the programmed feedrate value is 2000 MMPM (mm per minute) and a 50% variation is applied, the actual feedrate will be 1000 MMPM.

Spindle feedrate override 7.6

The procedure to change the spindle feedrate, programmed in the part program in execution with the “S value” operator is:

1. Use the mouse to activate on the screen the button to select the overrides and select SRO

(Spindle Speed Override).

2. Using the buttons “+” and “-“ on the right, increase or decrease the present override value.

Each time one of the two button is pressed, the override percentage has a 1,25% increase/decrease. The spindle override percentage has a range from 50% to 150% of the programmed value.

Example:

If the programmed spindle feedrate is 1500 RPM (round per minute) and you select a 50% override, the real spindle feedrate will be 750 RPM.

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Rapid Feedrate Override 7.7

The procedure to change the rapid feedrate configured in AMP is:

1. Use the mouse to activate on the screen the button to select the overrides and select RAP (RAPid

override).

2. Using the buttons “+” and “-“ on the right, increase or decrease the present override value.

Each time one of the two button is pressed, the override percentage has a 1,25% increase/decrease. The rapid feedrate override has a range from 0% to 125% of the programmed value.

Example: If the programmed rapid feedrate is 1500 3000 MMPM (millimetres per minute) and you select a 50% override, the real spindle feedrate will be 1500 MMPM.

Execution in Dry Run mode 7.8

In Dry Run mode, it is possible to try to execute a part program without any command being sent to the drives of the axes or to the machine logic (I/O inhibited). This feature is activated by pressing the “Setup” softkey and then “Dry Run”. With Dry Run active, it is also possible to verify program correctness graphically by way of the WinNBI Machine Plot utility. For further details about use of Machine Plot, see Ch.11.

When “Dry Run” is active, the block reading speed is inversely proportional to the values selected for FRO and RAP. The higher is the percentage, the slower is the block read rate. Maximum block read rate is equivalent to 0%.

Memory Search 7.9

Memory searching means searching for the interruption block and subsequently resume the interrupted cycle automatically or searching for a pre-set block where to start machining. The parameters which identify univocal an executing cycle are stored and continuously updated during the execution of the program. According to these parameters it is possible to carry out an automatic searching.

Memory searching can be accomplished in two ways:

Automatic memory search for the interruption block (due to switch-off or reset of the

machine)

Memory search for a pre-set block.

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7.9.1 Automatic Search

To search automatically for the block which interrupted the part program, proceed as follows:

1. Select the part program in which machining was interrupted.

2. Set “Automatic” operative mode

3. Select the “Setup” softkey and then “Search in memory”: the system starts searching. The

screen displays the reverse MemS flag.

4. Press “Cycle Start”: the system runs the searching and in the end the message NC156 end of

search in memory and the programmed dimensions of the axes position for the cycle reset are displayed. The block of the part program which will be executed at the end of the search, when the program is restarted, is displayed on reverse image. By switching to BLK/BLK and pressing “Cycle Start”, the search can be continued to the desired block.

5. Select again the softkey “Setup” and then “Search in memory” to exit the status of the stored

search.

The system is now ready to restart the working cycle.

7.9.2 Search for a pre-set block

To search for a Nxxxx block of a part program proceed as follows:

1. Select the part program

2. Set automatic mode

3. Select the “Setup” softkey and then “Search in memory”: the system starts searching. The

screen displays the reverse MemS flag.

4. Select the “Part Program” softkey and then “Exec From To”, set the starting and the finishing

blocks for the memory searching in the data entry. The starting block can also be omitted (by default part program starts with the first block); the finishing block stands for the previous block from which you want to restart the cycle. The searching blocks cannot be included in a subprogram

5. Press “Cycle Start”: the system runs the searching and in the end the message NC 156 End of

search in memory and the programmed dimensions for the position of the cycle reset are displayed. The block of the part program which will be executed at the end of the search, when the program is restarted, is displayed on reverse image. By switching to BLK/BLK and pressing “Cycle Start”, the search can be continued to the desired block.

6. Select again the “Setup” softkey and then “Search in memory” to exit the search memory

status. on the scree the flag MemS turns off.

Before exiting the search status, it is possible to continue the searching up to another block resetting the number by means of the “Exec From To” softkey and pressing “Cycle Start” again.

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Restart a working cycle 7.10

After exiting the MEMORY SEARCH mode to restart the working cycle, proceed as follows:

1. Press “Cycle Start”: the system send auxiliary functions to the machine logic and enters HOLD

status. Auxiliary functions are sent also in SEARCHING mode provided that the logic has been adequately pre-set.

2. Position axes on the programmed dimensions reversing on the profile (JOG RETURN softkey,

MANUAL mode).

3. Select again automatic or semiautomatic mode.

4. Press the button “Cycle Stop” to exit from HOLD status.

5. Press “Cycle Start “to restore the working cycle.

Searching Mode 7.11

When using multiprocess systems, memory searching can be accomplished on the first 4

processes only.

When an interrupted cycle is restored automatically, the program is restarted from the

beginning of the block where the interruption took place. When a cycle is restored from a preset block, it is restarted from the block next to the one searched.

Automatically resuming the search, if the position of the start of the search is changed, for

example, switching to BLK/BLK and using the arrow keys or setting the starting block only in the data entry “Exec From To”, the search starts from the new position and ends when the system has executed the number of blocks stored throughout the machining phase. The same thing happens when a search is carried out for a set block if the end block is not specified.

Automatic searching is only possible provided the relevant configuration (AMP) is enabled. It can

only be used when machining is executed at the beginning of the part program. Similarly, if during a working cycle MDI-blocks are executed, memory searching subsequently run on that part program would not work.

When machine is switched off, modified data-entry from “Program Set Up” or from other data

entries are erased.

When searching, variable allocation blocks are always executed.

Searching is not operating properly when part program makes use of variables written or read

from logic or from other environment.

Following are listed the strings that can and cannot be used within a part program in order to

execute a memory searching:

The following strings are accepted in searching mode:

DAN, IPB, UAO, UTO, UIO, SOL, DPA, PAE, PAD, MIR, ROT, SCF, AXO, LOA, RPT, ERP, CLS, PTH, EPP, EPB, GTO, IF, ELSE, ENDIF, GDV, RDV, UGS, CGS, DGS, DIS, DSB, GTA, ECM, PRO, PVS, GTP, CCP, SPA, SPF, SPP, CLP, TGL, OPN, WRT, REA, CLO, DEL, INS, PRO, RTP, ROP, GPS, PLS.

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The following string is accepted but non-executed in searching mode:

DLY.

The following strings are not accepted in searching mode:

RQO, RQT, RQP, TOU, DPP, UDA, SDA, UPR, UVP, UVC, TCP, REL, WOS, SND, WAI, EXE, DCC, FIL, SOP, GET, PUT, SCL, EPS, CON, COF, HON, HOF, RES, SMD, SAX, DIR, JOG, FHO, UVA,

Besides the following tracing cycles are not accepted: G72, G73, G74.

Block reading speed is inversely proportional to the values selected for FRO and RAP. The 0%

corresponds to the maximum block reading feed.

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8. Using Tables

The system manages several groups of parameters which, if they were not structured in an organised way, would be difficult to manage. These parameters have been arranged into a number of tables. These tables are:

Origins Tools Tool Offsets User

In the CNC OPENcontrol system, the tables are stored in a dual port memory, accessible directly from the machine logic (WinPLUS) or by the ISO user program. The tables are saved even after the system has been turned off.

Each of these tables is described later in this chapter. The tables are managed by the Table Editor, allowing both the tables stored in the dual port memory and the tables stored on the hard disk to be changed. Here are some of the editing operations available with the Table Editor:

Table uploading, opening and saving Modification of table data Incremental modifications to table fields Measure unit conversion (mm/inch) Backup and restore of the tables or all of the CNC memory

This manual describes the standard table configuration. The table structure can be modified by the OEM (amount of data, name and position of the fields) and can then appear to the end user in a manner different from the standard: in that case the OEM should describe the table functions.

Enabling Table Editor 8.1

To enable the Table Editor, just press the button in the icons bar

or select UTILITY and then TABLE EDITOR from the Tool Bar. At this point you will see the following window.

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The upper section displays the following information:

name of the connected CNC selected table (TOOL, OFFSET, ORIGIN, USER) working area (CNC memory or file on PC) unit of measurement (mm or inch) selected process

The following commands are available in the upper bar:

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FILE

Table Builder

This command allows you to access the Table Builder that is described in the next chapter. This ambient is reserved for the OEM, therefore it is password protected. Using this tool, the tables can be customised, i.e. configuring which tables and fields are displayed to the end user. It also configuration of up to 16 customised tables, where each field has a custom label. Finally, the graphical representation, i.e. the field positions can be customised, the text alignment, the dependence of the selected measurement units, etc.

Save

This command is only available when working on files. It allows the changes made to the data in the file to be saved to the file.

Save As

After making changes to a file, using this command the changes can be saved to a file with a different name. If working with the CNC memory, by using this command the data can be saved from the CNC memory to a file.

Update Memory

With this command data can be copied from a file to the corresponding table in the CNC memory: this is the reverse command to “Save As”.

Backup Memory

This command allows the entire area data of the tables (tool, offset, origin, user) to be saved from the CNC memory to a single file.

Restore Memory

This command allows all the data relating to the data area (tool, offset, origin, and user) to be copied from a file to the memory of the CNC. This is the reverse command to “Backup Memory”

Work on Memory

Allows the memory of the selected CNC to be modified. This is possible only with a connected CNC. Any change made is immediately active on the CNC and will affect its operation.

Work on File

Allows a file to be modified, therefore the changes made do not affect the CNC functioning. With this tool it is possible to prepare data files relating to the tools and to the origin without being connected to a CNC.

Command unavailable. Exit

Exit from Table Editor.

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SELECT

CNC

This command defines the CNC name with which the Table Editor will communicate. This setting is stored when the Table Editor is exited and the connection with the selected CNC is automatically restored following the next reboot of the Table Editor.

Process

This command defines the process number with which the Table Editor is associated. This is effective only when the Table origins change: because, the Tool, Offset and User tables apply to all processes while the Origins are specific to each process.

Project

This command allows a “project” created with the Table

Builder to be opened and changed and saved. Therefore, this is a command reserved for the OEM.

TABLES

Tool

If the “Work on Memory” mode is selected, this command

allows the tools table to be changed directly in the CNC working memory.

If the “Work on File” mode is selected, the name of the tools

data file to be edited is required.

Offset

If the “Work on Memory” mode is selected, this command

allows the tool offset tables to be changed directly in the CNC working memory.

If the “Work on File” mode is selected, the name of the tool

offsets data file to be edited is required.

Origin

If the “Work on Memory” mode is selected, this command

allows the origins tables to be changed directly in the CNC working memory. It should be noted that the origins are specific to each process.

If the “Work on File” mode is selected, the name of the

origins data file to be edited is required.

User

If the “Work on Memory” mode is selected, this command

allows the user tables to be changed directly in the CNC working memory.

If the “Work on File” file, the name of the user data file to

be edited is required.

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SELECT MAGAZINE

All

1..10

Selects the magazine to which the Tools Table applies (optional). Unavailable command.

OPTION

Edit Increment

This command allows definition of a value that will be added or subtracted from the value of the selected field in the table for each press of the button

Help

Enables the Table Editor on-line help

About Table Editor

Using this command displays the Table Editor release version.

Some of the commands described above can be accessed directly from the Tool Bar, as outlined in the following figures:

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