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MANUALSThe CNC-7's ButtonsThis chapter contains explanations of the different buttons used on the CNC-7. Each button description includes a description of its function, which pages it is present on, any special circumstances, and the equivalent keyboard command, if any. Please note that the button descriptions refer to the updated screen format beginning with Rev 3.4. If your system is configured for the original screen format, the button's name, location or functionality may differ somewhat from the description. In cases where there is a significant difference (e.g. the button is located on a different page), a brief "ORIGINAL SCREEN" description is included. CNC-7 buttons can be used to operate the vast majority of the machine's functions under normal circumstances. There are several types of buttons, and those are described here. CNC-7 buttons cause the system's beeper to beep when they are pressed. This gives feedback to the operator so he knows if the system has responded to his touch. Many buttons are used to move you from one display to another. These are blue in color, and in themselves, cause no action. They will simply take you to another display, or perhaps cause a pop-up window to appear which will give you certain information summaries. Some buttons are used to set parameters. For example, adjusting the table feedrate. These buttons do not cause any action in themselves, but cause parameters to be set up that may affect future operations. These buttons are yellow in color. Some of the yellow buttons are used to cause a value to change continuously while touched. An example of this would be the table feedrate buttons. As you touch these buttons, the value affected changes continuously until you let go, or it reaches its limit. Orange is used to designate buttons which cause direct action, or significantly affect important data. Examples of these buttons would be manual drill strokes, selecting the part program, doing a manual toolchange, or resetting tool data. Start, Stop, and Reset buttons are given the colors green and red, which are traditional for these type of actions. In addition, the Quit function, available on many pop-up windows, is also red. Several buttons cause a system switch to be toggled. For example, turning Single Cycle, Automatic Toolchange, or No Drill modes on and off. The text of these buttons change color when the switch changes state, in order to give the visual impression that the button is "lit up" when the switch is in the ON positon. For example, the Single Cycle button's text is displayed in white when single cycle mode is ON. When the button is touched, the switch moves to the OFF position, and the text changes to Black. Some buttons are used in a spreadsheet form, where a title (in blue) indicates what the value is. The button itself is white on black. The value in the center of the button itself is what is affected by the button. Touching the button will cause the 10-key pad to come up so that you can input a new value. Often, buttons are presence tested against some condition. For example, before the machine has been homed, or while the machine is running, the park button will be blanked. This removes from the screen many actions which cannot be performed at a particular time. When it is OK to use the button, the button will reappear on the screen. Basic CNC-7 buttonsThis section describes buttons which are the basic functions you, as an operator, need to know in order to be able to operate the machine in its simplest manner. These basic buttons include Selecting a program, Start, Stop/Reset, and Manual Toolchange. The Start button is available only from the Front Page and Manual Operations pages, in the lower left-hand corner of the screen. The Stop/Reset button is available from most pages, located in general in the lower right-hand corner of the screen. These buttons have retained their traditional colors (green for Start, and Red for Stop/reset) so that they can be quickly identified by the operator. Machine worktable movement buttonsThe buttons described in this section are used to move the worktable. Several of the buttons are located on the Manual Operations page, but others, such as the PARK XY button, are also located on the Front Page. Setting up the Coordinate SystemThe buttons described in this section are used to set up the work zero, axis orientation (version) and measurement mode (inch/metric) to be used during drilling. These functions can also be used from keyboard commands in many cases, and the keyboard commands can be placed in M48 headers of part programs. Each of these functions may be accessed from the Machine Setup page. Setting up the SpindlesThe buttons described in this section affect the spindles. There are buttons on how to select and deselect spindles, to raise and lower the spindles, enable or disable Quick Drill mode, and to adjust the limits of the drill stroke. Other related functions are also described here, such as manual drill strokes, No Drill and Single Cycle modes. Most of the spindle setup functions are available from the Machine Setup or Manual Operations pages. The Single Cycle button is available on the Front Page. Setting up Tool DataThe buttons described in this section are used to input, alter, and control tool data. Many of the buttons are available from the Tool and Router page. This page is available through the Tool Data Setup button located on the Machine Setup page, or through the keyboard command TP. The Diameter Page popup display described in this section is available from the Machine Setup page. Setting up the TMS systemThis section describes the buttons available to help you set up the TMS system. Most of these buttons are available from the TMS Setup page, which is accessed from the TMS Function button located on the Machine Setup page. These functions give you complete control over the layout and use of your TMS system. Setting up the Tool Status IndicatorsThis section describes the Tool Status Indicator buttons available from the Front page and the Machine Setup page. These functions give you the flexibility to control the TSI system (if your machine is so equipped), generate broken tool reports, and create recovery part programs to inspect and redrill holes where tool breakage occured. TSI Setup Menu
TSIPOP
The TSI button located on the Machine Setup page, displays the Tool Status Indicator (TSI) Setup menu. The popup menu provides you access to several TSI setup functions. The functions available in the menu vary depending on the tool detector hardware installed on the machine. For microwave detector equipped machines, the menu will automatically appear when the machine detects a broken tool, to provide the operator with instant access to microwave related functions. Included in the menu are the following items. See related sections of the CNC-7 User Reference manual for further details regarding each function.
tsivfyTSI Tool Tip Verification
This section describes the TSI Tool Tip Verification feature. TSI Verification is provided as a supplement to the Laser Tool Detector to assist in the identification and recovery of erroneous broken tool indications due to clogged tools. The verification system utilizes the depth control pod to verify the tool length whenever the LTC system detects a broken tool. TSI verification works by comparing the present length of a tool (detected as broken by the LTC system), against the length of the tool when it was known to be good. The tool length is initially obtained by doing a tool tip check following the tool change. (When the machine is operated in depth control or controlled penetration mode, this check is transparent since the machine checks the tool length anyway.) If the LTC system also detects the tool as good before drilling the first hole, the tool is considered to be good. If the tool is subsequently detected as broken by the LTC system, the machine performs a tool length check using the depth control pod. The tool is considered good if the length is basically the same as it was when it was originally picked up. If the tool length is found to be short (broken), the machine handles the broken tool based on the selected tool recovery mode. If the initial tool length check indicates a good tool, two counters are provided giving you the option of having the machine drill some number of additional holes before it considers the tool to actually be defective. This gives the tool the opportunity to clear itself of any debris that may be interfering with the LTC system. If the tool clears itself within the number of holes specified by the 'Max-Holes' count, a message is logged to the STATS file and the machine continues drilling. The tool must then remain clear for the number of holes specified by the 'Clean Holes' count. If the tool does NOT clear within the number of holes specified by the 'Max-Holes' count, or if after clearing the tool is again detected as broken within the number of holes specified by the 'Clean Holes' count, the machine performs a final length check on the tool, then handles the broken tool based on the selected tool recovery mode. The Tool Verification system may display one or more of the following messages. Each message is displayed on the CNC-7 screen and logged in the STATS file unless otherwise noted. The number preceding the message is the message ID number which may be used to locate the message in the STATS file.
TSI Tool Tip Verification Menu
TSIVPG
The TSI Tool Tip Verification Menu provides buttons allowing you to setup and enable the TSI Verification system. Included on the menu are the following items. See related sections of the CNC-7 User Reference manual for further details regarding each function. TSI Verify On/Off
TSIV,on/off
This function enables/disables the TSI Tool Tip Verification system. When enabled, the verification system utilizes the depth control pod to verify the tool length whenever the LTC system detects a broken tool. A button for toggling the verification feature on/off is located on the TSI Verification menu. A button to display the menu is located on the TSI Setup window, which may be displayed by touching the TSI button located on the Machine Setup page. TSI Verification Maximum Hole Count
TSIV-HOLES,#
Allows you to specify a maximum number of holes to drill if the LTC system detects a broken tool but the tool length check indicates the tool is good. Specifying a Max-holes count gives the tool the opportunity to clear itself of any debris that may be interfering with the LTC system. If the tool clears itself within the specified number of holes, a message is logged to the STATS file and the machine continues drilling. If the tool does NOT clear within the specified number of holes, the machine performs a final length check on the tool, then handles the broken tool based on the selected tool recovery mode. A Max-holes count of zero (the default setting) causes the machine to perform a tool length check if the LTC system detects a broken tool, but does not drill any additional holes. This may be used to distinguish between broken tool indications due to clogged tools and actual broken tool occurrences. A button to set the maximum hole count is located on the TSI Verification menu. A button to display the menu is located on the TSI Setup window, which may be displayed by touching the TSI button located on the Machine Setup page. TSI Verification 'Clean Holes' Count
TSIV-CLEAN,#
Used in conjunction with the 'Max-holes' count, the 'Clean Holes' count specifies a minimum number of holes the tool must drill after clearing before it is considered to be defect free. If the tool is again detected as broken before drilling the specified number of 'Clean Holes', the machine will perform a final length check of the tool, then handle the broken tool based on the selected tool recovery mode. Specifying a 'Clean Holes' count reduces the likelihood of a situation where a tool is continuously clogging then unclogging every few holes, causing the machine to perform a large number of tool length checks. A button to set the 'Clean Holes' count is located on the TSI Verification menu. A button to display the menu is located on the TSI Setup window, which may be displayed by touching the TSI button located on the Machine Setup page. TSI Verification Tolerance
TSIV-TOL,#
Used to specify a maximum tool length variation. A tool is considered broken if a tool length check determines the tool is shorter than the previous tool length check by an amount greater than the tolerance. The tolerance should be set to a value large enough to accommodate the normal variations in tool length readings due to changes in spindle temperature, etc. The default tolerance is set to .010 inches (.254 mm). There is normally no need to change the default setting. A button to set the tolerance is located on the TSI Verification menu. A button to display the menu is located on the TSI Setup window, which may be displayed by touching the TSI button located on the Machine Setup page. dpcontSetting up Depth ControlThis section describes buttons which allow you to operate the Depth Control features of your machine (if so equipped). Most of these buttons are located on the Depth Control Setup page, which may be accessed from the Depth Control (DC) Function button located on the Machine Setup page. Some other functions, such as declaring depths of individual tools, are described in the Tool Data section. The functions described in this section allow you to control Depth Control modes, which tools are Depth Controlled, plus applying offsets and allowing you to command tool checks. Setting up TMGThis section describes buttons which allow you to operate the TMG features of your machine (if so equipped). These buttons are located on the Machine Setup page. The functions described in this section allow you to control which tools are diameter and runout checked, and the machine sequence to be followed if a tool fails the diameter or runout check. peckingSetting up PeckingThis section describes the CNC-7's pecking functions. Pecking on the CNC-7 is easy and quick to set up, due to its spreadsheet layout and graphic feedback. Most of the buttons described in this section are available from the Peck Drilling Setup page, which may be accessed by touching the Pecking Setup button located on the Miscellaneous Tool Setup popup menu. To display the Tool Setup menu, touch the box displaying the current pecking on/off status located near the center of the Machine Setup page. Please note that the Pecking depths displayed here in most cases will include the Z-axis depth offset if one is being used. For example, if the stack height is 0.300 and the Lower Limit is 0.180, the total depth of all pecks will be 0.120. However, if a Z-axis depth offset of 0.020 is used, the total depth will be 0.100. This is reflected in all Pecking depth displays, inputs, and calculations. For a description of pecking keyboard commands, please refer to the Pecking Related Keyboard commands section of the Keyboard commands chapter. Miscellaneous functionsThe buttons described in this section are typically setup for a particular shop. These are special functions which may or may not be of benefit to you, depending on how you run your shop. Skipping holesThis section describes buttons and functions used to skip holes, patterns, and tools within a job. All of these functions are available from the Skip page, which is accessible from the machine front page. Menu button
The Menu button is available on all pages. It is used to take you from any screen to a special screen which allows you to access all other screens. The Menu button is located at the lower right-hand corner of the screen, next to the HELP button. Pushing this button will allow you to go to the Menu screen, which then allows you to go directly to the screen you select. Start button
The START button is used to start a program or to restart a program or toolchange after it has been paused by a machine sensor (like low air), a Stop button, or Single Cycle. The START button is located on the CNC-7 Front Page and Manual Operations pages in the lower left hand corner. Under certain conditions, the START button may not be available and will be displayed in grey background. For example, if the machine is not ready because it has not been homed, or if some other sensor is triggered (like low air). In any of these cases, messages explaining the problem will be displayed in the Job Status or Machine Status areas. While the machine is running, the Job status on the Front Page will typically read "Program in progress", and the Program Completion bar (across the top of the screen) will change from all grey to all yellow as the machine runs. All grey indicates the program has not run at all; all yellow indicates that the program is 100 percent complete. If the machine is equipped with the Autoload option, the following conditions will cause the START button to be ignored in addition to the conditions described above: Stop/Reset button
The STOP/RESET button is used to halt a part program or toolchange in progress. While the machine is active, this button displays as a STOP button. When the machine is inactive, it displays as a RESET button. If you wish to abort a program, you must press the button once to stop the machine, and then again to abort the program. The page will re-display after hitting the reset button. If the STOP button is pressed while the table is moving, and you are more than about 0.5 inch (12 mm) from your target position, the machine will be stopped in the middle of its move. When you restart the machine (with the START button), the machine will continue the move to the target position. If the RESET button is pressed while the table is moving, the move will be terminated immediately, and the involved function is aborted. Panic Panel
The Panic Panel is used to give you FAST access to START and STOP buttons in the event that you have entered a keyboard operation (like the Editor) and do not have the normal touchscreen control buttons available. While within the editor (for example), touch the screen in ANY location, and the Panic Panel will appear as a popup. This popup displays three buttons: a large STOP button, and smaller START and QUIT buttons. This popup overlays the main screen activity, and would allow you to start or stop the machine without needing to leave the editor. In fact, the main screen activity continues to operate behind the popup, even though the popup obscures part of the screen. The STOP button can be used to stop the machine quickly, and is quite large, giving you a big target to touch. The START button can be used to restart the machine after you've dealt with whatever caused you to stop it in the first place. The QUIT button exits the popup (not the main screen activity), which removes the popup from the screen so you can go back to what you were doing. Park XY button
PARK
The PARK XY button is used to take the worktable to a predefined park position. Typically there are three of these: left, center, and right in the front of the machine. Pressing the PARK XY button displays the XY Park popup Menu. The present worktable position is displayed near the top of the menu. Press the Left, Middle or Right park position button to park the worktable at the desired position. The spindles will automatically raise and turn off, then the table will move to the commanded position. The button will blink as the worktable moves towards the park position. Pressing the NEXT PARK POSITION button repeatedly will cause the worktable to go to each of the park positions in sequence. Pressing Reset or starting a program will cause the machine to go to center park the next time the NEXT PARK POSITION button is pressed. If the machine is already in the center park position, then the button will cause the machine to go on to the next park position in the sequence. ORIGINAL SCREEN: The PARK button behaves similar to the NEXT PARK POSITION button described above, no menu is displayed. HOME MACHINE button
The HOME MACHINE button is used to home the XY and Z axes. To use this button, turn on the servo power, and then press this button. The Z-axes will home first. After the Z-axes are successfully homed, the worktable will home and then go to the center park position. Until the machine has been homed, not much can be done. Most functions which begin actions (like commanding a toolchange) will not be available on the display or will give a message. This is because the machine does not know where it is yet. A message telling you to home the table will be displayed in the Machine Status box when the table needs to be homed. The HOME MACHINE button is initially displayed on the Front page, since it is generally one of the first functions which must be performed. After the machine has been initially homed, the button is replaced by the Park XY button. There is a HOME MACHINE button on the Manual Operations page which is permanently there, in case it becomes necessary later to home the table. If a part program is interrupted during execution, and for some unusual reason it becomes necessary to rehome the table (for example, due to a scale alarm), the HOME MACHINE button will be redisplayed on the Front page. JOG buttonsThe JOG buttons allow you to move the table in and out, and from left to right. There are four different buttons (one for each direction). These buttons are located on the Manual Operations and Skip pages. Touching the button causes the table to move in the indicated direction. Only one button may be pressed at a time. The JOG speed may be varied from 150 percent (about 150 inches per minute (63 mm/sec)) to 1 percent. A new JOG speed may be entered by touching the feedrate display located beneath the jog buttons. This will bring up the 10-key pad popup window allowing you to enter a new value. You may also use the feedrate adjust up/down arrow buttons located adjacent to the feedrate display to adjust the JOG speed. Press and hold the button down to scroll the feedrate up or down. See also: MOVES, PJOG, J, JI, JAZ, PARK Jog XY menu
JOGXYPOPUP
This button displays the Jog XY popup menu. Located on the Manual Operations and Skip pages, the JOG XY button displays a menu to provide you access to several related jog functions all in one place. Included in the menu are the following items. See related sections of the CNC-7 User Reference manual for further details regarding each function.
Jog Absolute
J,X#Y#
The Jog Absolute function is used to move the worktable to a given position relative to the work zero. The XY coordinates are in the current measurement mode and version, and tell the system which direction and how far to go. The XY coordinates are optional. You may jog only one axis by touching the red header bar at the top of the keypad when prompted for the ordinate of the axis you do not wish to move. The function is available from the Jog XY popup menu. The menu may be accessed by pressing the JOG XY button located on the Manual Operations and Skip pages. ORIGINAL SCREEN: This function available only as a Keyboard command. Incremental Jog
Jog Incremental
JI,X#Y#
The Incremental Jog function is used to move the worktable a given distance from the current position. The XY coordinates are in the current measurement mode and version, and tell the system which direction and how far to go. The function is available from the Jog XY popup menu. The menu may be accessed by pressing the JOG XY button located on the Manual Operations and Skip pages. ORIGINAL SCREEN: This function available only as a Keyboard command. Touch Point Jog button
PJOG
TOUCH POINT JOG allows you to position the table at an approximate table position without having to give thought to current version, work zero, or measurement mode. When this button is pressed, a pop-up window appears which has a black surface (representing the machine granite), with a small grey rectangle on it (representing the worktable). Touching the "granite" in another spot causes the machine worktable to move to the indicated position. The display updates as well. An empty blue rectangle indicates DPOS. When the table is in position, the grey rectangle should completely overlay the blue one. This feature is useful for gross table positioning, such as wanting to move the table to one side for access to boards or servicing. To exit TOUCH POINT JOG mode, touch the red header bar located at the top of the display. Table Feedrate adjustment buttons
The Feedrate up and Feedrate down buttons are used to adjust the table feedrate percentage. The percentage affects manual table JOGs, by varying the JOG speed between 150 percent (150 inches per minute or 63 mm/sec) and 1 percent. The Feedrate percentage also affects routing speed, allowing you to override the programmed routing speed in order to rout materials different from that for which the program was originally generated. The Feedrate Adjustment buttons are the up/down arrow buttons located beneath the worktable jog buttons on the Manual Operations and Skip pages. Press and hold the button down to scroll the feedrate up or down. A new feedrate percentage may also be entered by touching the feedrate display located between the Feedrate Adjustment buttons. This will bring up the 10-key pad popup window allowing you to enter a new value. No Drill mode button
The NO DRILL button is used to toggle between Drill and No Drill mode. Drill mode (No Drill off) allows you to do normal drill strokes from within a part program. No Drill mode disables drill strokes within a part program. This allows you, for example, to skip over some holes you do not want to drill. The NO DRILL button is available from the Front Page and Manual Operations page. The button's text and border "light up" when No Drill mode is active. No Drill mode is affected by manually raising and lowering the spindles. Raising the spindles manually automatically puts the system into No Drill mode, and lowering the spindles automatically takes the system out of No Drill mode. The NO DRILL button may be used separately, but it will not affect the position of the spindles. ORIGINAL SCREEN: The button is available on the Machine Setup and Spindle Setup pages. Single Cycle mode button
The Single Cycle button is used to toggle between automatic mode and Single Cycle mode. Automatic mode (Single Cycle off) is the default, and is used during normal drilling. Putting the machine in Single Cycle mode is generally used for stepping through a toolchange or part program as part of troubleshooting a machine or part program. The Single Cycle button is available from the Front Page. The button's text and border "light up" when Single Cycle mode is active. ORIGINAL SCREEN: The button is available on the Machine Setup and Spindle Setup pages. Quick Drill mode button
QDRL,on/off
The Quick Drill button is used to toggle between Quick Drill mode ON or OFF. Quick Drill mode is only available on machines equipped with Depth Control or some other sensing device like the secondary switch found on one spindle of a T-600 machine. When ON, Quick Drill examines the part program as the machine runs, and lowers the Upper Limit to just above the work surface, thus speeding production time. Quick Drill will restore the Upper Limit to the original position when the program commands a move close to the edge of the panel (usually within one inch), makes a long move (usually over one inch), or when the machine stops. The decision of whether or not to raise the Upper Limit is based on how much of the part program the machine "knows about" at the moment. Quick Drill variables, such as the panel border size, definition of a "long" move, and the Z-axis surface delta are provided by the VSB command QUICKDRILL. The benefit of this function is that the machine drills faster when it is in a "safe" area of the board, and is more cautious when nearing the edges where there might be tooling pins, or when the machine makes long moves, which might also imply a possible collision. Quick Drill requires no setup other than turning it on. It automatically determines the borders of the board, and automatically locates the board in Z at the first touchdown. Since Quick Drill learns the job's borders on the first run of the program, it may not be able to lower the upper limit as much on the first pass as it will on a subsequent run. The worst case of this is a program which moves back and forth along one axis while moving only one direction in the other axis (e.g.: back and forth along X while Y goes front to back). In this case, Quick Drill may not be able to lower the upper limit AT ALL during the first run. In order to improve Quick Drill's performance on the first run, you may choose to do one or both of the following: (1) You may choose to drill outer holes, such as silkscreening holes, first. This allows Quick Drill to determine the outer borders of the panel sooner. (2) You may choose to use DRYRUN to read through the program the first pass. DRYRUN will go through enough calculations to determine the outer borders of the panel. Quick Drill's performance may also be significantly improved by defining specific Non-Quick Drill zones. This allows the machine to Quick Drill at the known borders of the program except when the spindle is intruding into a Non-Quick Drill zone. Non-Quick Drill zones are established to prevent Quick Drilling around tooling features such as tooling pins and edge clamps. Non-Quick Drill zones are defined via the NO-QUICKDRILL-X and NO-QUICKDRILL-Y VSB commands. Refer to the command descriptions for additional information. NOTE: Quick Drill will not work on a particular spindle if the station's depth control pod is activated. This causes the depth control counter to be frozen, and hence stops that spindle from being able to detect the top of the stack. The result would be that Quick Drill "won't work" even though it is ON. If the machine has one digital Z axis and rocker arm (like T-600) and it is provided with a depth sensing switch installed on one spindle, that spindle must be selected for Quick Drill to be active. Otherwise, after a part-program is started a message will remind the operator of this condition and Quick Drill will just not work. Of course, a stack of panels with the same height as the other selected stations should be present on this reference station. If this is not possible and stacks of different heights need to be processed, the highest stack MUST be placed on the station that has the depth sensing switch. Also note that the lower position is relative to the top of the board, which is sensed at touchdown. So if the spindle never touches down, it will never be able to lower the upper limit. So you can't "demo" quick drill by doing dummy drill strokes in the air. When Quick Drill is ON, the Upper Limit value cannot be changed while the machine is running. The Upper Limit set by the Operator will be used as the "safe" elevation when Quick Drill decides to return to a higher elevation. The button is available from the Job Setup popup menu. The button is a toggle, and changes state each time you touch it. To display the Job Setup Menu, press the CURRENT JOB SETUP button located on the Machine Setup Page. ORIGINAL SCREEN: The button is available from the Spindle Setup page. Do A Drill Stroke button
The DO A DRILL STROKE button is used to cause a drill stroke manually from the panel. This button is only visible on the screen after the spindle are put into the down position, are brought up to speed, and there are no machine alarms (like low air). Pushing this button causes one drill stroke. The button is available from the Manual Operations page. Remember that the button may or may not be available depending on if the spindles are up to speed, table is at null, machine alarms (like low air), and so on. The button will only be available on the screen when all conditions are met, and pushing the button will immediately cause a drill stroke. ORIGINAL SCREEN: The DRILL CYCLE button is available on the Spindle Setup page. Lift Pressure Feet Up button
This button may be used to raise the pressure feet up and lower the spindles down to the drill ready position, for visual inspection. This is helpful because under these conditions the drill bits show below the pressure feet, and they are close to the work surface. Automatic Toolchange mode button
ATC,on/off
This button is used to toggle between Automatic and Manual toolchange mode. In Automatic mode, the machine will automatically change tools, putting away or picking up tools as required by the part program, max hit counters, or console. Manual toolchange mode causes the machine to park and request the next tool whenever a toolchange is required. Manual toolchange is supported on either the ATC (tool pod) or TMS (cassette) type toolchanger. A START button will be required to continue the program after a manual toolchange. The button is located on the Tool and Router page. The button's text and border "light up" when Automatic mode is selected. Turning on Extended Drilling Area (EXDA) will turn off Automatic toolchange. Turning Automatic toolchange off will turn off EXDA. However, turning EXDA off does not turn Automatic toolchange back on. Turning on Extended Drilling Area (EXDA) will turn off Diameter Check and Depth Control (if the machine is equipped with them). Turning EXDA back off will return these functions to their original state. Extended Drilling Area button
EXDA,on/off
This button turns Extended Drilling Area (EXDA) on or off. Extended Drilling Area is a mode in which you can use the area normally occupied by the toolchanger for drilling. When you turn EXDA on or off, the absolute zero of the version you are operating in is moved by the size of the toolchange area. Homing the table will be required for the machine to reference its new location. You can now use this extended area for drilling. Note that EXDA assumes that the Automatic toolchanger is deactivated. The EXTENDED DRILL AREA button is located on the Special Features page. Pressing the button toggles EXDA ON and OFF. The button's text and border "light up" when EXDA is active. Turning on Extended Drilling Area (EXDA) will turn off Automatic toolchange. Turning Automatic toolchange off will turn off EXDA. However, turning EXDA off does not turn Automatic toolchange back on. ORIGINAL SCREEN: The button is available on the Options and Switches page. Set High Upper Limit
This button raises the Upper Limit to its maximum position. This is useful at the start of a new program to be sure that the Upper Limit position clears the highest stack, and clears pins and clamps. This button is located on the Spindle Setup page, in the upper right-hand part of the display. A single touch is all it takes to raise the upper limit up. You can then use the Upper Limit Down button to lower the Upper Limit while the machine is running. Setting Upper and Lower limits
A set of four buttons, located on the Spindle Setup page, allows you to raise and lower the machine's Upper and Lower limits while the machine is running. These are located in the upper left-hand part of that screen. With any of these buttons, the adjustment begins slowly, and continues that way for the first three seconds. After that, the adjustment speed increases by a factor of four. Releasing the button, and then continuing to press it will return to the lower speed adjustment. These buttons can be disabled by the FSB command. On this screen, the number being adjusted is itself in a box. Pressing the number will allow you to make a direct entry using the 10-key pad. Raising and lowering the machine's spindles
This button is located on the Manual Operations page. The button allows you to change the position of the machine's spindles between up and stopped to down and running. The CNC-7 is set up to only have two spindle positions for drilling. The up position will allow you to manually open the spindle collet once the spindles have been brought to a complete stop. The pressure feet are lowered in this position, giving you maximum access to get your hand inside to reach the bit. Using this button to manually raise the spindle will automatically put the system into No Drill mode. In the down position, the spindles are started and brought up to speed, assuming that there is a tool in the collet. If there isn't, the machine will not take the spindles to the down position. In this position, the pressure feet are down to press against the work, and the manual collet is disabled. Using this button to manually put the spindles down will take the system out of No Drill mode and allow drilling. The NO DRILL button does not affect the position of the machine's spindles. NOTE: In a machine equipped with routing capabilities, the Upper Limit position also serves as the ROUT UP position, where the spindles retract to on an M16 or M17. The text of this button changes to tell you what the next action will be. For example, if the spindles are up, the button will be labeled something like "Turn On Spindles". When they are down, the button will be labeled something like "Raise The Spindles". Spindle Select buttons
The Spindle Select buttons are used to select and deselect the spindles currently being used by the machine for drilling and/or routing. These buttons are located on several pages including the Machine Setup and Manual Operations pages. There is one button for each spindle. Each button toggles between spindle selected and spindle deselected each time it is touched. When the station number is dark, the spindle is deselected. If the station number is displayed in white giving the button a "lit up" appearance, the spindle is selected, and will operate during the drilling operation. ORIGINAL SCREEN: The buttons are available on the Spindle Setup page. JOG Table to the Zero Corner
JAZ
This function allows you to move the worktable to the zero corner of the current version. This is useful when using certain older style part programs which zero set themselves relative to the current table position. The function is available from the Jog XY popup menu. The menu may be accessed by pressing the JOG XY button located on the Manual Operations and Skip pages. In order to use this function, the table must be homed, and the machine ready, free from any alarms (such as low air). ORIGINAL SCREEN: This function is available as a button from the Manual Table Moves page, or from the Set Work Zero page. JOG to Work Zero
J,0
This function allows you to move the machine to the current work zero position. This is useful for verifying the work zero position. The function is available from the Jog XY popup menu. The menu may be accessed by pressing the JOG XY button located on the Manual Operations and Skip pages. In order to use this function, the table must be homed, and the machine ready, free from any alarms (such as low air). ORIGINAL SCREEN: This function is available as a button from the Manual Table Moves page, or from the Set Work Zero page. Measurement Mode menu
MEASURE
The Measurement Mode popup menu allows you to select Inch or Metric measurement mode along with the coordinate zero format. A button to select Incremental or Absolute mode is also provided. The menu includes the following items. See related sections of the CNC-7 User Reference manual for further details regarding each function. Leading and Trailing zeros and zero format are discussed in more detail in the "X and Y coordinates" section of the Part Programming chapter.
Miscellaneous Coordinate Setup menu
BP1POP
The Miscellaneous Coordinate Setup popup menu provides functions allowing you to set up the coordinate system along with other miscellaneous functions. Included in the menu are the following items. See related sections of the CNC-7 User Reference manual for further details regarding each function.
Miscellaneous Tool Setup menu
BP2POP
The Miscellaneous Tool Setup popup menu provides buttons allowing you to command a tool change and also set up the CNC-7's pecking functions. Included in the menu are the following items. See related sections of the CNC-7 User Reference manual for further details regarding each function.
Work Zero Setup menu
WZPOPUP
The Work Zero Setup popup menu provides you access to several zero set functions and also displays the current work zero setting. Included in the menu are the following items. See related sections of the CNC-7 User Reference manual for further details regarding each function.
Setting Work Zero relative to Machine Zero
Z,X#Y#
This function allows you to set the work zero relative to machine zero. This allows you to put the zero of the part program anywhere, including off the table physically. This may be done from the COMMANDED ZERO button, from a keyboard command, or from part program commands, described in a separate section. The COMMANDED ZERO button and display is included in the Work Zero Setup menu. To display the menu from the Machine Setup page, touch the box containing the current work zero setting (this will display the Coordinate Setup menu), then select WORK ZERO from the menu. The Work Zero affects entered and displayed coordinates. Entering the Work Zero from the console will reset the Zero Correction values. ORIGINAL SCREEN: This button is available on the Work Zero Setup page. Setting Work Zero Correction
ZC,X#Y#
This function allows you to enter a zero correction value. This value is added to the work zero commanded by a button, keyboard command, or part program to alter the final zero, typically by a small amount. A normal use of the Zero Correction would be in drilling multilayers, where a test coupon is drilled, and then X-Rayed to check registration. A Zero Correction is then entered at the CNC-7 to compensate for tooling registration. Zero correction may be done from the ZERO CORRECTION button or from a keyboard command. Entering a Work Zero from the console will reset the Zero Correction values. The ZERO CORRECTION button and display is included in the Work Zero Setup menu. To display the menu from the Machine Setup page, touch the box containing the current work zero setting (this will display the Coordinate Setup menu), then select WORK ZERO from the menu. Like Work Zero, this value affects entered and displayed coordinates. ORIGINAL SCREEN: This button is available on the Work Zero Setup page. Setting an Auxiliary Work Zero Offset
ZA,X#Y#
This function allows you to enter an Auxiliary Work Zero offset. This value, like Zero Correction, is added to the work zero commanded by a button, keyboard command, or part program to alter the final zero. The Auxiliary Zero is only applied if the machine is running in other than an Excellon Format. It's purpose is to compensate between the Excellon machines in your shop, and the non-Excellon machines, which may have inherently different work zeros. For example, if you needed a two inch offset between programs run on your Trudril versus your MK-VI, this would be the time to use the Auxiliary Zero. Work Zero compensation between different sized Excellon machines is done through use of the False Zero, described in another section. This allows the same zero to be used on, for example, an EX-110 and a MK-VIE. Auxiliary Zero may be applied either from the AUXILIARY ZERO button, or from a keyboard command. The AUXILIARY ZERO button and display is included in the Work Zero Setup menu. To display the menu from the Machine Setup page, touch the box containing the current work zero setting (this will display the Coordinate Setup menu), then select WORK ZERO from the menu. Like Work Zero, this value affects entered and displayed coordinates. ORIGINAL SCREEN: This button is available on the Work Zero Setup page. Setting Work Zero relative to current table position
ZS,X#Y#
This function allows you to set the work zero relative to the current table position. This is useful for certain applications, including during digitizing (programming), and when running older style part programs which used an M46 and G92 combination to set work zero (format 1). Like Zero from machine zero, this function allows you to put the zero of the part program anywhere, including off the table physically. This function has the effect of setting the current table position to the entered coordinates. If, for example, you set work zero to X04Y05 using this function, the current table position would now be defined as X04Y05. This may be done from the ZERO PRESET button, from a keyboard command, or from part program commands (only in format 1), described in a separate section. The ZERO PRESET button and display is included in the Work Zero Setup menu. To display the menu from the Machine Setup page, touch the box containing the current work zero setting (this will display the Coordinate Setup menu), then select WORK ZERO from the menu. The Work Zero affects entered and displayed coordinates. Entering the Work Zero from the console will reset the Zero Correction values. ORIGINAL SCREEN: This button is available on the Work Zero Setup page. Axis Orientation version
VER,#
The Axis Orientation Version, known commonly as simply "version", determines which axis is "X", and which is "Y". It also determines which direction is positive and which direction is negative for each axis. There are eight possible version numbers, 1 through 8. The machine's movements appear to be exactly opposite if viewed from the perspective of the work piece or the work table. For example, if the work table were in the Upper Right-hand Corner of its travel, the spindles would be positioned at the Lower Left-hand corner of the work piece. The different versions are defined (from the perspective of the work piece) as follows: Inch mode
INCH,lz/tz
The INCH command puts the system into INCH measurement mode. After entering this command, all coordinates, displays, and part program values are assumed to be in inches or feet, depending on the item. The INCH command has an optional parameter, the LZ or TZ, which indicates leading or trailing zero usage. Leading and trailing zeros are discussed in more detail in the "X and Y coordinates" section of the Part Programming chapter. The LZ or TZ parameter is optional, and if not used, defaults to the last used mode, or leading zero if this is the first usage. The current measurement mode is displayed on the Machine Setup page. Buttons to select the desired measurement mode are included on the Measurement Mode popup menu. To display the menu from the Machine Setup page, touch the box displaying the current measurement mode setting (this will display the Coordinate Setup menu), then select Measurement from the menu. ORIGINAL SCREEN: This function available only as a Keyboard command. Metric mode
METRIC,lz/tz,zerofmt
The METRIC command puts the system into METRIC measurement mode. After entering this command, all coordinates, displays, and part program values are assumed to be in millimeters or meters, depending on the item. The METRIC command has two optional parameters, the LZ or TZ, which indicates leading or trailing zero usage, and the zero format. Leading and trailing zeros and zero format are discussed in more detail in the "X and Y coordinates" section of the Part Programming chapter. These parameters are optional, and if not used, default to the last used mode, or leading zero, 000.000 format if this is the first usage. The current measurement mode is displayed on the Machine Setup page. Buttons to select the desired measurement mode are included on the Measurement Mode popup menu. To display the menu from the Machine Setup page, touch the box displaying the current measurement mode setting (this will display the Coordinate Setup menu), then select Measurement from the menu. ORIGINAL SCREEN: This function available only as a Keyboard command. Incremental Input mode
ICI,on/off
The CNC-7 supports both Incremental and Absolute input modes. In Incremental mode, each coordinate is relative to the last coordinate, as if the work zero moved along with the machine as it drilled. In Absolute mode, all coordinates are typically relative to the same work zero point. Incremental mode is a leftover from early relay operated machines, but is still in use in several shops around the world. The main drawback to this mode of operation is that if it becomes necessary to edit the part program, all other coordinates beyond the one changed are also affected. Another problem with Incremental mode is that it is difficult for an operator to relate a part program block to a particular hole on the panel. For example, there might be 5000 blocks which read X001Y001. A button to switch the system between Incremental and Absolute modes is present on the Measurement Mode popup menu. To display the menu from the Machine Setup page, touch the box displaying the current measurement mode setting (this will display the Coordinate Setup menu), then select Measurement from the menu. The button toggles Incremental Off (the default) and On. ORIGINAL SCREEN: The button is available on the Options and Switches page. Tool number selection button
The CNC-7 tool page displays detailed information for one tool at a time. There are two ways of selecting which tool's information is displayed. First, there are two buttons labeled View located next to the tool number and diameter displays. Touching the up arrow button displays the next tool's data, touching the down arrow button displays the previous tool's data. Holding either of these buttons will cause the tool data to scroll through the various tool numbers. This can be used to fast advance to a particular tool number. Secondly, by touching the box containing the displayed tool number, you can directly enter the tool number for which you want the tool data displayed. These tool numbers can be between 1 and 99. All three of these buttons are located on the Tool and Router page (TP). Tool Diameter button
This button allows you to enter the diameter for the currently selected tool number. Entering diameters affects several parts of the system, which are only covered briefly here.
Entering a diameter may cause lookup of feed, speed, retract, max hit count, and Z offset if a diameter page has been selected. Entering a diameter may cause the system to resolve the specified diameter with a TMS tool group if the machine is TMS equipped, and if the TMS system is operating in mode 2. Entering a diameter enables computation of chipload and cutting speed entry and displays. Entering a diameter can affect certain NC functions, like nibbled (drilled) circles and slots.
By touching the box containing the displayed tool diameter, you can directly enter the tool diameter. The diameter entry button is located on the Tool and Router page (TP). The diameter may also be entered from the part program, or from the M48 header. Tool Infeed button
This button allows you to enter the Z-axis infeed for the currently selected tool number. This is the speed (in in/min or mm/sec) that the tool will plunge into the material, either during drill strokes or when moving to rout position. By touching the box containing the displayed tool infeed, you can directly enter the tool infeed. Infeed values must be positive, and are limited by the physical capabilities of the machine. Most machines are limited between 10 and 500 in/min. The infeed entry button is located on the Tool and Router page (TP). The infeed may also be entered from the part program, or from the M48 header. Tool Retract button
This button allows you to enter the Z-axis retract rate for the currently selected tool number. This is the speed (in in/min or mm/sec) that the tool will retract out of the material after a drill stroke. By touching the box containing the displayed tool retract rate, you can directly enter the tool retract rate. Retract values must be positive, and are limited by the physical capabilities of the machine. Most machines are limited between 10 and 1000 in/min. The retract entry button is located on the Tool and Router page (TP). The retract may also be entered from the part program, or from the M48 header. Tool Spindle Speed button
This button allows you to enter the Spindle speed (RPM) for the currently selected tool number. This is the speed (in RPM) that the tool will be spun during drilling or routing. By touching the box containing the displayed tool speed, you can directly enter the tool speed. Speed values must be positive, and are limited by the physical capabilities of the spindle. Most machines are limited between about 10,000 and 110,000 RPM. The Spindle speed (RPM) entry button is located on the Tool and Router page (TP). The RPM may also be entered from the part program, or from the M48 header. Tool tip Offset button
This button allows you to enter the Tool tip offset for the currently selected tool number. This is the Z-axis depth offset between different tool sizes, normally used to compensate for the tool point between diameters, larger offsets being needed for the larger tools. By touching the box containing the displayed offset, you can directly enter the new offset. Offsets can be positive or negative, and are limited by the limits of Z-axis travel. If the machine is equipped with Depth Control, the Z-axis offset can also be used as a way to enter the controlled depth for this tool, although the Offset and Depth can also be designated separately. See Depth Control. For Controlled Penetration mode (depth control mode 3) drilling or routing, the Z-axis offset specifies a depth relative to the top of the backup material. A negative Z offset drills or routs the specified amount deeper into the backup, a positive offset drills or routs a hole that is shallow by the specified amount. The Z-axis offset button is located on the Tool and Router page (TP). The offset may also be entered from the part program, or from the M48 header. Tool Depth button
This button allows you to enter the tool Depth for the currently selected tool number. This is the depth that this tool will drill or rout to, as measured from the top of the material surface. Depending on the Depth Control mode being used, this value will be the same as the Z-axis Tool tip Offset, or a separate value. This latter usage is more flexible. By touching the box containing the displayed depth value, you can directly enter the new depth. Depth values must be negative, and are limited by the limits of Z-axis travel. The Z-axis offset can also be used as a way to enter the controlled depth for this tool, although the Offset and Depth can also be designated separately. See Tool tip Offset. The Tool Depth button is located on the Tool and Router page (TP). The Depth may also be entered from the part program, or from the M48 header. Tool Flute Length button
This button allows you to enter the tool's flute length. This is the minimum length required for the job that will be executed, and it applies to all tools regardless of the tool number present in the spindles. By touching the box containing the displayed flute value, you can directly enter the new flute length. These values must be positive, and are limited by the limits of Z-axis travel. When the entered value is zero, the box becomes blank and this feature is turned off. If a value has been entered in the box, the machine will check the length of the tool, normally as part of a tool change, to verify that the flute has at least the indicated length. If it does not, it will be rejected. Tool Chipload button
This button allows you to enter the tool Chipload for the currently selected tool number. This is the amount of distance travelled by the Z-axis for each revolution of the tool bit. Chipload tends to be essentially constant for a material type regardless of the tool size. This "ideal" limitation may however, be limited also by the machine capabilities, stability, and tool bit geometry and construction. By touching the box containing the displayed Chipload, you can directly enter the new Chipload. Chipload values are positive, and will cause the infeed to be adjusted to match. A maximum (or minimum) chipload will be used if the entered value exceeds the machine capabilities. Entering the infeed directly will affect the chipload used. The Tool Chipload button is located on the Tool and Router page (TP). The Chipload may only be entered manually from the Tool and Router page, or by setting the infeed and spindle speed. Tool Cutting Speed button
This button allows you to enter the tool Cutting Speed for the currently selected tool number. This is the surface distance of the tool's cutting surface per minute. Cutting Speed tends to be essentially constant for a material type regardless of the tool size. This "ideal" limitation may however, be limited also by the machine capabilities, stability, and tool bit geometry and construction. By touching the box containing the displayed Cutting Speed, you can directly enter the new Cutting Speed. Cutting Speed values are positive, and will cause the Spindle Speed (RPM) to be adjusted to match. A maximum (or minimum) Cutting Speed will be used if the entered value exceeds the machine capabilities. Entering the Spindle Speed directly will also affect the Cutting Speed used. The Tool Cutting Speed button is located on the Tool and Router page (TP). The Cutting Speed may only be entered manually from the Tool and Router page, or by setting the infeed and spindle speed. Tool Maximum Hit Count button
This button allows you to enter the Max Hit Count for the currently selected tool number. This is the maximum number of hits the tool will be used before it is considered expired and the machine changes it for another tool. By touching the box containing the displayed max hit, you can directly enter the max hit value. Max hit values must be positive, and are limited only by tool life and hole quality. The Front page, Tool and Router page, and tool summary contain displays called H/Exp, or "Hits until Expired". This value counts DOWN as the machine runs, indicating the number of hits remaining on the tool. The TMS system supports a parameter called EXTOOL. This is a percentage at which a tool may be considered expired BEFORE it is picked up. If you wish to squeeze every possible hit out of each tool, then this should be left set to its default of 100 percent. If you would like to avoid picking up a tool with, say, a max hit count of 1000 hits to drill less than 10 holes, then set the EXTOOL parameter to 99 percent. The Max Hit entry button is located on the Tool and Router page (TP). The Max Hit may also be entered from the part program, or from the M48 header. TMS Group selection button
The TMS setup page displays detailed information for one TMS tool group at a time. In TMS, a "group" is a collection of tools of the same type. For example, all of the 0.020 drills can be considered one group. You must determine how many tools are in the group. TMS will manage the tools from there, keeping track of number sharp, expired, tool in use, and number of hits on the current tool. TMS has two distinctly different modes of operation: one, using the tool number from the part program (T#) as the group number. The other one uses the diameter specified in the part program as a key to the group. See MODE for further details. There are two ways of selecting which tool Groups information is displayed: First, there are up arrow and down arrow buttons located to the left and right of the displayed group number. Touching these buttons will cause the next or previous group's data to be displayed. Holding either of these buttons will cause the group data to scroll through the various group numbers. This can be used to fast advance to a particular group number. Secondly, by touching the box containing the displayed group number, you can directly enter the group number for which you want the group data displayed. These group numbers can be between 1 and 250. The TMS group display and select buttons are located on the TMS Setup page (TMS). On machines equipped with Extended TMS such as the MCH, each cassette contains a series of groups. For example, groups 1-50 may be on cassette #1, groups 51-99 on cassette #2 and so on. On standard TMS systems with one cassette, all groups must reside on the one cassette. TMS Group diameter button
This button is used to enter the tool diameter of the currently selected TMS group. If the system is operating in TMS mode 1, then this diameter is only for reference. If however, you're operating in TMS mode 2, then this diameter MUST BE SPECIFIED in order for the tool to be found by the system. In mode 2, the operator need not know where tools of a certain diameter are in the cassette. The system deals with that. By touching the box containing the displayed group diameter, you can directly enter the group diameter for the current TMS tool group. This button is located on the TMS Setup page (TMS). TMS Group allocation button
This button is used to specify how many cassette tool locations are assigned to the currently selected TMS group. Changing the number of allocated tools in a group may require resetting the cassette data on that cassette. If a reset is necessary, you will be prompted to be sure that this is really what you mean. The number of allocated tools may be specified between one and the maximum number of unassigned locations in the cassette. You cannot set the number of allocated tools to zero. Use the DELETE THIS GROUP button in order to dispose of a TMS group no longer needed. Changing the tool allocation automatically sets all tools in the group to sharp. By touching the box containing the displayed group allocation count, you can directly enter the group allocation count for the current TMS tool group. This button is located on the TMS Setup page (TMS). TMS Group tool hits
This button allows you to set and reset the number of hits counted on the current tool in the currently selected TMS group. The hit counter is used in conjunction with the Max hit counter on the tool page (TP) to determine when it is time to change to the next tool in the group. The hit counters are stored in the cassette file, which is written to disk after each toolchange or at end of program. By touching the box containing the displayed group hit count, you can directly enter the hit count for the current tool of the currently selected TMS tool group. This button is located on the TMS Setup page (TMS). TMS Group cutter distance
This button allows you to set and reset the accumulated cutter distance on the current tool in the currently selected TMS group. For routing tools the accumulated distance is used in conjunction with the Max rout distance on the tool page (TP) to determine when it is time to change to the next tool in the group. The display is in feet or meters, depending on whether the system is operating in Inch or Metric mode. The accumulated distance is stored in the cassette file, which is written to disk after each toolchange or at end of program. The distance is always written to the file in millimeters regardless of the current measurement mode. By touching the box containing the displayed distance, you can directly enter the accumulated distance for the current tool of the currently selected TMS tool group. This button is located on the TMS Setup page (TMS). TMS Tool in Use button
This button selects the tool in use for the currently selected TMS group. The in use tool is the tool in the collet or next to be picked up in this group if not in the collet. The in use tool is not considered to be a sharp tool, even if it has no hits on it. Sharp tools are those which have never been used or picked up. On the TMS Graphics pop-up window, the in use tool for each group is indicated by a filled grey circle. The in use values are stored in the cassette file, which is written to disk after each toolchange or at end of program. By touching the box containing the in use tool number, you can directly enter the in use tool number for the current tool of the currently selected TMS tool group. This button is located on the TMS Setup page (TMS). TMS Sharp tool select button
This button selects the number of sharp tools available in the currently selected TMS group. Sharp tools are those which have never been picked up or otherwise indicated as in use. Resetting a tool group or all of the cassette data, or changing the number of allocated tools in a group will reset the group to all sharp tools. On the TMS Graphics pop-up window, sharp tools for each group are indicated by a filled white or black circle, depending on if that group is the highlighted group or not. The sharp tool counts are stored in the cassette file, which is written to disk after each toolchange or at end of program. By touching the box containing the sharp tool count, you can directly enter the sharp tool count for the current tool of the currently selected TMS tool group. This button is located on the TMS Setup page (TMS). TMS Expired tool select button
This button selects the number of expired tools in the currently selected TMS group. Expired tools are those which have been detected as broken, or have passed their maximum hit count values. Resetting a tool group or all of the cassette data, or changing the number of allocated tools in a group will reset the group to all sharp tools. On the TMS Graphics pop-up window, expired tools for each group are indicated by an empty circle with an "X" through it. The expired tool counts are stored in the cassette file, which is written to disk after each toolchange or at end of program. By touching the box containing the expired tool count, you can directly enter the expired tool count for the current tool of the currently selected TMS tool group. This button is located on the TMS Setup page (TMS). TMS Mode of operation
MODE,#
The TMS system has two distinct modes of operation: TMS Tool Crib size button
This button is used to define the size of the TMS tool crib. The crib occupies tool cassette locations which are not assigned to any tool group, and is used as a place to store exhausted (expired or broken) tools. When a crib is used, exhausted tools are not put back into their group, but are placed in the crib. The Operator then easily knows which tools are exhausted, because they're all in the crib, and which are still good, since they're still in their groups. The tool crib may be reset manually by changing the number of spent tools, or it may be reset with the RESET TOOL CRIB button or command. On the TMS Graphics pop-up window, the crib is outlined in blue (blue on black), and spent tools in the crib are indicated by blue circles with an "X" through them. On machines equipped with Extended TMS such as the MCH, the tool crib may be located on any of the cassettes. Which cassette contains the tool crib is stored in the cassette file. The tool crib status is stored in the cassette file, which is written to disk after each toolchange or at end of program. By touching the box containing the tool crib size, you can directly enter the size of the TMS tool crib. This button is located on the TMS Setup page (TMS). Extended TMS Tool Crib location button
This button is used to define which cassette contains the TMS tool crib. This function is only available on machines equipped with Extended TMS such as the MCH. There must be enough unassigned spaces within the tool crib to hold the allocated groups in that cassette and the tool crib. When the button is pressed, you can directly enter the cassette number of which cassette contains the tool crib. This information is ultimately written to the cassette file, and becomes part of that cassette configuration. The tool crib may occupy between one tool position, up to a maximum of 120 tools (the size of one full cassette). The Extended Tool Crib button (X Crib) is located on the TMS Setup page (TMS). Extended TMS mechanism homing
This button is used to force re-homing of the Extended TMS mechanism, if any. This function is only available on machines equipped with Extended TMS such as the MCH. Not all variations of Extended TMS require homing, for example, two stationary TMS cassettes do not. This function should be seldom used, as the mechanism will home itself automatically the first time that the TMS cassette is accessed. Extended TMS mechanism indexing
This button is used to force index of the Extended TMS mechanism, if any. This function is only available on machines equipped with Extended TMS such as the MCH. Not all variations of Extended TMS require homing, for example, two stationary TMS cassettes do not. ORIGINAL SCREEN: The button is located on the secondary TMS Setup page (TMS2). Extended TMS cassette group definitions
The Starting Group/Cassette button is used to define which TMS cassettes contain which tool groups. This function is only available on machines equipped with Extended TMS such as the MCH. By default, all tool groups are located on the first cassette, and subsequent cassettes are unused. By touching the button, you can select the STARTING TMS group numbers of each cassette. Cassette #1 must start with group 1, and unspecified cassettes are assumed to be unused. For example, to have cassette #1 contain groups 1-49, and cassette #2 contain the remaining tool groups, specify "1,50". TMS allows you to specify up to 250 tool groups. When specifying the group numbers, the group layouts must be such that the capacity of each cassette (including the tool crib) does not exceed 120 tools per cassette. This information is ultimately written to the cassette file, and becomes part of that cassette configuration. When accessing tools in a TMS tool group, the system will automatically index the correct tool cassette. The TMS cassette graphics will also show only those tool groups assigned to each cassette by this function. The Starting Group/Cassette button is located on the TMS Setup page. TMS Spent tool count button
This button is used to define the number of spent tools in the TMS tool crib. The crib occupies tool cassette locations which are not assigned to any tool group, and is used as a place to store exhausted (expired or broken) tools. When a crib is used, exhausted tools are not put back into their group, but are placed in the crib. The Operator then easily knows which tools are exhausted, because they're all in the crib, and which are still good, since they're still in their groups. The tool crib may be reset manually by changing the number of spent tools, or it may be reset with the Reset Tool Crib button or command. On the TMS Graphics pop-up window, the crib is outlined in blue (blue on black), and spent tools in the crib are indicated by blue circles with an "X" through them. The tool crib status is stored in the cassette file, which is written to disk after each toolchange or at end of program. By touching the box containing the spent tool count, you can directly enter the number of spent tools in the crib. This button is located on the TMS Setup page (TMS). TMS Cutoff button
This button is used to define the minimum number of tools in a group using the "empty hole" TMS stocking method. Groups containing less than this number of tools do not use the empty hole method even if empty hole mode is on. This is to allow you to define small groups of infrequently used tools, and not waste space for an empty hole on a group that may have (say) only two tools. The cutoff value has no effect when empty hole mode is off. The cutoff value is stored in the cassette file, which is written to disk after each toolchange or at end of program. By touching the box containing the cutoff value, you can directly enter the cutoff value (minimum size of a TMS group utilizing the empty hole method). This button is located on the TMS Setup page (TMS). Depth Control ON/OFF button
DCONOF,on/off
This button is used to turn ON or OFF the Depth Control functions of the machine entirely, regardless of the current settings of any of the machine parameters, including tool data. This is a convenient way to disable Depth Controlled drilling on a part program that would normally be Depth Controlled, for example, to drill a test fixture. The Depth Control ON/OFF button is located on the Machine Setup Page, to the right of the Depth Control (DC) Function button. The button toggles between Depth Control ON or OFF each time it is touched (assuming that the machine is equipped with Depth Control capabilities). ORIGINAL SCREEN: This button is available on the Depth Control Setup page. Depth Control mode button
DEPMOD,#
This button selects the Depth Control system mode of operation. By touching the box you can directly enter the Depth Control Mode to be used (assuming that the machine is equipped with Depth Control capabilities). Mode 1 operation treats each Z offset (from keyboard, console, M48 header, or part program body) as a depth value on Depth Controlled tools. In this mode, the Z values for all Depth Controlled tools MUST be negative. Mode 2 operation is where the system uses different values for the Z offset (normally used to compensate for tool point lengths between different diameter tools), and the hole depth. In this second mode, offsets entered from the console, from the keyboard (T#Z#), or from the M48 header are assumed to be tool tip offsets. Values entered from the console as depths (see TP), or as Z offsets in the part program body are assumed to be depth offsets. This mode allows you to retain the function of the tool tip offset while having the flexibility of changing the drill depth on each hole if necessary (e.g.: X#Y#Z#). Mode 3, referred to as Controlled Penetration mode, is provided for drilling or routing operations where the depth is referenced from the top of the backup material. For non-depth controlled tools, the Z offset is treated as the desired amount of penetration relative to the top of the backup. A negative Z offset drills or routs the specified amount deeper into the backup, a positive offset drills or routs a hole that is shallow by the specified amount. For depth controlled tools, mode 3 operates exactly the same as mode 2. Mode 3 may be preferable over depth control for certain applications because the point of reference (the top of the backup) is not affected by the stack thickness. For accuracy, the reference is established by an automated procedure that "maps" the height of the backup material prior to drilling. Similar to depth control, mode 3 also utilizes the tool tip check to compensate for variations in the drill ring setting. For "through-hole" drilling, mode 3 may be used to control drill penetration into the backup. A negative Z offset is used to specify the desired depth into the backup. Mode 3 may also be useful for "blind-via" applications where the hole depth is referenced from the bottom of board. A positive Z offset is used to indicate the the depth of the hole relative to the bottom of the board. In the case of routing operations, this mode me also be utilized for "pocket routing", where the depth is referred to the bottom of the material rather than the top. Controlled Penetration mode does require that the backup material be "mapped" prior to drilling or routing, in order to determine its height. This is an automated process that must be performed after running VSB, or whenever the height or thickness of the backup material is changed. Since backup material thickness is fairly uniform, the mapping procedure should only need to be performed periodically. For further information regarding the backup mapping procedure, refer to the Map Backup Height button description. Depth Control Mode select buttons are located on the Machine Setup and Depth Control Setup pages. Depth Control tool selection
DCTL,OFF,#,#,#...
This function allows you to select those tools which will be Depth Controlled, or to turn off Depth Control for all tools (not the same as disabling Depth Control). The list of currently selected Depth Controlled tools is displayed on the Depth Control setup page. Touching the Depth Controlled Tools display box will allow you to enter the desired depth controlled tools using the keypad. Depth Control Lot offset
LOFS,#
This function is used to assign an offset to Depth Control values being used on a machine equipped with Depth Control. This function can be viewed as a sort of Zero Correction for the Z-axis. For example, if the job had been programmed initially with depths of -0.050 and -0.075, then setting the Lot offset to 0.010 would cause all Depth Controlled holes to be drilled 0.010 shallower. A negative value for the Lot offset would cause the Depth Controlled holes to be drilled deeper. The Lot offset does not affect non-Depth Controlled drilling. A button to display and adjust the Lot offset is displayed on the Depth Control Setup page. The Lot offset is displayed inside this button's box. Touching the button will allow you to directly enter a new value. Default Depth
DFDPTH,#
This function is used to assign a Default Depth value to be used when Depth Control is turned on for various tools with the DCTL command or button. When Depth Control is turned on for a tool and the depth on the tool is zero, the depth will be set to this default value. For example, if T1 has a depth of zero, and T2 has a depth of -0.01, if you set the Default Depth to -0.02 and then turn on Depth Control for T1 and T2, the depth of T1 will be set to -0.02, but the depth of T2 will remain unchanged at -0.01. The Default Depth does not affect non-Depth Controlled drilling or routing. A button to display and adjust the Default Depth is displayed on the Depth Control Setup page. The Default Depth is displayed inside this button's box. Touching the button will allow you to directly enter a new value. The function is also available from a keyboard command, which can be used from keyboard or from the MACH.DAT file, Login file, or M48 header. Depth Control Offsets
DCOFS,#,#
The Depth Offset Correction buttons allow you to make fine adjustments to the drill or rout depth of each spindle. The offset for each station is displayed directly below the corresponding Station Select button on the Depth Control Setup page. You may enter a new value by touching the display for the desired station. A positive offset value raises the depth (drill/rout shallower), a negative value lowers the depth (drill/rout deeper). This function applies to all drilling and routing depth control modes including Controlled Penetration mode 3. The offsets DO NOT affect non-depth control drilling or routing. ORIGINAL SCREEN: The Depth Control Offset Correction buttons are provided on a popup menu. The menu is accessed via the Depth Control Offsets button located on the secondary Depth Control Setup page. Tool Tip Check
TOLCHK
The tool tip check function uses a special test pod, which is present on all Depth and/or Diameter-Runout Controlled Excellon machines. When executed, it will verify the tip of the tool and set the proper offsets for depth control or Controlled Penetration (depth control mode 3) if these functions are enabled, and check for the correct diameter and runout when this function is available and enabled. Set Backup Corner Button
MBCINP
This button is used to define the size and location of the backup material prior to performing the Controlled Penetration (depth control mode 3) backup mapping procedure. The backup size and location is established by entering the coordinates of two diagonal corners. Pressing the Set Backup Corner button located on the Depth Control Setup page displays the Set Backup Corner popup window. The popup displays buttons to position the worktable at the corners or center of travel. Jog buttons are also provided for making fine adjustments to the table position. The Enter button sets the backup corner at the present table position. Touch the red header bar along the top of the window to exit the popup without logging the table coordinates. Select Panel Size Button
BUFSLCT
This button is used to define and/or select a panel size or type as used with controlled penetration mode drilling or routing. The button allows you to select predefined backup corner locations to make mapping of the backup material easier for customers who have repeat work using the same size panels on a regular basis. The function works by providing you with a list of panel size types using a variation of the File Selection popup. You select the panel size by name - e.g. "16x18" or "ABCXYZ". If the name is present in the list, the panel corners are read from a file and established so that you can map the backup material WITHOUT relocating the panel corners. This saves time and minimizes mistakes. If the name you provide is a new name, e.g. you are defining a new panel size, you will be prompted for "are you sure" and then put through the standard corner selection process. The file will then be updated with the new panel size name and the location of the corners. You should never have to locate the corners of this size panel again. The panel sizes are stored in a file called PNLSIZE.DAT, located in the SYSTEM directory. This is the file that is accessed by the Select Panel Size button. The file can be manually edited if necessary, although this is not recommended. This button is located on the Depth Control Setup page, and only applies to the use of Controlled Penetration drilling and routing. Backup Offset
BOFS,#
This function is used to assign an offset to the mapped backup height for Controlled Penetration mode drilling and routing. Specifying an offset allows you to change the backup surface height without remapping. The offset adjusts the backup height relative to the height of the mapped surface. A positive offset value raises the backup surface, a negative value lowers the backup height. The backup mapping procedure may be performed either by mapping material (preferably of known thickness) or by mapping the tooling plate itself. Care must be taken if the tooling plate is mapped directly, since surface irregularities, clamps, etc. could affect the surface map and result in drill or rout depth errors. A button to display and adjust the Backup Offset is located on the Depth Control Setup page. Touching the button allows you to directly enter a new value. This function applies only to Controlled Penetration drilling or routing. Move To Backup Corner Button
MOVEBC
This button may be used to verify the backup corner locations established by the Set Backup Corner button. The backup corners must be established before this button may be used. Each press of the button will cause the worktable to move back and forth between the two backup corner locations. If the backup corners are properly set, the spindle should position over the opposite (diagonal) corners of the backup material. The Move To Backup Corner button is located on the Depth Control Setup Page. Map Backup Height Button
B_HGT
This button executes the backup mapping function, which must be performed before drilling in Controlled Penetration mode (depth control mode 3). The backup material is "mapped" in order to determine its height. The mapping process must be performed after running VSB, or whenever the height or thickness of the backup material is changed. Since backup material thickness is fairly uniform, the mapping procedure should only need to be performed periodically. Pecking on/off Button
PECK,on/off
This button allows you to turn ON or OFF the pecking functions for all tools but still keep the current pecking set up for every individual tool as displayed on the Peck Drilling Setup page. This may be useful in those cases where the same tool, which is set for peck drilling, is also used for drilling pin holes, etc. You may want to temporarily turn pecking off to drill the pinning holes, then turn pecking back on with no changes to the pecking set up. The first time the machine is booted up, this button defaults to ON so it will not affect pecking unless it is turned off. The button toggles pecking Off and On each time it is touched. The button is located on the Peck Drilling Setup page and Miscellaneous Tool Setup menu. To display the Tool Setup menu, touch the box displaying the current pecking on/off status located near the center of the Machine Setup page Pecking Depth button
PCK_DPTH,#,#
This button is used to specify the peck depths used during Peck drilling. If you use the button on the Peck Drilling Setup page which allows you to specify the number of pecks, then the peck depths are evenly spaced from the top of the stack to the lower limit. Before pecking is setup for a tool, only one set of values is displayed on the pecking page for that tool. The depth value will be the depth of a drill stroke relative to the stack height. You can think of non-peck drilling as having just one peck. Sometimes you need more control over the pecking depths (say to drill through copper or fiberglass layers with longer strokes, and through Invar layers with several short strokes). Touching the Peck depth buttons allows you to directly enter new values giving you control over the depth of each peck. When you enter a new value manually, the length of the entered peck step is continued into all subsequent pecks. You can change the length of those pecks as well by simply touching the values you wish to change. Please note that the depth value entered is assumed to include the Z-axis depth offset if one is being used. Pecking Infeed button
PCK_INF,#,#
This button is used to specify the peck infeed used during Peck drilling. If you use the button on the Peck Drilling Setup page which allows you to specify the number of pecks, then the peck infeed will be the same for all pecks, and the infeed used will be the infeed from the Tool Data page (TP). Before pecking is setup for a tool, only one set of values is displayed on the pecking page for that tool. The infeed value will be the value from the Tool Data page (TP). Sometimes you need more control over the pecking infeeds (say to drill through copper or fiberglass layers with faster strokes, and through Invar layers with several slower strokes). Touching the Peck infeed buttons allows you to directly enter new values giving you control over the infeed rate of each peck. When you enter a new value manually, the infeed of the entered peck step is continued into all subsequent pecks. You can change the infeed of those pecks as well by simply touching the values you wish to change. Pecking Retract button
PCK_RET,#,#
This button is used to specify the peck Retract used during Peck drilling. If you use the button on the Peck Drilling Setup page which allows you to specify the number of pecks, then the peck retract will be the same for all pecks, and the retract used will be the retract from the Tool Data page (TP). Before pecking is setup for a tool, only one set of values is displayed on the pecking page for that tool. The retract value will be the value from the Tool Data page (TP). Sometimes you need more control over the pecking retracts. Touching the Peck retract buttons allows you to directly enter new values giving you direct control over the retract rate of each peck. When you enter a new value manually, the retract of the entered peck step is continued into all subsequent pecks. You can change the retract of those pecks as well by simply touching the values you wish to change. Pecking tool selection
PCK_TOOL,#,#,#...
The Peck Tools function allows you to select which tools are to be used either to input pecking data (so that pecking parameters may be set up for several tools simultaneously), or to select those tools which should be reset by the Reset Pecks button. Touching the Peck tools display box will allow you to use the keypad to enter a list of tools to be affected by pecking operations. The Peck Tools display is located on the Peck Drilling Setup page. Number of pecks select button
PCK_NUM,#
The ENTER NUMBER OF PECKS button is used to tell the system how many pecks are to be used to peck holes with this tool. When defined in this way, the stroke length (from stack height to the lower limit) is evenly divided across all pecks. Pressing this button will allow you to enter the number of pecks to be used when pecking this tool. It will replace any current pecking data for this tool, and propagate the tool's infeed and retract rate (by default) across all pecks for the tool. This button is located on the Peck Drilling Setup page. Please note that the total Pecking depth which is divided between the number of pecks specified will include the Z-axis depth offset if one is being used. Pecking Stack height button
PCK_STHG,#
This button is used to define the Stack height to be used in pecking. The Stack height is used for two purposes: First, it defines how far the first stroke must go before it will reach the material. When used in conjunction with the Number of pecks selection button, it will actually help determine the starting depth and depth of each subsequent peck. Secondly, it helps to define a secondary upper limit, which is used to set the retract height between pecks. Normally, this value is set by the system to 0.030 inch above the stack height. Each peck will retract to this height except the last one, which will retract all the way to the upper limit before moving on to the next hole. Pressing this button allows you to enter the Stack height directly using the keypad. The system will then set the secondary upper limit default value. The Stack Height is not used, except by the pecking graphics display, if the pecked tool is a Depth controlled tool. This button is located on the Peck Drilling Setup page. Pecking secondary upper limit
This button is used to define the secondary upper limit used during pecking. This value is used to set the retract height, relative to the Stack Height, between pecks. Normally, this value is set by the system to 0.030 inch above the stack height, but you can use this button to set it to any desired value. Each peck will retract to this height except the last one, which will retract all the way to the upper limit before moving on to the next hole. Pressing this button allows you to enter the secondary upper limit directly using the keypad. This button is located on the Peck Drilling Setup page. Final pecking depth
This button is used to display the final depth and modify the down limit and backup material offset. Pressing this button will show another popup menu. Pressing this button allows you to modify down limit and backup material offset using the keypad. This button is located on the Peck Drilling Setup page. Pecking minimum stroke length
PCK_MIN,#
This button is used to set the minimum stroke length used during pecking. If the system calculates a pecking stroke of less than this value, it simply adds the calculated length of the stroke to the last stroke, making it a little longer. This is used to eliminate wasteful pecking strokes which only cut a small amount of material. For example, if the minimum stroke were set to 0.030 inch, and you had defined a stroke length of 0.050 (by entering the first stroke length), and there was 0.155 of material to cut, the strokes would be to the following depths: 0.050, 0.100, 0.155. Note that the system DOES NOT do a fourth stroke, cutting only 0.005 inch of material. Pressing this button will allow you to directly enter the minimum stroke length using the keypad. This button is located on the Peck Drilling Setup page. Pecking tool disable
PCK_OFF
The RESET PECKS button allows you to disable pecking for the currently selected pecking tools (Refer to the Pecking tool select section). Pressing the button will reset the number of pecks equal to one peck. This can be thought of as disabling pecking, since a non-pecking stroke can also be viewed as a one peck stroke all the way to the bottom. This button is located on the Peck Drilling Setup page. Pecking cycle graphic display
This button displays a graphic representation of the pecking cycle for the current tool(s). The display uses a grey rectangle to represent the board stack, and a green line to represent the down limit. Each stroke in the pecking cycle is represented by two "drills". The red drill indicates a down stroke, and the blue drill represents the corresponding up stroke. Note that each up stroke retracts to the secondary upper limit with the exception of the last, which retracts all the way to the primary upper limit before continuing on to the next hole. Each down stroke goes progressively deeper (as specified by the pecking cycle that has been set up), until the last stroke reaches the lower limit (indicated by the green line). Touching the screen while this display is on screen will cause it to be removed, and control to be returned to the pecking setup screen. This button is located on the Peck Drilling Setup page. Pecking cycle resetPressing the RESET button located on most pages, will terminate the pecking cycle and cause the spindles to raise to the upper limit. The next hole will be drilled beginning with the first peck. The pecking cycle is reset automatically whenever the spindles are raised if a part program has not been started. Functions that raise the spindles (e.g. table park), will cause the next hole to be drilled beginning with the first peck. The pecking cycle is NOT automatically reset when the spindles are raised after a part program has been started. This provides for the drilling of test holes in single cycle mode. The worktable may be parked after each peck to examine the hole for proper depth, without causing the pecking cycle to start over. Upper limit
UP,#
The Upper limit is the top limit of the drill stroke, and the place that the Z-axis will return to after successfully completing a stroke. This position is also known sometimes as Drill Ready, since this is the position the Z-axis goes to when the spindles are brought down and back up to speed. Pressing the Upper limit button (located on the Machine Setup and Peck Drilling Setup pages), allows you to directly enter a new value using the 10-key pad. Lower limit
DN,#
The Lower limit is the bottom limit of the drill stroke, and the place that the Z-axis will stroke to when moving downward during a drill stroke. The Lower limit is only used during non-depth controlled drilling. During depth controlled drilling, the Lower limit is totally ignored, and the machine drills to the depth value programmed for that tool. Pressing the Lower limit button (located on the Machine Setup and Peck Drilling Setup pages), allows you to directly enter a new value using the 10-key pad, assuming Controlled Penetration mode is not selected. Lower limit value input is inhibited in Controlled Penetration mode (depth control mode 3). Instead, the lower limit is automatically set to the backup material reference height. The Z-axis offset is then used to specify the desired depth relative to the top of the backup material. Tool Summary
The Tool Summary is a pop-up window which displays tool data for all tools containing tool data. Even though the CNC-7 is capable of managing up to a hundred different tool sizes, it is not necessary for you to have to wade through the tool data for all 100 tools. The Tool Summary displays information on only those tools with tool data, such as diameters, infeed or spindle speed values, or max hits. Seven tools at a time are displayed. If the current tool (the one in the spindle collet) is displayed on the current page, it is highlighted. The Tool Summary groups information into Feeds and Speeds, Chipload and Retract, or Hits. Once selected, each use of the Tool Summary will come up with what was selected last time it was used. Other buttons on the Tool Summary are Page up and Page down, which display the next or last set of seven tools. Touch the red header bar at the top of the display to exit the popup. The Tool Summary display button is located on the Machine Setup and Tool and Router pages. Cassette Default Storage
CCFG,device
This function allows you to select which directory and/or device is used for the storage of TMS cassette files. By default, the cassette files are stored on USER. However, it is possible to use any directory, including floppy disks. Buttons for selecting the Cassette Default Storage are located on the Machine Setup and TMS Setup pages. Pressing the button will present you with the file selection button, which you use to select the device or directory. Each time you select a cassette file, or it is accessed, it will go to the device specified by the Cassette Default Storage unless otherwise specified. Cassette Replacement Default Storage
CRPLCFG,device
This function allows you to select which directory and/or device is used for the storage of individual TMS cassette files. By default, the cassette files are stored on USER. However, it is possible to use any directory, including floppy disks to store each individual cassette file. Each time you specify a command which involves storing portions of the cassette configuration file as an individual cassette file, it will store the individual cassette file in the directory or device specified by the Cassette Replacement Default Storage unless otherwise specified. Cassette file select
CAS,fileTMS data is kept in files called TMS cassette files. These files contain all pertinent information about cassette layout, use of a tool crib, which tools are sharp, which are expired, which are in use, and the number of hits on the in use tools. Many TMS related functions will cause an update to the cassette file. This includes changing the layout of the cassette, or resetting the cassette to sharp tools entirely or by group. The TMS cassette file is also updated after a toolchange or at end of program. The TMS cassette file defaults to a file called CASCFG.DAT, which is a basic TMS cassette file designed by Excellon. It is expected that you will design a cassette layout more suited to the needs of your own shop. All data about the layout of the cassette is stored in this file, so selecting a new cassette file can completely redefine the cassette layout. On machines equipped with Extended TMS such as the MCH, the layout of all cassettes in the system is stored together in the one file. Creating files
If you want to create a new TMS cassette file, simply select a file which does not exist (from the keyboard). The system will ask you if you want to create the file. If yes, a duplicate of the current file will be created and given the new name, which you can edit as desired with the TMS editing functions. So to create a file BBB based on file AAA, select file AAA, then select file BBB (which doesn't yet exist), say "yes" you want to create it, and edit as desired. Cassette files may be selected from the console, from the keyboard, or from a part program M48 header. Buttons for selecting the TMS cassette file are located on the Machine Setup and TMS Setup pages. Cassette Overlay
CAS,file,number
TMS data is kept in files called TMS cassette files. These files contain all pertinent information about cassette layout, use of a tool crib, which tools are sharp, which are expired, which are in use, and the number of hits on the in use tools. Many TMS related functions will cause an update to the cassette file. This includes changing the layout of the cassette, or resetting the cassette to sharp tools entirely or by group. The TMS cassette file is also updated after a toolchange or at end of program. The TMS cassette file defaults to a file called CASCFG.DAT, which is a basic TMS cassette file designed by Excellon. It is expected that you will design a cassette layout more suited to the needs of your own shop. All data about the layout of the cassette is stored in this file, so selecting a new cassette file can completely redefine the cassette layout. On machines equipped with Extended TMS such as the MCH, the layout of all cassettes in the system is stored together in the one file. The Cassette Overlay Command will permit you to change a cassette in the MCH and replace or insert the data associated with the new cassette into the current cassette configuration file, such as CASCFG.DAT. This command will first update the current cassette configuration file with the latest tooling data available. It will then copy the existing tooling information for the specified cassette number into a cassette file located in the specified directory or device. It then copies the new cassette data into the current cassette configuration file. TMS active station selection
LCATS,#,#,#...
This function allows you to select which TMS stations are active. If you are using a four headed machine, and only have panels on a particular job for two heads, you will want to deselect the use of the other two heads. The TMS Current State button is located on the Machine Setup page, to the right of the TMS Function button. The button displays the active TMS stations. Touching the button allows you to select the active station numbers using the keypad. Inactive TMS stations will not attempt toolchanges, thereby not requiring cassettes or tools. It should be noted that on most Excellon machines, all spindle collets actuate simultaneously, so that even if a TMS station is inactive, the spindle collet will still open and close on all spindles. Even with all stations inactive, TMS will actually go through the motions of a toolchange. ORIGINAL SCREEN: The ACTIVE TMS STATIONS button is available on the TMS Setup and Spindle Setup pages. Deleting TMS groups
This button is used to delete a TMS tool group within the cassette. Pushing this button may first warn you that all of the TMS cassette data will need to be reset for that cassette, and will then totally eliminate the tool group from the cassette, moving the other tool groups up within the cassette to take up the vacated tool positions. This button is located on the TMS setup page. Resetting TMS groups
R,G
This function will cause individual TMS tool groups to be reset, that is, restored to no expired, but all sharp tools (same number as number of allocated tools). Pressing the button will present you with the keypad for selecting the affected groups, and then the groups will be reset. If the special group reset function is turned on via the VSB command TMS_CONFIG, then the group reset will reset all SHARP tools to their original setting which is NOT necessarily the same as the number of allocated tools. This is done by adding the number of sharp tools left and the number of expired tools. Please note that this feature DOES NOT work well with tool crib enabled since the number of expired tools are now in the crib and not in the individual group. In this case, the operator must reset the number of SHARP tools manually. This is typically done between jobs, or even during a job, when one or more tool groups are expired (or close enough that you decide to deal with it now). This button is located on the TMS setup page. Resetting the TMS cassette
CAS,R
This function allows you to reset all of the cassette data. This means clearing the tool crib (if any), and resetting all groups to all sharp tools. This is typically done when starting a new job with a fresh set of tool cassettes. A button for performing this function is located on the TMS setup page, but the cassette may also be reset from the keyboard, or through any one of several functions which rearranges the cassette enough to require a reset. If the cassette data is reset through the button, and if the system is equipped with Extended TMS such as the MCH, you will be prompted for which cassette(s) are affected by the reset. You may use the pop-up window to select one cassette, a list of cassettes, or all cassettes. Expired tool group summary
This button displays a pop-up window which lists all tool groups which are expired. This means that all tools within the listed groups have reached their max hit count or are broken. The expired group summary lists each group along with its group number, specified diameter, number of allocated tools, and whether or not "empty hole" mode is active on that group. Buttons on the pop-up allow you to page through multiple pages (possibly) of expired tools. Touching the red header bar at the top of the window exits the display. This button is located on the TMS Setup page. TMS cassette graphics
This button displays a graphic representation of the TMS cassette. This is done in the form of a pop-up window, which near the bottom lists the highlighted group (the one displayed as white on black), and that groups diameter. The display includes buttons for selecting the next higher or next lower tool group number (which will affect the rest of the display), and a cassette select button for machines with extended TMS. Touching the red header bar at the top of the window will exit the display. Other groups are assigned different colors to help distinguish between the various groups. Unused tool positions are indicated by empty circles, sharp tools are indicated by filled circles, in use tools by grey circles, and expired tools by empty circles with an "X" through them. The tool crib, if any, is outlined in blue (blue on black). Unused crib locations are indicated by empty blue circles, used crib locations by empty circles with an "X" though them. On machines equipped with Extended TMS (more than one TMS cassette per station such as the MCH), the cassette select button indicates which cassette is currently displayed. Touching this button will select the next cassette. The TMS cassette graphics button is located on the Machine Setup and TMS Setup pages. Reset Tool Crib
R,TC
This function resets the TMS tool crib, if there is one in use. The function resets all crib locations to available, thus clearing the crib of all expired (spent) tools. This function has no effect if a tool crib is not allocated, or if there are no expired (spent) tools in the crib. The command causes the TMS cassette file to be written out to disk, since the tool crib status is kept in the TMS cassette file. A button to perform this function is located on the TMS Setup page. TMS Empty Hole mode
This button toggles the TMS system between Empty Hole mode and non-Empty Hole modes. In Empty Hole mode, all tool groups with more tools than specified by the "cut-off" will use this mode, groups with less tools won't. Empty Hole mode means that the system leaves one empty TMS cassette location between the expired tools and the sharp or in use tools. When an Empty Hole group is fresh, the first hole location will be empty, and all other locations containing good tools will be continuous. This mode makes it easier for the operator to identify spent tools visually, since the empty hole acts as a separator. Small tool groups with seldom used tools are generally set to contain less tools than the cut-off so that you do not waste cassette locations needlessly. As an aid in restocking the cassette, the Expired Group summary lists all expired tool groups, along with their diameters, and notifies you of those tools which are using the Empty Hole mode. A button to toggle between Empty Hole and non-Empty Hole modes is present on the TMS Setup page. The button's text and border "light up" when Empty Hole mode is active. Using this button will present you with an "are you sure" warning, since changing modes completely resets the TMS cassette data. TMS Rotate mode
This button toggles the TMS system between Rotate and non-Rotate modes. In Rotate mode, tool usage always moves forward in the group, allowing you to use all tools in the cassette, and not end up with any "old" tools. Primarily, when you reset the tool group or all of the cassette data, the tool in use will not change. As an example, imagine a tool group with eight tools. The machine has just completed a job which used five of the tools completely. This leaves tool six of the group as the in use tool, and numbers seven and eight as sharp. In Rotate mode, the in use tool is left as number six. The machine will use tools six, seven, eight, one, two, three, four, and five. The machine would stop after using tool five telling you that the group is expired. This mode allows you to make sure that tools are not left in a cassette for (possibly) months at a time. In non-Rotate mode in the same scenario as above, resetting the tool group or cassette would also reset the in use tool to number one, causing the first tool of the group to be picked up each time a group is reset. It should be noted here that Rotate mode and Empty Hole modes are not compatible, and cannot be used at the same time. A button for toggling between Rotate and non-Rotate mode is available on the TMS setup page. The button's text and border "light up" when Rotate mode is active. Using this button will present you with an "are you sure" warning, since changing modes will completely reset the TMS cassette data. Resetting Tool data
Tool data Reset
R,T
This function causes the Tool data to be completely reset. This is a complete reset which clears all feeds and speeds, TMS tool group assignments, hit counters, and tool types (e.g.: Depth controlled, pecking, etc). One popular place for this command is in the M48 headers of part programs, thereby assuring that all old tool data is deleted before assigning new tool parameters. This button is present on the Tool and Router page. Using this button will present you with an "are you sure" warning, since this can be a fairly severe operation if you have spent a long time manually entering tool data. Resetting Hit counters
Hit counter Reset
R,H
This function clears the Hit counters for selected tool numbers, or all tools (depending on your choice). On TMS equipped machines, this will also reset the hit counters stored in the TMS cassette file, thus causing a TMS cassette file update. This command does not reset the max hit count, but just the running hit counters. A button for performing this function is located on the Tool and Router page. Pressing this button will present you with a keypad, from which you can select a list of tools to reset hit counters on, or you may select all tools. If you select all tools, you will also be presented with an "are you sure" warning to assure that you REALLY want to do this. Miscellaneous Reset menu
TOP_INFO
The Miscellaneous Reset menu is available from the CNC-7 Front Page. Near the top of the page is a box spanning nearly the width of the display. The box contains the System Clocks, Program Completion Bar, Hit Rate Speedometer and Blocks displays. Touch anywhere within the box to display the menu. Included in the menu are the following items. See related sections of the CNC-7 User Reference manual for further details regarding each function.
Resetting the Run Clock
Run Clock
R,CR
This function resets the Run Clock. The Run Clock counts the amount of time that the system has been powered up. Used in conjunction with the Program Clock, this clock can be used to compute machine utilization. The Run Clock display is located in the upper left corner of the Front Page. Touching the display will bring up the Miscellaneous Reset menu. Pressing the RESET RUN CLOCK button resets the clock to zero, which will then resume counting up from zero. ORIGINAL SCREEN: The Run Clock and reset button are located on the Options and Switches page. Resetting the Program Clock
Program Clock
R,CP
This function resets the Program Clock. The Program Clock counts the amount of time that the system has been in automatic operation. Used in conjunction with the Run Clock, this clock can be used to compute machine utilization. The Program Clock display is located in the upper left corner of the Front Page. Touching the display will bring up the Miscellaneous Reset menu. Pressing the RESET PROGRAM CLOCK button resets the clock to zero. The clock will resume counting up from zero as soon as the machine is restarted. ORIGINAL SCREEN: The Program Clock and reset button are located on the Options and Switches page. Setting M99 default
M99 default
M99,device
This function selects the default device to be used in searching for M99 files. The system default is USER, which means that the directory USER will be searched to find M99 files if the part program command (M99,filename) does not specify a device, and if no default has been specified. Even though it is allowed, it is recommended that you do not specify device names within the part program M99 call. This will allow the same programs to be used without modification on CNC-2 through CNC-7. The M99 default set can be used on each system to select where the M99 files are to be found. The M99 Dev button, included on the Miscellaneous Coordinate Setup menu, presents you with a devices pop-up window allowing you to select the device. To display the Coordinate Setup menu, touch the box displaying the current M99 default device located near the top of the Machine Setup page. ORIGINAL SCREEN: The button is available on the Options and Switches page. Part Program formatThe functions described in this section will enable you, as an operator, to select Excellon part program format or non-Excellon part program formats on the CNC-7 system. Excellon formats 1 and 2 are supplied standard with all CNC-7 systems, while non-Excellon formats are available on request as software options. Part Program Format menu
FMAT
The Part Program Format menu allows you to select an Excellon or non-Excellon part program format. The menu includes the following items. See related sections of the CNC-7 User Reference manual for further details regarding each function.
Non-Excellon formats
As a software option, your CNC-7 can be supplied with non-Excellon part program format capability. This would include, for example, formats such as Trudril, Hitachi, or Posalux formats. These conversions are all automatic and are invisible to the operator. Once one of these formats is selected, the source part program is read and converted line by line into Excellon format. In case of a problem the system will stop and appropriate messages enable the operator to take the necessary steps in order to correct the problem. The formatters are implemented via a software program called a Universal Formatter, which can translate ANYTHING to and from Excellon format, given a grammatical definition of both formats. At this time, only conversion TO Excellon format is provided on the CNC-7. When a software option of a non-Excellon format is included, several additional files are provided on the software diskettes, and the format is installed automatically when the software is installed. Most of these files are internal to the system, and need not be altered by the customer. The format appears in the FORMATTERS directory, and can be seen when selecting a format with the Special Formats button (described below). Multiple formats can be provided with the system, or the directory will be blank if none have been included in your system. The one file which may need modification is the Numeric Formats file. This file allows you to ignore functions which you do not want translated, or to change the zero format or scaling factor of the various codes. For example, with Trudril format the feed rates can be expressed in inches per minute, millimeters per second or centimeters per minute, depending on which version of the control system you have. You can alter the Numeric Formats file to control how these codes are translated. The Numeric Formats file is stored in the SYSTEM directory (/cnc/data), and can be edited as any normal ASCII file. Numeric Format files have the file extension .NF1. NF1 files are saved when you install a software upgrade by copying the old file to a .BAK file, so that your edits are not lost. After installing the upgrade, you can merge the new NF1 file, and the BAK file. NF1 files have the following format: Selecting Part Program format
Excellon Part Program format
FMAT,#
The basic CNC-7 system recognizes two formats, Excellon format one (an older format used with some of the original Routing machines) and Excellon format two, which is the primary format supported by Excellon. Format two is the system default when you bring up CNC-2s through CNC-7. Other non-Excellon formats are also supported, but these are done through "formatters" which convert the "foreign" format into Excellon format one, or in some very specialized cases, into format two. Buttons to select the desired format are provided on the Part Program Format menu. To display the menu from the Machine Setup page, touch the box displaying the current format (this will display the Coordinate Setup menu), then select Format from the menu. Included on the Format menu are two buttons, Excellon Format 1 and Excellon Format 2. Select either format by touching the corresponding button. The button's text appears "lit up" to indicate the format is selected. The current format is also displayed on the Machine Setup page. ORIGINAL SCREEN: The button is available on the Options and Switches page. Selecting special part program formats
Running non-Excellon format programs
Special part program formats
SPCFMT
The CNC-7 is able to run non-Excellon part program formats by converting the "foreign" format into Excellon format. This is accomplished by selecting a "formatter" to do the conversion. Once the formatter is selected it will stay active until another non-Excellon part program formatter is selected, or until the format is set to Excellon format one or two. A button allowing you to select the desired formatter is provided on the Part Program Format menu. To display the menu from the Machine Setup page, touch the box displaying the current format (this will display the Coordinate Setup menu), then select Format from the menu. Clear part program from memory
I
This function clears the part program from memory and causes it to be read again the next time the machine is run without having to specify the program name again. It can be used after a program has been edited, and must be cleared from memory in order to load the new version. It can also be used when the name of the file does not change when going from program to program, as is the case with paper tape input. A RESET will occur as part of this function, so that when the machine is started, the new program will read from the beginning. The function is available from the Misc. Reset popup menu. The menu may be accessed by touching the large box on the Front Page that contains the System Clocks, Program Completion Bar, Hit Rate Speedometer and Blocks displays. ORIGINAL SCREEN: This function available only as a Keyboard command. Scheduled Maintenance - Show/Clear
MNT_SCH show/clear
The Show and Clear Scheduled maintenance functions provide a way for you to display pending maintenance procedures and to clear the reminder messages after those procedures are done, without having to go into the Maintenance Functions Page. The SHOW MAINTENANCE SCHEDULE button displays on the screen all maintenance items detected by the machine as due and pending of execution. The CLEAR MAINTENANCE SCHEDULE button brings up on the console's screen a window with all pending maintenance items one by one. After every reminder message is displayed, the user is presented with the opportunity to erase that message. However, if they choose to do so, the user's privilege is checked and the message will be cleared only when the granted privilege for that user is equal or greater than the one specified for that message. These functions are available from the Misc. Reset popup menu. The menu may be accessed by touching the large box on the Front Page that contains the System Clocks, Program Completion Bar, Hit Rate Speedometer and Blocks displays. ORIGINAL SCREEN: These functions are available only through the Maintenance Functions page or Keyboard commands. Extended Z-axis mode
ZEXT,on/off
Extended Z-axis mode is used for drilling soft plugs (such as Delrin plugs) used in soft tooling. In normal operation, the zero position of the Z-axis is at the tooling plate so that the operator cannot drill into the tooling plate (unless something is mechanically wrong, such as a tool which is ringed incorrectly). Traditionally on drilling machines, there is additional Z-axis travel beyond the tooling plate surface which is used for toolchange. Routers generally do not have this additional travel, since they generally use soft tooling plates (such as phenolic) which is located above the tooling plate. Enabling extended Z-axis mode lowers the zero position of the Z-axis to its lowest position. It displays a message in the machine status box to indicate that extended Z-axis mode is active until you take the machine out of extended Z-axis mode. Pressing the EXTENDED Z-AXIS button located on the Special Features page toggles between Extended Z-axis mode on and off. Since Extended Z-axis mode allows you to drill into the tooling plate, You will also be presented with an "are you sure" message to make sure that this is really what you want to do. The button's text and border "light up" when Extended Z-axis mode is enabled. ORIGINAL SCREEN: The button is available on the Options and Switches page. Toolchange Stop mode
TCST,on/off
This function turns on and off Toolchange Stop mode. Toolchange Stop will cause the machine to stop during automatic operation when a toolchange is encountered. Toolchange stop can be configured to stop before the current tool is deposited, after it is deposited, or after the new tool is picked up. You can configure your system to stop in one, two, or all three places. See the System Software section regarding Toolchange stop. On machines not equipped with TMS, tool detectors, depth control, or other productivity enhancements, this mode can be used by the operator to visually check tools for breakage, ring set, or collet slippage depending on how it is configured. A button to control this function is available on the Special Features page. Pressing the TOOLCHANGE STOP button toggles Toolchange Stop mode ON and OFF. The button's text and border "light up" when Toolchange Stop mode is enabled. ORIGINAL SCREEN: The button is available on the Secondary Options and Switches page. Manual Insert Exchange
MAN_INS,on/off
This function turns ON and OFF the Manual Insert Exchange. When this function is OFF (Default) the machine will automatically remove the inserts from the spindles before a tool change and replace them back after it. All necessary moves and actions will be executed, requiring no operator intervention. Default Retract rate
Retract rate
RTR,#
This function sets the default retract rate, assigned to tools upon software load or after a tool data reset. Normally, this defaults to the maximum programmable retract rate on the machine. Retract rates can be programmed per tool, but a retract rate is always required. This function allows you to specify the rate to be used if no specific value is given. A button to set the default retract rate is available on the Tool and Router page. The value is displayed on the face of the button. Touching the button will present you with the keypad, at which you can directly enter the new default value. ORIGINAL SCREEN: The button is available on the Secondary Options and Switches page. DNC default
SIXM,on/off
This function turns ON or OFF DNC as the default device for part program selection. Normally when you select the part program (either through the SI keyboard command or the button on the Job Setup menu) you must specify which device the program will come from. This function allows you to specify in advance that the program will come from DNC, so all you need to specify at part program selection time is the file name. A button for toggling this default on and off is available on the Job Setup popup menu. Pressing the button will toggle between default ON or OFF. To display the Job Setup Menu, press the CURRENT JOB SETUP button located on the Machine Setup Page. ORIGINAL SCREEN: The button is available on the Options and Switches page. Home Pulse Check mode
HPCK,on/off
Home Pulse Check mode is used to verify that there are no problems in the positioning system that are causing a "shift" of the machine's zero position. During homing, the machine's position counters are electronically zeroed when the machine crosses the home pulse. Moving in one direction counts up, and in the other direction counts down. Theoretically then, the position at the home pulse should always be zero. A non-zero value read at the home pulse indicates hardware problems. These can normally be attributed to scale electrical or alignment problems, or to problems with the counter circuitry or cabling. The result of these problems would be "lost" or "false" counts, which result in a position "shift". Home Pulse Check is a check made at end of program which drives the machine off to the home corner and finds the home pulse. It reads the counters at the home pulse, and expects to see zero. Due to computer timing, it is not possible to expect EXACTLY zero, so it looks for zero plus or minus some tolerance (set by system configuration). If there is no problem, the machine simply parks, and does not complain. If a problem is detected, a "SCALE COUNTS LOST" message is displayed in the machine status box. This function WILL NOT tell you right away if you have lost counts, and thus will not "save" boards in the event of a scale failure, but it will serve as an early warning indicator stopping you from producing any more scrap. A button to control this function is available on the Special Features page. Pressing the HOME PULSE CHECK button toggles Home Pulse Check ON and OFF. The button's text and border "light up" when Home Pulse Check is enabled. ORIGINAL SCREEN: The button is available on the Secondary Options and Switches page. Auto Path Optimizer
AUTOPOP,on/off
The Auto Path Optimizer is used to reduce XY travel in part programs by performing a simplistic optimization of the programs as they pass through the NC system. The Optimizer reorders strings of XY coordinates using a simple, but very fast and effective "peephole" method which optimizes only 40 coordinates at a time. Any action requiring more than a simple drilled hole (e.g.: toolchanges, programmed stops, etc) will cause the optimizer buffer to dump and the last input hole in the series will always be output as the last hole before the action which caused the dump. This is done so that coupon holes can be left in their proper place. The Auto Path Optimizer defaults to OFF, but should usually be turned ON since many customers run programs which are badly optimized and can thus gain considerable increases in production time by this method. To have the Auto Path Optimizer come up as the default, the command AUTOPOP,ON should be placed in the MACH.DAT file. There may be specific circumstances where Optimization IS NOT DESIRED, such as required orders of holes, or when the data being drilled has been pre-optimized very effectively upstream from the machine. In these cases, the Optimizer should be left off, or turned off via the keyboard command (which can also be placed in the MACH.DAT file), or the button. A button for enabling and disabling the Auto Path Optimizer is available on the Job Setup Menu. This button is a toggle, and changes state each time you touch it. To display the Job Setup Menu, press the CURRENT JOB SETUP button located on the Machine Setup Page. NOTE: This function is part of the Rev 3.0 Option Bundle. ORIGINAL SCREEN: The button is avaliable on the Secondary Options and Switches page. Lights Out Mode
LTOUT,on/off
This button turns on and off lights out operation. When on, the lights out software on the CNC-7 will automatically initiate recovery from events that occur during normal system operation. The system will use the normal recovery modes unless a lights out recovery mode is specified. The following are some examples:
Drill stroke dwell time
DWELL,#
This value is the amount of time that the table must be stopped within the null band before the table will be considered to be in position. The longer the time value, the more certain you can be that the table is stopped and stable. The shorter the time value, the faster the machine runs, but the less sure you are that the machine is stable when the drill stroke takes place. During automatic operation, this dwell occurs at the end of each move, and (or example) before the drill stroke. This is NOT a dwell at the top or bottom of the stroke, as is sometimes believed. There is a definite trade-off between accuracy and productivity as the dwell time is altered. Specific results will depend on machine type, and on what kind of shape you keep your machines in. The dwell time is set by Excellon for each machine type, and should normally not need to be changed. A button for displaying and selecting the dwell time is available on the Tool and Router page. Pressing the button will present you with a keypad for entering a new value. The value is in milliseconds. ORIGINAL SCREEN: The button is available on the Secondary Options and Switches page. Tool Status Indicator cutoff
BTIC,on/off
TSIC,on/off
This function enables and disables the Tool Status Indicator (also referred to as Broken Tool Indicator) cutoff function. When this function is enabled, the machine does not check tools outside a range of diameters for whether or not they are broken. This function only has effect when a range has been specified and when the tool detectors are enabled. Depending on the technology used, a tool detector may have problems with smaller tools, larger tools, or both. An accompanying VSB command (See TSI-TOOL-RANGE) will define the limits of the Tool Detectors (if any) currently installed on your machine. A button for toggling the Tool Status Indicator cutoff is located on the TSI Setup menu. To display the menu, press the TSI button located on the Machine Setup page. Pressing the TSI Cutoff button toggles the function on and off. The button's text and border "light up" when the cutoff is enabled. ORIGINAL SCREEN: The button is available on the TSI Setup page. Optional Stop
OSTOP,on/off
M06
The Optional Stop function is used in conjunction with the M06 part program code. This can be used (for example) to cause the machine to optionally stop at the end of a step and repeat section so that the operator can inspect or remove the pattern. The M06 code has no effect if the Optional Stop is turned off, but if on, it will cause the machine to stop, and will then require a START button push for the machine to continue. A button for toggling the Optional Stop is located on the Job Setup popup menu. Pressing the button will toggle the function on and off. To display the Job Setup Menu, press the CURRENT JOB SETUP button located on the Machine Setup Page. ORIGINAL SCREEN: The button is available on the Secondary Options and Switches page. Single Block mode
SBK,on/off
Single Block mode is used in helping to debug part programs. When Single Block mode is on, the machine only reads data from the input device (e.g.: a paper tape reader) when it absolutely requires data, or would otherwise stop altogether. This causes the input device to read only a few blocks ahead of the machine, and to therefore make locating a point in the program which caused a problem much easier to find. It should be noted here that when Single Block mode is on, it will cause the machine to run slower during the first run, since the machine will be paced by the input device. Normally, the part program is read far in advance of what the machine is doing at the moment to avoid delays. Once the program is loaded to memory however, Single Block mode has no impact. A button for toggling Single Block mode is located on the Job Setup popup menu. Pressing this button will toggle Single Block mode on and off. To display the Job Setup Menu, press the CURRENT JOB SETUP button located on the Machine Setup Page. ORIGINAL SCREEN: The button is available on the Secondary Options and Switches page. Feed and Speed Buttons
FSB,on/off
The Feeds and Speeds Buttons function turns ON or OFF manual entry of feeds, speeds, retracts, chiploads, or cutting speeds by the operator. This will allow you to control which operator have access to changing feeds and speeds, and which don't. This is intended as an aid in controlling your process. If an attempt is made to change the feeds and speeds when the feed and speed buttons are disabled, you will simply get a message. Typically, you would turn on or off the feeds and speeds from the Operator login script, or by allowing certain operators to change the status of this switch. The FEEDS AND SPEEDS button to toggle this switch on and off is located on the Tool and Router page. Pressing this button will cause the function to toggle on or off, assuming that the you have the privilege to change the state of the switch. The button's text and border "light up" to indicate when feeds and speeds are enabled. ORIGINAL SCREEN: The button is available on the Options and Switches page. Disabling feeds and speeds also disables use of the Upper Limit, Lower Limit, and Rout Depth yellow adjustment buttons. If disabled, pressing these yellow buttons will have no affect. Disabling FSB does not affect the UP, DN, or RD buttons or commands, which are restricted separately with standard command protection mechanisms. Block Delete mode
BLKD,on/off
Block Delete mode is used to cause the machine to optionally omit certain parts of the part program. Part program blocks affected by Block Delete begin with a slash character ("/"). When Block Delete is off, the slash character has no effect, and the program will operate normally. If Block Delete is on, the blocks which begin with slash characters are ignored by the system. This can allow you to optionally ignore a step and repeat sequence, or a series of setup instructions (e.g.: M47 codes), or to optionally drill tooling holes in soft tooling. A button for toggling Block Delete mode on and off is located on the Job Setup popup menu. Pressing this button will toggle the Block Delete mode on and off. To display the Job Setup Menu, press the CURRENT JOB SETUP button located on the Machine Setup Page. ORIGINAL SCREEN: The button is available on the Secondary Options and Switches page. Override M48 header
OM48,on/off
Override M48 header is used to get the system to ignore the M48 header, and not execute any of the commands in the header. This can be used (for example) when trying out new tool parameters that you wish to test before permanently changing the part program. Override M48 header is probably of most value on older machines with limited memory (such as a CNC-2), since it is likely that larger programs will not fit into memory, and could thus read the header repeatedly when running from a non-paper tape device such as disk or DNC. A button for toggling OM48 mode on and off is located on the Job Setup popup menu. Touching the button will toggle OM48 from on to off or vice versa.To display the Job Setup Menu, press the CURRENT JOB SETUP button located on the Machine Setup Page. ORIGINAL SCREEN: The button is available on the Options and Switches page. TMG Setup menu
TMGSET
This button displays the TMG Setup menu (for those machines so equipped). The menu allows you to select tools to skip both the diameter and runout checks, or to select tools to skip only the runout check. For an explanation of these functions, please refer to the individual button descriptions. The TMG Function button to display the TMG Setup menu is located on the Machine Setup page. To exit the popup, touch the red header bar at the top of the menu. Diameter Check (TMG) ON/OFF button
DCHK,on/off
This button is used to toggle between Diameter Check (TMG) ON and OFF. In ON mode, diameter checking is active and tools will be checked upon tool changes or when commanded to do so. In OFF mode, this feature is disabled. The TMG ON/OFF button is located on the Machine Setup Page, to the right of the TMG Function button. The button toggles between TMG ON or OFF each time it is touched (assuming that the machine is equipped with TMG capabilities). ORIGINAL SCREEN: The button is available on the TMG Setup window. Tool Diameter and Runout Check Recovery Mode - TMG Mode
DIRUNMODE,#
The Tool Diameter and Runout Check Recovery Mode button is used to set the sequence of operations to be followed by the machine after a tool fails to pass the diameter or runout check. When Mode is set to 1, a failed tool stops part program execution and a message on the screen indicates the problem. When Mode is set to 2, if an incorrect tool is detected, an attempt is made to replace the current tool and continue executing the part program. The TMG Mode button is located on the Machine Setup page. Skip TMG Diameter and Runout Check
NOTMG,OFF
NOTMG,#,#,#...
Skip TMG Diameter and Runout allows you to turn OFF both diameter and runout check for individual tools, or to turn diameter and runout check ON for all tools (not the same as enabling diameter check). This is provided to handle tools such as end mills or router bits that may not be compatible with the TMG system due to tool geometry, resulting in erroneous wrong diameter and excessive runout messages. For tools where only false runout readings occur, the runout check may be turned off with the NORNO command. The display is located on the TMG Setup menu. To display the menu, press the TMG button located on the Machine Setup page. Touching the Skip Diameter and Runout Check display box will cause the Keypad window to appear, allowing you to enter the tool number(s) for which the diameter and runout check is to be turned off. Entering OFF will clear the list, turning diameter and runout check ON for all tools. Skip TMG Runout Check
NORNO,OFF
NORNO,#,#,#...
Skip TMG Runout allows you to turn OFF the TMG runout check for individual tools, or to turn runout check ON for all tools. This is provided to handle tools such as end mills or router bits that may not be compatible with the TMG system due to tool geometry, resulting in erroneous excessive runout messages. For tools where false wrong diameter readings also occur, both the diameter and runout check may be turned off with the NOTMG command. The display is located on the TMG Setup menu. To display the menu, press the TMG button located on the Machine Setup page. Touching the Skip Runout Check display box will cause the Keypad window to appear, allowing you to enter the tool number(s) for which the runout check is to be turned off. Entering OFF will clear the list, turning the runout check ON for all tools. Tool Detector Recovery Mode
TSIMODE,#
The Tool Detector Recovery Mode button is used to set the sequence of operations to be followed by the machine after it detects a broken tool. When Mode is set to 1, a broken tool stops part program execution and a message on the screen indicates the problem. When Mode is set to 2, if tool breakage is detected, an attempt is made to replace the current tool and continue executing the part program. When Mode is set to 3, a broken tool stops part program execution and a message on the screen indicates the problem. After press the START button , an attempt is made to replace the current tool and continue executing the part program. This is a semi_auto mode. The active recovery mode is displayed on the Machine Setup page and TSI Setup menu. Touching the Mode button allows you to directly enter the recovery mode to be used. Tool Detector Clog Check
TSICLOG,#
The Tool Detector Clog Counter button is used to specify the number of consecutive clogged holes considered to be significant, for machines equipped with the Laser Tool Check (LTC) hardware with clogged tool detection. When the Clog Counter is set to zero the clogged tool check function is disabled, causing the machine to ignore clogged tool indications. When the Clog Counter is set to a value other than zero, the machine will tolerate a clogged tool for the specified number of consecutive holes before it is considered significant. Should a tool free itself of a clog before drilling the specified number of holes, the next time a clog is detected the machine will again tolerate the clogged condition for the full number of holes specified. Recovery from a clogged tool situation is the same as for broken tools, as determined by the Tool Detector Recovery Mode. The Clog Counter button is located on the TSI Setup menu only for machines equipped with LTC hardware with clogged tool detection. To display the menu, press the TSI button located on the Machine Setup page. Touching the Clog Counter button allows you to directly enter the desired value. Tool Detector spindle select
DETECT,on/off
This function is used to select the spindles to be monitored for broken tools during machine operation. The actual spindles monitored will be those which are selected by this command AND which are being used for drilling. You should turn the detectors on for all spindles on your machine, and you should not turn the detectors off for individual stations simply because you are not using that spindle on a particular job. During machine operation, the system will monitor those spindles which are selected and being used for drilling, and which are selected by this function. The Tool Status Indicators will be used to check for broken tools, mis-ringed tools, and other tool problems. The TSI Current state button is located on the Machine Setup page, to the right of the TSI Function button. The button displays the spindles to be monitored for broken tools. Touching this button will present you with the keypad, which can be used to enter the monitored spindle numbers. Tool Status OK (Microwave tool detector)
ROVR
This function sets the status of the tool to OK. The Tool Status Indicator System of the CNC-7 monitors tools as they are used, and builds a table of various tool diameters as the machine runs. Each time a tool of a particular diameter is picked up, it is checked to see if the tool looks valid compared to other tools of this diameter the system has seen before. In the event that the system decides a tool is bad when it's not (for example, if you use a step tool or different tool manufacturer), then this function can be used to tell the machine "The tool is good", and the machine will adjust its expectations of what to expect for this diameter, and continue drilling. A START button will be required. A button to perform this function is located on the TSI Setup menu. To display the menu, press the TSI button located on the Machine Setup page. Touching the Tool Is Good button will cause the machine to treat the broken tool in the collet as good, and continue drilling. This function should be used only on machines equipped with Microwave Tool Detectors. Tool Detector new spindle (Microwave tool detector)
RSPN,#,#,#...
This function is used to tell the Tool Status Indicator system that a new pressure foot has been installed on one or more stations, and to reset its expectations of what the various tool diameters will look like on those spindles. This command may also be needed when some other portion of the system has been altered which will significantly impact the reading on a particular station. A button to perform this function is located on the TSI Setup menu. To display the menu, press the TSI button located on the Machine Setup page. Touching the New Pressure Foot button will cause the machine to present you with the keypad, which will allow you to specify those spindles which are affected. This function should be used only on machines equipped with Microwave Tool Detectors. Tool Detector table reset (Microwave tool detector)
RTBL
This function clears the table which is built up by the system telling the machine what each tool diameter looks like on each spindle. Clearing the entire table should seldom if ever be necessary, but some situations might warrant it (such as completely changing drill types used within the shop). A button to perform this reset is available on the TSI Setup menu. To display the menu, press the TSI button located on the Machine Setup page. Pressing the Reset All TSI Data button will first present you with an "Are you Sure" verification, since this reset will overwrite and destroy the TSI diameter table. After verification, the table will be cleared. This function should be used only on machines equipped with Microwave Tool Detectors. Tool Detector diameter reset (Microwave tool detector)
RDIA
This function clears the TSI data for a particular diameter. This can be done in advance when it is known that you will be changing to a new tool geometry for a certain tool size without having to reset all of the TSI data for all tool sizes. A button to perform this reset is available on the TSI Setup menu. To display the menu, press the TSI button located on the Machine Setup page. Pressing the Reset This Size TSI Data button will first present you with an "Are you Sure" verification, since this reset will overwrite and destroy the TSI information for this diameter. After verification, the entry will be cleared. This function should be used only on machines equipped with Microwave Tool Detectors. Broken Tool Menu
BTRRPOP
The BROKEN TOOL MENU button located on the Front Page, displays the Broken Tool popup menu. The menu provides you with options to assist in dealing with broken tools when they occur. Included in the menu are the following items. See related sections of the CNC-7 User Reference manual for further details regarding each function.
Broken tool report
BTREPT[,part_pgm]
This function generates a broken tool report. The report is generated by searching the STATS log files for occurrences of broken tools. Each occurrence is then listed in the report by stack number. You may create a report listing all broken tools contained within the log files, or you may generate a report for a specific program. (If you are unfamiliar with the system log files, please refer to the Log Files chapter in the CNC-7 System Reference Manual for a description.) The message "Broken tool(s) detected: Refer to Broken Tool Report" will display in the machine status box at the completion of a part program if tool breakage was detected at any time during the program. This is a useful reminder if the broken tool locations are not inspected or repaired at the time of breakage. The report may be used in conjunction with the Create Recovery Program function to inspect or redrill locations where tool breakage was detected. The Broken Tool Report button is available on the Broken Tool menu. To display the menu, press the Broken Tool Menu button located on the Front Page. Pressing the Broken Tool Report button will display a popup asking if you want a report of all programs. If you select yes, the log files will be scanned and a broken tool report generated listing all occurrences of broken tools. If you select no, popups will display allowing you to enter the desired part program name. The log files will then be scanned, and a broken tool report generated for the LAST occurrence of that program. The maximum number of days back to scan the log files is set by the Scan Days button. The default is two days, meaning that the STATS files for today and yesterday will be scanned. After the report file is generated it is displayed automatically using the file display program. As shown in the following example, the report begins with the program name prefixed with the starting date and time. The broken tool data extracted from the log files is then listed by stack number. Create broken tool recovery program
BTRECV,part_pgm,stack,recv_pgm
This function creates a recovery part program for inspecting or redrilling locations where tool breakage was detected. The program is created by extracting the broken tool data contained within the STATS log files and converting it into a part program format. (If you are unfamiliar with the system log files, please refer to the Log Files chapter in the CNC-7 System Reference Manual for a description.) The Create Recovery Program button is available on the Broken Tool menu. To display the menu, press the Broken Tool Menu button located on the Front Page. Pressing the Create Recovery Program button will display popups allowing you to enter the part program name and stack number to be inspected or redrilled, plus a name for the recovery program. The log files are then scanned for the LAST occurrence of the specified part program. After the recovery program is generated for the desired stack, a popup will appear asking if you want to "SI" the recovery program. If you want to immediately inspect or redrill the broken tool locations, selecting yes will automatically "SI" the recovery program. The maximum number of days back to scan the log files is set by the Scan Days button. The default is two days, meaning that the STATS files for today and yesterday will be scanned. As mentioned earlier, you must provide the stack number to be inspected or redrilled. The Broken Tool Report should be consulted prior to invoking this function in order to obtain the correct stack number. For a description of stack numbers and how they are determined, please refer to the Broken Tool Report description. As shown in the following example, the recovery program begins with the M48 header of the original part program. In order to recover the M48 header, the original program must still be accessible to the CNC-7. An operator message follows the header indicating the stack number and also on which station the stack was originally drilled. The G06 is a format 2 NO DRILL code. Tool codes are inserted as needed to change to the correct tool size. The tool number is the same as in the original program. For depth control Mode 2 tools only, the hole depth is appended to the T code as indicated by T1Z-.120 in the example. The M47 messages cause the machine to halt at each broken tool coordinate allowing you to inspect the location and redrill if desired by pressing the DRILL CYCLE button. The program ends following the last broken tool location by replacing the current tool. Broken tool scan
BTSCAN,#
This function sets the maximum number of days back the STATS log files will be scanned for the Broken Tool Report and Create Recovery Program functions. For example, setting the maximum number of scan days to three will cause the STATS files for today, yesterday, and the previous day to be scanned. The Scan Days button is available on the Broken Tool menu. To display the menu, press the Broken Tool Menu button located on the Front Page. Touching the Scan Days button allows you to directly enter the desired value. NOTE: This function is part of the Rev 3.2 Option Bundle. ORIGINAL SCREEN: This function available only as a Keyboard command. Skipping holes
SKP,H
SKIP HOLES FORWARD:
This function allows you to skip forward a number of holes from your current position. The speed of the forward skip varies greatly depending on whether or not the program is loaded into memory. If the program has not been loaded, and the CNC-7 must simultaneously load the program while skipping, then skip speeds are about 3000 holes per minute. If the program has been loaded into memory, then skip speeds are about 85,000 holes per minute.
Skipping tools
SKP,T
This function allows you to skip forward from your present position to a particular tool number. For example, if you wanted to pick up holes in tool four, you'd skip forward to tool four, and then may do a separate hole skip within tool four. Tool skips happen at the hole skipping speeds. Skipping patterns
SKP,P
This function allows you to skip the specified number of step and repeat patterns. This would be used for example begin drilling at the fourth step and repeat pattern. Nested step and repeats are supported. Skips happen at the hole skipping speeds. Skip to here
SKP,HERE
This function allows you to locate the position in a part program which corresponds to a table position. To use this function, simply locate the spindle nose over the hole to be picked up. This must be located plus or minus 0.125 (3.0mm) from the hole location. Press the Skip to Here button. The part program will be scanned until a near match is found, and then the table will move to the location of the found hole. The pressure feet will be raised, giving you a better view of the drill bit and the work below. If that is exactly the hole to be used - fine - you're done and may continue drilling. The pressure feet will be lowered automatically. If this is not the place, press Skip to Here again, and the CNC-7 will locate the next hole within the vicinity of the original table position. Again, the table will move to that next position. This can be continued until the desired hole is found. Although Skip to Here is not as fast as the hole skip (due to the extra calculations involved), it is still very valuable in certain situations. Selecting the part program
SI,file
The Set Part Program function allows you to select the part program to be used for drilling. The function is available on the Job Setup popup menu. To display the Job Setup Menu, press the Current Job Setup button located on the Machine Setup Page. Pushing the Set Part Program button will cause the Input/Ouput selection window to come up, allowing you to select the input device to find the program on (for example, floppy, disk, DNC, reader) and the file name. If you select a device that is file-structured (like a floppy), you will then be presented with a list of files on that device. You select your file and press SELECT. If you select a device that is not file-structured (like a reader), then the selection is complete immediately. If the device is DNC, then it is not possible to display the available file names, and you will simply get a blank display list, and must enter the file name from the keyboard. After the desired program has been selected in the Input/Output selection window, press the Execute button to establish it as the new part program. The DNC Default button also available on the Job Setup Menu, allows you to set DNC as the default. When set, this causes the part programs to come off of DNC by default. The current part program name is displayed to the right of the CURRENT JOB SETUP button on the Machine Setup Page, and is also displayed on the Front Page. Also included on the Front Page in the upper right corner is a Blocks display. This display shows the number of blocks read from the input device, followed by the number of blocks created by the expansion of the part program (e.g.: Step and Repeats). It is normal for the part program reading to pause while the part program is expanded. Current Job Setup menu
JOBSET
This button displays the Job Setup popup menu. Located on the Machine Setup page, the CURRENT JOB SETUP button displays a menu to provide you access to several related setup functions all in one place. Included in the menu are the following items. See related sections of the CNC-7 User Reference manual for further details regarding each function.
Job Setup popup window
JOBSET
This button displays a popup window which allows you to select between part program file selection (see SI), program DRYRUN, Tool Forecast, Double Row of Panels ON/OFF, or a custom Job Setup script designed for your particular installation. This provides a convenient way to easily access several related functions and avoids switching of pages to use them. See related sections of this manual on each function for further details. The popup can be disabled and replaced by part program selection if you do not wish to have access to these functions when the Job Setup button is pressed. Double Row of Panels Selection
DROW,on/off
This button turns on and off the Double Row of Panels feature. When this machine function is active, two panels per station are drilled on one single job run, thus speeding the overall process. After completing all requested holes on the first panel for a given tool, the process continues on the second panel. Then tool change takes place and the machine goes back to the first panel, completes that tool run and switches to the second row of panels one more time. This is a convenient way to increase productivity when the size of the panels being fabricated allows for two rows. Job setup and tool change times are reduced by operating in this mode. No modifications are required to the part program, as the system automatically handles these duplicated rows. A machine configuration command specifies the separation between panels on the same station. Job dimentions and offset between panels must fit within the tooling plate specifications to prevent an 'out of limits' condition. Job setup should be done as usual for the first row, but keeping in mind that the machine will replicate the program on the second row with the addition of the specified offset between rows. On independent spindles machines both rows should contain panels for every selected station. This button is available from the Job Setup popup window. It must be enabled first by including the command DOUBLE-ROW-OFFSET,X#Y# in the machine description file. Manual Toolchange
T,#
Manual toolchange can be commanded from a keyboard command, or from a button. The machine must be not running, homed, and ready before a manual toolchange can be performed. If a tool is already present in the collet, the machine will put away the present tool before picking up the new tool, just as it would in automatic mode. A Change Current Tool button to perform manual toolchanges is located on the Manual Operations page. Additionally, a Change Current Tool button is available from the Machine Setup page via the Miscellaneous Tool Setup popup menu. To display the Tool Setup menu, touch the box displaying the current tool number located near the center of the Machine Setup page. When pressed, either button will cause the 10-key pad to appear for you to select your tool number. For TMS equipped machines, the tool number keypad also includes a "Remove and Replace" (R/R) button. Pressing this button will cause the machine to deposit the tools presently in the spindle collets into the transfer pistons and park the table. The tools may then be inspected and/or replaced as desired. Pressing the START button will then cause the machine to place the tools in the transfer pistons back into the spindle collets. ORIGINAL SCREEN: The button to perform manual toolchanges is present on the Setup and TMS pages. Diameter page and Selecting Materials
DIAP
Creating Diameter page files
The CNC-7 includes a directory called MATERIALS. This is meant specifically to hold Diameter page files, which can contain diameters, feeds, speeds, retract rates, Z-axis offsets, and max hit counts. These files should be given names indicating which materials they are used for. e.g.: FR4, 2SIDED, 8LAYER, etc. This will allow the operator to identify them easily when it is necessary for him to change materials. A DIAMETER PAGE button, located on the Machine Setup page, displays the Diameter Page popup window. This window is used to load and examine the diameter page data. To load the diameter page, a SET MATERIAL button is included in the popup window. Pressing the button effectively loads (or creates) the diameter page, by allowing the operator to select the Diameter page file from within the Materials directory. Once the diameter page is loaded, the popup window allows the operator to examine the data for the provided diameters. Once diameter page data is loaded, setting a tool's diameter will cause the tool data to be looked up in the diameter page, and loaded into that tool's tool data. The data will be used from an exact diameter match, or front the next larger tool. This allows you to put together part programs without any detailed tool data, and have that information provided by the machine, based on that particular machine's capabilities. The diameter page data must include a diameter (C), Feed (F), Speed (S), and may optionally include a Retract rate (B), Z-axis offset (Z), and Max hit count (H). If the requested diameter page file does not exist, you will be asked if you want to create it. If yes, you will be asked for the minimum and maximum diameters, the size of the diameter increments, the chipload (inches or mm per revolution), the cutting speed (surface feet per minute or meters per minute), and whether to calculate Z-axis offsets. If you ask the system to calculate Z-axis offsets, you must provide the point angle of the drill, which is usually something like 165 degrees. You may specify multiple point angles. For example, it is common to have point angles of 165 degrees on drills from 0.125 inches and up, and for drills smaller than 0.125 to have point angles of 135 degrees. You enter the point angles for the largest tools first. You'll be asked for a point angle, and you'll enter 165 degrees, then you'll be asked for the smallest diameter to which this point angle applies, and you'll enter 0.125. Next you'll be asked for another point angle, and you'll enter 135 degrees, and finally you'll be asked for the smallest diameter to which this point angle applies, and you'll enter zero. In calculation of the Z-axis offsets, the appropriate point angles will be used. When generating diameter page files, the system will use a maximum of a 0.001 (inch) chipload for tools above 0.1875 inches to avoid collapsing the air bearings on the air bearing spindles. ORIGINAL SCREEN: The SET MATERIAL button is located on the Machine Setup page. Setting up for RoutingThis section describes those buttons (and their related keyboard commands) which can be used to set up routing. Several of these functions may be things you will wish to determine once, and then add to the MACH.DAT file so that you no longer have to concern yourself with them. Most of the buttons described here are available from the Tool and Router and Machine Setup pages. The button to manually lower the spindles to the rout position is located on the Manual Operations page. Cutter Compensation Value selection
CP,#,#.#
This function is used to set the compensation value used with a particular compensation index. Each index can be assigned to a different tool size, or more than one index can be used on the same tool (for example, to account for cutter deflection). See "Tool Selection with Compensation index" in the chapter on Part Programming. This function can be used in either of two ways. First, as a command, you specify two arguments, the compensation index and the compensation value. The compensation value is the diameter of the tool to be used in offsetting the tool path from the part. Second, as a button located on the Tool and Router page, you enter the compensation value for the currently displayed index. Note that although the compensation value and tool diameter are often similar, there is no direct connection between the two, and that loading one does not load or affect the other. CP commands may be included in the M48 header, or may be used from the keyboard. The button generally requires you to use both this button and other buttons to display the desired compensation index. ORIGINAL SCREEN: The button is available on the Router Cutter Compensation page. Cutter Compensation Index selection
Detailed information is displayed on the Tool and Router page for one cutter index at a time. There are two ways of selecting which cutter index information is displayed. First, there are two buttons labeled View located next to the index display. Touching the up arrow button displays the next index data, touching the down arrow button displays the previous index data. Holding either of these buttons will scroll through the various indeces. This can be used to fast advance to a particular index number. Secondly, by touching the box containing the displayed index number, you can directly enter the index number for which you want the cutter data displayed. These index numbers can be between 1 and 99. Each of these buttons are located on the Tool and Router page (TP). Maximum Rout Distance
This button is located on the Tool and Router page, and indicates the maximum allowed cutter distance before the tool should be considered expired and changed for another. The tool is checked for Maximum Routed Distance before a rout position plunge, to avoid having the machine stop in the middle of a cut and request a change. The toolchange will proceed very much like a maximum hit count toolchange in drilling mode. The button displays and allows entry of a new maximum cutter distance for the currently selected tool number, as indicated on the Tool and Router page. The display indicates the maximum distance in feet or meters, depending on whether the system is operating in Inch or Metric mode. The Maximum distance can be set using the button or keyboard command. The keyboard command has two parameters, the tool number and Max Distance, respectively. Reset Accumulated Cutter Distance
R,D
This function allows you to reset to zero cutter distances for individual tool numbers, or for all tools. A button to perform this function is available from the Tool and Router page. The Accumulated Cutter Distances are displayed on the page for each tool number, and the values are used in determining when a tool is expired and should be changed out for a new tool. Counter-clockwise reversal
CCW,on/off
This function allows you to reverse the meaning of clockwise, as used by the G02, G03, G41, G42, G32, G33 part program commands. On Excellon equipment, clockwise is always clockwise, regardless of version. It may therefore be necessary when running a program in more than one version to change the selection of this switch, although normally it is set once and then left unchanged. This function will affect six routing commands, as described in the Part Programming chapter: Sliding Pressure Foot enable
PF,on/off
This function allows enabling and disabling of the Excellon Sliding Pressure Foot which allows parts to be clamped down when making the final cut on a part. This helps prevent parts from being gouged when they break free after the last cut. A button to toggle this switch is available from the Tool and Router page. The button's text and border "light up" when the sliding pressure foot is enabled. Prevacuum shut-off
PVS,on/off
This function allows enabling and disabling of the prevacuum shut-off, which allows the machine to open and close a butterfly valve located in the vacuum manifold when making the final part of a cut. This helps prevent small parts from being sucked up in the vacuum upon completion. A button to toggle this switch is available from the Tool and Router page. The button's text and border "light up" when the vacuum shutoff is enabled. Programmable Plunge Rate
PPR,on/off
This function allows the plunge rate to rout position to be programmed using the tool data's infeed rate (F#). When this switch is turned off, a constant plunge rate as defined by the ZFEED VSB command (usually 30ipm) is used. When this switch is turned on, the infeed rate from the tool data is used. A button to toggle this switch is available from the Tool and Router page. The button toggles between Fixed Plunge Rate (the default) and Programmed Plunge Rate each time it is touched. Velocity Calibration
Calibrate Velocity
CALV
This function calibrates the velocity of the XY servo system to minimize run time path correction during routing. It has NO IMPACT on point to point moves during drilling. The CALV function will be requested any time the machine is powered on via a message displayed in the Machine Status box. CALV makes five back and forth diagonal moves at varying speeds as it compensates the speed of the worktable. The status of CALV as it runs is displayed in the Machine Status box. The table must be homed before CALV can be run, and CALV will only compensate for velocity variances up to 25 percent. Variances above that are assumed to be hardware malfunctions and must be tended to separately. Note that the use of CALV is recommended to ensure best accuracy during routing, but is not required. A Velocity Calibration button to perform the CALV function is provided on the Tool and Router page. Rout position
RD,#
The Rout Position is the lower position, or "plunge" position used during routing. The Rout Position is only used during non-depth controlled routing. During depth controlled routing, the Rout Position is totally ignored, and the machine routs at the depth value programmed for that tool. The "Rout Up" position is simply the standard Drill Ready, or Upper Limit position. In going to Rout position, the Z-axis first goes to the Upper Limit, brings the spindles to speed, and then plunges to Rout position. To retract the spindles, simply command the spindles to the Upper Limit (by pressing the button labeled RAISE THE SPINDLES), or to the Retracted position by parking the table or pressing RESET. Pressing the Rout Position button located on the Machine Setup page, allows you to directly enter a new value using the 10-key pad. Rout Down limit input is inhibited in Controlled Penetration mode (depth control mode 3). Instead, the down limit is automatically set to the backup material reference height. The Z-axis offset is then used to specify the desired depth relative to the top of the backup material. Setting Rout position
A set of two buttons, located on the Spindle Setup page, allows you to raise and lower the machine's Rout position. This position cannot be changed while the machine is currently executing a part program, but can be used when the Z-axis is in the rout position. These buttons are located in the upper left-hand part of that screen. With these buttons, the adjustment begins slowly, and continues that way for the first three seconds. After that, the adjustment speed increases by a factor of four. Releasing the button, and then continuing to press it will return to the lower speed adjustment. On this screen, the number being adjusted is itself in a box. Pressing the number will allow you to make a direct entry using the 10-key pad. These buttons function very much like those used to adjust the upper and lower limits of a drill stroke. Going to rout position
Rout position action
This button is located on the Manual Operations page. The button allows you to change the position of the machine's spindles between the rout down or "plunged" position, and the rout up (Upper Limit) positions. Note that this function is only available on machines equipped for routing. This button manually performs the same movements that would happen using M15 or M16/M17 commands under part program control. When the spindles are commanded to rout down position, the machine first moves to the Upper Limit, the spindles are started and brought up to speed, assuming that there is a tool in the collet. If there isn't, the machine will not take the spindles to the down position. In this position, the pressure feet are down to press against the work, and the manual collet is disabled. After the spindles have been successfully brought up to speed, the Z-axis will plunge the cutter into the workpiece. Using this button to manually put the spindles down will take the system out of No Drill mode and allow drilling or routing. The No Drill button does not affect the position of the machine's spindles. When the spindles are commanded to the rout up position, they will raise to the Upper Limit position and continue to run. NOTE: In a machine equipped with routing capabilities, the Upper Limit position also serves as the ROUT UP position, where the spindles retract to on an M16 or M17. The text of this button changes to tell you what the next action will be. For example, if the spindles are up, the button will be labeled something like ROUT DOWN POSITION. When the spindles are in the rout down position, the button will be labeled something like ROUT UP POSITION. Setting up Reference ScalingThis section describes the CNC-7's functions for supporting Reference Scaling. Reference Scaling provides a relatively simple way to compensate for expansion and contraction of multilayer material that may occur during the manufacture of the multilayer "sandwich". The buttons described in this section are available from the Special Features page, accessible from the Machine Setup page. Reference Scaling general overview
The Reference Scaling software has been designed to facilitate the drilling of multilayer boards. Compared to the original ideal board, the production multilayer board may contract or expand due to it's fabrication process. Part programs are usually created based on the original board, thus Reference Scaling is a software tool that may be used to adjust the coordinates to compensate for the expansion or contraction of the individual multilayer board. The expansion or contraction is assumed to be uniform (linear) from some mid-point or Reference Point on the board. How the Reference Scaling is used is described in the following procedure and accompanying figure. Assume that you are working with a multilayer board which has expanded from the original board size (arrows in the figure indicate expansion). Secondly, assume that there are at least three test pads on the board. These are:
Reference Scaling Setup
REFSPOP
The Reference Scaling Setup menu allows you to enter the information needed to establish a reference scaling factor. The scaling factor is used to compensate for the expansion or contraction of multilayer material that may occur during the manufacturing process. Included in the menu are the following items. For further information, please refer to the individual button descriptions.
Reference Scaling on/off
SCLR,on/off
This function is used to turn on or off the Reference Scaling function, causing the Reference Scaling parameters to be applied to drilled hole coordinates as they come from the part program. These parameters are displayed on the Reference Scaling page. Reference Scaling can also be enabled and disabled by the SCLR keyboard command, or by the M60 and M61 part program commands. When Reference Scaling is on, a message "REFERENCE SCALING FUNCTION ON" will be displayed in the Machine Status box. A button to turn on or off the Reference Scaling function is available on the Special Features page, next to the Reference Scaling menu button. The button toggles between On and Off each time it is touched. ORIGINAL SCREEN: The button is available on the Reference Scaling page. Reference Point input
REFS,X#Y#,X#Y#
This function allows you to enter the coordinates of the Reference Points R1 and R2. These points represent the center of expansion or contraction of the multilayer board (generally, the dimensional center of the board is used), and the test pad (used in calculating the scaling factor). The REFS command allows specification of two optional parameters, one being the coordinates of the R1 Reference Point, and the second being the location of the R2 test pad used for computation of the Scaling Factor. Both R1 and R2 are relative to FLOATING zero. A button to enter the Reference Points is available on the Reference Scaling menu, as is a display of the current R1 and R2 values. To display the menu, press the Reference Scaling button located on the Special Features page. Error Point input
ERRP,X#Y#
This function allows you to enter the error point, which is the amount of variance measured between the test pad R2 and the actual drilled hole. Remember that this test pad is drilled and measured AFTER the zero correction has been entered to compensate for the Reference Point location. The ERRP command allows specification of this variance value, which is measured relative to R2. This value is NOT measured relative to FLOATING zero. A button to enter the Error Point is available from the Reference Scaling menu, as is a display of the current Error Point value. To display the menu, press the Reference Scaling button located on the Special Features page. Scale Factor input
SCLR,X#Y#
This function allows you to directly enter the Reference Scaling Scale factor, which represents the amount of expansion or contraction of the material being drilled. Normally, the scale factor is computed by the system as the Reference Points and Error point are entered. Entering the Scale factor directly will clear the values of R2 and the Error Point, but entry of the Reference Points or Error Point will calculate an appropriate Scale factor. A button to enter the Scale factor is available from the Reference Scaling menu, as is a display of the current Scale factor value. To display the menu, press the Reference Scaling button located on the Special Features page. Setting up Coupon DrillingThis section describes the CNC-7's functions for supporting Coupon Drilling. Coupon Drilling provides a fast way to check hole quality by drilling the first and last holes of any drill bit used in a user defined "coupon" area. Although you may not want to use this as your only method of verifying hole quality, it is a fast way to identify many process related hole quality problems. The buttons described in this section are available from the Special Features page, accessible from the Machine Setup page. Coupon Drilling general overviewThe Coupon Drilling software is designed to allow you to quickly check hole quality by checking primarily the first and last hits of each tool. These holes are drilled in a user defined "coupon" area which can be placed anywhere on the panel. Use of Coupon Drilling DOES NOT require special part programming, all setup is done at the control. However, the setup functions (described below) may be put into the MACH.DAT or Login files, or may be put into the M48 header of the part programs. Coupon Drilling can be set up to drill either a single or double row coupon. A single row coupon drills coupon holes only with the LAST hit of the drill. This is generally sufficient to check hole quality, since hole quality tends to degrade as the drill wears. Double row coupons drill coupon holes with the FIRST and LAST hit of the drill. These holes will be drilled using the same tool cycle as the rest of the holes - e.g.: Pecked, Depth Controlled, etc. Coupon holes ARE counted by the hit counters. ALL toolchanges are impacted by Coupon Drilling, this includes all programmed toolchanges as well as all toolchanges caused by reaching the Maximum hit count. A coupon hole will also be drilled at End of Program. Since Coupon Drilling is often not included in the part program, and is somewhat under the Operator's control, the CNC-7 will stop at the first coupon hole and instruct the Operator to verify the coupon location. If a single row coupon is being used, this will occur right before the first toolchange, if double row, this will be the first hole. This verification helps assure that coupon holes don't get drilled in the middle of the circuit because of an Operator mistake. The Operator presses the Start button to continue drilling, else he corrects the coupon location, Resets, and tries again. Coupon Drilling Setup
CPNPOP
The Coupon Drilling Setup menu allows you to establish and verify the coupon hole locations. Included in the menu are the following items. For further information, pleae refer to the individual button descriptions.
Coupon Drilling on/off
CHSZ,on/off
This button allows you to turn on or off Coupon Drilling. When OFF, the Coupon Drilling setup is ignored, and will not be used. When on, Coupon Drilling will come into play before and/or after each toolchange. This button is present on the Special Features page, next to the Coupon Drilling menu button. The button toggles between On and Off each time it is touched. Coupon Drilling mode select
CDBL,on/off
This button allows you to select single or double row coupon mode. Single row coupons will drill a hole before any toolchange (and at End of Program), double row coupons will drill before and after each toolchange. In order to use double row, the spacing between rows must be non-zero. The button is present on the Coupon Drilling Setup Menu, and toggles between Single and Double row coupon mode each time it is touched. To display the menu, press the Coupon Drilling button located on the Special Features page. Move to Coupon location
CMOV
This button causes the table to move to the current coupon location, allowing you to quickly check to see that the coupon is in the correct location. The coupon location is specified by the Coupon Location button or keyboard command (CHLC). The coupon location must be within the normal drilling area. Coupon starting location
CHLC,X#Y#
This button allows you to define the starting location of the coupon. You will need to input the XY coordinate location of the first coupon hole. The coordinate is displayed to the right of the button, and is relative to the current measurement mode, version, and floating zero. The coupon location can (and should) be verified by the "Move to Coupon Location" function. The machine will stop at the first coupon location to allow the operator to verify correct location of the coupon. Coupon spacing
CHSZ,X#Y#,X#Y#
This button allows you to define the coupon spacing. You will need to input two sets of coordinates: The first of these represents the spacing between tools in the coupon, the second represents the spacing between rows in double row mode. If you are setting up for single row mode, you can simply press ENTER when asked for the second set of coordinates. If you input row spacing, double row mode will automatically be enabled, else it will be automatically disabled. The coupon spacing is displayed to the right of the Coupon Spacing button. The upper XY coordinate pair is the spacing between tools, the lower set of coordinates is the spacing between rows. Setting up the Vision SystemThis section describes functions which are provided to assist in the setup of the Vision Assisted Drilling/Routing system (if your machine is so equipped). These buttons are located on the Vision System Setup page, available from the Special Features page. The Vision related part program codes G34-G39 and G45-G48 are described in the Part Programming chapter of this manual. There is also a chapter on configuration of the Vision System, usually done just one time at machine installation. The functions described in this section allow you to set up the Vision System modes of operation, as well as performing calibrations, training vision tools, and doing sample inspections. Enabling the Vision System
UVIS,on/off
The Vision Assist button is used to toggle between Vision System ON or OFF. When OFF, the Vision Software is completely defeated, and will not impact the operation of the machine. When ON, the system makes two passes through any part program, one to locate and process all vision functions, and one to do the actual drilling and/or routing. The Vision Assist button is available from the Vision System setup page. The button's text and border "light up" when the vision system is active. Use of Entry Material
UVIS,AUTO,on/off
This button is used to toggle between the Vision System's use of Entry Material or not. The first pass through the part program (the vision pass) is always done without entry material. This allows the Vision System to see the vision landmarks. When Entry Material Used is selected (UVIS,AUTO,off), the machine will stop after completing the vision pass and instruct you to install entry material, and then it will run the second pass to do the actual drilling and/or routing. When Entry Material Not Used is selected (UVIS,AUTO,on), the machine will automatically run the second drilling/routing pass without stopping for entry material. The button is available from the Vision System setup page. Activation of the External Vision Processor
UVIS,BOX,on/off
This button is used to toggle between Vision Processor Activated or Deactivated. When Vision System Active is selected (UVIS,BOX,off), the system will use the camera and external Vision Processor to locate vision landmarks in an automatic mode. When Vision Manual Override is selected (UVIS,BOX,on), the system will position to the approximate location of the vision landmark, and wait for you to manually (using the mouse) adjust the machine position to center the object in the field of view. The button is available from the Vision System setup page. Adjusting the Spindle to Camera Offset
UVIS,OFFSET,X#Y#
This function allows you to enter a new Spindle to Camera Offset into the system. This offset represents the distance between the spindle position and the center of the Vision System field of view in the X and Y axes. The Camera Offset button is located on the Vision System setup page. Pressing it will present you with 10-key popups to accept the X and Y values, which are displayed below the button. The values entered are both loaded into memory and written to the Vision Configuration file. Adjusting the Vision System Pixel Size
UVIS,PIXEL,X#Y#
This function allows you to enter a new Vision System Pixel Size, which is essentially the resolution of the Vision System. This resolution changes as the focus of the machine or size of the field of view is changed, since the same amount of vision "window" covers a smaller or larger amount of true distance. The Pixel Size button is located on the Vision System setup page. Pressing it will present you with 10-key popups to accept the X and Y values, which are displayed below the button. The values entered are both loaded into memory and written to the Vision Configuration file. Execution Direct Vision System Commands
UVIS,COMMAND
This function allows you to directly enter Vision System commands and to have them sent directly to the Vision System without interpretation. The results returning from the Vision System are displayed - again without interpretation. The default when Command mode is entered is to WAIT for results from the vision system. If you do not wish to wait for results, you may put the system into NOWAIT mode by typing NOWAIT at the "Command:" prompt. Otherwise, you would type a Vision System command at this point, such as "C8000=T". The Command Mode button is located on the Vision System setup page. Pressing it will clear the screen and begin accepting commands for the Vision System. Pressing RETURN only will terminate this function. Train a Vision Tool
UVIS,TRAIN,#
This function is used to train a Vision Tool, telling the system what a vision landmark is supposed to look like. The Vision System will record the features of the landmark and store it for future reference. The Train Tool button is located on the Vision System setup page. Pressing it will present you with a 10-key popup, which will request a vision tool number. After this, it will allow you to re-size the search and measurement fields using the mouse. The movement of the mouse without either mouse button pressed adjusts the size of the measurement field. The right button adjusts the search field. The left button terminates the re-sizing operation. Next the system will attempt to train the target in the field of view. If this fails, you will be instructed to re-center the target using the mouse and try again. The right button is a fast slew mode. The left button indicates repositioning is complete. At any time, touching the screen will abort the training function. Train Spindle to Camera Offset Hole
UVIS,SPNTRAIN
This function is used to train the Spindle to Camera Offset hole, telling the system what the hole is supposed to look like. The Vision System will record the features of the hole and store it for future reference. The Train Offset Hole button is located on the Vision System setup page. Pressing it will allow you to re-size the search and measurement fields using the mouse. The movement of the mouse without either mouse button pressed adjusts the size of the measurement field. The right button adjusts the search field. The left button terminates the re-sizing operation. Next the system will attempt to train the target in the field of view. If this fails, you will be instructed to re-center the target using the mouse and try again. The right button is a fast slew mode. The left button indicates repositioning is complete. At any time, touching the screen will abort the training function. Inspect Fiducial using Vision Tool
UVIS,M,#
This function is used to perform a sample measurement using a Vision Tool, reporting the measured results to the screen. The Inspect Tool button is located on the Vision System setup page. Pressing it will present you with a 10-key popup, which will request a vision tool number. Next the system will attempt to inspect the target in the field of view. If this fails and auto search is ON, the machine will try to find the target. If this fails also or it is aborted, you will be instructed to re-center the target using the mouse and try again. The right button is a fast slew mode. The left button indicates inspection is complete. At any time, touching the screen will abort the inspection function. Inspect Spindle to Camera Offset Hole
UVIS,SM
This function is used to perform a sample measurement of a Spindle to Camera Offset hole, reporting the measured results to the screen. The system will attempt to inspect the target in the field of view. If this fails, you will be instructed to re-center the target using the mouse and try again. The right button is a fast slew mode. The left button indicates inspection is complete. At any time, touching the screen will abort the inspection function. The Inspect Offset Hole button is located on the Vision System setup page. Display Vision System Caliper Tool
UVIS,CALIPER
This function is used to display the Vision Caliper tool. The Caliper button is located on the Vision System setup page. Pressing it will display the Vision Caliper tool on the Vision System monitor. You may use the mouse to center the target in the field of view. The right button is a fast slew mode. The left button indicates that use of the caliper is complete. At any time, touching the screen will abort use of the caliper. The Caliper mode can be used as a fine jog function to allow you to make fine adjustments of the worktable using the mouse. Calibrate Spindle to Camera Offset
UVIS,CALIBRATE
This function is used to calibrate the Vision System. It will calibrate the Spindle to Camera offset. The Calibrate button is located on the Vision System setup page. Pressing it will cause the machine to drill a hole (or series of holes) using the current tool and at the current position. After this, it will position the camera over the hole using the current Spindle to Camera offset, and attempt to inspect the hole(s). If this inspection fails, you will be allowed to reposition the machine using the mouse. The right button is a fast slew mode. Pressing the left mouse button will indicate that repositioning is complete. Once the system is able to successfully inspect the hole(s), it will reposition the table several times, and use the measured versus commanded position change to calculate the calibration. Both the updated Spindle to Camera offset and pixel size are written to memory but not to the Vision Configuration file. This function basically works by creating a temporary part program, called CALIBRATE.PP in the USER directory, which contains a G39 code, and then starting the machine so that the calibration is done by the G39 command. Move camera to spindle location
UVIS,CAMSPNJ
This function is used to jog the camera to the spindle location. The Jog Camera To Spindle button is located on the Vision System setup page. Pressing it will move the camera to the current spindle location. It does this by jogging the X and Y axes in the amount of the Camera to Spindle Offset. Therefore, if this values were previously made zero by the user, no actual motion will occur. If the spindle to camera offset is correctly set, this button is very useful to inspect the location on the work area where the machine will drill. Move spindle to camera location
UVIS,SPNCAMJ
This function is used to jog the spindle to the camera spindle location. The Jog Spindle To Camera button is located on the Vision System setup page. Pressing it will move the spindle to the current camera location. It does this by jogging the X and Y axes in the amount of the Camera to Spindle Offset. Therefore, if this values were previously made zero by the user, no actual motion will occur. Search Function for Vision
UVIS,SEARCH
This function is used to do automatic search in vision inspection. The Search button is located on the Vision System setup page. Pressing it will turn on or off the automatic search feature for the vision inspections in the system. The button's text and border "light up" when the search feature is active. When automatic search is on, if the machine fails to see a target it will start a radial search around the expected location until it either finds the target or reaches the search limit as indicated by the button "Search Area". Number of Vision Inspections
UVIS,INSP
This function is used to set the total number of times a target will be inspected by the vision system. If more than one inspection is requested, the machine averages the values returned by each inspection. The Number of Inspections button is located on the Vision System setup page. Pressing it will present you with a 10-key popup, which will request the total number of vision inspections desired. The current setting is displayed below the button. Search Area for Vision Inspections
UVIS,SEARCHAREA
This function is used to define the size of the area to be searched after an unsuccessful vision inspection. The Search Area button is located on the Vision System setup page. Pressing it will display the keypad, allowing you to enter the radius of the search area. The search area radius is then displayed below the button. The Vision Configuration File parameter "SEARCH-AREA" is updated each time a new radius is entered. The Search function must also be ON to enable the automatic search feature. vservoServo Vision SystemThis section describes functions which are provided to assist in the Servo Vision Assisted Drilling/Routing system (if your machine is so equipped) which is mainly characterized by Variable Servo Controlled Zoom Mechanism and Autofocus. These buttons are located on the Vision System setup page, available from the Special Features page. The Servo Vision related part program codes G34-G39 and G45-G48 are described in the Part Programming chapter of this manual. The functions described in this section allow you to perform all Servo Vision related operations, as well as doing manual focus, adjust light magnitude, auto focus, magnification and auto camera calibrations. Vision Camera Manual Focus - Move Camera Up
This button is one of the two used to manually focus the vision camera. This button is located on the Vision System page. Pressing it will move the camera up. Use this button along with the Down button to manually adjust the camera focus. Vision Camera Manual Focus - Move Camera Down
This button is one of the two used to manually focus the vision camera. This button is located on the Vision System page. Pressing it will move the camera down. Use this button along with the Vision Camera Manual Focus Move Up button to visually adjust the camera focus. Adjust Vision Light Intensity - Increase Magnitude
This button is used to manually change the light intensity. This button is located on the Vision System page. Pressing it will increase the light magnitude of the camera lamp. A percentage of the maximum lamp intensity is shown on the screen for the current selected value. Adjust Vision Light Intensity - Decrease Magnitude
This button is used to manually change the light intensity. This button is located on the Vision System page. Pressing it will decrease the light magnitude of the camera lamp. A percentage of the maximum lamp intensity is shown on the screen for the current selected value. Automatic Focus
This function is used to automatically focus the servo controlled camera. This function may be executed from the Auto Focus button located on the Vision System page, or a command from keyboard or part-program. If from the button or a command without coordinates, the camera will focus at the present table position; otherwise, the entered location (X and Y) will be used as the work table location where to focus. The entered coordinates will be affected by the current work zero and any vision correction presently in effect if this function is commanded from inside a part-program. Vision Magnification
This function is used to set the zoom factor of the servo camera. The Maginfication button is located on the Vision System page. Pressing it will present you with a 10-key popup, which will request a magnification number. This magnification number is ranged from 1 to 10. The actual camera image is zoomed based on this magnification number. The present magnification level is displayed below the button. Also, the Camera to Spindle Offset and pixel size corresponding to the new magnification are read from the Vision Zoom File. Auto Camera Offset Calibration
This function is used to perform the automatic camera offset calibration. It is available only on machines equipped with Servo Controlled Variable Zoom. Go to Vision System Setup page
This button or keyboard command is used to display the vision system setup page. This button is located on the Servo Vision page. Pressing it will bring the screen into the Vision System Setup page. Go to Servo Vision page
This button or keyboard command is used to display the servo vision page (On machines so equipped). This button is located on the Vision System setup page. Pressing it will bring the screen into the Servo Vision page, which contains all required buttons for auto focus, magnification, camera calibration, light intensity and support functions related to the servo controlled zoom and camera. aldsetupSetting up the Autoload SystemThis section describes functions which are provided to assist in the setup of the Automatic Panel Loading and Unloading system (or Autoload System) if your machine is so equipped. There are currently 2 configurations of Autoload systems available - Multi-Spindle Autoload System (as used in the SYSTEM 2000) and Modular Autoload System (as used in the SYSTEM 1000). All the buttons described here are located on the Autoload System Setup and Manual Operations pages for both types of autoload systems. Please refer to the CNC-7 display screens section to find the drawing of these display pages. As you may noticed in the drawings that some buttons are used in both types of Autoload Systems, in which case, the buttons perform the same function unless otherwise mentioned in their description. The functions described in this section allow you to set up the Autoload System's various modes of automatic operation, as well as semiautomatic and manual operation. Job Queue File Default Storage
JOBQ file default storage
JOBQDFL,device
This function allows you to select which directory and/or device is used for the storage of JOB QUEUE files. By default, the job queue files are stored on USER. However, it is possible to use any directory, including floppy disks. A button ("Device:") for selecting the Job Queue Default Storage is located on the Autoload System Setup page. Pressing the button will present you with the file selection popup menu, which you use to select the device or directory. The current default setting is displayed on the right of the button. Each time you select a Job Queue file, or it is accessed, it will go to the device specified by the Job Queue Default Storage unless otherwise specified. ORIGINAL SCREEN: For Modular Autoload systems, the button is available on the Job Queue page. Job Queue File Name Select
JOBQ default file name
Setup file name
JOBQ,file
Job Queue is a job scheduling function to allow pre-programming of jobs in conjunction with the use of the Autoload system. A job queue contains information about the undrilled panels in the load elevators or in the incoming conveyor system to be used at the machine, therefore permitting the mixing of different panels for different jobs in the same panel delivery system. A maximum of 75 jobs is allowed within a Job Queue. A job in the job queue is defined to be a group of panels to be drilled by the same part-program with the same setup file using the same spindle selection. There is a limit of 32,767 panels per job and no limit to the total # of panels in the entire job queue. This allows pre-programming of a CHAIN of load elevators if elevators are used. The software will stop and wait for load elevator change-over should all panels be exhausted before the end of the job queue. Of course, in a mass production environment where a machine tends to be used for the same job over a large number of panels, it will make more sense to use the SINGLE JOB MODE rather than the Job Queue mode. Please see Single Job/Job Queue Mode button description for a more detailed explanation of Single Job mode. A job in the job queue contains four pieces of information - A part-program name and its source device, a setup file name, a total number of panels, and the spindle configuration (stations to be used) for the job. The number of panels per job does not necessarily have to be a multiple of the number of stations selected. For example, a total of 11 panels can be drilled in a three station configuration, in this case, the software will automatically de-select the last spindle and drill only the 10th and the 11th panels using the first two selected stations. In the case of the Modular Autoload system, since all the machines involved are single spindle, therefore the spindle used is defaulted to spindle #1 and there is no provision to allow for machine selection because the system is designed for flexibility in which any panels can be drilled on any machines. All job information within a the same job queue is kept in readable ASCII files called Job Queue files. This file can be created using the editor (spread sheet) provided in the upper portion of the Autoload System Setup page or be brought from another computer. Each line in the file contains information for a single job in the following format:
Viewing Jobs in the Job Queue Editor
JOBQ editor View Job buttons
HIGHERJOB
LOWERJOB
There are two buttons (Up-arrow and Down-arrow) located in the Autoload System Setup page as part of the Job Queue Editor section to allow you to scan through all jobs currently in the Job Queue. Pressing the up arrow button displays the next higher number job and the down arrow button displays the next lower number job until job 0. Job 0 is not a valid job, its function is to allow you to INSERT a job at the top of the queue (Job #1). Please note that Job 1 is the first job in the queue which is the next job to be run. Display a specific job in the Job Queue Editor
JOBQ editor Job # button
DTJOBNO
There is a button ("Job number") located in the Autoload System Setup page as part of the Job Queue Editor section to allow you to display information about a specific job in the queue. The current job number is displayed inside the button. Pressing this button will display a keypad popup to allow you to specify a specific job number for display. Please note that Job 1 is the first job in the queue which is the next job to be run. Changing the Part-Program Name of a Job in the Job Queue Editor
JOBQ editor PART PROGRAM NAME button
Modular Autoload System's JOBQ editor SETUP FILE NAME button
DTPPN
There is a button ("Part Program Name") located in the Autoload System Setup page as part of the Job Queue Editor section to allow you to change the part-program name to be used for the currently displayed job. The current part-program name is displayed underneath the button which follows a PPN: prefix. Pushing the button will cause the file selection window to come up so that you may select the input device to find the program on (for example, floppy, disk, DNC, reader). If the device selected is a file-structured device (like a floppy), then you will be presented with a list of files on that device. You select your file and press SELECT. If the device is not file-structured (like a reader), then you are complete immediately. If the device is DNC, then it is not possible to display the available file names, and you will simply get a blank display list, and must enter the file name from the keyboard. There is a button on the Current Job Setup menu (accessed from the Machine Setup page), called DNC Default, that allows you to set DNC as the default. When set, this causes the part programs to come off of DNC by default. The file you selected MUST be a valid part-program file and must CURRENTLY exist on the device. This is to ensure that the Job Queue process (usually unmanned) will not be terminated pre-maturely due to a nonexistent part-program file. The file you selected will be SI'd (See SI,file) automatically when the job is called for and will be displayed at the Part Program name display on the Front Page and Machine Setup pages. Please note that the same button will become a SETUP FILE NAME button if the SETUP FILE OPTION is enabled for the Modular Autoload System. Please see that section of the document for a more detail description of SETUP File. Changing the Setup File Name of a Job in the Job Queue Editor
JOBQ editor SETUP FILE NAME button
DTCMD
There is a button ("Setup File Name") located in the Autoload Setup page (Multi-Spindle Autoload system) as part of the Job Queue Editor section to allow you to change the setup file name to be used for the currently displayed job. The current Setup file name is displayed underneath the button which follows a SFN: prefix. The setup file may contain any legal M48 header commands and is an optional item which is not required for every job. The purpose of the Setup file is to augment the M48 header of the part-program to be used for the job or simply serve as the function of a M48 header if the part-program does not contain any M48 header at all. Please note that the Setup file will be executed ONLY ONCE for every job (like an M48 header) and is executed BEFORE the part-program's M48 header. For example, if an "ATC,ON" command is in the Setup file and an "ATC,OFF" command is in the M48 header of the part-program, the final outcome of this is "ATC = OFF". Pushing the button will cause the file selection window to come up so that you may select the input device for the Setup file (for example, floppy, disk, DNC, reader). If the device selected is a file-structured device (like a floppy), then you will be presented with a list of files on that device and you may select the file by directly touching it. If the device is not file-structured (like FileServer), then you must enter the file name through the use of the keyboard. The file you selected MUST be a valid setup file name and must CURRENTLY exist on the device. Inserting or Deleting a job in the Job Queue Editor
JOBQ Editor Job Insert button
JOBQ Editor Job Delete button
JOBINSERT
JOBDELETE
There are two buttons ("Insert" and "Delete") located under the title Edit in the Autoload System Setup page as part of the Job Queue Editor section to allow you to insert a new job or delete an existing job in the job queue. The Insert button is to allow insertion of a new job AFTER (higher job number) the currently display job. For example, to insert job number 4, you must first cause job number 3 to display using either the View buttons or the Job Number (Job #) button, then press the Insert button. The job 4 which previously existed and any jobs after it will be pushed down the queue and assigned a job number one higher than before. Therefore, the old job 4 is now job 5. To insert a job at the top of the queue (e.g.: Job 1), you must first cause Job 0 (zero) to display before pressing the Insert button. Once the Insert button is pressed, several popups will display in a series to allow you to enter the total number of panels, the part-program device, the part-program name, the spindles to be used and the setup file name (optional). Please note that the software will NOT ALLOW you to insert a job to the top of the queue (Job 1) while the machine is in the middle of drilling a job with the Autoload Job Queue enabled. This is to prevent someone accidentally inserting a job in the wrong order. If you really wish to insert a job to the top of the queue, you must first enable "End of Job Optional Stop", wait until the machine unloads all the panels and displays the "Wait for START button" message, at this point, you reset the system by pressing the Reset button and you can now insert the job. This protection applies to Job 1 only and WILL NOT disable you from inserting jobs other than that. The Delete button is to allow you to delete the CURRENTLY DISPLAYED job. An "ARE YOU SURE" window will be displayed for your confirmation. Any jobs that followed the job you just deleted will be moved up in the queue by one slot, e.g. assigned a job number one lower than their old numbers. Purging a Job Queue
JOBQ editor Clear All Jobs button
CJOBQ
There is a button ("Clear All Jobs") located in the Autoload System Setup page as part of the Job Queue Editor section to allow you to purge the ENTIRE job queue (deleting all jobs from the current queue). Pressing this button will cause the "ARE YOU SURE" window to be displayed for your confirmation. Once confirmed, ALL jobs will be DELETED from the queue and Job 0 (zero) will appear in the editor buttons. Saving Jobs to Job Queue files
JOBQ editor Save All Jobs button
JOBQSAVE
There is a button ("Save All Jobs") located in the Autoload System Setup page as part of the Job Queue Editor section to allow you to update the current Job Queue file in its storage device with all the jobs currently created in the job queue editor memory. If the current Job Queue file does not exist in the default device, a new file will be created. The Job Queue file will also be updated or created automatically when one of the following happens:
Changing the Stack Lot size in the Job Queue Editor
JOBQ editor # Stack button
DTTTLPNL
There is a button ("# of Stacks") located in the Autoload System Setup page as part of the Job Queue Editor section to allow you to change the stack lot size for the currently displayed job. Pressing this button will cause a numeric Keypad window to display and you may specify a number between 0 to 32767. The current stack lot size is displayed inside the button. A zero (0) as number of stacks is legal and if used (typically in job 1), the software will only SI the part-program name and will not deliver stacks to any stations. If a zero stack lot size is found in any jobs other than job number 1, the job queue software will simply ignore the job and go on to the next job in line. The reason for accepting a zero for the stack lot size is so that you can repair stacks by skipping into a part-program. In this case, the software expects you to manually place the stacks onto the stations you want, press the START button with Job Queue mode on, and upon the completion of drilling, the autoload software will automatically remove the stacks and continue with the next job in line in the job queue. This, however, does not apply to the Modular Autoload System. Selecting Spindles in the Job Queue Editor [Multi-Spindle Autoload System]
JOBQ editor Spindle Used buttons [Multi-Spindle Autoload System]
DTSPIN1
DTSPIN2
DTSPIN3
DTSPIN4
DTSPIN5
There are 5 buttons ("Spindle Used") located in the Autoload Setup page (Multi-Spindle Autoload system) as part of the Job Queue Editor section to allow you to select the spindles to be used for the job display currently. If your machine has less than 5 spindles, only those button with an active spindle will be allowed. The buttons change color when you switch between selecting and deselecting the spindle. If the station number is dark, the spindle is deselected. If the station number is displayed in white giving the button a "lit up" appearance, the spindle is selected During Job Queue operation, the autoload system will deliver panels to only those stations with the spindle selected for the job. Selecting a remote setup file
Remote setup
LOADFILEMD,on/off
This button, located on the Autoload Setup page allows the operator to set up the machine so it will fetch a remote set up file at the beginning of the run. This setup file normally resides on the File Server, and it is accessed through DNC. This file may contain any legal machine command such as part-program name, job name, tooling configuration, etc. When this button is turned ON, the machine will execute the commands in the setup file immediately after the Start button is pushed. If a setup file is not available on the host computer, the machine will wait for one. Upon turning this mode ON, the system will be set to Single Job Mode. Also, switching between Job Queue Mode and Single Job Mode causes this button to turn OFF. For this mode to be operational, Autoload must be ON. Selecting Job Queue Mode/Single Job Mode
JOBQ mode
Single Job mode
OPENMD,on/off
There is a button located on the Autoload System Setup page to allow you to select either the Job Queue Mode or the Single Job Mode. If Job Queue Mode is selected (as indicated by the button) and if the autoload system is on, pressing the START button will cause the drilling software to start executing the jobs in the job queue beginning from job 1 and until all jobs are complete. For the Multi-Spindle Autoload system, panels will be delivered to the stations according to the spindle selection for the job entry and the part-program name in the job entry will be used for drilling. For the Modular Autoload system, panel will be delivered to any available machine and the part-program name will be send to the target machine via communication. The physical part-program MUST exist locally in the target machine unless a FileServer is the selected input source, in which case, the part-program must exist in the fileserver. If Single Job Mode is selected (as indicated by the button) and if the autoload system is on, pressing the START button will cause the drilling software to deliver panels to the stations selected on the Machine Setup page for drilling in the case of Multi-Spindle Autoload system. The software will continue placing and removing panels from the stations until all panels are exhausted from all LOAD elevators. In a sense, the single job mode is a way to remove the panel loading step by the operator in a manually loaded machine operation. Therefore, the operator is still expected to do all the necessary setup prior to running a job, this includes choosing the part-program, selecting the spindles, etc. For the Modular Autoload system, panels will be delivered to any available machine and the part-program name setup using the SI command (or button) at the Master Machine will be send to the target machine via communication. The physical part-program MUST exist locally in the target machine unless a FileServer is the selected input source, in which case, the part-program must exist in the fileserver. Both Job Queue and Single Job modes are disabled if Bar Code system is enabled as primary part-program name input. See "Barcode system on/off button" for details. Automatic Swap Side [Loading] button [Multi-Spindle Autoload System]
ALD auto swap button [Multi-Spindle Autoload System]
AUTO_SWAP,on/off
There is a button ("Auto Swap") located on the Autoload System Setup page (Multi-Spindle Autoload system) to allow you to turn ON and OFF the automatic swap loading side feature. This feature applies to both NORMAL and LARGE CAPACITY mode. The button's text and border "light up" when automatic swap is active. This feature, if on, will automatically switch the loading pattern from the current side to the other side of the machine when ALL LOADERS are exhausted. The idea is to reduce the number of elevator carts the operator has to contend with during reload. For example: In a 4 carts system (2x2), a Normal Capacity mode load from left will have this load pattern LL/UU, without the Automatic Swap feature, the operator would have to replace all 4 carts when both Loaders are exhausted. However, with the Automatic Swap feature switched on, the software will automatically change the load pattern to UU/LL when both Loaders are exhausted, therefore, the operator only have to replace the right most 2 carts with fresh Loaders before continuing. The same will apply to the 2 Carts system (1x1) and in the case of Large Capacity mode, the software will switch between LL/LU and UL/LL. During a Job Queue operation (Single Job mode will terminate as soon as all Loaders are exhausted), when all Loaders are exhausted, an "Auto Swap Stop" message will be displayed in the machine status box to instruct the operator to perform the change over. At this point, all the operator needs to do is to refer to the Load/Unload Pattern display on the Autoload Setup page and reload/replace all the elevators showing a "L" with fresh undrilled panels. Once complete, simply push the START button and the software will continue operation. Selecting the Loading Side [Multi-Spindle Autoload System]
ALD begin load button [Multi-Spindle Autoload System]
LOAD_R,on/off
There is a button ("Begin Load From Left/Right") located on the Autoload System Setup page (Multi-Spindle Autoload system) to allow you to select the starting load side i.e.: telling the autoload system which side to go to first to look for undrilled panels. The button's text changes when switching between LEFT and RIGHT. The Load/Unload Pattern display (on the same page) also changes to reflect the effect of the button. This button applies to both Normal Capacity mode and Large Capacity mode. In the Normal Capacity mode, this button simply swaps the load side with the unload side and vice versa. In the Large Capacity mode, this button swaps the load unload pattern left to right and right to left, e.g.: in the case of begin load from RIGHT, the only UNLOADER will be the RIGHT MOST elevator, and in the case of begin load from LEFT, the only UNLOADER will be the LEFT MOST elevator. Job Queue Analysis button [Multi-Spindle Autoload System]
There is a button ("Job Queue Analysis") located on the Autoload System Setup page (Multi-Spindle Autoload system) to allow you to quickly analyze jobs currently setup in the job queue AFTER ALL machine setups are done and immediately before beginning the drill operation. The software will tell you how long the Job Queue will approximately take to complete as well as whether you have enough tools in the TMS system to last through the entire queue. Autoload Stop Option button [Multi-Spindle Autoload System]
ALD Autoload stop mode button [Multi-Spindle Autoload System]
There is a button ("AUTOLOAD STOP ON/OFF") located in the lower portion of the Autoload Setup page (Multi-Spindle Autoload system) to allow you to enable/disable the Autoload Stop mode. Autoload Stop will cause the autoload system to stop (with Transporter's hand in the up position) during automatic loading and unloading. Autoload stop can be configured to stop after the panel is picked up from the Load elevator during a Load operation, after the panel is deposited onto the station during a Load operation, after the panel is picked up from the station during an Unload operation, or after the panel is deposited into the Unload elevator during an Unload operation. You can configure your system to stop in one, two, three or all four places. See the System Software section regarding autoload stop. The button changes color when switching between ON (white) or OFF (black) of the function. End of Job Optional Stop mode
ALD End of Job Optional Stop mode button
There is a button ("End of Job Optional Stop") located on the Autoload System Setup page to allow you to enable/disable the End of Job Optional Stop mode. For the Multi-Spindle Autoload system, the Optional Stop mode, if on, will cause the autoload system to stop after ALL the current panels on the table were cleared into the Unload elevator. The transporter's hand will be in its high position and on top of the last used Unload elevator and waits for the START to be pressed before continuing. This features works in both Single Job and Job Queue modes as well as both the Normal and Large Capacity modes. For a SINGLE transporter system, this function will become effective as long as this function is enabled ANYTIME before the VERY LAST panel is unloaded. However, for a DOUBLE transporter system, this function CAN ONLY be enabled BEFORE the VERY FIRST panel is begun unloading due to the overlapping of Loading and Unloading. For the Modular Autoload system, after the current panel is cleared off the machine, and if the optional stop mode is on, the autoload system will temporarily suspend delivering panel to the machine while it is still serving other machines. Pressing the AUTOLOAD START button in the Modular Autoload Control/Setup page will put the machine back on line. This option is useful in many ways, here are some examples:
Automatic Edge Clamping Option
ALD Edge Clamping button
AUTOEDGECLAMPING,on/off
There is a button ("Edge Clamping") located on the the Autoload System Setup page and Table Clamps Operations menu to allow you to turn on or off the automatic edge clamping system. If this option is on, edge clamps on the table are used to secure the panel once it is placed down. This is in addition to the Pin Clamping operation. If the option is off, ONLY Pin Clamping will be used to secure the panel. This switch affects the following operations:
Enabling the Autoload System
ALD enabling the autoload system
AUTOLOAD,on/off
The Autoload ON/OFF button is located on the Machine Setup Page, to the right of the Autoload (ALD) Function button. The button toggles the autoload system ON or OFF each time it is touched. For the Multi-Spindle Autoload system, When the autoload system is off, the Autoload Software is completely defeated, and will not impact the operation of the machine. When on, the system picks up panels from the load elevator and delivers them to the designated stations for drilling at the START button or between loads within a job queue. Furthermore, if the system is on, it will automatically remove panels from all stations upon completion of the part-program. All features, modes and options related to the Autoload System will not function without enabling the Autoload System using this button. For the Modular Autoload system, disabling the Autoload system means taking the LOCAL MACHINE off- line ONLY. Meaning, turning the current machine to a manual machine and the autoload system will not load or unload any panel from this machine, while the it is still serving other machines. You may use this button to enable or disable the Autoload feature for your machine at any time EXCEPT when the master machine is serving you (loading a panel to you or unloading a panel from you). At that time, the button is inactive and the only way you can kill the process is to press the RESET button at your local machine. ORIGINAL SCREEN: The button is available on the Autoload Setup page. Normal vs Large Capacity modes [Multi-Spindle Autoload System]
ALD Normal Capacity mode [Multi-Spindle Autoload System]
ALD Large Capacity mode [Multi-Spindle Autoload System]
INTMIX,on/off
There is a button ("Normal Capacity/Large Capacity Mode") located on the Autoload System Setup page (Multi-Spindle Autoload system) to allow you to switch between the two modes. This button is available in Multi-elevator systems ONLY (two or more elevators per EACH SIDE of the machine). For a Single elevator system (only 1 elevator per each side of the machine), this button is disabled from the operator and the Normal Capacity Mode is assumed. The button changes text within it when switched between modes, and the current elevator status display also changes to reflect the effect of each mode. In Normal Capacity mode, all Load elevator(s) must be on one side of the machine and all Unload elevator(s) must be on the opposite side of the machine. For example, in a single elevator system with begin load from left selected, the only load elevator is the left elevator and the only unloader elevator is on the right. In a 2x2 elevator system, if begin load from left is selected, BOTH elevators on the left will be used as Loaders and BOTH elevators on the right will be used as Unloaders. If ALL the Unloaders become full before the Loaders are exhausted, a message will be displayed in the machine status box to instruct the operator to replace AT LEAST one of the Unloaders with an empty one then press the START button to resume operation. If ALL the Loaders become exhausted, the system will terminate normally if in Single Job mode or if in Job Queue mode, it will prompt the operator to add more panels to the Loaders, the press the START button to continue. The advantage of the Normal Capacity mode if used in conjunction with the Automatic Swap side mode, is that the operator only has to deal with one side of the elevators during reload. The disadvantage, however, is its smaller total panel capacity and reloading is more frequent as a result (in multi- elevator systems only). In Large Capacity mode (available in multi-elevator systems only), ONLY ONE Unload elevator is allowed and the rest of the elevators serve as Loaders. Therefore, in the case of a 2x2 elevator system, the total panel capacity is increased by 50 percent over Normal Capacity mode (three loaders vs two loaders). This mode is also referred to as Loader/Unloader Intermix mode due to the fact that a loader and an unloader may be on the same side of the machine. The placement of the one and only Unloader (empty elevator) is important, it MUST be the OUTER MOST elevator on the initial unload side. During the autoload operation, the system re-utilizes the empty Loaders as Unloaders in a FIXED pattern. The system always starts the loading from the Load elevator next to the Unload elevator on the same side of the machine and work its ways to the other side of the machine as each loader is exhausted. For example, in a 2x2 elevators system and the begin load from LEFT is selected, the Unload (empty) elevator must be the OUTER MOST elevator on the LEFT side of the machine, the software will follow the following pattern as each loader becomes exhausted (U = Unloader, L = Current active Loader, x = Elevator filled with drilled panel, l = Inactive Loader): How to Load or Unload a Single panel automatically
ALD how to load a Single panel automatically
ALD how to unload a Single panel automatically
LD, station number
ULD, station number
LD_MACH, machine number
ULD_MACH, machine number
There are two buttons ("Auto Loading a Panel" and "Auto Unloading a Panel") located on the Manual Operations page to allow you to tell the Autoload system to LOAD a single panel from any loader to any station (or machine) or to UNLOAD a single panel from any station (or machine) to any unloader. For the Multi-Spindle Autoload system, please note that both buttons will NOT work if one or more elevator carts are NOT locked into their docking stations securely. This is a safety feature to prevent accidental injury to any person that may be working inside the machine while the carts are out. This restriction DOES NOT apply if the system is logged on as MAINTENANCE. Pressing either button will cause a graphical display window to be displayed to let you select both a station and an elevator to transfer the panel from and to. The "Auto Loading a Panel" button will be disabled all together if panels are on ALL stations. Furthermore, the graphical display will only enable the station buttons (Orange color) on the ones without any panels. Conversely, the "Auto Unloading a Panel" button will be disabled all together if none of the stations has any panel for unload, and the graphical display will only enable the station buttons on the ones with a panel. For System 2000 equipped with registration station, the loading sequence will first transport a panel to the registration station and then to the tooling plate. For any system config with W/ALD-SINGLE-SIZE-ML option in the MACH.DAT file, the REG-WO-BUMP,ON/OFF can be use to enable/disable the registration with/without bumping operation. For the Modular Autoload system, pressing either panel will cause a graphical display window to be displayed to let you select the target machine to transfer the panel from and to. The target machine may reject the request if it is busy drilling or it already has a panel in the case of load or it has no panel in the case of unload. Please note that for systems equipped with the Double Hand option, the software will automatically select the correct hand for the loading and unloading process. ORIGINAL SCREEN: The buttons are located on the Autoload Semi-automatic Operation page and the Modular Autoload Control/Setup page. Table Clamps button
The "Table Clamps" button located on the Manual Operations page, displays the Table Clamps Operations menu (for machines equipped with software controlled clamping systems). The menu provides buttons to activate the worktable edge and pin clamps. The following is a brief description of each item. Refer to the individual button descriptions for further details. How to Load or Unload a panel by hand
ALD How to Load or Unload a panel by hand
LOCKP, station number
UNLOCKP, station number
Two buttons ("Manual Lock" and "Manual Unlock") are provided to allow you to load a panel onto a station by hand and clamp it, or unclamp a panel from a station for removal by hand easily. The buttons are located on the Table Clamps Operations menu, which may be displayed by touching the Table Clamps button located on the Manual Operations page. The menu also provides buttons for actuating each clamping mechanism individually, but this is usually unnecessary. For Multi-Spindle autoload system, pressing either the Lock or Unlock button will cause a numeric keypad window to be displayed for you to enter the station number. Please note that the Edge Clamping option DOES affect the operation. An Edge Clamping button is included on the menu to display the current ON/OFF status, which you may change by touching the button. The button's text and border "light up" when edge clamping is turned on. If on, the edge clamp devices on the station will be used along with the pin clamp devices to clamp the panel in the Lock operation. Similarly, the edge clamps will be undone along with the pin clamps in the Unlock operation. During an UNLOCK operation, the software will automatically undo the edge clamps (if on), eject the panel upward (if config with W/MULTILAYER option) and open the pin clamp for panel removal. This should also be used FIRST on an empty station prior to using the the LOCK operation to lock down a panel. The UNLOCK-EJECT,ON/OFF command is used to enable/disable the ejection of a multilayer panel during UNLOCK. During a LOCK operation, the software will close the pin clamps and actuate the edge clamping devices (if on) to lock down the panel firmly. ORIGINAL SCREEN: The buttons are located on the Autoload Semi-automatic Operation page and the Modular Autoload Control/Setup page. How to release a panel from the Transporter's Hand
ALD How to release a panel from the Transporter's Hand
RPHAND
RPHAND_MOD
There is a button ("Release From Hand") located on the Manual Operations page that allows you to release a panel from the transporter hand's gripping mechanism (hooks). Pressing the button causes the hooks to open, releasing the panel from the hand. For systems equipped with the Double Hand option, this function will first request you to select the desired hand (Left or Right) through the Double Hand Autoload Hand Selection popup window before releasing the panel. ORIGINAL SCREEN: The button is located on the Autoload Semi-automatic Operation page and the Modular Autoload Control/Setup page. How to JOG the Transporter System - HAND
ALD How to JOG the Transporter
Jog T button
JT, coord
JIT, +/- coord
JOGT
JT_MOD, coord
JIT_MOD, +/- coord
JOGT_MOD, coord
There are three JOG functions available to you for moving the transporter system (hand) - Jog Absolute, Jog Incremental and Preset position Jog. The buttons are included on the T Axis Jog Menu, which may be displayed by pressing the "Jog T" button located on the Manual Operations page. Please note that the jog buttons will NOT work if one or more elevator carts are NOT locked into their docking stations securely if elevator systems are used. This is a safety feature to prevent accidental injury to any person that may be working inside the machine while the carts are out. This restriction DOES NOT apply if the system is logged on as MAINTENANCE or conveyor system is used. Pressing the JOG ABSOLUTE button will cause a numeric keypad to display for you to enter a T axis (transporter axis) coordinate follow by an enter. The transporter will be jogged to the coordinate specified. Pressing the JOG INCREMENT button will cause a numeric keypad to display for you to enter an offset follow by an enter. A POSITIVE offset will move the transporter AWAY from the Zero by the amount specified. A NEGATIVE offset will move the transporter TOWARDS the Zero by the amount specified. Pressing the PRESET JOG button will cause a Preset Position Jog window to display. Preset Jog provides a quick way to jog the transporter to the various panel pick up and drop off point used by the autoload software. The moving yellow bar at the lower portion of the window shows the current physical location of the transporter. For the Multi-Spindle system, the active buttons in the window are in orange and the inactive buttons are in grey e.g. the two outer most elevator buttons are in grey in a 1x1 elevator system. There is one button for every elevator and every station. Pushing the button will jog the transporter directly over the designated elevator or station. Please note that pressing the station button will move BOTH the T-axis (transporter) and the Y axis (table) to either their LOAD or UNLOAD position. A button above the station buttons (LOAD/UNLOAD) will allow you to switch between the two positions. For the Modular Autoload system, pushing any active button will move the T-axis directly over the designated conveyor or machine. Please note that, unlike the Multi-Spindle system, there are no different Load and Unload positions for the T-axis and the preset jog DOES NOT move the machine's Y axis (table). Please note that for systems equipped with the Double Hand option, all three Jog functions will first request you to select the desired hand (Left or Right) through the Double Hand Autoload Hand Selection popup window before going to the next step. All three Jog functions will cause the Hand assembly to move up prior to jogging the transporter for protection of the machine. Should the hand assembly fail to move up for any reason, the jog functions will not move the transporter and a message will be displayed in the machine status box. ORIGINAL SCREEN: The buttons are located on the Autoload Manual Operations page and the Modular Autoload Control/Setup page. Transporter's HAND UP/DOWN button [Multi-Spindle Autoload System]
ALD Operates the transporter's hand up and down manually
MVHNUP
There is a button (UP/DOWN arrow) under the title "HAND" in the Autoload Manual Operation page (Multi-Spindle Autoload system) to allow you to move the hand up and down. The arrow inside the buttons reflects the opposite direction of where the hand position is currently at. If the hand is at the down position, the arrow becomes an up arrow and vice versa. Please note that the hand mechanism is driven by two air solenoids, one solenoid merely turns OFF the counter weight air (upward air to support the hand at whatever the position the hand is at), the other turns ON the high pressure air (downward air to push the hand down at high pressure). The button merely turns turns off the counter weight air on a down command and vice versa. The reason is protection of the machine, if the hand is driven down with high pressure to a wrong surface, things could be damaged. Therefore, depending on the air pressure setting, you may need to push the hand assembly down by hand after commanding it to go down. This function applies to systems equipped with the non-motorized transporter hand only. For motorized hand systems, this function is included as part of the "HAND OPERATION" button. Transporter's HOOKS Manual Control buttons [Multi-Spindle Autoload System]
ALD Operates transporter's hook manually [Multi-Spindle Autoload System]
MVHKIN
MVHKUP
There are two buttons (IN/OUT arrows and UP/DOWN arrow) under the title "HOOKS" in the Autoload Manual operation page (Multi-Spindle Autoload system) to allow you to manually operate the panel grabbing mechanism (HOOKS). There are two types of movement the hooks can do, horizontal (in/out) and vertical (up/down). Those two buttons are designed to do just that. The arrows inside the buttons change in direction when switched between in and out or up and down. These functions apply to systems equipped with the non-motorized transporter hand only. For motorized hand systems, these functions are included as part of the "HAND OPERATION" button. Table Clamps Manual Control buttons
ALD Table Clamps manual control buttons
OPCLMP
CPCLMP
OECLMP
CECLMP
XECLMP
RECLMP
Table Edge Clamp and Pin Clamp control buttons are provided to command discreet pin and edge clamp movements (for machines equipped with software controlled clamping systems). The buttons are located on the Table Clamps Operations menu, which may be displayed by touching the Table Clamps button located on the Manual Operations page. Buttons grouped under the Edge heading cause Edge clamp movement, the buttons grouped below the Pin heading cause Pin clamp movement. The arrows inside the buttons show the direction of the particular clamping device to be moved. Pressing any one of the buttons will cause a numeric keypad window to display, you may select the station or stations (separated by commas) you want for the operations to be done. In the case of Modular Autoload system, since all of the machines are single station, therefore the numeric keypad will NOT be displayed and all the operations are assumed to be done on that station. The following are the clamping operations allowed:
Elevator Manual Control buttons [Multi-Spindle Autoload System]
ALD Operate the elevators manually [Multi-Spindle Autoload System]
Elevator Operations
ELEVPOPUP
Buttons are provided on the Elevator Operations popup menu (Multi-Spindle Autoload system), to allow you to operate the individual elevators manually. The menu may be displayed by touching the Elevator Operations button located on the Manual Operation page. Each button has two states - Active state (in orange) and Inactive state (in grey). The arrow buttons are active and the STOP button is inactive when ALL the elevators are still. Conversely, the STOP button is the only active button when ANY ONE of the elevators is in motion. Each elevator is represented by a pair of Up arrow and Down arrow buttons. For a 1x1 elevator system (one elevator on each side of the machine), touch the innermost Up/Down arrow buttons on either the left or right side to put the corresponding elevator in motion. Please note that the system is designed to allow ONE and ONLY ONE elevator to be in motion (counting both LEFT and RIGHT sides) at any given point of time. Here are the functions of the buttons: Registration Station's OPEN/CLOSE button
ALD Registration Station's OPEN/CLOSE button
CREGSTA
There is a button (IN/OUT arrows) under the title "REG. STATION" in the Autoload Manual operation page (Multi-Spindle Autoload system) to allow you to manually OPEN or CLOSE the air control self-clamping type Registration Station if so equipped. The arrows inside the buttons change in direction when switched between open(out arrows) and close(in arrows). Jogging the table to the LOAD/UNLOAD position [Modular Autoload System]
ALD Jogging the table to the LOAD/UNLOAD position [Modular Autoload System]
YLOAD
There is a button ("Table Load/Unload Position") to allow you to manually jog the X and Y axes to the position which the Autoload system uses for loading and unloading panels. The button is located on the Jog XY menu, which may be displayed by touching the JOG XY button located on the Manual Operations page. This button applies to Modular type Autoload systems only. ORIGINAL SCREEN: The button is provided on the Modular Autoload page. How to enable the Bar Code system [Modular Autoload System]
ALD How to enable the Bar Code system [Modular Autoload System]
AUTOBCRON,ON/OFF
There is a button ("Barcode") located on the Autoload System Setup page (Modular Autoload System) to allow you to enable or disable the bar code system. The Bar Code system is currently available for the Modular Autoload system only. The purpose of the system is to obtain part-program name from the bar code imprinted on top of the incoming panels. The bar code, in its simplest form, contains ONLY the name of the part-program to be used in drilling the panel. However, prefix and postfix can be attached to the name, please refer to the section that describe the VSB command for details of how to setup prefix and postfix strings. The bar code should NOT include the input device name of the part-program. The input device for the part-program is specified using the Bar Code Input Default Storage button. When the Bar code system is switched on, the software reads the part-program name from the next incoming panel's bar code and appends it to the default input device name specified by the Bar Code Input Default Storage button (please see the Bar Code Input Default Storage button description for details). The complete string will then be sent over to the target machine for verification. Please note that when the Bar Code system is on, the Job Queue and Single Job modes are disabled automatically and its button is therefore dimmed. The barcode button's text and border "light up" when the Bar code system is enabled. ORIGINAL SCREEN: The button is provided on the Modular Autoload Control/Setup page. Bar Code Input Default Storage [Modular Autoload System]
ALD Bar Code Input Default Storage [Modular Autoload System]
BCRDFL,device
This function allows you to select which directory and/or device is used for the input device of part-program names read from the Bar Code. The button ("Device") is located on the Autoload System Setup page (Modular Autoload System) below the "Barcode" button. Pressing the button will present you with the device selection popup menu, which you use to select the device or directory. The current setting is displayed below the Bar code "Device" button. Currently, the Bar code system is available for the Modular Autoload system only. In order to keep things under control, the bar code system is designed to allow only a single input device for the part program. Meaning the Bar Code imprinted on the incoming panel contains nothing but just the Part-program name (no input device is allowed) and the part-program's input device is determined by what's setup here by this button. For example, if the selected input device is a floppy disk then ALL the machines involved are expected to have the same floppy disk installed in their local system. In general, we recommend the use of a FileServer (DNC) as input device for it provides the convenience of centralizing the part-programs. ORIGINAL SCREEN: The button is provided on the Modular Autoload Control/Setup page. LOADING ON/OFF button [Modular Autoload System]
ALD LOADING ON/OFF button [Modular Autoload System]
LOADCYCLE,ON/OFF
There is a button ("Loading") in the Autoload System Setup page (Modular Autoload system) to allow taking the autoload system off-line from loading while it is still able to perform automatic unload. This button is not to be confused with the "AUTOLOAD ON/OFF" button located on the Machine Setup page which disables both load and unloading completely. The button applies to Modular Autoload System only. If it's off, the autoload system will suspend the loading process completely while still able to unload the panels from each individual machines as their jobs are completing. This has the same effect as if there are no more incoming panels. This function allows the operator to shut down the line for the night or for system maintenance without having to stop the panel delivery system (conveyor...). To resume the loading process simply switch the function to ON by touching the button again. The button's text and border "light up" when automatic loading is enabled. ORIGINAL SCREEN: The button is provided on the Modular Autoload Control/Setup page. End of Cycle Stop button [Modular Autoload System]
ALD End of Cycle Stop button [Modular Autoload System]
There is a button ("End of Cycle Stop") on the Autoload System Setup page (Modular Autoload system) to allow you to take the modular autoload system off-line from any further Loading and Unloading upon completion of the current Loading or Unloading cycle. If the autoload system is currently not active, enabling this function simply stops the autoload system from further activities (similar to the Autoload Stop button). If, however, the autoload system is busy loading or unloading, enabling the function does not stop the system immediately (like the Autoload Stop button), but rather, the software will wait until the current load or unload cycle is complete before halting the system. Without this function, the operator can achieve the same thing by waiting for the current cycle to complete before pressing the AUTOLOAD STOP button. Please note that the End of Cycle Stop option is a one shot operation, meaning the software will automatically switch the option to OFF after one execution. This is to prevent any unintentional stop for the following run. The operator must re-enable this option before using it each time. The button's text and border are "lit up" when End of Cycle Stop is enabled. To resume the autoload system's operation, simply press the AUTOLOAD START button. ORIGINAL SCREEN: The button is provided on the Modular Autoload Control/Setup page. AUTOLOAD START/STOP button [Modular Autoload System]
ALD AUTOLOAD START/STOP button [Modular Autoload System]
ALDSTART
There is a button ("Autoload Start/Stop") on the Autoload System Setup page (Modular Autoload system) to allow you to start/stop the Modular Autoload system. This button switches between AUTOLOAD START and AUTOLOAD STOP when pressed. The AUTOLOAD START button in general works much the same way as the regular drilling system's START button in that it is used both in starting the system as well as a method of continuing from a single cycle or problem condition. If the system is currently inactive, pressing the AUTOLOAD START button will cause the complete autoload system to beginning scanning each slave machine (include the master itself which is also treated as a slave machine) on a round robin basis for any load/unload request. If a panel is available from the incoming conveyor and if the Load process is not halted temporarily (see LOADING ON/OFF button), the system will deliver it to the first machine that requested a load. On the contrary, the system will remove the panel from the first machine that requested an unload. If the system is currently active, the same button will now show AUTOLOAD STOP. Pressing it will halt the autoload system immediately from whatever it's doing (it will stop the Transporter immediately if it's moving). At this point, the button will become AUTOLOAD START again and pressing it will resume operation. IMPORTANT: As mentioned in the introduction section (Setting Up the Autoload System), the Master Machine controls the Autoload Transport system as well as performing drilling like the rest of the slave machines. The master unit therefore in itself is a slave machine, and the regular drilling system's START and STOP buttons DO NOT have any effect on the Modular Autoload system as in other slave machines. The button described here is the ONLY button to START and STOP the modular autoload system. On the other hand, the AUTOLOAD START/STOP button DOES NOT affect the Master machine's drilling process, to do that, you must use the regular drilling system's START/STOP buttons which are available in all Modular Autoload Display pages as well. ORIGINAL SCREEN: The button is provided on the Modular Autoload Control/Setup page. AUTOLOAD RESET button [Modular Autoload System]
ALD AUTOLOAD RESET button [Modular Autoload System]
ALDRESET
There is a button ("Autoload Reset") in the Autoload System Setup page (Modular Autoload system) to allow you to RESET the Modular Autoload system. The AUTOLOAD RESET button generally works much the same way as the drilling system's RESET button in that it immediately stops the Modular Autoload system from whatever it's doing (stops the transporter movement immediately if it's moving). If the system is currently inactive, pressing the AUTOLOAD RESET button does not do anything. However, if the system is active (pressing the AUTOLOAD START button), pressing this button will immediately stops whatever the autoload system is doing and return the system to an idle state. Pressing the AUTOLOAD START button is needed to restart the system. The AUTOLOAD RESET button is different from the AUTOLOAD STOP button in that the RESET button cancels whatever the autoload system is doing and pressing the AUTOLOAD START button afterward DOES NOT continue from the last operation. IMPORTANT: As mentioned in the introduction section (Setting Up the Autoload System), the Master Machine controls the Autoload Transport system as well as performing drilling like the rest of the slave machines. The master unit therefore in itself is a slave machine, and the regular drilling system's RESET button DOES NOT reset the Autoload system as in other slave machines. The button described here is the ONLY button to RESET the modular autoload system. On the other hand, the AUTOLOAD RESET button DOES NOT reset the Master machine's drilling process, to do that, you must use the regular drilling system's RESET button which is available in the lower right corner of most screen displays. ORIGINAL SCREEN: The button is provided on the Modular Autoload Control/Setup page. AUTOLOAD HOME button [Modular Autoload System]
ALD HOME button [Modular Autoload System]
There is a button ("Autoload Home") on the Manual Operations page (Modular Autoload system) to allow you to home the transporter axis of the Modular Autoload system. The AUTOLOAD HOME button in general works much the same way as the drilling system's HOME button in that it re-establishes the zero position of the transporter axis. Pressing this button will cause the Transporter axis (T-axis) to move towards the zero position and re-establish the zero there. This is a required operation after an initial power up of the Master machine. The Modular Autoload system will not start unless it is homed at least once or whenever the operator is instructed by the system (message on the screen) after a problem condition. Please note that as soon as the the Master machine is powered up, the transporter's T-axis can be homed by either pressing the regular drilling system's HOME button or the AUTOLOAD HOME button. The difference is that the regular HOME button homes all the machine axes (XYZ) as well whereas the AUTOLOAD HOME button homes the T-axis ONLY. Please remember, however, the regular drilling system's HOME button will only work ONCE (ie after power up) and after the T-axis is successfully homed, any subsequent homing of the T-axis must be done by using the AUTOLOAD HOME button. This is done so that in the case of a transporter problem and re-homing is required, the operator does not need to stop the drilling on the master machine before homing the T-axis. ORIGINAL SCREEN: The button is provided on the Modular Autoload Control/Setup page. AUTOLOAD SINGLE CYCLE button [Modular Autoload System]
ALD SINGLE CYCLE button [Modular Autoload System]
There is a button ("ALD Single Cycle") in the Autoload System Setup page (Modular Autoload system) to allow you to single step through the Modular Autoload system's loading and unloading process. The AUTOLOAD HOME button in general works much the same way as the regular drilling system's SINGLE CYCLE button in that it toggles between automatic mode and Single Cycle mode. The button's text and border "light up" when Single Cycle mode is active. Automatic mode is the default, and is used in normal loading and unloading process. Putting the autoload system in single cycle mode is generally used for stepping through the load or unload process as part of troubleshooting the system. IMPORTANT: As mentioned in the introduction section (Setting Up the Autoload System), the Master Machine controls the Autoload Transport system as well as performing drilling like the rest of the slave machines. The master unit therefore in itself is a slave machine, and the regular drilling system's SINGLE CYCLE button DOES NOT has any effect on the Autoload system as in other slave machines. The button described here is the ONLY button to turn on the Single Cycle on the modular autoload system. On the other hand, the ALD SINGLE CYCLE button DOES NOT affect the Master machine's drilling process, to do that, you must use the regular drilling system's SINGLE CYCLE button which is available through out the system's display pages. ORIGINAL SCREEN: The button is provided on the Modular Autoload Control/Setup page. HAND OPERATIONS button
ALD HAND OPERATIONS button
HANDOPER
There is a button ("Hand Operations") on the Manual Operations page (Autoload systems only) to allow you to perform various manual functions related to the transporter system's hand assembly. Pressing the button will cause a popup to come on with a sub-menu of the various functions you can perform. Here are the list of operations allowed:
For system equipped with Motorized (2 stage) type hand mechanism:
SEMI-AUTOLOAD button
ALD SEMI_AUTOLOAD button
SEMI-AUTOLOAD
There is a button ("Semiautoload ON/OFF") on the Autoload System Setup page (Double Hand Multi-Spindle Autoload system) which is only active on systems equipped with the DOUBLE transporter system. SETUP FILE OPTION ON/OFF button
ALD SETUP FILE OPTION ON/OFF button
SETUP FILE OPTION ON/OFF
There is a button ("Setup File Option ON/OFF") on the Autoload System Setup page (Modular Autoload system) to allow switching the SETUP file option on or off. This option applies to Modular type Autoload System's Bar Code or Job Queue mode. It DOES NOT apply to the SINGLE JOB mode. aldstkchkAutoload Stack CheckThis section describes the Autoload Stack Check function. The Stack Check function is invoked following the automatic load operation to verify the stacks have been properly loaded and are laying flat on the tooling plate. This is accomplished by measuring the stack height at various locations using the spindle/pressure foot assembly. Before the Stack Check function can be used, it must be configured by editing the TCVLD.DAT file located in the SYSTEM directory. This file contains XY touchdown locations along with other set-up information. A default version of the file is shipped with the system software. The default version contains only header information to explain it's usage. The following is a sample TCVLD.DAT file header: ;------------------------------------------------------------------------ ; ; This file contains information relating to the Autoload Stack Check ; function. ; ; At the completion of an automatic load cycle, the stack check function ; determines whether the stack has been loaded properly by verifying that ; it is laying flat on the tooling plate. This is accomplished by measur- ; ing the stack height at various locations using the spindle/pressure ; foot assembly. ; ; Before performing a stack check, the machine automatically puts away ; any tool present in the spindle collet. If the machine is equipped ; with multiple pressure foot inserts, the machine will perform the ; stack check using the designated special pressure foot insert if one ; is available, otherwise it will use the large insert. ; ; This file defines the stack height reading XY locations. Optional ; set-up parameters may also be included to establish the measurement ; mode, stack height tolerance, etc. ; ; A stack reference height is established at the first XY coordinate. ; The stack height reading taken at each subsequent XY location is then ; compared to the reference height. If a location is found to be out of ; tolerance, the machine stops with a "Load Error" message. ; ; The recovery from a load error is to manually correct the problem ; then press START. The machine will re-check the stacks before con- ; tinuing with the part-program. ; ; PROGRAM CODES: ; ; Data is organized within this file similar to a part program. The ; following is a list of valid program codes. Each code (except for ; XY coordinate pairs) should be programmed on a line by itself. ; Leading/trailing zero numeric formats are NOT supported. XY coor- ; dinates and stack height tolerance values should include the decimal ; point. ; ; Code Description ; ---- ----------- ; ; Comment line. Comments must be on a separate ; line, but may appear anywhere in the file. ; ; Q Quit. You may effectively turn off the stack ; check function by inserting a 'Q' at the ; beginning of the file or data area. File exe- ; cution terminates when a 'Q' is encountered. ; ; Note: To disable the stack check function use ; either the 'Q' code, or deselect the function ; with the TCFGTASK VSB command. ; ; I Declares data is INCH format (this is definitely ; optional, INCH is the default format) ; ; M Declares data is METRIC format ; ; C# Retry count. In the cases where the stack ; tolerance is exceeded, the machine will re- ; check the height up to the number of times ; specified by the retry count. The default ; is not to retry. ; ; Z# or Z-# Stack height tolerance. This is the maximum ; allowable height deviation relative to the ; reference height. ; ; A positive tolerance value is enforced for ; height variations both above and below the ; reference height. This means the machine ; will indicate an error if the height exceeds ; the tolerance by being either too high or too ; low. The default tolerance is +.050 inches. ; ; A negative tolerance value is enforced only ; for height variations ABOVE the reference ; height. In this case, the machine will in- ; dicate an error if the stack height is too ; high, but will NOT indicate an error if the ; height is low. This may be useful in cases ; where the machine must accept panels that vary ; greatly in size. This allows stack height read- ; ing locations to be programmed at pinning hole ; locations outside the boundarys of the smaller ; panels, as illustrated in the example below. ; ; R Set reference height. The initial reference ; height is established automatically at the ; first XY coordinate, and will probably not ; need to be changed. You may, however, set a ; new reference height at any location by in- ; serting an 'R' code. A new reference height ; will be established at the first XY coordinate ; following the 'R' code. ; ; P type-pins-size Start of panel reading locations for the ; specified panel. 'P' codes allow you to ; specify different stack height reading ; locations for each panel size. The line ; consists of a 'P' code followed be a space ; ' ' followed by the panel description. ; The panel description must exactly match ; the type-pins-size panel description in ; the TCFG.DAT file. ; ; The XY stack height reading locations for ; the panel are given immediately below the ; panel description line. An 'E' code follows ; the XY locations to indicate end of data ; for the specified panel. ; ; E End of panel height reading locations for ; the preceding panel type. ; ; X#Y# Stack height reading location relative to ; absolute machine zero ; ; EXAMPLE: ; ; One method for checking stack flatness is to first establish a ref- ; erence height near the middle of the stack, then compare this height ; with measurements taken at each pinning hole location. In this example ; stack height readings are taken to accommodate two basic panel sizes. ; ; ; --------------------- ; | O | ; | P4 | ; | | ; | | ; | | ; | Ref | ; | O O O | ; | P1 P2 | ; | | ; | | ; | | ; | P3 | ; | O | ; --------------------- ; ; ; Allow two retries ; C2 ; ; Start of data for this panel size ; MLB-4-24X18 ; ; Set reference height mid-panel ; X12.0Y15.0 ; ; Check small/large panel locations P1 thru P4 ; X2.0Y15.0 ; X12.0Y7.0 ; X22.0Y15.0 ; X12.0Y23.0 ; ; End of data for this panel size ; E ; ; Start of data for this panel size ; MLB-4-24X30 ; ; Set reference height mid-panel ; X12.0Y15.0 ; ; Check small/large panel locations P1 thru P4 ; X2.0Y15.0 ; X12.0Y1.0 ; X22.0Y15.0 ; X12.0Y29.0 ; ; End of data for this panel size ; E ; ; VLOAD KEYBOARD COMMAND: ; ; The VLOAD keyboard command is provided to facilitate initial set-up ; of the stack check function. Entering the command causes the machine ; to perform a stack check at the currently selected station(s). ; ; ENABLING THE STACK CHECK FUNCTION ; ; Before the stack check function may be used, it must first be enabled ; with the TCFGTASK VSB command. Please refer to the TCFGTASK command ; description in the System Reference Manual for information regarding ; this command. ; ;------------------------------------------------------------------------ See also: TCFGTASK tool-configTooling ConfigurationThis section applies to machines equipped with optional automatically adjustable tooling plates. The functions described here allow you to activate the individual clamping mechanisms, clamp/unclamp panels and configure the tooling for a particular type or size of panel. Edge Clamp Operations
TCEDGEOPS
The "Table Clamps" button located on the Manual Operations page, displays the Edge Clamp Operations menu. The menu provides the following buttons allowing you to lock or unlock panels, activate individual edge clamps, raise/lower the DSR board stops, and turn off or on the automatic edge clamping system. A button providing you access to the Pin Tooling Operations menu is also included. Pin Tooling Operations
TCPINOPS
The "Pin Tooling Operations" button located on the Edge Clamp Operations menu, displays the Pin Tooling Operations menu. Access to the Edge Clamp menu is via the "Table Clamps" button located on the Manual Operations page. The Pin Tooling Operations menu displays the currently selected tooling configuration, along with various buttons allowing you to lock/unlock the adjustable pins, raise/lower the ejectors, adjust the tooling configuration and set the adjustable pin height. Tooling Configuration File
TCFG.DAT
A Tooling Configuration file provides the CNC-7 with the information it needs to configure the tooling for the different panel types and sizes. The various tooling configurations are defined in the TCFG.DAT file located in the SYSTEM directory. A default version of this file is shipped with the system software, which you may then tailor to meet your individual needs. Edge Clamping Sequence File
TCDSR.DAT
The standard Double Sided (DSR) panel clamping sequence may be changed by specifying an alternate edge clamping sequence. This may be useful to accommodate special tooling, or to modify the sequence based upon the panel size. To specify an alternate clamping sequence you must create a file called TCDSR.DAT, located in the SYSTEM directory. If the file exists the machine performs the clamping sequence specified in the file, otherwise it performs the standard clamping sequence. Note that the file is a plain ASCII text file which may be created using the EP editor on the CNC-7. The file contains the following items. Each item must appear on a separate line. Edge Clamp Lock/Unlock Switches
Table Clamp Lock/Unlock Switches
The following describes the operation of the edge clamp lock/unlock switches located on the front of the worktable, for machines equipped with automatically adjustable tooling plates. This description applies only to machines equipped with table mounted edge clamp switches with software control. The switches (one per station) have three positions: left, right and center. Momentarily moving the switch to the left or right position commands the machine to lock or unlock the panels. The switch is spring loaded to automatically return to the center (neutral) position when released. The machine will perform a multilayer or double sided edge clamping sequence determined by the currently selected tooling configuration. The tooling configuration may be selected via the "Adjust Tooling" button located on the Pin Tooling Operations window. The present tooling configuration is displayed near the top of the window. The procedures for locking and unlocking multilayer and double sided panels are as follows:
UNLOAD command
The UNLOAD command is used to unclamp the panels on all stations at once. Entering the command displays the 10-key popup allowing you to select ALL or individual station(s) to unclamp. For multilayer boards, the ejectors are also activated after unclamping to facilitate their removal. When the ejectors are raised, a "Touch Here To Lower Ejectors" popup is displayed on the CNC-7 console. The ejectors remain extended until the popup is touched, allowing the ejectors to assist in removing the panels. This command is available only for machines equipped with optional automatically adjustable tooling. pulse-drillPulse DrillingThis section describes the CNC-7's pulse drilling option. Pulse drilling is provided primarily as a chip breaking mechanism to reduce problems related to "bird nesting", where long chips wrap themselves around the flutes and shank of some of the larger sized drills. Pulse drilling has also been found useful in some other specialized applications such as drilling high aspect ratio holes into difficult to drill materials. Pulse drilling works as a chip breaker by driving the Z-axis into the material using a series of short steps or pulses. The Z-axis pauses between each pulse in order to break the chip. Due to the rapid rate at which chips grow the duration of each pulse must necessarily be kept very short, resulting in a decreased infeed rate. To reduce this effect, pulse drilling uses the depth control senser to detect the top of the stack. Once detected, the spindle begins the pulse drilling process. Since pulse drilling doesn't begin until a stack is detected, it cannot be "demoed" by drilling dummy drill strokes in the air. The buttons described in this section allow you to turn pulse drilling on/off and also allow you to specify a range of tool diameters for which pulse drilling will be active. NOTE: Pulse Drilling must be enabled in order to access the features described in this section. Refer to the PULSE-ENABLE,ON command description in the VSB section for details. Pulse Drilling menu button
PULSEPOP
This button displays the Pulse Drilling setup menu. The menu allows you to turn on pulse drilling for a specific range of tool diameters. Two buttons are provided, one is used to select the minimum pulse tool diameter, the other is used to select the maximum pulse tool diameter. The Pulse Drilling button to display the setup menu is located on the Special Features page. To exit the popup, touch the red header bar at the top of the menu. ORIGINAL SCREEN: The Pulse Drilling button is located on the Options and Switches page. Pulse Drilling On/Off button
PULSE,on/off
This button allows you to turn pulse drilling on/off. The button is located on the Special Features page, next to the Pulse Drilling menu button. ORIGINAL SCREEN: The button is included on the Pulse Drilling setup menu. Pulse Drilling Diameter buttons
Two buttons located on the Pulse Drilling setup menu allow you to turn pulse drilling on for a specific range of tool diameters. Touching either button displays the 10-key popup allowing you to enter the minimum or maximum diameter. When pulse drilling is turned on, tool sizes within the selected diameter range will be pulse drilled while all other tool sizes will be drilled normally. Note that you must specify a minimum diameter that is less than or equal to the maximum pulse diameter. Conversely, the maximum diameter must always be greater than or equal to the minimum pulse diameter. This means, for example, when you initially select the diameter range (both diameter values are zero), you must set the maximum diameter before entering the minimum diameter. Binary Map Location
This command will move the tooling plate to the location for binary map drilling. This command confirms the location. forecastTool Forecast - Multiple Job
The Multiple Job Tool Forecast function provides you with a program run time and tool usage analysis for multiple jobs. The function is available for non-autoload systems to provide essentially the same features as the autoload Job Queue Analysis function. The multiple job forecast allows you to determine for example, if the tools presently stocked in the TMS cassette are sufficient for the entire shift's worth of work. The forecast function reports the approximate run time for each job in the forecast queue, as well as the total run time for the entire forecast queue. It also predicts any interruption caused by insufficient tools in the toolchange system. A problem tool summary may be displayed if there are an insufficient number of tools. The summary provides information for each tool size where the number of required tools exceeds the number of available tools. All of the information generated is also duplicated in a readable file called "forecast.rpt" located in the SYSTEM directory. This file can be used to generate hard copies through the use of a printer or is transferable to a remote host for further analysis. This file is OVERWRITTEN each time the analysis function is run. Tool Forecast Window
The Multiple Job Tool Forecast popup window may be accessed through the Dry Run menu available from the Machine Setup page. Touching the Dry Run menu's Tool Forecast button displays the Tool Forecast menu, allowing you to select Current Job Tool Forecast (to analyze only the part program currently set as the input source) or Multiple Job Tool Forecast (to display the Multiple Job Tool Forecast window). The Multiple Job Tool Forecast popup provides the following buttons allowing you to enter part program names, number of stacks to be drilled, etc. into the forecast queue:
tlen-chkTool Length Check
This section describes the Tool Length Check feature. When enabled, Tool Length Check compares the length of the tool before it is removed from the spindle collet against the tool length when it was first picked up. Comparing the tool length before and after it is used allows the machine to detect if the tool has slipped up or down in the spindle collet. If slippage is detected, the machine pauses allowing the operator to inspect the tool and/or panels as required. The initial tool length is obtained by doing a tool tip check following the tool change. (When the machine is operated in depth control or controlled penetration mode, this check is transparent since the machine checks the tool length anyway.) The machine subsequently obtains the final tool length by performing a tool tip check before replacing the tool (a final length check will also be made at end of program if a tool is in the collet). The final tool length is compared to the initial length to determine if the tool has slipped in the collet. If the tool length variance exceeds a specified tolerance the machine will pause and display a message after removing the tool from the spindle, allowing the operator to inspect the tool and panels as needed. The operator then presses the Start button to continue the tool change. Please note that if a tool fails the length check, it is NOT considered to be a defective tool. The tool is deposited in the normal manner following the length check. The Tool Length Check function may display one or more of the following messages. Each message is displayed on the CNC-7 screen and logged in the STATS file unless otherwise noted. The number preceding the message is the message ID number which may be used to locate the message in the STATS file.
Tool Length Check Menu
TLENPG
The Tool Length Check Menu provides buttons allowing you to set up the Tool Length Check function. Included on the menu are the following items. See related sections of the CNC-7 User Reference manual for further details regarding each function. Tool Length Check On/Off
TLEN,on/off
Toggles the Tool Length Check function on/off. When enabled, the length check function utilizes the depth control pod to check for tool slippage before replacing the tool. A button to toggle the Tool Length Check function on/off is located on the Special Features page next to the Tool Length Check menu button. Tool Length Check Short Tool Tolerance
TLEN-SHORT-TOL,#
Used to specify the maximum short tool tolerance. The tool is considered to be too short if it is shorter than the original length by an amount greater than the tolerance. The tolerance should be set to a value large enough to accommodate the normal variations in tool length readings due to changes in spindle temperature, etc. The default tolerance is set at .010 inches (.254 mm). A button to set the short tool tolerance is located on the Tool Length Check menu. The button to display the menu is located on the Special Features page. Tool Length Check Long Tool Tolerance
TLEN-LONG-TOL,#
Used to specify the maximum long tool tolerance. The tool is considered to be too long if it is longer than the original length by an amount greater than the tolerance. The tolerance should be set to a value large enough to accommodate the normal variations in tool length readings due to changes in spindle temperature, etc. The default tolerance is set at .010 inches (.254 mm). A button to set the long tool tolerance is located on the Tool Length Check menu. The button to display the menu is located on the Special Features page.
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