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XYZ Turret Mill ProtoTRAK SMX CNC

1. XYZ FEEDRATE the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 FIN FEEDRATE the finish milling feedrate for both the island and pocket finish cuts TOOL is the tool number you assign 9 7 3 Irregular Island Advanced Features Option Press the IRREG ISLAND key if you wish to mill an island other than a rectangle or circle The Irregular Island gives you the powerful Auto Geometry Engine to define a shape made up of straight lines and arcs The first screen in an Irregular Island event will define the beginning point and some of its general parameters The last event of the irregular pocket must end at the same point as defined in the first event Prompts for the Irregular Island event X BEGIN X dimension to the beginning of the island Y BEGIN Y dimension to the beginning of the island Z RAPID is the Z dimension of the transition from rapid to feed Z END is the Z dimension at the bottom of the pocket incremental is from the previous event PASSES the number of roughing passes to the depth ENTRY MODE choose between zigzag ramp and plunge The plunge will machine straight down Z to the appropriate Z depth The zigzag ramp will move in a zigzag pattern to depth See the previous section for more information about the zigzag ramp FIN CUT ISL Finish cut for the Island If 0 is input there will be no finish cut See the previous section for a bottom finish cut X1 POCKET X dimension fo
2. YES and NO Yes and no appear when the Dwell Request Auxiliary Function Request and the Event Comments are highlighted Choosing Yes will give you prompts for using these options while you are programming You may return to the Program Header Screen at any time to choose or cancel these prompts PART GEO sets up the programming as Part Geometry TOOL PATH sets up the programming as Tool Path This function is part of the Advanced Features Option 7 4 Auxiliary AUX Functions Three Axis CNC Models Only When the Auxiliary Function Option is installed and active the ProtoTRAK SMX CNC can control four different auxiliary functions You can select whether to activate or deactivate these functions at the beginning or end of each event If Auxiliary Functions are selected on the program header the system will prompt for AUX BEG and AUX END in each event When running programs with Auxiliary functions the ACCESSORY hard key on the front panel must be in the correct position If you want the program to automatically turn the Auxiliary functions on and off press the ACCESSORY key until the light is on in the AUTO position 53 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual AUX BEG options Input Function Comments 0 None No Auxiliary functions will begin when this event begins to run 1 Coolant Air The coolant pump or air solenoid will be turned on
3. Don t use dull or damaged cutting tools They break easily and become airborne Inspect the sharpness of the edges and the integrity of cutting tools and their holders Use proper length for the tool 23 Large overhang on cutting tools when not required result in accidents and damaged parts 24 Prevent fires When machining certain materials magnesium etc the chips and dust are highly flammable Obtain special instruction from your supervisor before machining these materials 25 Prevent fires Keep flammable materials and fluids away from the machine and hot flying chips 26 When working in manual mode not CNC make sure the computer control is switched to DRO or OFF 13 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 3 0 Description 3 1 ProtoTRAK SMX CNC Specifications In its base form the ProtoTRAK SMX CNC is powerful and easy to use For turret mill applications the two axis CNC is usually preferred because of its simplicity and ease of use When three axis CNC is required a ballscrew and motor is mounted to the head to drive the quill The list below summarizes the features and specifications Each feature is described in more detail in the appropriate section of the manual 3 1 1 Basic System Specifications Control Hardware 2 or 3 axis CNC 3 axis DRO Real handwheels for manual operation 10 4 color active
4. XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual ProtoTRAK SMX CNC on a machine that does not have a ProtoTRAK SMX CNC and vice versa Each ProtoTRAK SMX CNC comes with converters for other ProtoTRAK and TRAK CNC s Converters for other brands of CNC s are sold separately Program conversions take place by first translating the file into a neutral run engine then from neutral to the desired file format For this reason you should think of conversions as being only one way The conversion process changes the file in ways that are harmless and so the results are correct However when converted back it will not be the same as it was originally written it will create the same part but some of the lines of code will be different 15 9 1 Activating Converters Converters must be activated before you can use them Standard converters include those that handle the translation between the ProtoTRAK SMX CNC and other TRAK CNC s Optional converters are purchased separately Standard converters and optional converters that are ordered and shipped with the machine are activated at the factory You can tell which converters are activated by looking in the Open As see Figure 15 9 3 or Save As windows see Figure 15 4 If you purchase a converter after you have installed your machine you must activate it yourself using the procedure described in Section 3 1 7 15 9 2 Converting From a D
5. XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual FIGURE 11 2 4 Pressing the Change All softkey highlights the Z feed for all the Mill events FIGURE 11 2 5 Type the new Z Feed and then SET to change all the highlighted values from 5 to 7 103 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 11 3 Erase Program Use the ERASE PROG soft key to erase the program from the current memory Erasing the program from current memory will not affect any programs that are stored If you have made changes to the program and wish to save this modified program you will need to store it See Section 13 4 11 4 Clipboard Advanced Features Option The Clipboard feature is a way to copy events in one program in order to put them into a different program It is a two part process that takes place in two different Modes First in the Edit Mode the desired events are copied or placed on the Clipboard from the source program Then the events are inserted into the destination program in the Program Mode When you press the Clipboard key from the Edit Mode you start the process that copies the events that you want to put into a different program than the one in current memory Before you do that you should write a program or open the program file that has the events you want to copy This is called the source program Inspect
6. LIST STEP displays the list of events on the left side of the screen and with a purple highlight on the first event As LIST STEP is pushed the highlight shifts to the next event As this happens that event is also highlighted in the graphics by having its color change to purple START EVENT NUMBER will prompt you to enter an event number for highlighting This is useful for moving quickly to a particular event in a large program XY displays a view in the XY plane YZ displays a view in the YZ plane XZ displays a view in the XZ plane 3D displays an isometric view Softkeys in Adjust view FIT DRAW automatically resizes the drawing to fit the entire part program on the screen 6 shifts drawing down 5 shifts drawing up 3 shifts drawing to the left 4 shifts drawing to the right ZOOM IN makes the drawing larger ZOOM OUT makes the drawing smaller RETURN returns you to the first LOOK screen The adjustments you made will stay on the screen until you press another selection that overrides those adjustments The LIST STEP function may be used with the adjustment unaltered Note The LOOK routine does not check for programming errors Use Tool Path in the SET UP Mode to check movement of the tool 7 12 Finish Cuts The Pocket and Profile events are designed with built in finish cut routines because they are complete and stand alone pieces of geometry Shapes machined with a series of Mill or Arc events
7. Mm min 999 99 to max 99 999 Rapid moves rapid moves are generated by the ProtoTRAK automatically as part of the definition of an event For this reason G0 moves are discarded unless they specify a location other than the beginning of the following event Linear moves G01 are formatted the same as rapid moves Arcs Arc centers are specified by the address I J and K for the X Y and Z axes The number following the I J and K are incrementally referenced from the startin g point of the arc Radius values are not allowed Tool Numbers and Tool Changes the format of the tool number is from T1 to T99 During program run the ProtoTRAK will rapid to home for a tool change and pause for the tool to be loaded manually and the operator to press GO Feed rates the ProtoTRAK is programmed in inches or mm per minute using the F address Spindle speed If the Programmable E Head Option is active S represents RPMs if not active the S values are ignored File name use the CAM extension so the ProtoTRAK will recognize the file as a CAM file and convert it into ProtoTRAK events when it is opened File names may include up to 20 alpha numeric characters 15 13 2 Convertible G Codes The following G codes may be used in a CAM file that you want to have converted to a ProtoTRAK program G Codes that are not on the list below have no correspondent operation in the ProtoTRAK events and will be ignored when the program is converted If
8. PAGE FWD The arc is tangent to the previous line Selects CCW arc direction Unknown endpoint guess Unknown endpoint guess Known print value Known print value Skip Known print value No more data is available from the print EVENT 6 AGE ARC NOTES Tangent Direction X End Y End X Center Y Center Conrad Radius Chord Length Chord Angle 1 SET 1 SET GUESS 20 ABS SET GUESS 100 ABS SET GUESS 60 ABS SET GUESS 120 ABS SET DATA FWD 38 SET PAGE FWD The arc is tangent to the previous arc Selects CW arc direction Unknown endpoint guess Unknown endpoint guess Unknown center guess Unknown center guess Skip Known print value No more data is available from the print 158 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual EVENT 7 AGE ARC NOTES Tangent Direction X End Y End X Center Y Center Conrad Radius Chord Length Chord Angle 1 SET 2 SET GUESS 29 ABS SET GUESS 70 ABS SET 0 ABS SET 82 5 ABS SET DATA FWD 31 75 SET PAGE FWD The arc is tangent to the previous arc Selects CCW arc direction Unknown endpoint guess Unknown endpoint guess Known print value Known print value Skip Known print value No more data is available from the print EVENT 8 AGE MILL NOTES Tangent X End Y End Conrad Angle End Length Line Angle 1 0 ABS SET GUESS 20 ABS SET DATA FWD DATA FWD DATA FWD 300 SET Tangent By defaul
9. Pressing the START EVNT soft key allows you to start in the middle of a program When you press the START EVNT soft key the conversation line will prompt Input Event Input the number of the first event you wish to run and press SET If the START EVNT is a Repeat or Rotate the conversation line will prompt Starting Repeat Number asking which repeat or pass you wish to start 13 4 Program Run When you have started by any of the means above the display will show FIGURE 13 4 Press the GO feed key to start running i01145 119 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Where The part number being run is shown in the status line The event number and type and the repeat number if applicable being run is shown at the top of the screen The current X Y Z absolute positions are shown in the information area The SHOW ABS soft key which is automatically assumed if one of the other 3 show keys are not selected will show the absolute X Y Z positions as the part is run The SHOW INC soft key will show the incremental or distance to go within the event X Y Z positions as the part is run The SHOW PATH soft key will show the tool path graphics as the part is run The SHOW PROG soft key will show the programmed data for the event being run and the next event as the part is run The run procedure is very
10. Whether the ProtoTRAK SMX CNC is in two or three axis The Look In area shows the storage areas or drives and directories that are being displayed below in the listing area In the listing area the biggest part of the screen appears all the files and folders for the location shown in the Look In box The C Drive of the ProtoTRAK SMX CNC is not accessible for program storage The File Name box shows the program file on which the operation will be performed Parts of the screen unique to specific operations will be discussed below 129 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 15 2 2 Softkeys in the Program In Out Mode Screens Use the softkeys to move around any of the screens in the Program In Out Mode TAB Moves the highlight between the parts of the screen Where applicable tabbing to an area will cause a drop down box to appear showing all the selections possible DATA FWD DATA BACK Moves the highlight up and down through the list Press and hold for automatic advancement OPEN FOLDER Use this key to open a highlighted folder that contains program files When the highlight is on the root directory this will collapse the list displayed and show the next level up The root directory is represented by a folder with an up arrow followed by two periods The root directory will disappear when the most basic organization for the drive in the Lo
11. either with or without A G E Profile don t have an automatic routine for making finish cuts There is however a very simple technique that can be used a Program the shape using the print dimensions and ignore the need to leave material for a finish cut b Using a subroutine event Repeat all the events in a but call out a different tool number 58 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual c In Set Up Mode lie about the tool diameter for the tool called out in events in a Input a tool diameter equal to the actual tool diameter plus 2 times the finish cut you wish to leave The ProtoTRAK SMX CNC will think the tool is bigger than it really is and therefore shift a little further away from the machined shape d In Set Up Mode input the actual diameter for the tool called in the Repeat event b This will produce the final dimensioned cut 7 13 Two Versus Three Axis Programming for Three Axis CNC Models For mills with the Z axis ballscrew and motor assembly installed the ProtoTRAK SMX CNC may be operated as either a two or three axis CNC Many jobs in tool rooms are simply easier to do with a two axis CNC Other jobs are more complex or require a lot of metal removal so the extra programming and set up of the three axis is worth the effort The ProtoTRAK SMX CNC lets you choose how much CNC you want to use on the job at hand See
12. moves forward through the programmed events PAGE BACK moves backwards through the programmed events DATA FWD moves forward through the event inputs Note use the DATA FWD key and not a SET key when you do not want to input a value DATA BACK moves backwards through the event inputs DATA BOTTOM puts the Highlight on the last input INSERT EVENT use this to insert a new event into the program This new event will take the place of the one that was on the right side of the screen when you pressed the INSERT EVENT key That previous event and all the events that follow increase their event number by one For example if you started with a program of four events if you were to press the INSERT EVENT key while Event 3 was on the right side of the screen the previous Event 3 would become Event 4 and the previous Event 4 would become Event 5 If you insert a Subroutine event the event numbers will increase by one as when you insert another kind of event If you insert a copy event the event numbers will increase by the number of events that are copied DELETE EVENT this will delete the event on the right side of the screen 7 9 Programming Events Once you press the appropriate GO TO soft key you will begin to define your part as a series of Events For the ProtoTRAK SMX CNC an Event is a geometry or a feature of a part FIGURE 7 8 Soft keys used while programming an event FIGURE 7 9 1 The header screen has been completed a
13. 1 IRREGULAR PROFILE NOTES X Begin Y Begin Tool Offset Finish Cut Feedrate Fin Feedrate Tool 0 ABS SET 0 ABS SET 1 SET 2 SET 250 SET 200 SET 1 References lower left corner Sets tool offset RIGHT Means finish cut of 2mm Sets feedrate to 250 mmpm Sets tool to 1 157 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual EVENT 2 AGE Mill NOTES Tangent X End Y End Conrad Angle End Length Line Angle 95 ABS SET 0 ABS SET PAGE FWD Not required for the first event Known print value Known print value Press Page Forward now as no further data is required EVENT 3 AGE Mill NOTES Tangent X End Y End Conrad Angle End Length Line Angle 2 SET 114 ABS SET GUESS 35 ABS SET DATA FWD DATA FWD 38 5 SET DATA FWD For no Add radius value to line length No print data so we make a guess Skip over this prompt Skip over this prompt Known print value Skip over this prompt and to the next event EVENT 4 AGE Mill NOTES Tangent X End Y End Conrad Angle End Length Line Angle 2 SET 114 ABS SET 70 ABS SET PAGE FWD For no Same as above Known print value No more data is available from the print EVENT 5 AGE ARC NOTES Tangent Direction X End Y End X Center Y Center Conrad Radius Chord Length Chord Angle 1 SET 2 SET GUESS 90 ABS SET GUESS 80 ABS SET 95 ABS SET 70 ABS SET DATA FWD 19 SET
14. Dwell The Advanced Features Option is not active 50 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 7 3 Program Header Screen The first screen you see when you enter the Program Mode is the Program Header Screen The Program Header Screen gives you options that apply to the entire program The softkey selections allow you to ente r the program at any point The program name and general programming options you choose in the Program Header Screen will be summarized in the program as Event 0 7 3 1 Program Name Programs written on the ProtoTRAK SMX CNC are usually named for the part that is to be machined When programs or files are named using the ProtoTRAK SMX CNC the name can be up to 20 characters long Programs imported into the ProtoTRAK SMX CNC may be longer While 20 characters are allowed the entire program name may not be shown in the status line or the program header screen FIGURE 7 3 Pressing the Help hard key when the Program Name is highlighted calls up alpha keys Program names can include numbers letters spaces and other characte rs When the Program name prompt is highlighted the Data Input Line will show Program Name At this point you may Press number keys Press Help to access alpha keys and special characters in the ProtoTRAK SMX CNC Use a keyboard plugged into the ProtoTRAK SMX CNC to name the program T
15. G47 Tool offset double increase G48 Tool offset double decrease G62 Automatic corner override mode G63 Tapping mode G65 User macro simple call G66 User macro modal call G67 User macro modal call cancel G74 Counter tapping cycle G76 Fine boring G86 Boring cycle G87 Back boring cycle G88 Boring cycle G92 Programming of absolute zero point G95 Feed per revolution 15 13 6 Accepted M Codes M Code Function M00 A pause is generated The axes will not move but the motors will be engaged The spindle motor will not turn off M02 Executed automatically at the end of all programs Turns off the servo motors and all auxiliary functions The auxiliary function box must be present for this function to work M05 Stops the spindle at the end of the current event The auxiliary function box must be present for this function to work M06 Tool change The M06 is ignored as the tool change on the ProtoTRAK is accomplished by changing the tool number M07 Flood coolant on T his will turn on the auxiliary box A C outlet before the event M08 Spray coolant on This will turn on the air supply from the auxiliary box before the event M09 Coolant off This will turn off the auxiliary box A C outlet and air supply after the event M12 amp M20 Send a pause to the indexer and wait for an in position response All other M codes will be ignored Notes 1 Place M Codes on same line as mo
16. Opening a File To open a program from the list simply place the highlight on the program and press the OPEN softkey Opening a program will move it from the floppy to the current memory of the ProtoTRAK SMX 14 5 Saving a File To save a file that is in current memory press the SAVE softkey You will usually want to do this after you put a significant amount of work into writing a program Before you press the SAVE softkey you should make sure that the program name doesn t already exist on the list If you save a new program over one that was already there the previous one will be lost Once the program name appears on the list it is stored on the floppy If you make changes to the program you must save it again for the changes to be stored 14 6 Deleting a File To delete or remove a program from the list put the highlight on the program and press the DELETE key A warning will appear in order for you to confirm you want to delete the file 125 XYZ Machine Tools Ltd TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 14 7 Renaming or Copying a File To rename a file simply highlight the original file so that the name appears in the File Name box Tab to the File Name box and enter a new name When you Tab to the File Name box the Blue appears indicating that you can use the alphabet matrix to help name the file by pressing the Help hardkey Once you type in the n
17. RESTORE then re enter all keys Inch to MM or MM to Inch Press IN MM and note LCD screen status line Reset One Axis Press X or Y or Z INC SET This zeros the incremental position in the selected axis Preset Press X or Y or Z numeric data INC SET to preset selected axis Reset Absolute Reference Press X or Y or Z ABS SET to set selected axis absolute to zero at the current position Note This will also reset the incremental dimension if the absolute position is being displayed when it is reset Preset Absolute Reference Press X or Y or Z numeric data ABS SET to set the selected axis absolute to a preset location for the current machine position Note This will also reset the incremental dimension if the absolute position is being displayed when it is preset 46 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Safety Programming Operating amp Care Manual Recall Absolute Position of All Axes Press INC ABS Note the dimension for each axis is labeled INC or ABS Press INC ABS again to revert to the original reading Recall Absolute Position of One Axis Press X or Y or Z INC ABS Note the INC or ABS label for each axis Repeat to get selected axis back to original reading 6 3 Jog The servomotors can be used to jog the table saddle and ram a Press the JOG soft key b A flashing message will appear saying CAUTION JOG KEYS ARE ACTIVE c To jog press the X Y or Z hard keys
18. SMX SLV machines the draw bar included in the option may be M16 or 5 8 UNC The standard type of power draw bar is of the appropriate length to fit tool holders that have a threaded tang on the top ISO 40 BT40 and CAT 40 tool holders have a different arrangement at the small tapered end so a longer drawbar is required to thread into the tool holder when the retention knob is removed These longer drawbars can be provided on request please talk to your Area Sales Manager or XYZ Machine Tools parts department 3 16 4 Remote Stop Go Switch For the convenience of operation while running the program a Remote Stop Go switch may be purchased This switch is on a ten foot cable and operates like the FEED Stop and Go keys on the display 29 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Safety Programming Operating amp Care Manual 4 0 Basic Operation The ProtoTRAK SMX CNC combines the simplicity and flexibility of using a knee mill with the easy natural user interface that makes the ProtoTRAK the top brand in CNCs for small lot machining 4 1 ProtoTRAK SMX Basic Operation Most of the operations of the ProtoTRAK SMX CNC are organized in Modes Modes are logical groups of activities that naturally belong together This eliminates the need to memorize operations just select a mode and choose among the soft keys Most operations will be discussed within the section that treats the particular mode later in this
19. Section 4 6 for switching between two and three axis operation Programming is very similar between the two EVENT 1 BOLT HOLE EVENT 1 BOLT HOLE DRILL OR BORE HOLES HOLES X CENTER X CENTER Y CENTER Y CENTER RADIUS Z RAPID ANGLE Z END TOOL RADIUS ANGLE PECKS FOR DRILL Z REEDRATE TOOL FIGURE 7 13 Programming a Bolt Hole On the left the prompts required in programming in three axis CNC On the right the prompts required for two axis In Figure 7 13 the prompts for programming a Bolt Hole in two axis and in three axis are shown side by side Note that the difference is that the three axis requires a few additional prompts For the convenience of users who have two axis CNC models the programming will be explained in two different sections If you have a three axis CNC model we suggest you skip the two axis programming section since the programming is very similar 59 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 49 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 7 0 Program Mode Getting Started amp Some General Information 7 1 Programming Overview The ProtoTRAK SMX CNC makes programming easy by allowing you to program the actual part geometry as defined by the print The basic strategy is to first fill in the initial program informat
20. XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual X Offset is the distance from Y absolute 0 to the Y axis line of reflection Y Offset is the distance from X absolute 0 to the X axis line of reflection 8 9 3 Rotate Press the ROTATE soft key First Event is the event number of the first event to be rotated Last Event is the event number of the last event to be rotated if only one event is to be rotated the last event is the same as the first X Center is the X absolute position of the center of rotation Y Center is the Y absolute position of the center of rotation Angle is the angle of rotation of the repeated events positive is counterclockwise negative is clockwise Repeats is the number of times events are to be rotated up to 99 8 10 COPY Events Advanced Features Option Copy Events are programmed exactly like Subroutine Events The only difference is that in Copy the events are rewritten into subsequent events If for example in Event 11 you Copy Repeated Events 6 7 8 9 10 with 2 repeats Events 6 10 would be copied with the input offsets into Events 11 15 and recopied into 16 20 Copy Events may be Repeat Mirror or Rotate Copy is very useful With copy you can Edit the events that are being repeated mirrored or rotated without changing the original events Connect so that the quill will not mo
21. XYZ Machine Tools on 01823 674200 or contact your Area Sales Manager with your purchase order number and the numbers you wrote down in step 4 above 6 When you receive your Password Activation Number input it into the ProtoTRAK where indicated on the screen obtained in step 2 above Some options require you to reboot the ProtoTRAK to activate 7 Refer to the appropriate section of this manual for instructions on using your new features 18 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 3 2 Display Pendant 3 2 1 Front Figure 3 2 1 The ProtoTRAK SMX CNC front panel Keyboard Hard Keys Feed Keys GO initiates motion in Run The green LED on the GO key will be lit when the servomotors are moving the machine either in jog or when the program run has been initiated by the GO key STOP halts motion during Run The red LED on the STOP key will be lit when the servos motors are not moving the machine Override Keys F S selects the function for the override operation F is for feedrate When the LED above the F is lit arrow presses will increase or decrease axis feedrate S is for spindle RPM When the LED above the S is lit arrow presses will increase or decrease the spindle RPM Note the spindle override is active only when the Programmable Electronic Head Option is installed Feedrate Override to increase feedrate or spindle rpm up to 1
22. XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Safety amp Information Labels Used On The XYZ Turret Mills It is forbidden by law to deface destroy or remove any of these labels 8 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Safety amp Information Labels Used On The XYZ Turret Mills It is forbidden by law to deface destroy or remove any of these labels 9 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Safety amp Information Labels Used On The XYZ Turret Mills It is forbidden by law to deface destroy or remove any of these labels 10 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 415 VOLTS Safety amp Information Labels Used On The ProtoTRAK SMX CNC It is forbidden by law to deface destroy or remove any of these labels 11 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 2 3 Safety Precautions 1 Do not operate this machine before the ProtoTRAK SMX CNC Safety Installation Maintenance Service and Parts List Manual and the Safety Programming Operating amp Care Manual have been studied and understood 2 Do not run this machine without know
23. a G Code is essential to your program and you do not see it here you can do one of two things Convert the file from CAM to ProtoTRAK and add an event to the resulting ProtoTRAK program Run the program as a GCD file See Section 13 11 149 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual G Code Description G00 Rapid positioning G01 Linear interpolation G02 Circular interpolation CW G03 Circular interpolation CCW G20 Input in inch G21 Input in metric G40 Cutter compensation cancel G41 Cutter compensation left G42 Cutter compensation right G54 Work coordinate system 1 selection G55 Work coordinate system 2 selection G56 Work coordinate system 3 selection G57 Work coordinate system 4 selection G58 Work coordinate system 5 selection G59 Work coordinate system 6 selection G73 Peck drilling cycle G80 Hole machining canned cycle cancel G81 Drilling cycle spot boring G82 Drilling cycle counter boring G83 Face hole machining cycle G84 Tapping canned cycle VM only G85 Face boring cycle G89 Boring cycle dwell at bottom G90 Absolute programming G91 Incremental programming G98 Return to initial point in canned cycle G99 Return to point R in canned cycle 15 13 3 Supported Addresses CAM information is communicated through the use of ADDRESS WORD pairs For example i
24. and A G E Arcs Programming with the Auto Geometry Engine is explained in Section 9 0 9 8 PROFILE Events This event allows you to mill around the outside or inside of a circular or rectangular frame or an irregular profile The irregular profile may be closed or open All profiles are limited to the XY plane When the irregular profile event is started the ProtoTRAK SMX CNC will automatically initiate the powerful Auto Geometry Engine See Section 10 0 for programming with A G E 9 8 1 Circle Profile Press the CIRCLE soft key if you wish to mill a circular frame Prompts in the Circle Profile event X Center is the X dimension to the center of the circle Y Center is the Y dimension to the center of the circle Z Rapid is the Z dimension to transition from rapid to feed Z End is the Z dimension to the bottom of the frame incremental is from the previous event Radius is the finish radius of the circle Direction is the clockwise input 1 or counterclockwise input 2 direction for milling Tool Offset is the selection of the tool offset to the right input 1 offset to the left input 2 or tool center no offset input 0 relative to the programmed edge and direction of the cutter movement Passes is the number of cycles to machine to the final depth spacedequally from Z Rapid to Z End hint keep Z Rapid small Fin Cut is the width of the finish cut If 0 is input there will be no finish cut RP
25. and by the operation of the electronic handwheel A limit switch in the assembly prevents damage from over travel Z axis traverse is limited to 115mm 3 15 Limit Switches Limit switches are mounted for the saddle and table travel 3 16 Optional Equipment 3 16 1 Electronic Handwheels When ordered as part of the TRAKing Electronic Handwheels Option see Section 3 1 6 the electronic handwheels replace the standard mechanical handwheels for table and saddle traverse The electronic handwheels will operate when the ProtoTRAK SMX CNC is in a Mode where the machinist controls the motion of the table and saddle This includes the DRO Mode the Set Up Mode and the TRAKing operation in the Run Mode The electronic handwheels will not operate during other functions such as when the Select a Mode message appears on the screen Handwheel resolution is determined by the F C key on the display Fine feed moves 5mm 0 200 inches per revolution Course feed moves 20mm 0 800 inches per revolution 3 16 2 Linear Scales 28 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual The ProtoTRAK SMX CNC may be configured to run either with or without Linear Scales for X and Y travel Linear scales have a feedback resolution of 5 Microns 3 16 3 Power Draw Bar A manual draw bar comes standard with the machine A power draw bar option may be ordered For the SMX 3000 and
26. and next event then the X table and Y saddle will move at to the programmed position To program a Position event press the POSN soft key Prompts for the Position event X END is the X dimension to the position Y END is the Y dimension to the position Z Rapid is the Z dimension to the position RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is active Tool is the tool number you assign SET will use the tool number of the previous event 9 2 DRILL Events This event positions the table to the specified X and Y position moves the HEAD at rapid to the Z RAPID location feeds the quill to the Z END location and rapids back to Z RAPID for drill and feeds back for bore Press the DRILL soft key Prompts for the drill event Drill 1 Bore 2 selects whether the hole is to be drilled or bored X is the X dimension to the hole Y is the Y dimension to the hole Z Rapid is the Z dimension to transition from rapid to feed Z End is the bottom of the hole PECKS is the number of tool withdrawal cycles Each cycle drills and then retracts to the Z rapid position The factory setting is for each peck to be successively smaller taking the largest cuts at the beginning and the smallest at the end Variable You may change this to equal pecks To do this press the HELP key when the highlight is on
27. between circle pocket rectangular pocket and irregular pocket within the XY plane Pockets include machining the circumference as well as all the material inside the circumference of the programmed shape If a finished cut is programmed it will be made at the completion of the final pass The cutter will arc in and arc out of the finish cut and position itself the finish cut dimension away from the part before moving the tool out of the part The factory setting for tool stepover while machining a pocket is 70 This may be changed When you first enter the pocket event the blue will appear next to the help key Pressing Help will give you the choice of entering a new tool stepover percentage The value you enter here will remain the same until you change it again 77 XYZ Machine Tools Ltd XYZ Machine Tools Ltd and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 9 6 1 Circular Pocket Press the CIRCLE PCKT soft key if you wish to mill a circular pocket Prompts for the circle pocket X Center is the X dimension to the center of the circle Y Center is the Y dimension to the center of the circle Z Rapid is the Z dimension to transition from rapid to feed Z End is the Z dimension at the bottom of the pocket incremental is from the previous event Radius is the finish radius of the circle Direction is the clockwise input 1 or counterclockwise input 2 direction for milling P
28. enclosures 2 2 Danger Warning Caution and Note Labels and Notices As Used In This Manual DANGER Immediate hazards that will result in severe personal injury or death Danger labels on the machine are red in color WARNING Hazards or unsafe practices that could result in severe personal injury and or damage to the equipment Warning labels on the machine are orange in color CAUTION Hazards or unsafe practices that could result in minor personal injury or equipment product damage Caution labels on the machine are yellow in color NOTE Call attention to specific issues requiring special attention or understanding 4 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Safety amp Information Labels Used On The XYZ Turret Mills It is forbidden by law to deface destroy or remove any of these labels 5 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Safety amp Information Labels Used On The XYZ Turret Mills It is forbidden by law to deface destroy or remove any of these labels 6 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Safety amp Information Labels Used On The XYZ Turret Mills It is forbidden by law to deface destroy or remove any of these labels 7 XYZ Machine Tools Ltd
29. event s One new tool number may be assigned for each Repeat Event MIRROR Advanced Features Option is used for parts that have symmetrical patterns or mirror image patterns In addition to specifying the events to be repeated you must also indicate the axis or axes X or Y or XY are allowed that the reflection is mirrored across In addition you must specify the offset from absolute zero to the line of reflection You may not mirror another mirror event or mirror a rotate event Consider the figure FIGURE 8 9 1 Holes 1 4 are mirrored across the Y axis to 5 8 respectively about a line X OFFSET from X absolute 0 ROTATE is used for polar rotation of parts that have a rotational symmetry around some point in the XY plane In addition to specifying the events to be repeated you must also indicate the absolute X and Y position of the center of rotation the angle of rotation measured counterclockwise as positive and clockwise as negative and the number of times the specified events are to be rotated and repeated You may not rotate another rotate event or rotate a mirror event Consider the figure below 70 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual FIGURE 8 9 2 Shape A programmed with 4 MILL events and Conrads Using ROTATE these 4 events are rotated through a 45 degree angle about a point offset from absolute zero by X Center and Y Center dimensio
30. finish cut RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is active FIN RPM is the spindle RPM for the finish cut FIN RPM programming is available only if the Programmable Electronic Head Option is active Z FEEDRATE is the Z feedrate from Z rapid to Z end XYZ FEEDRATE the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 FIN FEEDRATE the finish milling feedrate for both the island and pocket finish cuts TOOL is the tool number you assign 9 7 2 Rectangular Island Advanced Features Option Press the RECT ISLAND softkey if you wish to machine a rectangular island Prompts for the RECT ISLAND X1 ISLAND X dimension for one corner of the rectangular island Y1 ISLAND Y dimension for one corner of the rectangular island X3 ISLAND X dimension for the opposite corner of the island Y3 ISLAND Y dimension for the opposite corner of the island Z RAPID is the Z dimension of the transition from rapid to feed Z END is the Z dimension at the bottom of the pocket incremental is from the previous event CONRAD ISL the value of the tangential radius in the corners of the island DIRECTION is the milling direction clockwise or counterclockwise PASSES the number of roughing passes to the depth ENTRY MODE choose between zigzag ramp and plunge The plunge will machine
31. has been completed and is on the left side Select an event type from the soft keys Three axis CNC events are shown 56 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual When the MORE soft key is selected the soft keys change to After an event type is selected from the soft keys the prompts for that event will appear on the right side of the screen The data you need to enter to program the event will appear in the Data Input Line As soon as you enter one piece of data by pressing the INC SET or ABS SET key the next prompt will appear in the Data Input Line 7 10 Editing Data While Programming While programming an event all data is entered by pressing the appropriate numeric keys and pressing INC SET or ABS SET If you enter an incorrect number before you press INC SET or ABS SET you may clear the number by pressing RSTR Restore Then input the correct number and press SET If incorrect data has been entered and SET you may correct it as long as you are still programming that same event Press the DATA BACK or DATA FWD Forward soft key until the incorrect prompt and data are highlighted and shown in the conversation line Enter the correct number and SET The ProtoTRAK SMX CNC will not allow you to skip past prompts by pressing DATA FWD which need to be entered to complete an event except when using the A G E in the Irregular Pocket or Irregular Profile
32. header with the highlight on the program name the blue question mark appears Pressing the HELP key at that time will call up a table with alpha and special characters you can use to name your program Math Helps When the blue question mark does not appear pressing HELP will initiate the Math Helps FIGURE 4 1 6 1 The first Math Helps screen Choose among the alternatives based on the information you need to calculate Math Helps are powerful routines that enable you to use the data you have available to calculate missing print data For example Math Help type 28 enables you to solve an entire right triangle by giving two known pieces of data To exit from the Math Help press the Mode key 32 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Safety Programming Operating amp Care Manual You may have the Math Help solutions load directly into your program This saves you from having to write down the solution and then key it in While you are programming the event that needs the data from Math Help simply press the HELP key to start the Math Help Once a solution is obtained you will have the following soft key selections Load Begin will load the displayed solution into the eve nt as the X and Z beginning Load End will load the displayed solution into the event as the X and Z end Load Center will load the displayed solution into the event as the X and Z center Next Solution when there is more than
33. highlight around the table ERASE TABLE clears all tool information so you can start over See 12 1 4 below JOG puts the ProtoTRAK SMX CNC into the DRO jog operation see Section 6 3 RETURN reverts to the SET UP mode screen The electronic handwheels are active including the fine coarse selection while you are in the tool table 12 1 2 The Logic of the Tool Table For three axis CNC models the diameters and Z Offsets must be set up for each tool For two axis CNC models the diameter is essential for the tool compensation to work but the Z Offset information is not mandatory However even in two axis or DRO operation Z Offset information will be applied to the Z axis DRO dimension for each tool saving you the need to touch off every time the tool is changed The tool table is organized to do the following Make it easy to set up tools Make it easy to replace a tool or add a tool Retain tool information in memory to reduce set up You assign tool numbers as you write a program These tool numbers may be from 1 to 99 Before machining the diameters and Z offset of each of the tools in the program must be defined so that the ProtoTRAK SMX CNC can calculate the tool path Tools that are used in the program that is in current memory are called active tools and their numbers are in red in the tool table When you save a program all the tool information for active tools is saved with it When the program is ope
34. is the Z dimension to the center of the arc incremental is from Z End The Z Center dimension is programmed only if the Advanced Features Option is active Conrad is the dimension of a tangential radius to the next event which must lie in the same plane Direction is the clockwise input 1 or counterclockwise input 2 direction of the arc as viewed looking down for an arc in the XY plane looking from the front for a vertical plane or looking from the right for a vertical YZ plane Tool Offset is the selection of the tool offset to right input 1 offset to left input 2 or tool center no offset input 0 relative to the programmed edge and direction of tool cutter movement and as projected in the XY plane RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is active Z Feedrate is the Z feedrate from Z Rapid to Z Begin XYZ Feedrate is the milling feedrate from Begin to End in in min from 1 to 100 or mm min from 5 to 2540 Tool is the tool number you assign Continue Yes or no This prompt appears when the Advanced Features Option is not active in order to program a continuous tool path without stops and eliminate repetitive prompts in the next event If the Advanced Features Option is active use the Profile event to accomplish the same thing 9 6 POCKET Event This event selection gives you a choice
35. manual The operations described in this section either don t fit in a particular mode or they are relevant to more than one mode 4 1 1 Switching on the ProtoTRAK SMX CNC To turn the ProtoTRAK SMX CNC on move the toggle switch on the display side panel to the Up position The Windows operating system and the ProtoTRAK SMX CNC software will take a few seconds to load from the system s flash memory If you have connected the ProtoTRAK SMX CNC to a network it may take as long as 90 seconds for the communications to be established When complete the ProtoTRAK SMX CNC Select Mode screen will appear Select the Mode of operation by pressing the soft key beneath the labeled box Notice that the EDIT and RUN soft keys are grayed out when the system is first turned on They will not function because there is no program in the ProtoTRAK SMX CNC Once a program is entered the EDIT key will function Once a program is entered and the necessary SET UP operations are complete the RUN key will function FIGURE 4 1 1 The main select a mode screen Shown here the Edit and Run Modes are grayed out because there is no program in current memory 30 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Safety Programming Operating amp Care Manual If the machine has been shut off since the last time the ProtoTRAK SMX was on you will have to press the green E Stop Reset button on the right side of the ProtoTRAK display pendant be
36. occur between a mill and arc or an arc and arc Specifically it means necessary but not sufficient that the two geometries share one and only one You would answer yes to the TANGENCY prompt if the event you are programming is tangent to the previous event The information that events are tangent helps the Auto Geometry Engine calculate other dimensions You can often tell by looking at the print if events are tangent tangent intersections tend to blend smoothly without a sharp corner smooth probably tangent sharp not tangent For the A G E the tangent mill or arc is assumed to continue in the same direction and not double back on the previous event like this not this 99 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 11 0 Edit Mode Within Program Mode you can recall and re input specific data prompt by prompt When the Advanced Features Option is active the Edit Mode contains powerful routines for more extensive program changes The changes you make in the Edit Mode affect only the program in current memory In order to preserve the changes for future use the program must be stored again under the same name in the In Out Mode 11 1 Delete Events To delete a group of events in the program press Delete Events The Data Input Line will prompt for the first event to be deleted Input the event number of the first event and press set Next the Dat
37. on a ProtoTRAK SMX run on a previous version ProtoTRAK or TRAK CNC you will need the MX2 and MX3 converters activated see section 15 9 above Save the program as either a MX2 or MX3 file depending on the control or program you want to run Since there are some feature differences between the CNC s the process will generally yield a useable mx2 or mx3 program but with the following exceptions Event or feature Comment Result Hidden Areas in Irregular Pocket The ProtoTRAK or TRAK CNC does not recognize Hidden Areas in Irregular Pockets The Irregular Pocket will be converted to an Irregular Pocket however the ProtoTRAK or TRAK CNC will display an error message that there are Hidden Areas in the Irregular Pocket We recommend that you separate the Irregular Pocket into two or more Irregular Pockets using the ProtoTRAK SMX before conversion Tap Events This routine does not exist in The routine will be ignored in the converted 137 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual all models of the ProtoTRAK or TRAK CNC program We recommend that you reprogram the Tap Events into Drill or Position events before conversion Copy Repeat Subroutines with Feed or RPM The Feed or RPM function does not exist in all models of the ProtoTRAK or TRAK CNC The Feed or RPM information will be removed from the Copy Repeat Subroutines The
38. only if the Programmable Electronic Head Option is active FIN RPM is the spindle RPM for the finish cut FIN RPM programming is available only if the Programmable Electronic Head Option is active TOOL is the tool number you assign 9 13 PAUSE Events The purpose of the Pause Event is to allow you to program a stop condition within the program The effect of this event is to turn off the spindle move the head to the Z retract location with the X and Y position corresponding to the end of the previous event and stopping the program run Pause events are useful if you want to stop the program to make a measurement change a fixture etc NOTE In general you should avoid programming a PAUSE event between two connective events The Pause event will cause the events to NOT be connective To program a Pause Event press the PAUSE soft key Because there is no input required simply press SET to load and the event counter will advance by one and the Select Event screen will reappear In run press the GO key after a pause to continue 9 14 Engrave Event Advanced Features Option The Engrave Event allows you to machine numbers letters and special characters as part of a part program See Figure 9 14 below for the letters and special characters that are available in the Engrave Event When programming with the Engrave Event the ProtoTRAK will construct a box to contain the text you define This box is oriented along the X axis like
39. other information that applies to the entire profile X Begin is the X dimension of the beginning of the profile Y Begin is the Y dimension of the beginning of the profile 68 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Tool Offset is the selection of the tool offset to right input 1 offset to left input 2 or tool center no offset input 0 relative to the programmed edge and direction of tool cutter movement Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 up to 3800 for model SLV Fin Cut is the width of the finish cut If 0 is input there will be no finish cut Fin Feedrate is the finish cut milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 up to 3800 for model SLV Tool is the tool number you assign When the initial Irregular Profile screen is complete the rest of the profile is programmed using A G E Mill and A G E Arc events Programming with the Auto Geometry Engine is explained in Section 10 0 Irregular Profile and Auto Geometry Engine programming is part of the Advanced Features Option 8 8 Engrave Event Advanced Features Option The Engrave Event allows you to machine numbers letters and special characters as part of a part program See figure 8 8 below for the letters and special characters that are available in the Engrave Event When programming with the E
40. pocket Both the shape of the island and the dimension of the surrounding pocket are defined within the island event The tool path for machining the island event is that the tool will first plunge or ramp into the material next to the island offset by the programmed finish cut to the depth of the first pass The tool will machine the perimeter of the island offset by the island finish cut Then the tool will machine the material in the pocket in a spiral path moving away from the island in the programmed clockwise or counterclockwise direction It will continue this outward spiral motion until it encounters the programmed rectangular perimeter or pocket It will then follow t he perimeter offset by the pocket finish cut It will proceed in this manner through the number of programmed passes On the final pass it will machine the island finish cut then the pocket finish cut If a Z finish cut is programmed it will do this in the same spiral pattern as the roughing passes between machining the island and pocket finish cuts The tool will ramp away from the finish cut by the amount of the finish cut before it raises out of the part 9 7 1 Circular Island Advanced Features Option Press the Circle Island soft key if you wish to mill a circular island Prompts for the Circular Island X CENTER is the X dimension of the center of the Island Y CENTER is the Y dimension of the center of the Island Z RAPID is the Z dimension of
41. programmed feed rates will be run We recommend that you inspect the feed rates before running the program on the ProtoTRAK or TRAK CNC when the s are other than 100 Tool Path Programming Only Part Geometry programming is supported on the ProtoTRAK or TRAK CNC You can only tran sfer Part Geometry programs to the ProtoTRAK or TRAK CNC Zig Zag Entry Mode Ramps This routine does not exist in the ProtoTRAK or TRAK CNC The routine will be converted to a Plunge routine We recommend that you check your Z feedrate to make sure it will be correct for a plunge Event Comments Event comments are not supported on the ProtoTRAK or TRAK CNC Event comments will be ignored Thread Mill This routine does not exist in the ProtoTRAK or TRAK CNC Thread Mill events will be ignored We recommend that you replace these events with the Helix Events and Mill Events to ramp in and ramp out of the helix Tool Table Info The part programs for ProtoTRAK or TRAK CNC do not contain tool table information This information is kept separately T ool table information will have to be set in the ProtoTRAK or TRAK CNC as usual Irregular Profile The ProtoTRAK or TRAK CNC does not contain an Irregular Profile Event The Irregular Profile Event will be converted to Mill and Arc Events and the programming of the finish cut and steps will be lost We recommend that after conversion you add repeat events for the steps and finish cut us
42. rotated without changing the original events Connect so that the quill will not move up to the Z Rapid position and back down unnecessarily However to be connective you must be certain that the X Y Z begin of the first event once offset or rotated coincides with the X Y Z end of the last event Program an event parallel to X or Y where the geometry is the easiest to describe rotate it to the desired position then delete the original Use the Clipboard to paste previously stored events from another program into the current program After you press the Clipboard key you will enter the offset from the previous program s absolute zero to the current program s absolute zero see figure below For information about putting events into the clipboard see Section 10 4 89 XYZ Machine Tools Ltd XYZ Machine Tools Ltd and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Figure 9 11 In the above example the offset that puts the group of holes in the desired location is X 1 50 and Y 1 00 9 12 Thread Mill Event Advanced Features Option To program a Thread Mill event press the Thread mill soft key This event includes an automatic move in and out by 1 25mm of the thread Prompts in the Thread Mill event X CENTER the X dimension of the center of the thread Y CENTER the Y dimension of the center of the thread Z RAPID the Z dimension where the Z rapid feed slows to Z pr
43. screen You may edit or insert other events 10 7 Guessing Data Whenever you are missing X or Y Ends or Centers you should generally enter a guess Guessed data is treated differently by the ProtoTRAK SMX CNC than regular data Often the information you put into the system will allow it to calculate a mathematically correct line or arc that would satisfy the conditions of the hard data you entered This line or arc may yield more than one solution to particular point you are looking for That is where the Guess comes in the A G E uses the guess to choose from the mathematically possible solutions In most cases your guesses do not have to be very precise The smaller the lines or arcs the more precise the guess should be FIGURE 10 7 The X End dimension has been entered as a guess note the letter G Guesses should always be entered as absolute dimensions Once entered the guessed data is green and there is a G next to it Guessed data will be labeled this way in all the events that are flagged NOT OK Once an event is OK the guessed data will be replaced by calculated data If you wish to edit your guesses placing it on the right side of the screen will cause your original guessed data to reappear 10 8 LOOK and Guess Guessed data may be entered by pressing the number keys and then SET However you may find it more convenient to use the LOOK graphics to enter guesses 97 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SM
44. screen will show the part graphics Press LOOK again or RETURN to revert back to the Program In Out screen The graphics displayed in this process are not exact but are a handy representation of the program Note DXF and GCD files may not be previewed with the LOOK feature 130 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 15 4 Saving Programs To save a program file to a storage location press the SAVE softkey from the Program In Out Mode screen Find the drive and folder you want to save the program file in using the softkeys as described above in the section on basic navigation Three additional parts of the screen appear once the SAVE softkey is pressed FIGURE 15 4 The Save screen File Name displays the name of the file that is in current memory Save As lists the formats for which the file may be saved The default is ProtoTRAK4 Three additional softkeys appear CREATE FOLDER Use this to create a new folder for the program file This new folder will be added to the list shown in the listing area at the same level of organization as the files and folders shown Once the CREATE FOLDER softkey is pressed a Data Input Line will appear for entering the name of the folder The name Folder1 will be written in the box To accept this name press SET You may input a name you select by writing over this name Use the same procedure for nami
45. simple Follow the instructions on the conversation line and proceed by pressing the GO key Once the STOP hard key is pressed additional softkeys will be available TRAKing select this softkey to control the X Y and Z programmed motion with the table or saddle handwheel See section 13 5 below The TRAKing Electronic Handwheels Option must be active for this function CNC Run select this softkey to start the CNC run 13 5 TRAKing TRAKing Electronic Handwheel Option TRAKing is a special kind of CNC run When you press the TRAKing softkey the programmed head table and saddle motion is controlled by turning the table or saddle electronic handwheel Moving the X or Y handwheel in the clockwise direction moves forward through the program moving counterclockwise moves backward through the program To TRAK slowly use the Y handwheel To TRAK quickly use the X handwheel TRAKing comes in handy whenever you are a little unsure about any aspect of your program or set up For example on the first run of a part instead of pressing GO and holding your hand on the stop button use TRAKing to bring the tool to the part while you watch the DRO Once assured that everything is all right press STOP and get into CNC run The table guard must be closed to use TRAKing 13 5 1 TRAKing in Two Axis CNC When running the ProtoTRAK SMX as a two axis CNC on a three axis CNC model TRAKing works with the manual operation of the Z The tool may b
46. so end mill is tangent to BC R from center of tool is perpendicular to BC Note how the tool at the beginning point point B starts below in the Z direction point B so that it can actually touch this point If this were not true a cusp would remain to the left of point B Now consider a similar example milling from A to B to C in the XZ plane FIGURE 5 7 2 Examples of tool left 43 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual FIGURE 5 8 2 In order to respect the lines defined by the programmed points the ball end mill never touches point B Tool starts centered over A offset up by the tool radius R It moves right until it is tangent to both AB and BC Then moves to point C as in the first example Note the Tool at B does not drop below the AB line and therefore never touches point B As a result a fillet is formed at point B equal to the tool radius This second example of continuous machining from one cut AB to another BC with full cutter compensation between requires the two cuts to be made with events which are connective see Section 5 9 or 5 10 for a more complete discussion of this requirement 5 9 Connective Events Connective events occur between two milling events either Mill or Arc when the X Y and Z ending points of the first event are in the same location as the X Y and Z starting points of the next event In addition the t
47. t use a tool that you use to machine your part as a reference If your reference tool breaks you have to reset all your tools 3 Always use the same surface for touching your tools to Use the machine table a gage block or the vice something you can always count on being there If you use the top of the part your reference is changing all the time 12 1 12 The Tool Table and Two Axis CNC Operation The information entered in the tool table will also be used when operating the ProtoTRAK SMX CNC as a two axis CNC Instead of positioning the head the DRO information seen in the Run Mode will be adjusted for the differences in tools When a new tool is loaded the Z dimension will change according to the offsets in the tool table This change will occur when the GO key is pressed after the Load Tool ___ prompt 112 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 12 2 Tool Path When the TOOL PATH soft key is pressed the program is processed and the tool path graphics are displayed i01143 FIGURE 12 2 The Tool Path graphics show the program and tool positions Three axis CNC graphics are shown above Two axis graphics will be simpler Most programming errors that would prevent the program from running are detected when the tool path graphics are selected For example if you were to have omitted a minus sign from a Z End dimension the system would give you
48. table and saddle to ensure smooth traverse and positive control for manual and CNC machining 3 7 Electrical Cabinet XYZ Turret Mills require a 415V power supply into the electrical cabinet 3 8 Z Axis Feedback Scale For two axis CNC models a Z axis feedback scale is mounted either to the quill or the knee in order to provide digital readout of the Z axis position 3 9 Auxiliary Functions Three Axis CNC Models Only Auxiliary functions are controlled through the ProtoTRAK SMX CNC either in the program or with the accessory key on the front panel The Auxiliary functions consist of the following Spindle off command An air solenoid to control spray coolant or other pneumatically activated peripheral equipment Shop air should not exceed 125 psi Switched and fused 120 VAC 8 Amp outlet for coolant pumps automatic oilers etc INPUT OUTPUT to interface with programmable indexers dividing heads etc o Output from ProtoTRAK SMX CNC is 3 second actuation of a solid state relay between pin 3 plus and pin 4 minus o Input to the ProtoTRAK SMX CNC is 3 second actuation of a solid state relay between pin 1 plus and pin 2 minus o Note Pin 1 is on top 2 on right 3 on left 4 on bottom 27 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 3 10 Work Light An halogen work light is supplied with the machine It mounts to
49. the end of the arc cut incremental is from X Begin Y END is the Y dimension to the end of the arc cut incremental is from Y Begin X CENTER is the X dim ension to the center of the arc incremental is from X End Y CENTER is the Y dimension to the center of the arc incremental is from Y End CONRAD is the dimension of a tangential radius to the next event RADIUS is the radius of the arc CHORD LENGTH is the straight line distance from the begin point to the end point CHORD ANGLE is the angle spanned by the arc In addition to the normal Softkeys this additional one will appear in A G E Arc programming GUESS this softkey will appear when the prompt is on X or Y dimensioned data Press the Guess key before you press INC SET or ABS SET to enter the data as a guess See Section 10 7 10 4 Skipping Over Prompts In the A G E events don t have to be fully defined before you can go to the next one You can skip the data you don t know by using the DATA FWD softkey After you press the DATA FWD key at the last prompt the event will move to the left side of the screen and the Select Event screen will appear When skipping over prompts or editing always use the DATA FWD or DATA BACK key Using INC SET or ABS SET will change the data If you want the event back on the right side use the BACK hard key 10 5 The OK NOT OK Flag Each A G E event has a flag that tells you if it has been fully defined Sometimes dat
50. the lever to the left to engage or to the right to disengage 4 2 15 Fine Automatic Quill Feed Two Axis CNC Models 1 Be certain the quill lock is off 2 Set the quill micrometer dial to the proper depth 3 Engage the Power Feed Engagement lever when the motor is stopped 4 Select proper quill feed see above 4 2 16 Setting Stops for Three Axis CNC Models When the Z axis ballscrew and motor assembly is installed for three axis CNC operation the quill stop mechanism is not available Instead there are convenient inputs in the DRO Mode and the Run Mode for setting quill stops 39 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 5 0 Definitions Terms amp Concepts 5 1 ProtoTRAK SMX CNC Axis Conventions X Axis positive X axis motion is defined as the table moving to the left when facing the mill Consequently measurement to the right is positive on the workpiece Y Axis positive Y axis motion is defined as the table moving toward you Measurement toward the machine away from you is positive on the workpiece Z Axis positive Z axis motion is defined as moving the head up Measurement up is also positive on the workpiece FIGURE 5 1 ProtoTRAK SMX CNC conventions The Z RAPID dimension is the position at which Z will stop rapid traversing and switch to its programmed Z feedrate Z motion will continue until Z End depth has been reached 5 2
51. the previous event RPM programming is available only if the Programmable Electronic Head Option is active XYZ Feedrate is the feedrate from beginning to end in in min from 1 to 100 or mm min from 5 to 2540 Tool is the tool you assign 86 XYZ Machine Tools Ltd XYZ Machine Tools Ltd and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 9 10 Subroutine Events The Subroutine Events are used for manipulating previously programmed geometry within the XY plane The Subroutine Event is divided into three options Repeat Mirror and Rotate Repeat and Rotate may be connective As long as the rules of connectivity are satisfied see Section 5 9 the ProtoTRAK SMX CNC will continue milling between preceding and subsequent events REPEAT allows you to repeat an event or a group of events up to 99 times with an offset in X and or Y and or Z This can be useful for drilling a series of evenly spaced holes duplicating some machined shapes or even repeating an entire program with an offset for a second fixture Repeat events may be nested That is you can repeat a repeat event of a repeat event of some programmed event s One new tool number may be assigned for each Repeat Event MIRROR Advanced Features Option is used for parts that have symmetrical patterns or mirror image patterns In addition to specifying the events to be repeated you must also indicate the axis or axes X or Y or XY are
52. the transition from rapid to feed Z END is the Z dimension at the bottom of the pocket incremental is from the previous event RADIUS is the finish radius of the Island DIRECTION is the milling direction clockwise or counterclockwise PASSES the number of roughing passes to the depth ENTRY MODE choose between zigzag ramp and plunge The plunge will machine straight down Z to the appropriate Z depth The zigzag ramp will move in a zigzag pattern to depth See the previous section for more information about the zigzag ramp FIN CUT ISL Finish cut for the Island If 0 is input there will be no finish cut See the previous section for a bottom finish cut X1 POCKET X dimension for one corner of the rectangular pocket that surrounds the island Y1 POCKET Y dimension for one corner of the rectangular pocket that surrounds the island X3 POCKET X dimension for the opposite corner of the rectangular pocket that surrounds the island Y3 POCKET Y dimension for the opposite corner of the rectangular pocket that surrounds the island 81 XYZ Machine Tools Ltd XYZ Machine Tools Ltd and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual CONRAD PCKT the value of the tangential radius in the corners of the rectangular pocket that surrounds the island FIN CUT PCKT finish cut along the perimeter of the pocket If 0 is input there will be no finish cut See the previous section for a bottom
53. this prompt This will take you to a screen where you may choose to have the same amount of material taken per peck Fixed You can also choose Chip Break where the tool will perform fixed pecks but only rapid out about 0 5mm after each peck instead of going back to the Z rapid position after every peck This new setting will remain until you change it again 74 XYZ Machine Tools Ltd XYZ Machine Tools Ltd and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is active Z Feedrate is the drilling feedrate Tool is the tool number you assign 9 3 BOLT HOLE Events This event allows you to program a bolt hole pattern without needing to compute and program the position of each hole Prompts for the Bolt Hole event Drill 1 Bore 2 selects whether the hole is to be drilled or bored If the Programmable Electronic Head Option is active you will also have the choice Tap 3 Holes is the number of holes in the bolt hole pattern X Center is the X dimension to the center of the hole pattern Y Center is the Y dimension to the center of the hole pattern Z Rapid is the Z dimension to transition from rapid to feed Z End is the bottom of the hole Radius is the radius of the hole pattern from the center to the center
54. 0 1 1 1 bytes 32 time lt 1ms TTL 255 Reply from 10 1 1 1 bytes 32 time lt 1ms TTL 255 Reply from 10 1 1 1 bytes 32 time lt 1ms TTL 255 147 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Reply from 10 1 1 1 bytes 32 time lt 1ms TTL 255 Ping statistics for 10 1 1 1 Packets Sent 4 Received 4 Lost 0 0 loss Approximate round trip times in milli seconds Minimum 0ms Maximum 0ms Average 0ms NET USE New connections will be remembered Status Local Remote Network Disconnected V 10 1 1 3 software eng Microsoft Windows Network The command completed successfully 15 13 CAD CAM and Post Processors In addition to running G code files the ProtoTRAK will also accept CAM files and convert them into the ProtoTRAK events This is a great advantage as it allows you to have your CAD CAM programmer send files to the machine that the machinist can then work with in the familiar ProtoTRAK interface The machinist can modify the program as necessary without having to go back to the CAD CAM programmer In order to be able to convert the program from a CAM system to a ProtoTRAK program the CAM program must be two or 2 axis A 2 axis program is defined as a program where the Z axis is stationary while X and Y is moving If you want to run a full three axis program you
55. 1 The Tool Table 108 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 12 1 1 The Tool Table Screen When you first enter the tool table by pressing the TOOL TABLE soft key you will see the screen shown in Figure 12 1 Tool the number of the tool from 1 to 99 Tool numbers shown in red are active for the program in current memory Diameter the diameter of the tool Z Offset the difference between the Z position of the tool and the Z position of the reference The Z offset is always relative to a reference point Before the reference point is set the highlight will not go into the Z Offset column because setting a Z offset before the Z reference is set has no meaning Z modifier a value you enter to make adjustments for the tool depth See 12 1 7 below Tool Type allows you to select the type of tool from a list Input the number that corresponds to the desired name eg 1 Drill and press SET The tool name will be in the prompt at the beginning of the program Run Ref the reference position for the Z offset Before the reference position is set and the Ref row reads NOT SET the highlight will not go into the Z Offset column Once set the highlight will not go into the Ref row that is you will not be able to highlight and reset your reference once it says SET The soft keys in the tool table DATA DOWN DATA UP DATA LEFT DATA RIGHT move the
56. 2 Machine Operation This section covers the operation of the XYZ Turret Mills If you purchased your ProtoTRAK SMX CNC as a retrofit please refer to the user manual that came with your machine 4 2 1 Spindle On Off Forward Reverse The spindle switch is located to the left of the SMX display Turn the Spindle switch to left to 1 for forward clockwise spindle rotation if the Hi Lo Neutral lever is in the low position Turn the Spindle switch right to 2 for forward clockwise spindle rotation if the Hi Lo Neutral lever is in the high position Turn the Spindle switch straight ahead for off 34 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Safety Programming Operating amp Care Manual Figure 4 2 0 XYZ SMX 1500 Mill head front view Shown without the standard quill glass scale 35 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Safety Programming Operating amp Care Manual 4 2 2 Table Saddle Knee Clamps The table clamps are located on the front of the saddle Rotate them clockwise until snug overtightening is not necessary The saddle clamp is located on the left side of the saddle Pull forward to clamp the table until snug overtightening is not necessary The knee clamps are located on the left side of the knee for the K2 and K3 mills and on the right side for the K4 CAUTION Do not run ProtoTRAK SM program unless the table and saddle clamps are f
57. 50 Feedrate Override to decrease feedrate or spindle rpm down to 10 Each button push Modifies the feedrate in 10 increments and the spindle speed in 5 increments 19 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual ACCESSORY When the switch is in the On position the flood coolant pump or spray coolant will come on and stay on during machining operations In the Auto mode the coolant pump or spray coolant will be controlled as programmed by the Auxiliary functions To get to the Auto operation press and hold the Accessory key If neither light is on the coolant pump or spray coolant will not operate F C Selects between fine and course resolution for the X and Y handwheels when the TRAKing Electronic Handwheels Option is installed The LED above the letter indicates which feed is active Fine feed moves the axis 5mm 200 inches per revolution Course feed moves 20mm 800 inches per revolution INC SET loads incremental dimensions and general data ABS SET loads absolute dimensions and general data INC ABS switches all or one axis from incremental to absolute or absolute to incremental IN MM causes Inch to Metric or Metric to Inch conversion of displayed data LOOK part graphics in Program mode X Y Z selects axis for subsequent commands RESTORE clears an entry aborts a keying procedure 0 9 inputs numeric data with fl
58. AK SMX CNC is currently operating in three axis and it will say GO TO 3 AXIS when the ProtoTRAK SMX CNC is currently operating in two axis See Figure 4 1 4 4 1 5 Coolant Pump Your mill is supplied with a coolant pump If you do not have the Auxiliary Functions active they are active for the three axis models only the coolant pump is operated by the Accessory key on the ProtoTRAK SMX front panel If you do have the Auxiliary Functions the operation of the coolant system may be programmed within the program FIGURE 4 1 4 You will see this screen when the SYS hard key is pressed The choice GO TO 2 AXIS shows that the CNC is currently in 3 Axis operation 31 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Safety Programming Operating amp Care Manual events With the Auxiliary Functions set up manual control of the coolant system is through the Accessory key on the front panel of the SMX CNC Use of the ACCESSORY hard key ON will turn on the coolant pump until you turn it off AUTO will turn on the coolant pump as programmed into events for three axis models will turn on the coolant pump when the machine is feeding for two axis models Off no light the coolant pump stays off 4 1 6 Help Functions When a blue question mark appears next to the HELP hard key that means special functions or configuration settings are available for the current operation For example at the program
59. ALLPRK1122 118 XYZ Machine Tools Ltd XYZ Turret Mill andProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 1 The way the tool table works between two and three axis operation See Section 12 1 2 2 Positioning of the Z axis is automatic in the 3 axis CNC but in two axis the ProtoTRAK SMX CNC will prompt Check Z before a rapid move and Set Z for you to position the cutter to the machine part 13 3 Starting to Run Before running a part you must establish the position relationship between the part and quill That is you need to identify where the part is on the table relative to the tool or quill centerline This is done by using an edge finder or dial indicator to move the table so that the part program absolute zero is under the quill centerline ABS SET this position as absolute zero in the DRO mode In addition load the tool for Event 1 and position it at Z absolute zero If this is impossible position the tool some known distance above absolute zero and ABS SET this dimension The program may be started in the two ways identified as soft keys in the screen in Section 13 1 Pressing the START soft key begins the program at Event 1 and assumes that the absolute zero that was last set in the DRO mode corresponds to the part program zero That is if you were in the DRO mode and you moved the table to X 0 ABS and Y 0 ABS the part program zero would be directly under the quill centerline
60. By programming events you tell the ProtoTRAK SMX CNC what geometry you want to end up with it figures the tool path for you from your answers to the prompts and the tool information you give it in the Set Up Mode 8 1 POSN DRILL This event type positions the table and quill at a specified position The positioning is always at rapid speed modified by feedrate override and in the most direct path possible from the previous location You would use this event type to program a hole for drilling In program run the CNC will move to the dimension you program and will wait for you to press GO before moving to the next event You may also use this event type to position the table for some other purpose such as to avoid a clamp or to move off the workpiece for a tool change To program a Position event press the POSN DRILL soft key Prompts for the Position event X END is the X dimension to the position Y END is the Y dimension to the position Tool is the tool number you assign SET will use the tool number of the previous event 8 2 BOLT HOLE Events This event allows you to program a bolt hole pattern without needing to compute and program the position of each hole Prompts for the Bolt Hole event Holes is the number of holes in the bolt hole pattern X Center is the X dimension to the center of the hole pattern Y Center is the Y dimension to the center of the hole pattern Radius is the radius of the hole pattern f
61. Care Manual 9 Keep clicking OK until you get back to the Select a Mode screen 10 You must now save the changes so that the ProtoTRAK control may retain your settings See section 15 12 2 15 12 2 A Basic Peer To Peer Network The following instructions will help you set up the most basic peer to peer network between a ProtoTRAK SMX CNC and a computer A peer to peer network simply connects two computers of equal status together Hardware 1 Obtain aDSL Cable router with DHCP services Acceptable routers are made by Linksys and Netgear and are available at computer stores This type of router will automatically assign IP addresses to your ProtoTRAK and computer saving you a confusing step 2 Obtain a sufficient quantity of twisted pair category 5 rated Network Cable This looks like a telephone cable and is available at computer stores 3 Make sure your computer has a Network Interface Card installed This is also known as an Ethernet Card 4 Plug both the computer and the ProtoTRAK SMX into the router in the hub side of the router The hub side is the side with multiple cable ports Avoid the port that is by itself unless you really know what you are doing The ProtoTRAK SMX is configured to get IP addresses automatically from the router That means that the computers are probably connected when you turn them on and plug the cables into the routers You can confirm that the ProtoTRAK and computer are connected by looking at the l
62. Feedrate is the milling feedrate for the finish cut Tool is the tool number you assign 9 6 3 Irregular Pocket Advanced Features Option Press the IRREG PCKT soft key if you wish to mill a pocket other than a rectangle or circle The Irregular Pocket event gives you the powerful Auto Geometry Engine to define a shape made up of straight lines Mills and arcs The first screen in an irregular pocket event will define the beginning point and some of its general parameters The last event of the irregular pocket must end at the same point as defined in the first event X Begin is the X dimension of the beginning of the pocket Y Begin is the Y dimension of the beginning of the pocket Z Rapid is the Z dimension to transition from rapid to feed Z End is the Z dimension of the depth of the pocket Passes is the number of cycles to machine to the final depth spaced equally from Z rapid to Z end hint keep Z Rapid small Entry mode choose between a zigzag ramp and a plunge The plunge will machine straight down Z to the appropriate Z depth The zigzag ramp will move in a zigzag pattern to depth See Section 9 6 5 for more information about the zigzag ramp Z Feedrate is the Z feedrate from Z rapid to Z end XYZ Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Fin Cut is the width of the finish cut If 0 is input there will be no finish cut See Section 9 6 7 for a bottom finis
63. ILL softkey the prompts for information that cannot change will be suppressed See Section 8 3 for a description of Mill event prompts When a Teach event is unfinished the words NOT OK will appear next to the event type Once the prompts are completed the words NOT OK and Teach will disappear The event will become a normal POSN DRILL or MILL event 73 XYZ Machine Tools Ltd XYZ Machine Tools Ltd and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 9 0 Three Axis Program Events This section describes the program events and prompts that are available in three axis programming If your ProtoTRAK SMX CNC is configured for two axis programming only you should skip this section Events are fully defined pieces of geometry By programming events you tell the ProtoTRAK SMX CNC what geometry you want to end up with it figures the tool path for you from your answers to the prompts and the tool information you give it in the Set Up Mode 9 1 POSN Position Events This event type positions the table and quill at a specified position The positioning is always at rapid speed modified by feedrate override and in the most direct path possible from the previous location The most common use of the position event is to move the tool around an obstacle such as a clamp For this reason Z and X Y motion will not occur simultaneously First the Z head will move to the higher of the Z rapid position of the current
64. M is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is active FIN RPM is the spindle RPM for the finish cut FIN RPM programming is available only if the Programmable Electronic Head Option is active Z Feedrate is the Z feedrate from Z rapid to Z end XYZ Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Finish Feedrate is the milling feedrate for the finish cut Tool is the tool number you assign 9 8 2 Rectangular Profile Press the RECTANGLE soft key if you wish to mill a rectangular frame all corners are 90o right angles Prompts for the rectangular profile 84 XYZ Machine Tools Ltd XYZ Machine Tools Ltd and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual X1 is the X dimension to any corner Y1 is the Y dimension to the same corner as X1 X3 is the X dimension to the corner opposite X1 incremental is from X1 Y3 is the Y dimension to the same corner as X3 incremental is from Y1 Z Rapid is the Z dimension to transition from rapid to feed Z End is the Z dimension at the bottom of the frame incremental is from the previous event Conrad is the value of the tangential radius in each corner Direction is the clockwise input 1 or counterclockwise input 2 direction for milling Tool Offset is the selection of
65. NC machining only Allows you to input a dwell at the bottom of a drill bolt hole or bore cycle for events you select Select the appropriate YES or NO soft key If you select YES you will be prompted to input a dwell time in seconds from 1 to 99 9 when appropriate to the event being programmed Auxiliary Function Request Asks if you wish to activate any of the optional auxiliary functions see Section 7 4 at any time during the program Select the appropriate YES or NO soft key If you select YES you will be prompted to input the type and sequencing of the auxiliary functions during event programming Auxiliary Functions are optional for three axis CNC models only Event Comments If you select Yes for event comments you will have the opportunity to insert a comment in each event For Irregular Pocket and Irregular Profile events you will be able to enter a comment at the header event but not for each A G E Turn and A G E Arc event This function is part of the Advanced Features Option Comments appear in the RUN mode on the Data Input Line as the event begins to run Comments may be composed of letters numbers and some symbols and may be up to 20 characters While programming the event with the Event Comments set to Yes when the highlight is on the Event Comments prompt you may enter a comment using the same methods used to enter a program name as described above Multiple Fixtures Asks you if you wish to turn on the multiple fi
66. Part Geometry amp Tool Path Programming The ProtoTRAK SMX CNC gives you ultimate flexibility in programming Programs that are entered through the ProtoTRAK SMX CNC system can be entered as either Part Geometry or Tool Path optional Part Geometry programming is the popular programming style of the ProtoTRAK family of products This is done by defining the final geometry of the part and the ProtoTRAK SMX CNC has the job of figuring out the tool path from the part dimensions and the tool set up information This is a great benefit compared to regular CNC because it doesn t force the programmer to do the difficult job of defining tool path A consequence of part geometry programming is that the following are not allowed connection of an incline plane and another event connection of two events that lie in different planes Using Geometry Programming it is impossible for the ProtoTRAK SMX CNC to calculate a tool path for these cases without creating a problem in cutting the geometry desired in the first event the tool ends up out of position for the next event Resolving the difference in tool position where the first event ends and the next event begins means either the CNC calculates and makes an unprogrammed move or it retracts the tool out and then back into the part These cases are not encountered often but when they are you have the option of using Tool Path programming In Tool Path programming you define the events the same
67. Spindle Taper R8 R8 40 ISO 40 ISO Spindle Speed 75 4200 75 4200 70 3600 70 3600 Head Tilt fore amp aft 45 45 45 45 45 45 45 45 Head Tilt left right 90 90 90 90 90 90 90 90 Spindle Motor Power 3 HP 3 HP 5 HP 5 HP Power requirements machine 16 Amp 16 Amp 20 Amp 20 Amp Maximum Weight on Table 350 Kg 350 Kg 550 Kg 580 Kg Machine Weight 1100 Kg 1250 Kg 1650 Kg 1850 Kg Machine dims l w h 3220 x 2520 x 2200 3220 x 2580 x 2180 3670 x 2690 x 2340 4000 x 2690 x 2340 Max rapid feed X Y 2500 2500 2500 3800 Max rapid feed Z CNC 2500 2500 2500 2500 Way surface type Hard chrome V way Hard chrome V way Hardened Box way Hardened Box Way Precision 7207 CP4 spindle bearings Chrome hardened and ground quill Meehanite castings Slide ways are Turcite coated Wide way surfaces are hardened and ground 3 4 Auto Lubrication System The way and ballscrew lubrication are supplied by a pump located on the side of the machine body The interval and discharge time of the pump are set by XYZ Machine Tools and should not be changed or altered otherwise your warranty will become invalid After periods of non operation of the machine we recommended that before you operate the machine you first press the pump button located on the pump itself This will ensure that adequate lubrication is supplied to key parts of the machine before you start Factory Default Val
68. X CNC Retrofit Safety Programming Operating amp Care Manual When the high light is on the prompt for which you wish to enter a guess press the Guess key The Data Input Line will say Enter Guess for X END for example At this point press the LOOK key Figure 10 8 1 When the Data Input Line says Enter Guess pressing LOOK gives you the ability to use graphics to make your guesses On the screen shown in the figure above the Data Input Line says Enter Guess for X BEG Pressing LOOK at this point will take you to a special version of the LOOK graphics Using a mou se or the cursor keys you may move a point around the screen When you come to the place where your point is use the Enter key The softkeys for this special version of the LOOK graphics move the cursor around the screen ZOOM IN makes the drawing larger ZOOM OUT makes the drawing smaller ENTER END when the cursor is at the point you want to use as a guess use this to enter the end point of a line or an arc ENTER CENTER use this to register a guess for the center of an arc You can enter a combination of guessed and non guessed data For example if you were to enter the dimension for X End without guessing you would still be able to enter the dimension of Y End using guess Your guess entries are loaded into the program when you exit the LOOK screen by pressing BACK or by pressing LOOK again The ProtoTRAK will use the last ENTER key press and lo
69. XYZ Turret Mill ProtoTRAK SMX CNC Safety Programming Operating amp Care Manual Covers Models XYZ Turret Mill with 2 Axis CNC SMX SLV SMX2 SMX 1500 SMX2 SMX 2000 SMX2 SMX 3000 SMX2 XYZ Turret Mill with 3 Axis CNC SMX SLV SMX3 SMX 1500 SMX3 SMX 2000 SMX3 SMX 3000 SMX3 Document P N 25049 Version 032006 XYZ Machine Tools Ltd Woodlands Business Park Burlescombe Tiverton Devon EX16 7LL T 07000 999 583 F 07000 999 584 www xyzmachinetools com i XYZ Turret Mill ProtoTRAK SMX CNC Safety Programming Operating and Care Manual Table of Contents 1 0 Introduction 1 1 Manual Organization 1 2 0 Safety Specifications amp Lubrication 2 1 Health and Safety Directives 3 2 2 Danger Warning Labels amp Notes 3 2 3 Safety Precautions 11 3 0 Description 3 1 Control Specifications 13 3 2 Display Pendant 18 3 3 Machine Specifications 23 3 4 Auto Lube System 25 3 5 Servo Motors 26 3 6 Ballscrews 26 3 7 Electrical Cabinet 26 3 8 Z Scale 26 3 9 Auxillary Functions 26 3 10 Work Light 27 3 11 Coolant Pump 27 3 12 Chip Pan Splash Shield 27 3 13 Table Guard 27 3 14 Z Ballscrew and Motor Assy 27 3 15 Limit Switch 27 3 16 Optional Equipment 27 4 0 Basic Operation 4 1 Basic Control Operation 29 4 2 Basic Machine Operation 33 5 0 Definition Terms amp Concepts 5 1 ProtoTRAK Axis Conventions 39 5 2 Part Geometry amp Tool Path Prog 39 5 3 Planes and Vertic
70. a Input Line will prompt for the last event number to be deleted Put in the last number and press Set The remaining events will be renumbered 11 2 Spreadsheet Editing Advanced Features Option Spreadsheet Editing allows you to view program inputs in a table and make global changes to the program This is particularly useful if you are working with a large program and you need to make a change to many events When you press the SEARCH EDIT softkey the screen will load a table that contains data for every event See Figure 11 2 1 The first time the screen appears the data is sorted by event number Each row represents the data for the event number shown in the first column on the left The event number is always displayed in the first column but the other data displayed on the table can be changed Soft Keys in Search Edit FIGURE 11 2 1 The Search Edit softkey launches Spreadsheet Editing View the entire program by the variables you select 100 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual PAGE FWD pages forward through the table PAGE BACK pages backwards through the table 6534 highlights data for editing Only data that is highlighted and appears in the Data Input Line may be edited Note the EVT event number and event TYPE may not be edited in Search Edit so the highlighter will not go there SORT enables you to change the sort to a
71. a from later events is needed to define previous events To the immediate right of the event type the words OK or NOT OK appear depending on whether that particular event is defined Once the OK flag appears for the event you do not need to enter more information Skip past the rest of the prompts with the DATA FWD softkey If you leave the Program Mode and then return pressing the GO TO END softkey will take you automatically to the first NOT OK event 10 6 Ending A G E Any time all the events are of an Irregular Profile are OK the A G E may be ended If you are programming an Irregular Pocket there is an additional requirement that must be satisfied before the A G E may be ended the X and Y end point of the last event must be the same as the X and Y beginning point so that the pocket is closed 96 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Otherwise the ProtoTRAK SMX CNC cannot program the tool path to clear the pocket The Irregular Profile has no such restriction since profiles may be open or closed Once the A G E is ended the Irregular Pocket or Irregular Profile event is complete and you may then choose from all the programming canned cycles from the Select an Event screen To reopen the A G E Profile or Pocket simply use the BACK hard key or the PAGE FWD or PAGE BACK softkeys to position on of the A G E events on the right side of the
72. acking up The basic procedure for backing up is 1 Use the navigation procedure described in Section 15 2 above and highlight the program file or folder you wish to back up 2 Press the BACKUP FROM softkey You will see the item appear along with its directory path in the new listing area under the main listing area 3 Repeat the above for as many item s as you wish 4 Use the navigation procedure to select a different drive or a different folder 5 Open the drive or folder using the Open folder key 6 Press BACKUP TO When the back up operation is completed you will see the items and their directories in the new location Note It is good practice to back up files to a different drive rather than to a different folder on the same drive For example if you keep your programs on the ProtoTRAK SMX CNC flash drive it is a good idea to back them up on a floppy disk or to another computer that is networked into the ProtoTRAK SMX CNC That way if the ProtoTRAK SMX CNC flash drive becomes unusable you will have the part programs somewhere else so that you can reload them when the problem with the ProtoTRAK SMX CNC flash drive is resolved 15 9 Converters Converters are programs within the ProtoTRAK SMX CNC that translate CNC program files of another format into a ProtoTRAK SMX CNC file or a ProtoTRAK SMX CNC file into a different format With converters you can run programs written on the 134 XYZ Machine Tools Ltd
73. ad that into the program When you use the graphics to guess dimensions on arcs you may load in guesses for both the X Y End and the X Y Center before leaving the LOOK screen When you have not first pressed the Guess key pressing LOOK gives you the same screen as in regular programming Whether you enter the guesses as key presses or by using the graphics the drawing of the LOOK screen distinguishes between events that are fully defined and those that rely on guessed data OK events are represented by solid lines NOT OK events are represented by dashed lines 98 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual FIGURE 10 8 2 When the events are calculated based on Guessed data they are represented by a dotted line 10 9 Calculated Data Prompts that are skipped or for which guesses are entered may be replaced by data calculated by the ProtoTRAK SMX CNC Calculated data is shown in red in order to distinguish it from the data that you entered You cannot edit calculated data but you may edit your original input By putting the event with the calculated data on the right side of the screen you may position the cursor to the prompt and re input the data 10 10 Arcs and Conrads If the print is missing a lot of data it may be desirable to program arcs as separate events where possible This gives the system more information to work with 10 11 Tangency Tangency can
74. ader screen and then program the features of the part by selecting the soft key event types geometry and then follow all instructions in the Data Input Line When an event is selected all the prompts that need to be input will be shown on the right side of the screen The first prompt will be highlighted and also shown in the Data Input Line Input the dimension or data requested and press INC SET or ABS SET For X or Y dimension data it is very important to properly select INC SET or ABS SET For all other data either SET will do As data is being entered it will show in the Data Input Line When SET the data will be transferred to the list of prompts in the right side of the screen and the next prompt will be shown in the Data Input Line When all data for an event has been entered the entire event will be shifted to the left side of the screen and the conversation line will ask you to select the next event 7 2 Enter Program Mode Press MODE select PROGRAM soft key The ProtoTRAK SMX CNC will allow only one program in current memory To write a new program you must first erase the one in current memory you may want to first store the program for use in the future If there is already a program in current memory entering the Program mode will allow you to edit or add to that program FIGURE 7 2 The Program Mode header screen Most selections above relate to the Advanced Features Option If your screen shows only Program Name and
75. al Planes 40 5 4 Absolute and Incremental Refs 40 5 5 Referenced amp Non Ref Data 40 5 6 Incremental Ref Position and Prog 41 5 7 Tool Diameter Compensation 41 5 8 When Contouring in Z 42 5 9 Connective Events 43 5 10 Conrad 43 5 11 Memory and Storage 44 6 0 DRO Mode 6 1 Enter DRO Mode 45 6 2 DRO Functions 45 6 3 Jog 46 6 4 Power Feed 46 6 5 Do One 46 6 6 Go To 47 6 7 Teach 47 6 8 Return Abs Zero 48 6 9 Tool 48 7 0 Program Mode 7 1 Programming Overview 49 7 2 Enter Program Mode 49 7 3 Program Header Screen 51 7 4 Auxillary Funtions 53 7 5 Multiple Fixtures 54 7 6 Assumed Inputs 55 7 7 Z Rapid Positioning 55 7 8 Softkeys within Events 56 7 9 Programming Events 56 7 10 Editing Data while Programming 57 7 11 Look 58 7 12 Finish Cuts 58 7 13 2 vs 3 axis Programming 59 8 0 Program Mode Part Two Programming Events 8 1 Position Drill 61 8 2 Bolt Hole Events 61 8 3 Mill Events 61 8 4 Arc Events 62 8 5 Pocket Events 62 8 6 Islands Events 64 8 7 Profile Events 66 8 8 Engrave Events 68 8 9 Subroutine Event 69 8 10 Copy Event 71 8 11 Finish Teach Event 72 9 0 Three Axis Program Events 9 1 Position Events 73 8 2 Drill Events 73 8 3 Bolt Hole Events 74 8 4 Mill Events 74 8 5 Arc Events 75 8 6 Pocket Events 76 8 7 Islands Events 80 8 8 Profile Events 83 8 9 Helix Events 85 8 10 Subroutine Event 86 8 11 Co
76. allowed that the reflection is mirrored across In addition you must specify the offset from absolute zero to the line of reflection You may not mirror another mirror event or mirror a rotate event Consider the figure below FIGURE 9 10 1 Holes 1 4 are mirrored across the Y axis to 5 8 respectively about a line X OFFSET from X absolute 0 ROTATE is used for polar rotation of parts that have a rotational symmetry around some point in the XY plane In addition to specifying the events to be repeated you must also indicate the absolute X and Y position of the center of rotation the angle of rotation measured counterclockwise as positive and clockwise as negative and the number of times the specified events are to be rotated and repeated You may not rotate another rotate event or rotate a mirror event Consider the figure below 87 XYZ Machine Tools Ltd XYZ Machine Tools Ltd and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual FIGURE 9 10 2 Shape A programmed with 4 MILL events and Conrads Using ROTATE these 4 events are rotated through a 45 degree angle about a point offset from absolute zero by X Center and Y Center dimensions A is rotated 3 times to produce shape B C and D Press the SUBROUTINE SUB soft key to call up the Repeat Mirror and Rotate options 9 10 1 Repeat Press the REPEAT soft key Where First Event is the event number of the first eve nt to be repeated Last Ev
77. am in the Program Mode See Section 8 11 104 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual i01142 11 5 G Code Editor Advanced Features Option The G Code Editor allows the edit of G Code programs that are opened as GCD files Once edited the program may be re saved as GCD files ProtoTRAK Geometry style programs may not be saved as GCD files You must connect a mouse and keyboard in order to use the G Code Editor When you enter the G Code Editor the G Code program is displayed starting at the first Block Number Use the scroll bar to move up and down through the program Use the mouse and keyboard to edit like you would an MS Notepad file Search allows you to launch a simple find and replace routine to aid in editing large G Code files Figure 11 5 1 Use the G Code Editor to modify G Code programs Figure 11 5 2 The find and replace routine i01141 105 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Click in the Find What box and enter the item you want to find Click on the Find Next box and the G Code Editor will locate the next occurrence of that item Successive clicks on Find Next will continue to search through the program Use Match Whole Word to limit the search to the entire word For example if you want to find G2 but not G20 or G22 select Match Whol
78. ame the program To use the alpha keys and special characters on the ProtoTRAK SMX CNC Use the Clear softkey to erase the entire line the Backspace softkey to erase the last character or number Use the arrow softkeys to move around the table 51 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Once the character you want is highlighted use the Enter softkey to load the character into the program name Use the blank space on the lower right of the table to insert a space into the program name Once you finish entering the letters and special characters press the End softkey This tells the ProtoTRAK SMX CNC that you are finished with the alpha table Numbers may still be added to the program name When you are finished with the program name press SET to enter it into the current memory Note It is not necessary to enter a part number If none is entered and a GO TO soft key is pushed the system will assume a part number 0 7 3 2 General Program Options Use the DATA FWD softkey to select general programming options See Section 3 1 2 for more information about the Advanced Features Option Scale Allows a scale factor between 1 and 10 An input of 5 means the part will be 5 times as big as the programmed dimensions A value of 1 0000 is assumed if nothing is input This function is part of the Advanced Features Option Dwell Requ
79. an error message that the Z End should not be higher than the Z Rapid The displayed graphic is automatically sized to fit the screen and an icon that represents the X Y and Z orientation is placed at the program s absolute 0 reference point The path shown on the screen represents the cente r of the tool Position and drill events are drawn in yellow Rapid moves are in red Programmed geometry is in blue 12 2 1 Soft Keys in Tool Path ADJUST VIEW calls up additional softkeys to adjust the view See below FIT DRAW will re draw automatically sizing to fit the screen necessary only if an adjustment changed the drawing from its initial sizing STEP each press of the STEP button shows the next tool move You may hold the STEP button down to draw the graphic without repeated button presses To complete the drawing automatically press FIT DRAW XY YZ XZ 3D shows the same drawing on the screen with adjustments in the view you select Soft keys in ADJUST VIEW 113 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual FIT same as the FIT DRAW 6534 moves the drawing in that direction ZOOM IN ZOOM OUT resizes the drawing RETURN returns to the previous soft keys retaining the adjustments that were made to the drawing 12 3 Reference Positions REF POSN The Reference Positions screen for three axis CNC models shows the re
80. anual 12 1 8 Resetting the Reference Point Once the reference reads SET you are not allowed to highlight and reset it If you need to reset the reference there are two ways to change the reference to NOT SET You can erase the table and lose all the tool information or load in a program 12 1 9 Saving Tool Information Tool information is saved with the program If you have made changes to the program or to the tool table that you wish to keep you must save or store the program in the Program In Out Mode 12 1 10 Opening a Program When you open a program the tool information that is saved with the program will be loaded into the tool table The numbers for the tools that are used in the program are in red The diameters Z Offsets and Z modifiers that were saved with the program will overwrite any information that was in the tool table before the program was opened If these tools were not set very recently we recommend that you check them before running the program The Ref row will read NOT SET A reference may be set at this point If you do not go into the tool table after opening a program and before running you will get a reminder message to check your tools 12 1 11 Making Tool Set Ups Easy We highly recommend the following to make tool set ups easy 1 Always use the same tool to set your reference Preferably you should use a tool you don t use to machine something that you keep in your toolbox 2 Don
81. are very powerful and may change system settings in a way you don t want Some of the routines cause the servos to come on and move at rapid speed The Service Codes are divided into logical categories The table below summarizes the more important ones See the service manual for more information on using Service Codes 115 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Software Code Description Comment 33 Software and firmware version Displays current software versions and system settings 141 Load configuration file from Floppy A To load set up files from a disk in the floppy drive 142 Save configuration file to Floppy A To save the set up files for reloading later When a computer replacement is necessary saving the settings to a disk for reloading them later may be desirable 313 Display configuration file Displays certain values set through other service codes or machine parameters 316 Update Master Software Runs the routine that copies new master software from a disk to the ProtoTRAK system Use this routine to install new ProtoTRAK software This operation will may restart computer 317 Update Slave Software Runs the routine that copies new slave software from a disk to the ProtoTRAK system 318 Activate Converter To activate converters and other software options See Section 3 1 7 How to Buy Software Options Machine S
82. arer that way 7 5 1 The Default Fixture In the program header screen you entered a default fixture number if you didn t it assumed fixture 1 as the default fixture If there are program events already in current memory when you change the multiple fixture from NO to YES they will all receive the default fixture number automatically When you change the default fixture number in the program header screen from one fixture to another all the events that had the previous default fixture number will be changed to the new default fixture number 54 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual If there are no program events in current memory when you change the multiple fixture feature from NO to YES the prompt will be added to the end of every event you then program The default fixture number will be assumed if you press SET without specifying a different number If you do specify a different fixture number that fixture number will become the assumed input for subsequent events when SET is pressed 7 5 2 Fixtures and Running the Program To run the program first go to the DRO mode and set absolute 0 at the base fixture Fixture 1 In the Run mode the SHOW ABS displays the absolute position relative to the fixture in the event being run that is the absolute dimension that was programmed 7 5 3 Editing Fixtures With the Multiple Fixtures feature turned
83. asses number of cycles to machine to the final depth spaced equally from Z Rapid to Z End hint keep Z Rapid small Entry mode choose between a zigzag ramp and a plunge The plunge will machine straight down Z to the appropriate Z depth The zigzag ramp will move in a zigzag pattern to depth See Section 9 6 5 for more information about the zigzag ramp Fin Cut is the width of the finish cut If 0 is input there will be no finish cut See Section 9 6 7 for a bottom finish cut RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is active FIN RPM is the spindle RPM for the finish cut FIN RPM programming is available only if the Programmable Electronic Head Option is active Z Feedrate is the Z feedrate from Z rapid to Z end XYZ Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Fin Feedrate is the milling feedrate for the finish cut Tool is the tool number you assign 9 6 2 Rectangular Pocket Press RECTANGLE soft key if you wish to mill a rectangular pocket all corners are 90o right angles and the sides are parallel to the X and Y axes The prompts for the rectangular pocket X1 is the X dimension to any corner Y1 is the Y dimension to the same corner as X1 X3 is the X dimension to the corner opposite X1 incremental is from X1 Y3 is the Y dimension to t
84. ath yourself you may choose the TOOL PATH softkey Otherwise Part Geometry programming is assumed Tool Path operates under the same rules as standard RS274 A program must be entirely written in Part Geometry or Tool Path programming you cannot combine the two methods in one program Tool Path programming is part of the Advanced Features Option 7 3 3 Program Header Softkeys The following softkeys are encountered in the Program Header Screen The first five listed below are always there The last four appear when relevant to the general programming option DATA FWD moves the highlight forward through the programming options without setting an input into the program DATA BACK moves the highlight backward through the programming options without setting an input into the program GO TO BEGIN puts the Program Header on the left side of the screen and the first event on the right side GO TO END puts the last programmed event on the left side of the screen and the next event to be programmed on the right side GO TO enter the event number you wish to go to and then press SET Puts the requested event number on the right side of the screen and the previous event number on the left Note for a new program that has no Events all the GO TO selections will take you to the beginning with the program header information summarized on the left as Event 0 and the Select an Event options for Event 1 on the right YES and NO Yes a
85. autions taken by each operator Read and study this manual Be certain every operator understands the operation and safety requirements of this machine before its use Always wear safety glasses and safety shoes Always stop the spindle and check to ensure the CNC control is in the stop mode before changing or adjusting the tool or workpiece Never wear gloves rings watches long sleeves neckties jewellery or other loose items when operating or around the machine Use adequate point of operation safeguarding It is the responsibility of the employer to provide and ensure point of operation safeguarding 2 1 Health and Safety Directives and Standards XYZ Milling Machines are certified to comply with the following Directives and Standards EC Machinery Directive 98 37EC EMC Directive 89 336 EEC Low Voltage Directive 73 23 EEC BS EN 13128 Safety of machine tools Milling machines including boring machines BS EN 1837 Safety of machinery Integral lighting of machines BS EN 60204 Safety of machinery Electrical equipment of machines BS EN 954 1 Safety of machinery Safety related parts of control systems BS EN 292 2 Safety of machines Basic concepts general principles for design BS EN 1050 Safety of machinery Principles for risk assessment BS EN 953 Safety of machinery Guards general requirements for the design and construction of fixed and movable guards BS EN 60529 Degrees of protection provided by
86. avel limit Also check that the quill is fully retracted Press GO to begin 13 10 Data Errors In order to run a program must make sense geometrically For example you can t machine a 10mm diameter circular pocket using a 20mm end mill Data errors will nearly always be detected when the ProtoTRAK SMX CNC runs through a program either as a Trial Run or on an actual part run They may also be detected in the Set Up mode when using the Tool Path Graphics routines Whenever the ProtoTRAK SMX CNC detects a data error a message will appear that will tell you the error number you may wish to record this number for troubleshooting purposes and the event where the error was detected This is not necessarily the event that is in error since the system often looks ahead to make sure there is compatibility from one event to another In addition an explanation is given for each data error type as well as a suggested solution Press the RETURN soft key to go back to the Select Mode screen correct your error and proceed Figure 13 6 The Run Time Clock is in the center of the status line 121 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 13 11 Fault Messages The ProtoTRAK SMX CNC performs a number of automatic checks or self diagnostics If problems are found a message will appear Fault __ __ __ __ The information area will display an explanation and suggested s
87. be programmed with a CONRAD if it is connective with the next event this next event must lie in the same plane as the Mill event Prompts for the Mill Event X Begin is the X dimension to the beginning of the mill cut 75 XYZ Machine Tools Ltd XYZ Machine Tools Ltd and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Y Begin is the Y dimension to the beginning of the mill cut Z Rapid is the Z dimension to transition from rapid to feed Z Depth is the depth of the cut in Z If the Advanced Features Option is active Z Begin and Z End prompts will appear in the place of Z Depth Z Begin is the Z dimension to the beginning of the mill cut Advanced Features Option X End is the X dimension to the end of the mill cut incremental is X Begin Y End is the Y dimension to the end of the mill cut incremental is Y Begin Z End is the Z dimension to the end of the mill cut incremental is Z Begin Advanced Features Option Conrad is the dimension of a tangential radius to the next event that must lie in the same plane for part geometry programming Tool Offset is the selection of the tool offset to right input 1 offset to left input 2 or tool center no offset input 0 relative to the programmed edge and direction of tool cutter movement and as projected in the XY plane RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is a
88. been painstakingly refined to bring you the best in technology while retaining the ease of use that has made ProtoTRAK the top brand in controls for low volume production The ProtoTRAK SMX CNC allows you to chose the CNC configuration that is right for you The base system is a powerful CNC for toolroom work You may add options for additional features and capabilities This manual will describe the operation of all basic and optional features in the appropriate context Where optional features are discussed a note will explain in which option the particular feature is found 1 1 Manual Organization Notes This manual covers the operation of all XYZ Turret Mill products that use the ProtoTRAK SMX CNC Some Sections do not apply to all users For example if you own a ProtoTRAK SMX 2 axis machine you should skip Section 9 Three axis program events Sections that may not apply to all users contain a note to inform you of this fact Section 2 of this manual provides important safety information It is highly recommended that all operators of this product review this safety information carefully 2 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 3 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 2 0 Safety The safe operation of your turret mill depends on its proper use and the prec
89. ce such as a printer While the ProtoTRAK has many similarities to a desktop computer it is different in that the use of the computer s resources have been optimized for running part programs and the resulting sensor feedback in real time In order to avoid causing a slow down or instability in the operating system of the control keep the following in mind when setting up the network Do not use a resource intensive networking program such as SMS Use the Windows XP utilities in the ProtoTRAK SMX instead Avoid loading programs that direct background tasks Some examples are e mail web browsers and anti virus programs Virus Protection As a device ProtoTRAK CNCs are not generally susceptible to viral infections The part programs they run are non executable text files You can further assure protection by avoiding e mail programs and web browser programs loaded onto the ProtoTRAK and by using a hub with a firewall An anti virus program is not necessary since the virus risk is low and is not recommended because the background tasks may cause damage by interfering with ProtoTRAK real time operation 145 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 15 12 4 Network Tools On The ProtoTRAK SMX There are a handful of utilities on the ProtoTRAK SMX in order to aid network set up for Network Administrators or experienced users To access these utilities
90. d To stop jogging release the key e The speed of jog is displayed in the box next to the words Feed Rate on the lower left side of the LCD screen f Press the hard key to reverse direction When the number in the Feed rate box is negative this indicates the minus direction g Press the RATE keys to reduce and to increase the jog speed in 10 percent increments The changes in speed may be seen in the Feed rate box and on the green feed rate indicator The amount of override is displayed in the Override box h To jog at a certain rate simply enter that number as inches or mm per minute and then press the X Y or Z key You may also use the override key to adjust this number Press RSTR to return to 150 ipm or 3800mm min i Press RETURN soft key to return to manual DRO operation 6 4 Power Feed The servomotors can be used as a power feed for the table saddle or quill or all three simultaneously a Press the POWER FEED soft key b A message box will appear that shows the power feed dimensions All power feed moves are ente red as incremental moves from the current position to the next position c Enter a position by pressing the axis key the distance to go and the key if needed Input the entry by pressing INC SET For example if you wanted to make a power feed move of 50mm of the table in the negative direction you would enter X 50 INC SET d Initiate the power feed move by pressi
91. d 128MB or higher Other brands may require the installation of separate drivers If the Networking Memory Option is not active you may purchase it This option consists of the software and the USB Thumb Drive flash memory device The software is already contained in the ProtoTRAK SMX CNC you simply need to activate it to use the features by inputting software Activation Password You may receive your password to activate the option over the telephone The USB Thumb Drive flash memory device will be shipped to you To obtain the Password see the instructions in section 3 1 7 below 16 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 3 1 4 The DXF File Converter Option The DXF File Converter Option gives you powerful capability for quickly and easily translating DXF and DWG files into ProtoTRAK SMX programs If you work with CAD drawings we highly recommend that you get a demo of the DXF file converter Import and convert CAD data into ProtoTRAK programs DXF or DWG files Chaining Automatic Gap Closing Layer control Easy prompted process you can do right at the machine To tell if the DXF File Converter is active on your ProtoTRAK SMX CNC go to the options screen using Service Code 318 If the AutoCAD DXF option is in black letters it is activated If it is in gray letters you will need to purchase the option to activate it The DXF Option Consists of a
92. dditional software and an Activation Password The software can be shipped to you See Section 3 1 7 below for instructions on ordering and obtaining your Activation Password The DXF Option has its own manual which is shipped with the software 3 1 5 Converter Options Optional converters are available for running programs created on other CNCs on the ProtoTRAK and vice versa See section 13 9 for instructions on using converters If the converter you want is not active you may purchase it easily Converte rs are software options so it is simply a matter of entering the correct Activation Password into the ProtoTRAK To obtain the Password see the instructions in section 3 1 7 below 3 1 6 TRAKing Electronic Handwheels Option The TRAKing Electronic Handwheels Option extends the power of the ProtoTRAK SMX CNC beyond the ordinary by combining the electronic handwheels with software routines in the DRO and RUN Modes If you did not buy this option with the original machine you may add it later The option includes Electronic Handwheels on X and Y replaces the mechanical handwheels see Section 3 4 1 TRAKing of programs during program run see Section 12 5 Go To Dimensions see Section 6 6 Selectable Fine Coarse handwheel resolution see Section 3 4 1 If you order this option do not activate the software for the TRAKing Electronic Handwheels Option until the electronic handwheels are installed on the machine Contact XYZ Machine Tool
93. dimension meaningless You have two choices 1 Use the tool table setting the reference and absolute dimension for one of them per the instructions above This will save you from having to touch off tools every time they are changed in program Run 2 Don t use the tool table Erase the entire tool data so that the ProtoTRAK SMX CNC will not try to apply offsets 12 1 3 Initial Tool Set Up This procedure is used for setting up tools when the tool table is clear 1 When you enter this screen for the first time the words NOT SET appear directly under the Z OFFSET column in the REF row The Data Input Line reads TOUCHOFF REFERENCE POINT This is prompting you to establish a reference for the rest of your tools 2 To establish a reference put a cutting tool or some other reference setting tool into the spindle and touch the tool to a surface We recommend that you use something besides a tool that you intend to use machining the job Ideally you will have a reference tool that you keep handy for setting up your tools every time That way a reference point can be easily re established later 3 We also recommend that you use the top of the vice or table as your reference surface because it is constant and never changes 4 With the highlight on the screen on the words NOT SET and the tool touching some reference point press SET NOTE If you do use a tool as your reference tool and it breaks you must retouch off all t
94. e Word Only Instead of typing the item into the Find What box you may simply highlight an item on the G Code Editor screen That item will be entered into the Find What box for you To make changes to Find What items type what you want to have into the Replace With box You can replace items one at a time by clicking first the Find Next box then the Replace With box for as many changes as you want to make You can replace every item in the program with a single click of the Replace All box Return closes the G Code Editor and returns the screen to the Edit Mode Note If you use the USB Thumb Drive to store a G code gcd program file you must leave the Thumb Drive plugged into the USB port the entire time the program is in current memory If you unplug the thumb drive with the program still in current memory the ProtoTRAK will display an error message 106 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 107 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual i0114 12 0 Set Up Mode The Set Up Mode contains the tool library the tool path graphics and the machine s reference positions Enter the Set Up Mode by pressing the SET UP soft key at the Select Mode screen 12 1 The Tool Table From the screen above press the TOOL TABLE softkey FIGURE 12 0 The Set Up mode FIGURE 12
95. e clockwise input 1 or counterclockwise input 2 direction for milling Fin Cut is the width of the finish cut If 0 is input there will be no finish cut Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 up to 3800 for model SLV Fin Feedrate is the milling feedrate for the finish cut Tool is the tool number you assign 8 5 2 Rectangular Pocket Press RECTANGLE soft key if you wish to mill a rectangular pocket all corners are 90o right angles and the sides are parallel to the X and Y axes The prompts for the rectangular pocket X1 is the X dimension to any corner Y1 is the Y dimension to the same corner as X1 X3 is the X dimension to the corner opposite X1 incremental is from X1 Y3 is the Y dimension to the same corner as X3 incremental is from Y1 Conrad is the value of the tangential radius in each corner Direction is the clockwise input 1 or counterclockwise input 2 direction for milling Fin Cut is the width of the finish cut If 0 is input there will be no finish cut XY Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 up to 3800 for model SLV Fin Feedrate is the milling feedrate for the finish cut Tool is the tool number you assign 8 5 3 Irregular Pocket Advanced Features Option Press the IRREG PCKT soft key if you wish to mill a pocket other than a rectangle or circle The Irregular Pocket event gives y
96. e put in position when the messages Set Z or Check Z appear When TRAKing through an XY move the Z axis handwheel is not active 13 6 Program Run Messages While in the Run Mode clear instructions and prompts from the SMX CNC will tell you exactly what to do to run the program These messages will appear in a green box in the middle of the screen When a tool change is required the tool information entered in the Tool Table will appear in the green box Any Event Comments you entered during programming will appear on the Data Input Line See section 7 3 2 to use Event Comments The Event Comments feature is part of the Advanced Features Option Once the program starts a Run Time Clock will appear in the center of the status line at the top of the screen This clock displays the time remaining until the end of the program or the next tool change and will count down as the program is run The Run Time Clock is 120 XYZ Machine Tools Ltd XYZ Turret Mill andProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual part of the Advanced Features Option Note the program must first be viewed as Tool Path in the Set Up Mode to initialize the Run Time Clock Otherwise it will show 0 00 Section 12 2 13 7 Stop At any time the program may be halted by pressing the STOP key This freezes the program at that point You may choose to continue running the program by pressing the CNC RUN softkey or pressing the GO k
97. ection 14 0 for the operation of the Program In Out Mode in the basic system If you have the Networking Memory Option but wish to use the system in the more simple configuration described in Section 14 0 do Service Code 334 for the screen that turns the option off If you have the Networking Memory Option installed but not active do Service Code 334 for the screen that turns the option on If you do not have the Networking Memory Option installed see Sections 3 1 3 and 3 1 7 for more information about buying the Networking Memory Option From the Select Mode screen press the PROG IN OUT softkey The first screen you see will ask LIST SUPPORTED PROGRAMS ONLY With a highlighted YES or NO FIGURE 15 0 Supported programs are part programs that can run on the ProtoTRAK SMX CNC You do not have to answer this question every time you are at this screen Simply press the softkey for the operation you want Supported programs are the programs that will run on your ProtoTRAK SMX CNC It is possible to view other types of files through the Program In Out Mode for example Microsoft Word files This type of file is not supported on the ProtoTRAK SMX CNC in the sense that you cannot open it and work on it We recommend a Yes response to this prompt Filenames and File Extensions Most places in the ProtoTRAK SMX CNC we refer to the program or part In Program In Out Mode this program or part is called a file Filenames are pro
98. ed in its own section because it works differently than the other event types Unlike other events the A G E allows you to Enter the data you know and skip the prompts you don t Use different types of data like angles that may be available from the print Enter guesses for the X and Y ends and centers not available on the print With the A G E you can easily overcome limitations in the data the print provides without having to spend time in laborious calculations 10 1 Starting the A G E The A G E is started automatically when you enter the Irregular Pocket or Irregular Profile event The first set of prompts you encounter will be the header information Once that information is entered you will see the following screen Where A G E Mill A straight line from one X Y point to another A G E Arc Any part of a circle FIGURE 10 1 Once the profile header screen is finished you choose between an A G E Mill and an A G E Arc to define the shape Two axis CNC programming will not require Z data 94 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual End A G E Ends the A G E programming for the Irregular Pocket or Irregular Profile Abort A G E Aborts all A G E events The data for all the events is lost 10 2 A G E Mill Prompts Press the A G E Mill key FIGURE 10 2 A G E Mill prompts Enter what you know skip or
99. en The events you have defined with their X and Y dimensions are finished in the Program Mode See Section 8 14 6 8 Return To Absolute Zero At any time during manual DRO operation you may automatically move the table to your absolute zero location in X and Y by pressing the RETURN ABS 0 soft key When you do the message window will read Ready to Begin Press Go when Ready Make sure your tool is clear and press the GO key The servos will turn on move the quill to Z retract for three axis CNC models then move the table at rapid speed to your X and Y absolute zero position and then turn off You will be at zero and in manual DRO operation 6 9 Tool The ProtoTRAK SMX CNC allows you to use the data for tools in your Tool Table see Section 11 1 in the DRO Mode To change tools press the TOOL soft key and enter the tool number when prompted by the Data Input Line Even when you set up a tool in the Set Up Mode if you do not wish to use the tools in the Tool Table simply ignore the Tool feature 49 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 7 0 Program Mode Getting Started amp Some General Information 7 1 Programming Overview The ProtoTRAK SMX CNC makes programming easy by allowing you to program the actual part geometry as defined by the print The basic strategy is to first fill in the initial program information in the Program He
100. ent is the event number of the last event to be repeated if only one event is to be repeated the Last Event is the same as the First Event X Offset is the incremental X offset from event to be repeated Y Offset is the incremental Y offset from event to be repeated Z Offset is the incremental Z offset from event to be repeated Z Rapid Offset is the incremental Z rapid offset from event to be repeated Repeats is the number of times events are to be repeated up to 99 RPM is the percentage of RPM in the programmed events SET will load in the assumed of 100 RPM programming is available only if the Programmable Electronic Head Option is active Feed the percentage of the feeds programmed in the repeated events 100 is assumed Tool is the tool number you assign 9 10 2 Mirror Advanced Features Option Press the M IRROR soft key First Event is the event number of the first event to be mirrored Last Event is the event number of the last event to be mirrored if only one event is to be mirrored the last event is the same as the first 88 XYZ Machine Tools Ltd XYZ Machine Tools Ltd and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Cutting Order input 1 to cut from the lowest mirrored event to the highest forward and 2 to machine from the highest mirrored event to the lowest backward This way you can keep all the machine motion in a consisten
101. ents may be edited by pressing the BACK hard key to the left of the soft keys The previous event will be shifted from the left side of the screen to the right and may be edited The BACK key may be pressed all the way to the Program Header Screen the PAGE BACK softkey will work as well FIGURE 7 9 2 When the More soft key is selected these additional event types are available for three axis CNC models If the Advanced Features or E Head Option are not active relevant functions will be grayed out FIGURE 7 9 3 Here a Bolt Hole event was selected for three axis CNC For two axis Z programming prompts do not appear The ProtoTRAK SMX CNC is prompting you to enter the number of holes 57 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 7 11 LOOK As you program each event it is helpful to see your part drawn For quick graphics while in the Program Mode press the LOOK hard key This function is active at the end of each event or whenever the conversation line is prompting Select Event Press the LOOK key and the ProtoTRAK SMX CNC will draw the part Press LOOK again or BACK to bring back the Select Event screen You may also select a new view or adjust the view Softkeys in LOOK ADJUST VIEW gives additional options for adjusting the view of the drawing See below FIT DRAW automatically resizes the drawing to fit the entire part program on the screen
102. est For three axis CNC machining only Allows you to input a dwell at the bottom of a drill bolt hole or bore cycle for events you select Select the appropriate YES or NO soft key If you select YES you will be prompted to input a dwell time in seconds from 1 to 99 9 when appropriate to the event being programmed Auxiliary Function Request Asks if you wish to activate any of the optional auxiliary functions see Section 7 4 at any time during the program Select the appropriate YES or NO soft key If you select YES you will be prompted to input the type and sequencing of the auxiliary functions during event programming Auxiliary Functions are optional for three axis CNC models only Event Comments If you select Yes for event comments you will have the opportunity to insert a comment in each event For Irregular Pocket and Irregular Profile events you will be able to enter a comment at the header event but not for each A G E Turn and A G E Arc event This function is part of the Advanced Features Option Comments appear in the RUN mode on the Data Input Line as the event begins to run Comments may be composed of letters numbers and some symbols and may be up to 20 characters While programming the event with the Event Comments set to Yes when the highlight is on the Event Comments prompt you may enter a comment using the same methods used to enter a program name as described above Multiple Fixtures Asks you if you wish to tu
103. et up 11 Backlash Hysterisis Test Runs a routine that helps the system compute lost motion 12 Feed Forward Test Caution Machine parameters may change Run this test only if indicated by service personnel 100 Open Loop Test Caution Machine will move Check for crash conditions before running Run under the direction of service personnel 123 Calibration Mode 127 Auto Backlash Configuration 128 Backlash Calibration Constant Diagnostic Codes 54 Continuous Run Mode Cycles through the program in current memory without Z motion 81 Keyboard Test Gives a tone feedback to a button push 131 Manual DRO 132 Electronic Handwheel Test 314 Toggle Test Lights in Status Line 319 Error Logging 326 Error Message Display 327 Display Memory Check Operator Defaults Options 66 Metric Boot Up Default To have the ProtoTRAK open up in mm measurement 67 English Boot Up Default To have the ProtoTRAK open up in inch measurement 79 Turn On Beeper 116 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 80 Turn Off Beeper 129 Arc Accuracy To enter the preference Default is 001 334 Set Control Options Turn on or off the control options Advanced Features Option and Network Memory Turn the ProtoTRAK off then on to activate the change 117 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Sa
104. event Previous events may be edited by pressing the BACK hard key to the left of the soft keys The previous event will be shifted from the left side of the screen to the right and may be edited The BACK key may be pressed all the way to the Program Header Screen the PAGE BACK softkey will work as well FIGURE 7 9 2 When the More soft key is selected these additional event types are available for three axis CNC models If the Advanced Features or E Head Option are not active relevant functions will be grayed out FIGURE 7 9 3 Here a Bolt Hole event was selected for three axis CNC For two axis Z programming prompts do not appear The ProtoTRAK SMX CNC is prompting you to enter the number of holes 57 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 7 11 LOOK As you program each event it is helpful to see your part drawn For quick graphics while in the Program Mode press the LOOK hard key This function is active at the end of each event or whenever the conversation line is prompting Select Event Press the LOOK key and the ProtoTRAK SMX CNC will draw the part Press LOOK again or BACK to bring back the Select Event screen You may also select a new view or adjust the view Softkeys in LOOK ADJUST VIEW gives additional options for adjusting the view of the drawing See below FIT DRAW automatically resizes the drawing to fit the entire part pr
105. event of the irregular pocket must end at the same point as defined in the first event Prompts for the Irregular Island event X BEGIN X dimension to the beginning of the island Y BEGIN Y dimension to the beginning of the island FIN CUT ISL Finish cut for the Island If 0 is input there will be no finish cut X1 POCKET X dimension for one corner of the rectangular pocket that surrounds the island Y1 POCKET Y dimension for one corner of the rectangular pocket that surrounds the island X3 POCKET X dimension for the opposite corner of the rectangular pocket that surrounds the island Y3 POCKET Y dimension for the opposite corner of the rectangular pocket that surrounds the island CONRAD PCKT the value of the tangential radius in the corners of the rectangular pocket that surrounds the island FIN CUT PCKT finish cut along the perimeter of the pocket If 0 is input there will be no finish cut FEEDRATE the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 up to 3800 for model SLV FIN FEEDRATE the finish milling feedrate for both the island and pocket finish cuts TOOL is the tool number you assign When the initial screen is complete you will define the perimeter of the island with a series of A G E Mills and A G E Arcs Programming with the Auto Geometry Engine is explained in Section 10 0 8 7 PROFILE Events This event allows you to mill around the outside or inside of a circu
106. ew name press the SAVE softkey Two files will now be on your list the new and the previously named versions of the file you copied 14 8 Backing Up We highly recommend that you back up your floppy disk regularly The easiest way to do this is to take the floppy out and go to another computer to copy the program files to another floppy or to a hard drive Floppies and floppy drives fail on occasion It is a good practice to protect your hard work by cultivating the habit of backing up your files 14 9 Additional Topics This section has dealt with only the basic operation of the Program In Out Mode of the basic ProtoTRAK SMX CNC Other capabilities exist even on this basic system See the following Topic See section Networking Memory Option 3 1 3 3 1 7 Memory and storage 5 11 Filenames and file extensions 15 0 DXF and other converters 15 9 SMX compatibility with other ProtoTRAK and TRAK CNCs 15 10 Running CAM files 15 13 126 XYZ Machine Tools Ltd TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 127 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 15 0 Program In Out Mode with the Network Memory Option Active This section deals with the advanced capabilities of the ProtoTRAK SMX with the Networking Memory Option active If you do not have the Networking Memory Option see S
107. ey If the Advanced Features Option is active You may also run the program by using the table or saddle handwheels by pressing the TRAKing softkey 13 8 Feedrate and Speed Overrides In program Run Mode the programmed XYZ axis feeds as well as the rapid speeds may be adjusted temporarily Likewise if the Programmable Electronic Head Option is installed the programmed spindle speed may be adjusted temporarily You may override the spindle speeds or feeds with the OVERRIDE display hard key Press the F S key until the LED is lit on the side corresponding to the speed you wish to override S for Spindle F for feed Use the up and down arrow keys to change the feedrate in 10 increments per button press and the spindle speed in 5 increments 13 9 Trial Run Trial Run allows you to quickly check out your program with no Z movement for three axis CNC programs before you actually start to make parts In trial run the table will move at rapid speed regardless of what feedrates are programmed the rapid speed may be overridden with FEED and FEED keys The table will stop at each stop location for example at each drill location but immediately continue on without your input To do a trial run press the TRIAL RUN soft key from the screen shown in Section 13 1 The message box will read Ready to begin trial run Press GO to start Be certain the table is positioned so that if it moves through the part program it will not reach its tr
108. f Mill or Arc events either with or without A G E Profile don t have an automatic routine for making finish cuts There is however a very simple technique that can be used a Program the shape using the print dimensions and ignore the need to leave material for a finish cut b Using a subroutine event Repeat all the events in a but call out a different tool number 58 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual c In Set Up Mode lie about the tool diameter for the tool called out in events in a Input a tool diameter equal to the actual tool diameter plus 2 times the finish cut you wish to leave The ProtoTRAK SMX CNC will think the tool is bigger than it really is and therefore shift a little further away from the machined shape d In Set Up Mode input the actual diameter for the tool called in the Repeat event b This will produce the final dimensioned cut 7 13 Two Versus Three Axis Programming for Three Axis CNC Models For mills with the Z axis ballscrew and motor assembly installed the ProtoTRAK SMX CNC may be operated as either a two or three axis CNC Many jobs in tool rooms are simply easier to do with a two axis CNC Other jobs are more complex or require a lot of metal removal so the extra programming and set up of the three axis is worth the effort The ProtoTRAK SMX CNC lets you choose how much CNC you want to use on
109. f print data Multiple fixture offsets Event comments Tool path conversational programming Mirror of programmed events Copy with or without offsets Copy Rotate Copy Mirror Clipboard to copy events between programs If the Advanced Features Option is not active you may purchase it easily The Advanced Features Option is a software option so it is simply a matter of entering the Activation Password into the ProtoTRAK To obtain the Password see the instructions in section 3 1 7 below 3 1 3 Networking Memory Option In its base form the ProtoTRAK SMX CNC has a very simple user interface All program storage and retrieval uses the standard floppy disk drive The Networking Memory Option gives you powerful choices in program storage and handling This option may be ordered with your machine or at any time after it is installed in your shop The following features are included in the Networking Memory Option Directory File Folder Program organization Automatic file back up routine Preview Graphics for unopened files USB Thumb Drive flash memory 256 Mb or more Networking via RJ 45 port Installing and using the USB Thumb Drive Flash Memory The first time you install the USB Thumb Drive we recommend that you install it after the ProtoTRAK SMX has booted up Once it is installed the memory will be accessible on Drive D If you want to buy additional thumb drives these are readily available in computer stores We recommend SanDisk bran
110. familiar with writ ing a post processor we recommend that you contact your CAD CAM supplier We will be happy to work with him to get you the post processor you need 148 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 15 13 1 Writing a Post Processor The following are modifications to a Fanuc 6 post processor that are nece ssary for writing the ProtoTRAK post processor Beginning file format The ProtoTRAK has no special requirements it does not need any special characters End of file format the ProtoTRAK requires the to show the end of the file Characters after the will be ignored Beginning of an operation the ProtoTRAK requires that the tool number feedrate and tool offset appear before or on the same line as a move command In addition the ProtoTRAK requires the spindle speed be set if the Programmable E Head Option is active The absolute zero of the ProtoTRAK is set in a different mode and does not need to be set at the beginning of each operation The feedrate is modal once it is set it remains the same until changed Lines the line feed or carriage return line feed signals the end of the line ASCII code hex 0A or 0D 0A A semicolon is optional Coordinates may be formatted in inch or metric The addresses used for specifying coordinates are X Y Z I J K The valid ranges are Inch min 99 9999 to max 99 9999
111. fety Programming Operating amp Care Manual 13 0 RUN MODE 13 1 Run Mode Screen Press MODE and select the RUN soft key The display will show I i01144 Items on the Run Screen Event counter this will be the current event number and event type Repeat if a repeat event is in the event counter this will show which repeat number for example if you program a drill with 5 repeats this will show which repeat of the event that is being machined Spindle RPM the programmed RPM as adjusted by the Spindle Override The Programmable Electronic Head Option must be active for this function Red bar graphical representation of Spindle override described above Feed Rate programmed feedrate of the current move as adjusted by the feed override Green bar graphical representation of the feed override Override of feed override 13 2 Two Versus Three Axis Running For three axis CNC models the three axis run will control all three axes Three axis models also allow you to run two axis programs When you run two axis programs with either a two or three axis CNC model the ProtoTRAK will control the X and Y table and saddle only with you manually positioning the Z quill and or knee Most differences that occur as a consequence of either two or three axis operation are obvious Two issues are worth noting FIGURE 13 1 The Run Mode The ProtoTRAK SMX CNC awaits your instructions for how to begin machining Part Number B
112. fies the X dimension ParseXval Y Specifies the Y dimension ParseYval Z Specifies the Z dimension ParseZval I Specifies the incremental X dimension ParseIval J Specifies the incremental Y dimension ParseJval K Specifies the incremental Z dimension ParseKval L An Optional Parameter ParseLval P An Optional Parameter ParsePval Introduces a comment ParseComment 139 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 15 12 Networking The subject of networking is extensive This portion of the manual will give you basic instructions for setting up a simple peer to peer network and some system information useful to network administrators A network is simply two or more computers connected usually by a cable so they may share information Networks within a single building are called LANs for Local Area Network The benefit of networking is that you can move information easily between computers This ease of use enables some handy functionality for example 1 An effective file Back up routine File back ups are essential if you want to retain programs for future use Any hard drive or floppy drive could fail Having program files backed up to a different location saves you from rewriting the programs from scratch if a failure occurs 2 An easy way to import CAD CAM or DXF files from other computers 3 An effective revision control Having a si
113. for one corner of the rectangular pocket that surrounds the island Y1 POCKET Y dimension for one corner of the rectangular pocket that surrounds the island X3 POCKET X dimension for the opposite corner of the rectangular pocket that surrounds the island Y3 POCKET Y dimension for the opposite corner of the rectan gular pocket that surrounds the island CONRAD PCKT the value of the tangential radius in the corners of the rectangular pocket that surrounds the island FIN CUT PCKT finish cut along the perimeter of the pocket If 0 is input there will be no finish cut FEEDRATE the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 up to 3800 for model SLV FIN FEEDRATE the finish milling feedrate for both the island and pocket finish cuts TOOL is the tool number you assign 8 6 2 Rectangular Island Advanced Features Option When the Advanced Features Option is active press the RECT ISLAND softkey if you wish to machine a rectangular island Prompts for the RECT ISLAND X1 ISLAND X dimension for one corner of the rectangular island Y1 ISLAND Y dimension for one corner of the rectangular island X3 ISLAND X dimension for the opposite corner of the island Y3 ISLAND Y dimension for the opposite corner of the island CONRAD ISL the value of the tangential radius in the corners of the island DIRECTION is the milling direction clockwise or counterclockwise FIN CUT ISL Finish cut f
114. fore using operations that involve the servo motors The ProtoTRAK SMX CNC has a screen saver already programmed in If the system is not used either by a key stroke or by counting for 20 continuous minutes the display will turn itself off The LED s on the keypad will flash every few seconds to indicate that the system is still on Press any key or move any axis to bring the screen back to its previous display The key you press will be ignored except to turn the screen on 4 1 2 Shutting Down the ProtoTRAK SMX CNC Important the system must be turned off properly First press the SYS hard key and then press the SHUT DOWN soft key see Figure 4 6 After a few seconds you will see the message it is now safe to turn off your computer Turn the ProtoTRAK SMX CNC off by moving the toggle switch on the display side panel to the down position Note When you turn the PROTOTRAK SMX CNC off always wait a few seconds before turning it back on 4 1 3 Emergency Stop Press the button to shut off power to the spindle motor and axis motors Rotate the switch to release Once the switch is released you must reset the relay by pressing the green button on the right side of the ProtoTRAK SMX pendant figure 3 2 3 4 1 4 Switching Between Two and Three Axis Operation For three axis XYZ Turret Mill models The ProtoTRAK SMX CNC may be operated as a two or three axis CNC Press the SYS hard key Softkey F2 will read GO TO 2 AXIS when the ProtoTR
115. gaged or disengaged with this selector Pull out the knob and rotate it clockwise to disengage power feed Rotate it counterclockwise to engage power feed i00166 37 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Safety Programming Operating amp Care Manual CAUTION It is recommended that the selector be disengaged when the spindle is not running Never have the feed engaged when the spindle RPM is over 3000 Always leave the selector in the disengaged position unless the feed function is being used 4 2 11 Fine Feed Direction Shaft Two Axis CNC Models Figure 4 2 10 2 The direction of the fine feed is set by the position of the fine feed direction shaft IN sets the direction down OUT sets the direction up and NEUTRAL in the middle i00166 38 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Safety Programming Operating amp Care Manual 4 2 12 Quill Feed Selector Two Axis CNC Models Figure 4 2 10 3 Quill Feed Selector one model Figure 4 2 10 4 Quill Feed Selector one model This selector is used to set the quill feed speed To change speeds pull the knob out and rotate the selector to the proper position It is generally easier to change speeds with the spindle running or rotated by hand Do not force the lever 4 2 13 Feed Trip Lever Two Axis CNC Models The Feed Trip Lever stops the quill feed motion when the quill stop knob reaches the quill micrometer dial Move
116. go clockwise or counterclockwise around the equator or you could go up over the north pole or down under the south pole The ProtoTRAK SMX CNC will automatically assume that all 180o arcs that have the same beginning ending and center dimensions for Z lie in the XY plane If you want a 180o arc in a vertical plane you must program two 90o arcs or some equivalent Prompts for the Arc event X Begin is the X dimension to the beginning of the arc cut Y Begin is the Y dimension to the beginning of the arc cut Z Rapid is the Z dimension to transition from rapid to feed 76 XYZ Machine Tools Ltd XYZ Machine Tools Ltd and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Z Depth is the depth of the cut in Z If the Advanced Features Option is active Z Begin and Z End prompts will appear in the place of Z Depth Z Begin is the Z dimension to the beginning of the arc cut Advanced Features Option X End is the X dimension to the end of the arc cut incremental is from X Begin Y End is the Y dimension to the end of the arc cut incremental is from Y Begin Z End is the Z dimension to the end of the arc cut incremental is from Z Begin The Z End dimension is programmed only if the Advanced Features Option is active X Center is the X dimension to the center of the arc incremental is from X End Y Center is the Y dimension to the center of the arc incremental is from Y End Z Center
117. gram names or part names They are the name you give to the programs you write on the ProtoTRAK SMX CNC plus a file extension Although the ProtoTRAK SMX CNC can have program names up to 25 characters that use letters and special symbols most other CNC s must have file names that are eight or fewer characters using numbers only 128 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual File extensions are part of filenames that help describe the file They appear after the filename and are composed of three letters following a period For example doc is the extension that appears after a file name for a file st ored using Microsoft Word Usually but not always the file name indicates what program was used to create the file Sometimes this is not the case Some programs like those found in early models of CNC do not attach a file extension to a file name at all Also a user may attach his own extension to a file name for his own purposes ProtoTRAK and TRAK A G E CNC s always attach an extension to every file that is stored The extension MX2 is used for files or programs written and stored on a ProtoTRAK MX2 ProtoTRAK M2 or TRAK A G E 2 CNC The extension MX3 is used for the ProtoTRAK MX3 ProtoTRAK M3 and TRAK A G E 3 CNC s The ProtoTRAK SMX CNC uses the extension ProtoTRAK4 whether the program is two or three axis Before opening the file the Pr
118. guess the ones you don t Prompts in A G E Mill programming Tangent this refers to the tangency of the mill to the previous event See Section 10 11 for a discussion of tangency X END is the X dimension to the end of the mill cut incremental is X Begin Y END is the Y dimension to the end of the mill cut incremental is Y Begin CONRAD is the dimension of a tangential radius to the next event ANGLE END is the angle measured counterclockwise from this mill event to the next Do not input if the next event is an arc LENGTH is the length of the mill from beginning to end LINE ANGLE is the angle of this mill line moving from begin to end measured counterclockwise from the positive X axis that is 3 o clock GUESS This softkey will appear when the prompt is on X or Y dimensioned data Press the Guess key before you press INC SET or ABS SET to enter the data as a guess See Section 10 7 for using Guess and Section 10 8 for using the Grap hics to enter a Guess 95 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 10 3 A G E Arc Prompts Press the A G E ARC key Prompts in A G E Arc programming Tangent this refers to the tangency of the mill to the previous event See Section 10 11 for a discussion of tangency DIRECTION is the clockw ise input 1 or counterclockwise input 2 direction of the arc X END is the X dimension to
119. h Networking Memory Option Active 15 1 Softkey Selections 128 15 2 Basic Navigation of Screens 128 15 3 Opening a File 129 15 4 Saving Programs 129 15 5 Copying Programs 130 15 6 Deleting Programs 131 15 7 Renaming Programs 132 15 8 Backing Up Programs 132 15 9 Converters 133 15 10 Compatibility with other Models 135 15 11 Running G Code Files 137 15 12 Networking 139 15 13 Cad Cam Post Processor 147 16 0 Sample Program 16 1 Sample Program 1 153 16 2 Sample Program 2 156 1 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 1 0 Introduction Congratulations Your new XYZ Turret Mill with the ProtoTRAK SMX CNC is an excellent all around addition to your shop The ProtoTRAK SMX has an easy to use interface and dozens of features that maximize your productivity for any small lot production job Manual Machining is always available and made easier with features like power feed 2500 mm per minute rapids tool offsets and all the best features of sophisticated DRO s Two Axis Machining is available at the touch of a button for the prototyping and moderately complex low volume work that is typically done on knee mills Three Axis CNC Machining is also available for models with the ProtoTRAK SMX3 Programs may be entered at the control or imported from other applications such as CAD CAM The operation of the ProtoTRAK SMX CNC has
120. h cut RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is active FIN RPM is the spindle RPM for the finish cut FIN RPM programming is available only if the Programmable Electronic Head Option is active Fin Feedrate is the finish cut milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Tool is the tool number you assign 79 XYZ Machine Tools Ltd XYZ Machine Tools Ltd and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual When the initial screen is complete you will define the perimeter of the pocket with a series of A G E Mills and A G E Arcs Programming with the Auto Geometry Engine is explained in Section 9 0 No islands may exist in an irregular pocket 9 6 4 Tool Path in Pocket Events In Program Run the pocket path will be either the plunge or zigzag cuts to Z depth along either the X or Y followed by the required number of cuts to clear out the interior material and then the rough cut along the inside of the perimeter This will be repeated for each pass and then followed by a finish pass if FIN CUT was not zero along the inside of the perimeter at the Finish Feedrate and final depth If a bottom finish cut was programmed it will be machined before the perimeter finish cut Whether the cuts to clear the interior material of the irregular pocket are al
121. he same corner as X3 incremental is from Y1 Z Rapid is the Z dimension to transition from rapid to feed Z End is the Z dimension at the bottom of the pocket incremental is from the previous event Conrad is the value of the tangential radius in each corner Direction is the clockwise input 1 or counterclockwise input 2 direction for milling 78 XYZ Machine Tools Ltd XYZ Machine Tools Ltd and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Passes is the number of cycles to machine to the final depth spacedequally from Z Rapid to Z End hint keep Z Rapid small Entry mode choose between a zigzag ramp and a plunge The plunge will machine straight down Z to the appropriate Z depth The zigzag ramp will move in a zigzag pattern to depth See Section 9 6 5 for more information about the zigzag ramp Fin Cut is the width of the finish cut If 0 is input there will be no finish cut See Section 9 6 7 for a bottom finish cut RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is active FIN RPM is the spindle RPM for the finish cut FIN RPM programming is available only if the Programmable Electronic Head Option is active Z Feedrate is the Z feedrate from Z rapid to Z end XYZ Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Fin
122. ifferent Format into a ProtoTRAK SMX CNC Conversions from a different format into a ProtoTRAK SMX CNC occur when the file is opened FIGURE 15 9 2 Use the Open As box to tell the ProtoTRAK SMX CNC what kind of file it is Use the Open As box to tell the ProtoTRAK SMX CNC what format the file is in so that it knows how to convert it to the ProtoTRAK SMX CNC format In Figure 15 9 1 the ProtoTRAK SMX CNC could guess that the file to be converted was from a previous version of ProtoTRAK because of its file extension mx3 But since file extensions 135 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual may be missing or may not really describe the file format correctly you can use the Open As box to declare the file type All files or programs open on the ProtoTRAK SMX CNC as a PT4 file with one exception G Code files see below Once the file is opened as ProtoTRAK SMX CNC file you may store it as ProtoTRAK SMX CNC file with the same filename and the extension PT4 The drop down menu in the Open As box shows which converters are available Open As types that are grayed out indicate converters that are available for purchase 15 9 3 Converting From the ProtoTRAK SMX CNC to a Different Format Files or programs are converted from the ProtoTRAK SMX CNC to a different format using the Save function of Program In Out Mode FIGURE 15 9 3 Use the Save As box
123. ights on the front of the router Once the connection is made you still need to do a couple more steps before the network is useful Figure 15 12 4 Enter the computer name and workgroup name i01134 143 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual On The Desktop Computer You Want To Network There are differences in the process of setting up a network between Windows 98 Windows 2000 Windows XP and other operating systems Fortunately there are just a couple of things you need to do and the instructions for these are already on your computer 1 Set your computer to automatically obtain IP addresses For instructions on how to do this go to Windows Help and search for the topic IP Addresses If the lights above the cable on the router are on you don t have to do this 2 Create a Workgroup name for your computer For instructions on how to do this go to Windows Help and search for the topic Workgroup Names If there is a workgroup name already write it down This is the name required in step 8 Section 15 12 1 above 3 Share a part of your computer This will allow the ProtoTRAK SMX to look into the drives or folders you share For instructions on how to do this go to Windows Help and search for the topic Sharing or How to Share a Folder In order to allow the ProtoTRAK SMX to read and write programs to this folder
124. igure 7 8 PAGE FWD moves forward through the programmed events PAGE BACK moves backwards through the programmed events DATA FWD moves forward through the event inputs Note use the DATA FWD key and not a SET key when you do not want to input a value DATA BACK moves backwards through the event inputs DATA BOTTOM puts the Highlight on the last input INSERT EVENT use this to insert a new event into the program This new event will take the place of the one that was on the right side of the screen when you pressed the INSERT EVENT key That previous event and all the events that follow increase their event number by one For example if you started with a program of four events if you were to press the INSERT EVENT key while Event 3 was on the right side of the screen the previous Event 3 would become Event 4 and the previous Event 4 would become Event 5 If you insert a Subroutine event the event numbers will increase by one as when you insert another kind of event If you insert a copy event the event numbers will increase by the number of events that are copied DELETE EVENT this will delete the event on the right side of the screen 7 9 Programming Events Once you press the appropriate GO TO soft key you will begin to define your part as a series of Events For the ProtoTRAK SMX CNC an Event is a geometry or a feature of a part FIGURE 7 8 Soft keys used while programming an event FIGURE 7 9 1 The header screen
125. in D word from the X axis G17 Selects the XY plane for circular interpolation G18 Selects the XZ plane for circular interpolation G19 Selects the YZ plane for circular interpolation G20 input in inch G21 input in mm G40 cutter compensation cancel for SWI it means center G41 cutter compensation left G42 cutter compensation right G61 exact stop check mode G64 cutting mode no hesitation between events NOHES true G80 Hole machining canned cycle G81 Drill canned cycle G82 Spot drilling canned cycle G83 Peck drilling canned G84 Tapping canned cycle G85 Boring canned cycle 15 11 2 M Codes Supported by the ProtoTRAK SMX CNC M00 program stop with prompt press go to procd M01 optional stop M02 end of program no rewind M03 spindle CW M04 spindle CCW M05 spindle stop M06 tool change M07 mist coolant ON M08 flood coolant ON M09 coolant OFF M30 end program rewind stop M79 Send SWI O ascii 79 commands value in P word M98 Subroutine Call to block PWORD repeat L WORD 15 11 3 Valid Characters for Word Address Sequences G Prepare to execute a G COMMAND ParseGcode M Prepare to execute a M COMMAND ParseMcode N Introduces a block number ParseEventNum T Specifies the tool number to use ParseToolNum F Specifies a feedrate ParseFcode S Specifies a spindle rpm ParseScode D Specifies the diameter for the current tool ParseDval E Optional parameter ParseEval X Speci
126. in a mouse They may also be used for a keyboard or for plugging in the USB Thumb Drive flash memory that comes with the Networking Memory Option Section 3 1 3 Items used by USB ports will be recognized even if they are plugged in after the ProtoTRAK is turned on If you need more than two USB ports we recommend that you install a USB hub If you use the USB Thumb Drive to store a G code gcd program file you must leave the Thumb Drive plugged into the USB port the entire time the program is in current memory If you unplug the thumb drive with the program still in current memory the ProtoTRAK will display an error message FIGURE 3 2 3 The ProtoTRAK SMX CNC right side 23 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Drivers for most major brands of mouse and keyboard are already in the ProtoTRAK SMX If a mouse or keyboard is not recognized by the ProtoTRAK it means that the driver is not available Loading a new driver is not difficult for a qualified computer administrator who can access the start menu on the ProtoTRAK with a keyboard plugged in see the Catch 22 However most users would be happier to simply go get a keyboard and mouse that are already supported We recommend Microsoft Logitech and Belkin brand products AC on off The ProtoTRAK should be shut down properly before turning off Sections 4 1 and 4 2 Reset The reset button re ene
127. indexer or rotary table as a GO command and continue machining without you having to press the GO key 7 5 Multiple Fixtures This function is part of the Advanced Features Option You may run your program using up to six fixtures plus a base A fixture is a location on your machine with a defined offset from your absolute 0 When you program an event to have a fixture it will treat the offset as if it were absolute zero shift The programmed X Y and Z absolute dimensions are relative to the absolute reference for the specified fixture For example say you had two vises on the table On the first vise you established the lower left jaw as the absolute 0 At the same time you measured the distance between the absolute zero you just established and the lower left jaw of the other vise You entered that measurement as an offset from your base vise the first one and the other vise which is Fixture 2 Any events that you programmed using Fixture 2 would treat the lower left corner of that second vise like the absolute 0 for the X Y and Z dimensions in the events Fixture offsets are handy for combining different programs together to run at the same time or to make multiple parts by repeating the events with different fixtures The fixture offsets are entered in the Set up mode There is a base fixture called fixture number one We recommend that Event 1 in your program uses fixture number one It doesn t have to we just believe it is cle
128. ing the function of every control key button knob or handle Ask your supervisor or a qualified instructor for help when needed 3 Protect your eyes Wear approved safety glasses with side shields at all times 4 Don t get caught in moving parts Before operating this machine remove all jewellery including watches and rings neckties and any loose fitting clothing 5 Keep your hair away from moving parts Wear adequate safety headgear 6 Protect your feet Wear safety shoes with oil resistant anti skid soles and steel toes 7 Take off gloves before you start the machine Gloves are easily caught in moving parts 8 Remove all tools wrenches check keys etc from the machine before you start Loose items can become dangerous flying projectiles 9 Never operate a milling machine after consuming alcoholic beverages or taking strong medication or while using non prescription drugs 10 Protect your hands Stop the machine spindle and ensure that the CNC control is in the stop mode Before changing tools Before changing parts Before you clear away the chips oil or coolant Always use a chip scraper or brush Before you make an adjustment to the part fixture coolant nozzle or take measurements Before you open safeguards protective shields etc Never reach for the part tool or fixture around a safeguard 11 Protect your eyes and the machine as well Don t use a compressed air ho
129. ing the technique of overstating the size of the cutter you will use to cut the profile 15 11 Running G Code Files The ProtoTRAK SMX allows you to run G Code files directly without having them converted to the ProtoTRAK SMX programming format You may want to do this if you have a very large CAM file made up of small XYZ position moves or if there is complex surface contouring In these cases the ProtoTRAK SMX can handle the files more efficiently by running the G Code directly While running the G Code file directly does not give you the benefit of the easy programming format of the ProtoTRAK SMX you are not likely to be able to use this benefit with a very large or complex file anyway To run the G Code file directly open the file using OPEN AS G Code GCD The entire program will be brought into current memory You will be able to view the tool path when you run the program in the Run Mode but you will not be able to edit the program or view it in the Program Mode In order to edit the program use the G Code Editor in the Edit Mode Section 10 5 15 11 1 G Codes Recognized by the ProtoTRAK SMX CNC G00 positioning rapid G01 linear interpolation feed G02 circular interpolation CW G03 circular interpolation CCW G06 CW Helix 138 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual G07 CCW Helix G16 Selects a vertical plane via a bearing angle value
130. initial Irregular Profile screen is complete the rest of the profile is programmed using A G E Mill and A G E Arc events Programming with the Auto Geometry Engine is explained in Section 10 9 9 Helix Events Advanced Features Option The Helix Event is found after you press the MORE softkey from the Select Event screen It allows you to machine in a circular path in the XY plane while you simultaneously move the Z axis linearly Press the HELIX soft key X Center is the X dimension to the center of rotation of the helix Y Center is the Y dimension to the center of rotation of the helix Z Rapid is the Z dimension to transition from rapid to feed Z Begin is the Z dimension to the beginning of the helix Z End is the Z dimension at the end of the helix Radius is the radius from the center of rotation to the helix Angle is the angle from the positive X axis that is 3 o clock to the starting position of the helix Rev is the number of revolutions in the helix for example 0 75 would be 270 degrees or 3 25 would be three times around plus 90 degrees Direction is the clockwise input 1 or counterclockwise input 2 direction of the helix Tool Offset is the selection of the tool offset to right input 1 offset to left input 2 or tool center no offset input 0 relative to the programmed edge and direction of the cutter movement RPM is the spindle RPM for the event INC SET will use the RPM of
131. ion FIGURE 5 7 1 Examples of tool right 42 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Tool center means no compensation either right or left That is the centerline of the tool will be moved to the programmed points 5 8 Tool Diameter Compensation when Contouring in Z with Part Geometry Note Z contouring requires the Advanced Features Option Section 3 1 2 Left and right tool diameter offsets are always those projected into the XY plane Tool offsets in the Z direction are always up and assume the use of a ball end mill When contouring in the Z axis this up tool offset is always activated regardless of left right center if the Part Geometry option is selected There is no Z axis up tool offset applied when the Tool Path option is selected Special atte ntion must always be paid to tool offsets when machining with a ball end mill The reason for this is that the tool diameter changes in the bottom part that portion equal to the tool radius of the tool The tool is always positioned at the beginning of a milling operation so that the correct point on the ball end of the tool is tangent to the beginning point and offset perpen dicular to the machined edge by the radius of the tool Consider the example below of milling a ramp in the XZ plane from point B to point C FIGURE 5 8 1 Ball end mill position with respect to program points Tool starts
132. ion in the Program Header screen and then program the features of the part by selecting the soft key event types geometry and then follow all instructions in the Data Input Line When an event is selected all the prompts that need to be input will be shown on the right side of the screen The first prompt will be highlighted and also shown in the Data Input Line Input the dimension or data requested and press INC SET or ABS SET For X or Y dimension data it is very important to properly select INC SET or ABS SET For all other data either SET will do As data is being entered it will show in the Data Input Line When SET the data will be transferred to the list of prompts in the right side of the screen and the next prompt will be shown in the Data Input Line When all data for an event has been entered the entire event will be shifted to the left side of the screen and the conversation line will ask you to select the next event 7 2 Enter Program Mode Press MODE select PROGRAM soft key The ProtoTRAK SMX CNC will allow only one program in current memory To write a new program you must first erase the one in current memory you may want to first store the program for use in the future If there is already a program in current memory entering the Program mode will allow you to edit or add to that program FIGURE 7 2 The Program Mode header screen Most selections above relate to the Advanced Features Option If your screen shows
133. it Mode See Section 10 3 To remove a program file from a storage location press the DELETE softkey from the Program In Out Mode screen Use the navigation procedure described in Section 15 2 above and highlight the program file or folder you wish to delete Press the DELETE FILE or DELETE FOLDER softkey A warning message will appear for confirmation Additional Softkeys in DELETE DELETE FILE Press this to delete a file DELETE FOLDER Press this to delete a folder 132 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Softkeys that appear with the confirmation message YES Press this if you want to delete NO Press this if you do not want to delete The delete operation will be aborted and the previous softkey selections will return When the delete operation is finished the file or folder name will disappear from the listing area 15 7 Renaming To rename either a file or a folder press the RENAME softkey from the Program In Out Mode screen To rename a file or folder 1 Use the navigation procedure described in Section 15 2 above and highlight the program file or folder you wish to rename 2 TAB to the New Name area and enter a new name Use the same procedure as for naming a program see Section 7 3 1 3 TAB to the New Extension and enter a new extension 4 Press either RENAME FILE or RENAME FOLDER Additional parts of
134. l Sets finish cut for the wall of the pocket Sets the ramp feedrate in mmpm Sets the pocket cutting feedrate Sets the finish pocket feedrate Sets mill tool EVENT 4 RECTANGULAR PROFILE NOTES select PROFILE and then IRREG PROFILE X1 Y1 X3 Y3 Z RAPID Z END CONRAD DIRECTION TOOL OFFSET PASSES FIN CUT Z FEEDRATE XYZ FEEDRATE FIN FEEDRATE TOOL 50 ABS SET 50 ABS SET 50 ABS SET 50 ABS SET 3 ABS SET 7 5 ABS SET 0 SET 1 SET 2 SET 2 SET 25 SET 100 SET 250 SET INC SET 3 SET Start at lower left corner Through the p late Sets tool offset LEFT Machined at 2 depths No change of feedrate This is the end of the program 156 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 16 2 Sample Program No 2 2 Axis Profile with Limited Print Data This program is designed to provide practice with the ProtoTRAK SMX A G E programming system that is part of the Advanced Features Option A basic rule of thumb for A G E programming When you have unknown tangent elements you may skip data When you have unknown non tangent elements you use the Guess feature The Program All programs start by first selecting Program from the front panel softkeys You may enter in an alphanumeric program description or simply press Go to Begin to get started Be certain to start your program by selecting Profile EVENT
135. l always show 2 Axis 124 XYZ Machine Tools Ltd TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual The current measurement system inch or mm Look In box For the basic system the Look In box will always show drive A the floppy drive of the ProtoTRAK SMX Information area The large white area in the middle of the screen displays a list of the programs on the floppy File Name When you enter the Program In Out Mode this will be the name of the file in current memory If there was no program in current memory the first program name on the list will appear there When you select another file from the list the name will appear here Open Save As This is the file type See Section 15 0 for an explanation of Filenames and File Extensions Blue This indicates that the alphabet matrix is available for entering file names The Softkeys will be explained in the sections below 14 3 Basic Navigation Use the first five softkeys to move about the screen Tab moves the highlight from section to section on the screen Data Fwd moves the highlight forward through a list such as the list of programs in figure 14 1 Data Back moves highlight backward through a list Page Fwd if your list of programs is too large to fit on the screen this will move forward through the pages of the list Page Back moves backwards through the pages of the list 14 4
136. l and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 12 1 4 Starting Over Erasing Tool Information There will be times when you don t completely trust the information that is in the tool table For example perhaps you have loaded in a program that you wrote a month ago and you recall that one of the tools you used was held in a chuck In that case you probably want to erase the table and start over In order to do this simply press the ERASE TABLE softkey and answer yes to the prompt All the data in the tool table will be erased including the reference The numbers of the tools used in any program in current memory will still be red 12 1 5 Adding a Tool When the reference is SET and the original touch off surface is still available you can add a tool very easily 1 First make the tool number active by using it in the program in current memory 2 Put the new tool in the spindle 3 Go to the Set Up Mode tool table 4 Enter the diameter 5 Touch the new tool to the same surface as the reference 6 Press SET If the surface is not available it will be necessary to establish a new reference before adding the new tool See Section 12 1 8 below Once the reference is reset use the procedure above on the new surface used to set the reference 12 1 6 Replacing a Tool If you need to replace a tool that was not used as the reference simply do the following 1 Put the replacement to
137. lar island An island is a shape that is left standing when the surrounding material is removed The ProtoTRAK give s you the ability to machine almost any shape as an island within a rectangular pocket Both the shape of the island and the dimension of the surrounding pocket are defined within the island event The tool path for machining the island event is that the tool will machine the perimeter of the island offset by the island finish cut Then the tool will machine the material in the pocket in a spiral path moving away from the island in the programmed clockwise or counterclockwise direction It will continue this outward spiral motion until it encounters the programmed rectangular perimeter or pocket It will then follow the perimeter offset by the pocket finish cut 8 6 1 Circular Island Advanced Features Option When the Advanced Features Option is active press the Circle Island soft key if you wish to mill a circular island Prompts for the Circular Islands X CENTER is the X dimension of the center of the Island 65 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Y CENTER is the Y dimension of the center of the Island RADIUS is the finish radius of the Island DIRECTION is the milling direction clockwise or counterclockwise FIN CUT ISL Finish cut for the Island If 0 is input there will be no finish cut X1 POCKET X dimension
138. lar or rectangular frame or an irregular profile The irregular profile may be closed or open When the irregular profile event is started the ProtoTRAK SMX CNC will automatically initiate the powerful Auto Geometry Engine See Section 10 0 for programming with A G E 8 7 1 Circle Profile Press the CIRCLE soft key if you wish to mill a circular frame Prompts in the Circle Profile event X Center is the X dimension to the center of the circle Y Center is the Y dimension to the center of the circle 67 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Radius is the finish radius of the circle Direction is the clockwise input 1 or counterclockwise input 2 direction for milling Tool Offset is the selection of the tool offset to the right input 1 offset to the left input 2 or tool center no offset input 0 relative to the programmed edge and direction of the cutter movement Fin Cut is the width of the finish cut If 0 is input there will be no finish cut Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 up to 3800 for model SLV Finish Feedrate is the milling feedrate for the finish cut Tool is the tool number you assign 8 7 2 Rectangular Profile Press the RECTANGLE soft key if you wish to mill a rectangular frame all corners are 90o right angles Prompts for the rectangular pr
139. matrix screen Industrial grade Intel processor 256 Mb Ram P S 2 Keyboard connector 2 USB connectors Override of program feedrate LED status lights built into display TEAC floppy drive Software Features General Operation Clear uncluttered screen display Prompted data inputs English language no codes Soft keys change within context Windows operating system Selectable two or three axis CNC three axis CNC models Color graphics with adjustable views Inch mm selectable Convenient modes of operation DRO Mode Features for Manual Machining Incremental and absolute dimensions Jog at rapid with override Powerfeed X Y or Z for three axis CNC models Do One CNC canned cycle Teach in of manual moves Servo return to 0 absolute Tool offsets from library Z Go To three axis CNC models only Program Mode Features Geometry based programming Incremental and absolute dimensions Automatic diameter cutter comp Circular interpolation Linear interpolation Look graphics with a single button push List step graphics with programmed events displayed Alphanumeric program names Program data editing Canned cycles o Position o Drill o Bolt Hole o Mill o Arc 14 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Opera
140. meric filenames when storing a file on a ProtoTRAK SMX CNC that will be retrieved by previous ProtoTRAK and TRAK CNC s Before conversion you can easily rename the file in the ProtoTRAK SMX CNC current memory 15 10 1 File Formats The ProtoTRAK SMX CNC can store and retrieve the following ProtoTRAK and TRAK CNC file formats Previous ProtoTRAK and TRAK CNC file formats ProtoTRAK M2 mx2 ProtoTRAK MX2 mx2 ProtoTRAK MX2E mx2 TRAK AGE2 mx2 ProtoTRAK EDGE mx2 ProtoTRAK M3 mx3 ProtoTRAK MX3 mx3 ProtoTRAK MX3E mx3 TRAK AGE3 mx3 TRAK QMV mx3 15 10 2 Opening MX2 and MX3 Files on a ProtoTRAK SMX CNC Programs written on previous generation ProtoTRAK and TRAK CNC s may be opened and run on the ProtoTRAK SMX CNC You will need to have the MX2 or MX3 converters activated see Section 15 9 above The ProtoTRAK SMX CNC will automatically convert the file MX2 or MX3 to a PT4 file The original file will remain on the storage device unchanged and the converted file will be in current memory You will have to save the converted file using the procedure in Section 15 4 above in order to place in into storage Note that previous generation ProtoTRAK and TRAK CNCs had a 3 and 4 sided pocket canned cycle This event type will be recognized and run by the SMX CNC but converted into a Irregular Profile event 15 10 3 Running ProtoTRAK SMX Files on ProtoTRAK and TRAK CNC Controls In order to have a program written
141. n the line N01G0X1 Y2 N G X and Y are addresses The other information 01 1 and 2 are Data Words The line starts with the Address N and the data word 01 The N address is defined as meaning LINE NUMBER therefore N01 means Line 1 and so on X Y Z Dimensions along the specified axis I J K Distance to arc center I X J Y K Z M Miscellaneous Functions G Preparatory Function H Tool Length Offset Selector silently ignored N Line Number silently ignored T Tool Number F Feedrate P Dwell time for drill bore canned cycles L Repetition count for drill bore canned cycles Q Depth of cut for drill bore canned cycles R Reference point for drill bore canned cycles S Spindle Speed 150 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 15 13 4 Format Terms and Definitions Number formats A preparatory function number denoted lt prep func gt 1 format dd 2 leading 0 suppression 3 range 0 to 99 B sequence or line number denoted lt seq number gt 1 format independent of units dddd 2 leading 0 suppression 3 range 1 to 9999 C Unsigned coordinate word denoted lt coord gt 1 format metric ddddd ddd inch dddd dddd 2 the sign is implied and therefore may be omitted 3 leading 0 suppression 4 if no decimal point is given the supplied number will be interpre
142. nd is on the left side Select an event type from the soft keys Three axis CNC events are shown 56 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual When the MORE soft key is selected the soft keys change to After an event type is selected from the soft keys the prompts for that event will appear on the right side of the screen The data you need to enter to program the event will appear in the Data Input Line As soon as you enter one piece of data by pressing the INC SET or ABS SET key the next prompt will appear in the Data Input Line 7 10 Editing Data While Programming While programming an event all data is entered by pressing the appropriate numeric keys and pressing INC SET or ABS SET If you enter an incorrect number before you press INC SET or ABS SET you may clear the number by pressing RSTR Restore Then input the correct number and press SET If incorrect data has been entered and SET you may correct it as long as you are still programming that same event Press the DATA BACK or DATA FWD Forward soft key until the incorrect prompt and data are highlighted and shown in the conversation line Enter the correct number and SET The ProtoTRAK SMX CNC will not allow you to skip past prompts by pressing DATA FWD which need to be entered to complete an event except when using the A G E in the Irregular Pocket or Irregular Profile event Previous ev
143. nd no appear when the Dwell Request Auxiliary Function Request and the Event Comments are highlighted Choosing Yes will give you prompts for using these options while you are programming You may return to the Program Header Screen at any time to choose or cancel these prompts PART GEO sets up the programming as Part Geometry TOOL PATH sets up the programming as Tool Path This function is part of the Advanced Features Option 7 4 Auxiliary AUX Functions Three Axis CNC Models Only When the Auxiliary Function Option is installed and active the ProtoTRAK SMX CNC can control four different auxiliary functions You can select whether to activate or deactivate these functions at the beginning or end of each event If Auxiliary Functions are selected on the program header the system will prompt for AUX BEG and AUX END in each event When running programs with Auxiliary functions the ACCESSORY hard key on the front panel must be in the correct position If you want the program to automatically turn the Auxiliary functions on and off press the ACCESSORY key until the light is on in the AUTO position 53 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual AUX BEG options Input Function Comments 0 None No Auxiliary functions will begin when this event begins to run 1 Coolant Air The coolant pump or air solenoid will be turned on when this event begin
144. ne Software but must be purchased separately for each ProtoTRAK SMX CNC It is easy to tell if you have the Advanced Features Option If you have the Advanced Features Option the features listed below will be active If you do not the features listed below will not be active and any Softkey for that feature will be grayed out For example in the Program Mode under Pocket check the Softkey labeled IRREG PCKT If the words IRREG PCKT are black the Advanced Feature Option is active If they are gray the Advanced Feature Option is not active The other way to tell if the Advanced Features Option is active is to go to Service Code 318 The Advanced Features Option is active if the letters are in black inactive if they are in gray With the Advanced Features Option you get the following Auto Geometry Engine see Section 9 0 3 axis conversational programming three axis CNC models Additional Canned Cycles Irregular Pocket 8 6 3 Circle Island 8 7 1 15 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Rectangular Island 8 7 2 Irregular Island 8 7 3 Irregular Profile 8 8 3 Helix three axis CNC models 8 9 Thread milling three axis CNC models 8 12 Engrave 8 14 Tapping 8 15 G Code editor Countdown clock to next pause or tool change Total program time estimator Spreadsheet editing Global data change Scaling o
145. ned the tool information is put into the tool table This information will replace any information that already is in the tool table for the same tool numbers In addition to information about the tools used in a program you may load in information for tools to be used in 2 axis CNC or in the DRO mode for machining manually When you tell the ProtoTRAK SMX CNC which tool you are using it will adjust the Z DRO dimensions accordingly so you don t have to touch off and reset after a tool change The idea of retaining tool information in memory in order to reduce the amount of set up needed requires that care be taken to avoid mistakes Milling work usually requires a lot of 109 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual tools many of which are not preset into fixed tool holders That means tool information that is not very recent is probably no good Think of the information in the tool table this way if you clearly remember setting the tools and entering the diameters very recently then use the tool table in DRO and CNC run If you can t remember setting the tools clearly erase the table and start over it only takes a moment This may cause some confusion because the normal sequence for running a two axis program is to load in a tool touch it off and set zero then press GO The ProtoTRAK SMX CNC will apply the tool offset after the GO press making the Z
146. nformation that applies to the entire profile X Begin is the X dimension of the beginning of the profile Y Begin is the Y dimension of the beginning of the prof ile Z Rapid is the Z dimension to transition from rapid to feed Z End is the Z dimension of the depth of the profile Tool Offset is the selection of the tool offset to right input 1 offset to left input 2 or tool center no offset input 0 relative to the programmed edge and direction of tool cutter movement Passes is the number of cycles to machine to the final depth spaced equally from Z rapid to Z end hint keep Z Rapid small Z Feedrate is the Z feedrate from Z rapid to Z end 85 XYZ Machine Tools Ltd XYZ Machine Tools Ltd and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual XYZ Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Fin Cut is the width of the finish cut If 0 is input there will be no finish cut RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is active FIN RPM is the spindle RPM for the finish cut FIN RPM programming is available only if the Programmable Electronic Head Option is active Fin Feedrate is the finish cut milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Tool is the tool number you assign When the
147. ng GO e The feedrate is automatically set to 254 mm per min or 10 ipm Press FEED or FEED to adjust the feedrate from 254 to 2540 mmpm or 1 ipm to 100 ipm f Press STOP to halt power feed Press GO to resume g Repeat the process beginning at c above as often as you wish h Press RETURN soft key to return to manual DRO operation 6 5 Do One The Do One routines in the DRO mode allow you to do one CNC operation while machining manually without having to write a program The programming and tool path of the events in Do One are nearly identical to those in the Program Mode See Section 8 for instructions for programming 47 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Safety Programming Operating amp Care Manual 6 6 Go To TRAKing Electronic Handwheels Option The Go To function in the DRO mode allows you to set a dimension in X Y or Z at which you want the machine to stop moving when you are cranking manually For example if you wanted to machine manually exactly 5omm of table motion you would input Go To X 50 Inc Set While the Go To window is displayed the ProtoTRAK SMX will not let you pass that 50mm dimension you set a Press the Go To key b Enter the axis X Y Z or any combination Input the dimension s c Press Inc Set or Abs Set d Crank the handwheel Motion will stop at the entered dimension even if you continue to crank the handwheel 6 6 1 Go To for Three A
148. ng a program see Section 7 3 1 SAVE FILE Saves the program file to the location shown in the Look In area RETURN Returns to the Program In Out Mode screen Once the save operation is finished you will see the file name added to the files in the listing area 131 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 15 5 Copying Programs To copy a program file from one storage location to another press the COPY softkey from the Program In Out Mode screen Only one file may be copied at a time using this operation To copy multiple files or folders see Section 15 8 FIGURE 15 5 The Copy screen The copy operation is in two parts First use the navigation procedure described in Section 15 2 above and highlight the program you wish to copy Press the COPY FILE softkey to copy the file Then go to the new file or drive open it using the Open Folder softkey and press PASTE FILE Once the file has been copied it can be pasted to as many other locations as you want Additional softkeys in COPY COPY FILE Makes a copy of the highlighted file PASTE FILE Writes a copy of the file to the location shown in the Look In box RETURN Returns to the Program In Out Mode screen When the pasting operation is finished you will see the file name added to the listing area 15 6 Deleting Programs Programs in current memory are removed from current memory in Ed
149. ngle shared folder on the network enables you to have a single location with all the latest versions of the programs Of course the above functions are possible without a network by shuttling floppy disks around The reason to have a network is that it saves time Once it is se t up you can do repetitive functions without much work For example if a particular job requires you to run a CAM file that you don t have on the ProtoTRAK SMX already going to the pre arranged networked location using the Program In Out of the SMX gets you going right away Without networking someone has to make you a disk with the file on it Another example is program file back ups With networking you can back up with a simple routine in the Program In Out Mode Without networking you must have a good system for managing floppy disks including labeling storage and retrieving program files You are more likely to do regular back ups if the process is easier Networking can be tricky If you do not have experience setting up a network be warned Computer companies haven t done for networks what we have done for CNCs Getting everything to work properly can require hours of troubleshooting even for experts There are instructions below to guide you through the most basic case of establish ing a peer to peer network Beyond that you should consult a qualified Network Administrator 15 12 1 Assigning a Name and Selecting a Workgroup No matter what kind of netw
150. ngrave Event the ProtoTRAK will construct a box to contain the text you define This box is oriented along the X axis like the text in this sentence and you may program up to 40 characters per event although you will only be able to see 20 characters on the prompts screen To machine text in a direction other than the X axis simply use multiple Engrave Events and place the lower left corner of the box wherever you would like The numbers and letters you program will always have a standard orientation like the letters on this page you cannot program tilted or inverted letters with the Engrave Event The letters are of the font shown in the figure and all capitals Prompts for the Engrave Event First define the lower left corner of the box that will contain your text X BEGIN The X coordinate of where you want your text to begin Y BEGIN The Y coordinate of where you want your text to begin HEIGHT The height of your text Each character varies in width the set height of the character will change the width in order to keep the overall size of the character proportional TEXT The text to be milled When you get to this prompt the Alpha keys will automatically pop up to allow you to enter the text Once you have finished entering text you must press End F8 and then any of the SET keys to successfully enter your text into the event The alpha keys will appear automatically if the text field is blank If you have already entered te
151. ns A is rotated 3 times to produce shape B C and D Press the SUBROUTINE SUB soft key to call up the Repeat Mirror and Rotate options 8 9 1 Repeat Press the REPEAT soft key Where First Event is the event number of the first event to be repeated Last Event is the event numbe r of the last event to be repeated if only one event is to be repeated the Last Event is the same as the First Event X Offset is the incremental X offset from event to be repeated Y Offset is the incremental Y offset from event to be repeated Repeats is the number of times events are to be repeated up to 99 Feed the percentage of the feeds programmed in the repeated events 100 is assumed Tool is the tool number you assign 8 9 2 Mirror Press the M IRROR soft key First Event is the event number of the first event to be mirrored Last Event is the event number of the last event to be mirrored if only one event is to be mirrored the last event is the same as the first Cutting Order input 1 to cut from the lowest mirrored event to the highest forward and 2 to machine from the highest mirrored event to the lowest backward This way you can keep all the machine motion in a consistent direction as it moves from the original shape to the mirrored shape and keep all cuttin g either climb or conventional Mirror Axis is the selection of the axis or axes to be mirrored input X or Y or XY SET 71
152. nt Position X Y and Z programmed Drill X Y Z RAPID and Z END programmed Bolt Hole X CENTER Y CENTER Z RAPID and Z END programmed Mill X END Y END Z RAPID and Z END programmed Arc X END Y END Z RAPID and Z END programmed Circle POCKET or FRAME X CENTER Y CENTER Z RAPID and Z END programmed Rectangle or Irregular POCKET or PROFILE X1 and Y1 corner Z RAPID and Z END programmed Helix The X END Y END Z RAPID and Z END programmed Helix programming requires the Advanced Features Option Sub The reference position as defined for the specific events above for the event prior to the first event that was repeated A G E PROFILE The appropriate reference position as defined for the specificevents above for the last event that is programmed A G E Profile Programming requires the Advanced Features Option For example if an ARC event followed a MILL event a 50mm incremental X BEG would mean that in the X direction the beginning of the ARC event is 50mm from the end of the MILL event 5 7 Tool Diameter Compensation Tool diameter compensation allows the machined edges shown directly on the print to be programmed instead of the center of the tool The ProtoTRAK SMX CNC then automatically compensates for the programmed geometry so that the desired results are obtained Tool cutter compensation is always specified as the tool either right or left of the workpiece while looking in the direction of the tool mot
153. ny of the data displayed See Section 11 2 2 CHANGE ALL enables you to make global changes of data See 11 2 3 11 2 1 Selecting Data to be Displayed on the Search Edit Table In order to change the data selected in the table press the HELP hard key There will be a listing of all the data types that may be edited in Search Edit Press the RETURN soft key and the table will be reloaded with the data that you selected FIGURE 11 2 2 Pressing Help while viewing the spreadsheet lets you change the program parameters After you press the HELP hard key the screen will display all the different parameters that can be displayed on the spreadsheet To either select or deselect any parameter simply highlight that parameter and press SET When you are finished press the Return softkey and return to the spreadsheet 11 2 2 Sorting Data Data may be sorted by any of the data types displayed in the column head Red letters show which column is used for sorting the data To change the sort press the SORT softkey then select the type of data you want to use for sorting from the softkeys The table will be changed to sort the data in ascending order the smallest value first the largest last 101 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 11 2 3 Making Global Changes to Data Sometimes it is useful to be able to change data in a program without having to go
154. o use the alpha keys and special characters on the ProtoTRAK SMX CNC Use the Clear softkey to erase the entire line the Backspace softkey to erase the last character or number Use the arrow softkeys to move around the table 51 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Once the character you want is highlighted use the Enter softkey to load the character into the program name Use the blank space on the lower right of the table to insert a space into the program name Once you finish entering the letters and special characters press the End softkey This tells the ProtoTRAK SMX CNC that you are finished with the alpha table Numbers may still be added to the program name When you are finished with the program name press SET to enter it into the current memory Note It is not necessary to enter a part number If none is entered and a GO TO soft key is pushed the system will assume a part number 0 7 3 2 General Program Options Use the DATA FWD softkey to select general programming options See Section 3 1 2 for more information about the Advanced Features Option Scale Allows a scale factor between 1 and 10 An input of 5 means the part will be 5 times as big as the programmed dimensions A value of 1 0000 is assumed if nothing is input This function is part of the Advanced Features Option Dwell Request For three axis C
155. oating point format Data is automatically unless key is pressed All input data is automatically rounded to the system s resolution MODE to change from one mode of operation to another SYS To shut down the ProtoTRAK SMX CNC change from 2 axis to 3 axis or 3 axis to 2 axis operation and other functions reinstates a window eliminates a window HELP displays help information math help or additional functions Active for additional functions when the help symbol a blue question mark is displayed on the screen next to the HELP key Soft Keys Beneath the display are 8 keys that are labeled with arrows These keys are called software programmable or soft keys A description of the function or use of each of these keys will be shown at the bottom of the display directly above each key If at any time there is no description above a key that key will not operate Sometimes the description or function of the key is visible but grayed out This indicates that the particular function is not available because of some other condition For example if there is no program in the current memory the EDIT Mode softkey will be grayed out because there is no program to edit Emergency Stop Switch The emergency stop E stop switch kills all power to the spindle and ProtoTRAK s servomotors The computer and pendant remain powered If the Emergency Stop switch is pushed it will be necessary to press the Reset Button on the right side
156. of the holes Angle is the angle from the positive X axes that is 3 o clock to any hole positive angle is measured counterclockwise from 0 000 to 359 999 degrees negative angles measured clockwise Pitch is the pitch of the tap that is used if the Tap option is chosen Tap is available only if the Programmable Electronic Head Option is active PECKS is the number of tool withdrawal cycles Each cycle drills and then retracts to the Z rapid position The factory setting is for each peck to be successively smaller taking the largest cuts at the beginning and the smallest at the end Variable You may change this to equal pecks To do this press the HELP key when the highlight is on this prompt This will take you to a screen where you may choose to have the same amount of material taken per peck Fixed You can also choose Chip Break where the tool will perform fixed pecks but only rapid out about 0 5mm after each peck instead of going back to the Z rapid position after every peck This new setting will remain until you change it again RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is active Z Feedrate is the drilling feedrate Tool is the tool number you assign 9 4 MILL Events This event allows you to mill in a straight line from any one XYZ point to another including at a diagonal in space It may
157. of the pendant see Section 3 2 3 below to reenergize the relay The Liquid Crystal Display LCD 20 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual The display of the ProtoTRAK SMX CNC is a 10 4 active matrix color LCD The very top is the Status Line that shows the overall status of the ProtoT RAK SMX CNC This includes the current Mode the current program part number the current tool number 2 or 3 axis mode and whether the X Y and Z dimensions are in inch or millimeter mm Just above the soft keys is a data input line that appears when an input is required 21 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 3 2 2 Pendant Left Side See Figure 3 2 2 FIGURE 3 2 2 The ProtoTRAK SMX CNC left side with connectors labeled 22 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 3 2 3 Pendant Right Side See Figure 3 2 3 Keyboard P S2 port This port is for the keyboard only If this port is used the connection must be made before the ProtoTRAK is turned on If the ProtoTRAK is already on it will not recognize the keyboard until it is rebooted with the keyboard plugged in You may also plug the keyboard into one of the USB ports USB Ports The USB ports are the only ports available for plugging
158. ofile X1 is the X dimension to any corner Y1 is the Y dimension to the same corner as X1 X3 is the X dimension to the corner opposite X1 incremental is from X1 Y3 is the Y dimension to the same corner as X3 incremental is from Y1 Conrad is the value of the tangential radius in each corner Direction is the clockwise input 1 or counterclockwise input 2 direction for milling Tool Offset is the selection of the tool offset to the right input 1 offset to the left input 2 or tool center no offset input 0 relative to the programmed edge and direction of the cutter movement Fin Cut is the width of the finish cut If 0 is input there will be no finish cut Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 up to 3800 for model SLV Fin Feedrate is the milling feedrate for the finish cut if programmed Tool is the tool number you assign 8 7 3 Irregular Profile Advanced Features Option When the Advanced Features Option is active press the IRREG PROFILE soft key if you wish to mill a profile other than a rectangle or circle The Irregular Profile event gives you the powerful Auto Geometry Engine to define a shape made up of straight lines Mills and arcs The Irregular Profile is a series of events that are programmed to machine continuously The first event of the series will be called an IRR PROFILE and it will define the beginning point of the profile and
159. ogram feed Z BEGIN the Z dimension where the threading pass begins Z END the Z bottom of the thread PITCH the distance from one thread to the next in inches or mm It is equal to one divided by the number of threads per mm or inch For example the pitch for a M5 x 1mm screw is 1 mm For Imperial units it is equal to one divided by the number of threads per inch For example the pitch for a 1 4 20 screw is 1 divided by 20 0 05 MAJOR DIA the largest diameter of the thread the root for an ID thread the crest for an OD thread MINOR DIA the smallest diameter of the thread the root for an OD thread the crest for an ID thread SIDE input 1 for inside 2 for outside ANGLE the angle the tool feeds into the beginning depth DIRECTION clockwise or counterclockwise PASSES the number of passes to cut the thread to its final depth Z FEEDRATE The feedrate from Z Rapid to Z Begin XYZ FEEDRATE The feedrate of XYZ along the path of the helix FIN CUT width of the finish cut If 0 is input there is no finish cut If something other than 0 is input for finish cut the following prompt appears FIN FEEDRATE the milling feedrate for the finish cut 90 XYZ Machine Tools Ltd XYZ Machine Tools Ltd and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available
160. ogram on the screen LIST STEP displays the list of events on the left side of the screen and with a purple highlight on the first event As LIST STEP is pushed the highlight shifts to the next event As this happens that event is also highlighted in the graphics by having its color change to purple START EVENT NUMBER will prompt you to enter an event number for highlighting This is useful for moving quickly to a particular event in a large program XY displays a view in the XY plane YZ displays a view in the YZ plane XZ displays a view in the XZ plane 3D displays an isometric view Softkeys in Adjust view FIT DRAW automatically resizes the drawing to fit the entire part program on the screen 6 shifts drawing down 5 shifts drawing up 3 shifts drawing to the left 4 shifts drawing to the right ZOOM IN makes the drawing larger ZOOM OUT makes the drawing smaller RETURN returns you to the first LOOK screen The adjustments you made will stay on the screen until you press another selection that overrides those adjustments The LIST STEP function may be used with the adjustment unaltered Note The LOOK routine does not check for programming errors Use Tool Path in the SET UP Mode to check movement of the tool 7 12 Finish Cuts The Pocket and Profile events are designed with built in finish cut routines because they are complete and stand alone pieces of geometry Shapes machined with a series o
161. ok In box is reached 15 3 Opening a File To open a program file from a storage location press the OPEN softkey from the Program In Out Mode screen The ProtoTRAK SMX CNC will always default to the last folder you had open Find the file using the softkeys as described above in the section on basic navigation When a program file name is highlighted press the LOOK hard key to see a graphical representation of the part program The graphics are not a precise representation of the tool path but should be very handy in helping to identify a file before opening In addition to the basic parts of the screen described above two additional parts of the screen appear in the open operation File Name Displays the name of the file that is highlighted from the list Open As lists the format s for which the file may be opened The default is ProtoTRAK4 Two additional softkeys appear OPEN FILE Opens the highlighted program file and puts it in current memory Only one file may be in current memory at a time if one is there already a warning message will appear before that file is overwritten RETURN Returns to the Program In Out Mode screen When the open operation is finished the system will return to the Select Mode screen 15 3 1 Preview Graphics As an aid to finding the file you want to open the ProtoTRAK SMX allows you to look at the part graphics before opening Simply select the file and press the LOOK hardkey The
162. ol is the tool number you assign Continue input 1 for Yes if you want to mill continuously from this line to the next event input 2 for No if you want the ProtoTRAK SMX to stop at the end of the event 8 5 POCKET Event This event selection gives you a choice between circle pocket rectangular pocket and irregular pocket Pockets include machining the circumference as well as all the material inside the circumference of the programmed shape If a finished cut is programmed it will be made at the completion of the final pass The cutter will arc in and arc out of the finish cut and position itself the finish cut dimension away from the part before moving the tool out of the part The factory setting for tool stepover while machining a pocket is 70 This may be changed When you first enter the pocket event the blue will appear next to the help key Pressing Help will give you the choice of entering a new tool stepover percentage The value you enter here will remain the same until you change it again 63 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 8 5 1 Circular Pocket Press the CIRCLE PCKT soft key if you wish to mill a circular pocket Prompts for the circle pocket X Center is the X dimension to the center of the circle Y Center is the Y dimension to the center of the circle Radius is the finish radius of the circle Direction is th
163. ol in the spindle 2 Put the highlight in the correct row for the tool number 3 Reenter the diameter if different 4 Touch the tool to the same surface that was used to touch off the reference 5 With the highlight in the Z OFFSET column for the correct tool number press SET If you need to replace a tool that was used as a reference we recommend that you press the ERASE TABLE softkey and start all over again Not to nag but that is why it is a good idea to have a separate reference setting tool and use a constant reference surface If you work with programs that use a lot of tools this practice can really save time 12 1 7 Z Modifiers Z modifiers make it easy to adjust the depth of cut of particular tools without having to change programmed Z end dimensions or change the tool offsets For example say an end mill was under cutting the depth of a part by 01mm An easy way to correct this is to enter a Z modifier 1 Highlight the number in the Z MODIFIER column in the row for the correct tool 2 Enter the amount of the adjustment you wish to make To cut deeper enter a negative number To cut shallower enter a positive number In the example above to correct this undercut we would enter 01mm 3 Press SET The ProtoTRAK SMX CNC will apply this modifier each time this tool is used 111 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care M
164. olute reference from which all absolute dimensions are measured in DRO and program operation can be set at any point on or even off the workpiece To help understand the difference between absolute and incremental position consider the following example FIGURE 5 4 Each point has both an absolute and an incremental reference in the X axis The ProtoTRAK SMX CNC allows you to program using either 5 5 Referenced amp Non Referenced Data Data is always loaded into the ProtoTRAK SMX CNC by using the INC SET or ABS SET key X Y Z positions are referenced data In entering any X Y or Z position data you must note whether it is an incremental or absolute dimension and enter it accordingly All other information non referenced data such as tool diameter feedrate etc is not a position and may therefore be loaded with either the INC SET or ABS SET key This manual uses the term SET when either INC SET or ABS SET may be used interchangeably 5 6 Incremental Reference Position in Programming FIGURE 5 3 Vertical Planes 41 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual When X Y Z RAPID and Z data for the beginning position of any event are input as incremental data this increment must be measured from some known point in the previous event Following are the positions for each event type from which the incremental moves are made in the subsequent eve
165. olution 122 XYZ Machine Tools Ltd XYZ Turret Mill andProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 123 XYZ Machine Tools Ltd TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual i01149 14 0 Basic Program In Out Mode This section is written for the user who wants the most basic capability for storing and retrieving ProtoTRAK programs on his ProtoTRAK SMX CNC It assumes that the Networking Memory Option is either not installed or has been turned off at the screen accessed by Service Code 334 If you are interested in using the more advanced file storage and networking capability of the ProtoTRAK SMX CNC skip this section and go to Section 15 0 14 1 Entering the Program In Out Mode From the Select Mode screen press the PROG IN OUT softkey The following screen will appear Figure 14 1 The Basic Program In Out screen When you enter the Program In Out mode the ProtoTRAK SMX will display the content of the floppy in the floppy drive 14 2 What Is On The Screen Status Line On the Status Line at the top of the screen are the following items The current mode Program In Out The program or part number for the program that is in current memory see Section 5 11 for a definition of Current Memory The current active Tool not really useful at this point The current state of the CNC two axis or three axis two axis models wil
166. one solution to the problem this will display the alternative solutions Edit this allows you to go back to the data you entered in order to make changes Once you do this the Resolve key will appear Resolve press this to have the Math Help use the new data to give new solutions 4 1 7 Windows Up or Down Some of the selections in the ProtoTRAK SMX CNC will cause a window to appear with a message To eliminate the window in order to see what is behind it press the u hard key To restore the window press the t hard key 4 1 8 Turning Options On and Off If the Advanced Features Option and Networking Memory Options have been installed you may run the ProtoTRAK SMX with them turned off This has the benefit of making the system easier to use To turn the options on or off press the SYS hard key You will get the screen shown in Figure 4 1 4 above Press the Options On Off softkey This will take you directly to the screen that will allow you to turn options on and off You can also get to this screen using Service Code 334 FIGURE 4 1 6 2 Math Help 28 In this example by entering the length of line A and the value of angle G the other values are calculated 33 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Safety Programming Operating amp Care Manual The Programmable E Head Option and TRAKing Electronic Handwheel Option may not be turned on or off If they are installed they must remain active 4
167. ong the X or Y axis depends on if there are hidden areas of the pocket The ProtoTRAK SMX CNC always looks to cut along the X axis first If there are areas that are hidden to the X axis it will machine along the Y axis If there are hidden areas that cannot be machined continuously in the X or Y axis the tool will return to Z retract and then reposition to machine the hidden area 9 6 5 Zigzag Z Depth Cuts In programming pocket events you have a choice to program the cuts to Z depth either as a plunge or a zigzag ramp For rectangular and circular pockets the tool will start in the center of the pocket For irregular pockets since there is no center defined the tool will start in the lower left corner of the pocket The direction of the ramp will be the same as the initial direction in either X or Y depending on how the pocket is to be cut The tool will zigzag back and forth along the X or Y over a length of one tool radius while at the same time moving in the Z direction When it travels one tool radius along this direction it will have traveled a distance of ten percent of the tool diameter along the Z This works out to roughly ramping into the part at an angle of 11 degrees In order to use a zigzag ramp the X or Y move must be larger than the diameter of the tool plus the radius of the tool minus the finish cut of the pocket The formula is the pocket x or y move gt tool diameter tool radius fin cut If the tool is t
168. only Program Name and Dwell The Advanced Features Option is not active 50 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 7 3 Program Header Screen The first screen you see when you enter the Program Mode is the Program Header Screen The Program Header Screen gives you options that apply to the entire program The softkey selections allow you to ente r the program at any point The program name and general programming options you choose in the Program Header Screen will be summarized in the program as Event 0 7 3 1 Program Name Programs written on the ProtoTRAK SMX CNC are usually named for the part that is to be machined When programs or files are named using the ProtoTRAK SMX CNC the name can be up to 20 characters long Programs imported into the ProtoTRAK SMX CNC may be longer While 20 characters are allowed the entire program name may not be shown in the status line or the program header screen FIGURE 7 3 Pressing the Help hard key when the Program Name is highlighted calls up alpha keys Program names can include numbers letters spaces and other characte rs When the Program name prompt is highlighted the Data Input Line will show Program Name At this point you may Press number keys Press Help to access alpha keys and special characters in the ProtoTRAK SMX CNC Use a keyboard plugged into the ProtoTRAK SMX CNC to n
169. onrad at which time you input the numerical value of the tangentially connecting radius r k The system will calculate the tangent points T1 and T2 and direct the tool cutter to move continuously from X1 Z1 through T1 r k T2 and on to X3 Z3 5 11 Memory amp Storage Computers can hold information in two ways Information can be in current memory or in storage Current memory also known as RAM is where the ProtoTRAK SMX CNC holds the operating system and any part program that is ready to run While a program is being written it is in current memory For the base system of the ProtoTRAK SMX CNC storage of programs is on a disk in the floppy drive We strongly recommend you habitually back up programs When the Network Memory Option is purchased program storage can be on a floppy disk on the 128MB or higher flash drive that comes with the option or on an offline computer that is networked to your SMX CNC FIGURE 5 10 2 A Conrad is added between an arc and a line 45 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Safety Programming Operating amp Care Manual 6 0 DRO MODE The ProtoTRAK SMX CNC operates in DRO Mode as a sophisticated 3 axis digital readout with jog and power feed capability 6 1 Enter DRO Mode Press MODE select DRO soft key The screen will show FIGURE 6 1 The DRO screen Note the RETURN soft key is lit when in Jog or Power Feed operation 6 2 DRO Functions Clear Entry Press
170. ontinue input 1 for Yes if you want to mill continuously from this line to the next event input 2 for No if you want the ProtoTRAK SMX to stop at the end of the event 8 4 ARC Events This event allows you to mill with circular contouring any arc fraction of a circle In ARC events when X Center and Y Center are programmed incrementally they are referenced from X End and Y End respectively An ARC event may be programmed with a CONRAD if it is connective with the next event Prompts for the Arc event X Begin is the X dimension to the beginning of the arc cut Y Begin is the Y dimension to the beginning of the arc cut X End is the X dimension to the end of the arc cut incremental is from X Begin Y End is the Y dimension to the end of the arc cut incremental is from Y Begin X Center is the X dimension to the center of the arc incremental is from X End Y Center is the Y dimension to the center of the arc incremental is from Y End Conrad is the dimension of a tangential radius to the next event Directio n is the clockwise input 1 or counterclockwise input 2 direction of the arc Tool Offset is the selection of the tool offset to right input 1 offset to left input 2 or tool center no offset input 0 relative to the programmed edge and direction of tool cutter movement XY Feedrate is the milling feedrate from Begin to End in in min from 1 to 100 or mm min from 5 to 2540 up to 3800 for model SLV To
171. oo large for the zigzag ramp the ProtoTRAK SMX CNC will give an error message during program run and will then default to plunge This will occur for each pass of the pocket depth 9 6 6 Conrad in Pocket Events A Conrad may be added to the last event of an Irregular Pocket The Conrad will be inserted between the end of the last event and the beginning of the next event 9 6 7 Bottom Finish Cut The standard finish cut is along the walls of the part but you may have the ProtoTRAK machine a finish cut along the bottom as well When the highlight is on the Fin Cut prompt the blue appears next to the Help key Pressing help gives you the ability to choose a Finish cut in Z You can remove the bottom finish cut by placing the highlight on the Fin Cut prompt and pressing Help again When you select Yes to the bottom finish cut the following prompt will appear Z FIN CUT the finish cut at the bottom 80 XYZ Machine Tools Ltd XYZ Machine Tools Ltd and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 9 7 Islands Advanced Features Option Islands programming is available as part of the Advanced Features Option See Section 3 1 2 Within the Pocket event choices you may also select a circular rectangular or irregular island An island is a shape that is left standing when the surrounding material is removed The ProtoTRAK gives you the ability to machine almost any shape as an island within a rectangular
172. ool offset and tool number of both events must be the same And both events must lie in the XY plane or the same vertical plane see Section 5 2 5 10 Conrad Conrad is a unique feature of the PROTOTRAK SMX CNC that allows you to program a tangentially connecting radius between connective events or tangentially connecting radii for the corners of pockets and frames without the necessity of complex calculations For the figure below you program an Arc event from X1 Y1 to X2 Y2 with tool offset left and another Arc event from X2 Y2 to X3 Y3 also with tool offset left During the programming of the first Arc event the system will prompt for Conrad at which time you input the numerical value of the tangentially connecting radius r K3 The system will calculate the tangent points T1 and T2 and direct the tool cutter to move continuously from X1 Y1 through T1 r k3 T2 to X3 Y3 FIGURE 5 10 1 A Conrad is added between the two intersecting lines Note Conrad must always be the same as or larger than the tool radius for inside corners If Conrad is less than the tool radius and an inside corner is machined the ProtoTRAK SMX CNC will ignore the Conrad 44 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual For the figure below you program an Arc event from X1 Z1 to X2 Z2 and a Mill to X3 Z3 During the programming of the Arc event the system will prompt for C
173. ools 5 The words will change from NOT SET to SET and the highlight will shift to the DIAMETER column of Tool 1 Note that you may not be interested in setting up Tool 1 if it is not one of the active tools of the program If this is the case use the DATA softkeys to move to a tool you are interested in 6 Input the diameter for the tool and press SET 7 The highlight will move to the Z OFFSET column Put this tool in the spindle and touch it to the same surface as you used to touch the reference tool in Step 2 above 8 Press set 9 The highlight moves to the Z Modifier column Input and set a Z modifier if you wish see below or simply press SET to input no modifier 10 The highlight moves to Tool Type and a green window appears with your choices Input 1 to 9 corresponding to your choice and then SET This moves you to the Diameter input for your next tool 11 Repeat steps 5 to 8 for each of the tools you want to set up Remember to touch the same surface you used to set the reference tool Once the reference position is set you will not be able to move the highlight back to the word SET Note You must set an absolute zero reference in the DRO Mode before machining the part You may use any tool that you have set up with the above procedure to set your reference and the ProtoTRAK will automatically compensate for the difference in length for the rest of the tools 110 XYZ Machine Tools Ltd XYZ Turret Mil
174. or the Island If 0 is input there will be no finish cut X1 POCKET X dimension for one corner of the rectangular pocket that surrounds the island Y1 POCKET Y dimension for one corner of the rectangular pocket that surrounds the island X3 POCKET X dimension for the opposite corner of the rectangular pocket that surrounds the island Y3 POCKET Y dimension for the opposite corner of the rectangular pocket that surrounds the island CONRAD PCKT the value of the tangential radius in the corners of the rectangular pocket that surrounds the island FIN CUT PCKT finish cut along the perimeter of the pocket If 0 is input there will be no finish cut FEEDRATE the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 up to 3800 for model SLV 66 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual FIN FEEDRATE the finish milling feedrate for both the island and pocket finish cuts TOOL is the tool number you assign 8 6 3 Irregular Island Advanced Features Option When the Advanced Features Option is active press the IRREG ISLAND key if you wish to mill an island other than a rectangle or circle The Irregular Island gives you the powerful Auto Geometry Engine to define a shape made up of straight lines and arcs The first screen in an Irregular Island event will define the beginning point and some of its general parameters The last
175. ork you establish you must assign a name and select a workgroup for your ProtoTRAK SMX CNC 1 Plug a keyboard and mouse into your ProtoTRAK SMX CNC and turn it on Go to the Select a Mode screen 2 On the keyboard press simultaneously Ctrl Esc This will show the Start Menu 3 Select Settings from the Start menu and then select Control Panel 140 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual i01138 4 Double click on the System icon 5 Select the Computer Name tab 6 Do not enter the computer description here Instead click the Change button Figure 15 12 1 Settings then Control Panel Figure 15 12 2 Double click on the System icon i01139 141 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 7 Enter a name for the ProtoTRAK SMX in the Computer Name box We suggest something descriptive for example TRAK SX3 8 Enter a workgroup This workgroup must match the name of the workgroup on your computer Assigning a workgroup name for your computer is discussed below If you have not selected a workgroup for your computer we suggest shop or toolroom Figure 15 12 3 Click on the Change button to enter the name i01137 142 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp
176. otoTRAK SMX CNC is able to determine what kind of file it is A file extension that is unique to the ProtoTRAK SMX CNC is GCD The GCD extension tells the ProtoTRAK SMX CNC that a particular program is a standard RS274 or G Code program When you specify this extension the ProtoTRAK SMX CNC will treat that program in a special way This is explained in Section 15 11 15 1 Softkey Selections in the Program In Out Mode YES to display only supported programs NO to display all files OPEN to bring a program from storage into the current memory SAVE to save the program that is in current memory to storage COPY to select and make a copy of a file in storage for pasting in another storage location DELETE to remove a file from a storage location without altering the current memory RENAME to rename a file or folder BACK UP to perform a convenient back up of program files to another storage location 15 2 Basic Navigation of Program In Out Mode Screens The screens in the Program In Out Mode do not have the normal ProtoTRAK look and feel because they are derived from the Windows operating system Most functions may be performed using a mouse or keyboard Softkeys are provided to operate the system through the control s keys 15 2 1 Basic Parts of the Program In Out Mode Screens The status line at the top of the screen will display The Mode The program name for the program in current memory if any
177. ou the powerful Auto Geometry Engine to define a shape made up of straight lines Mills and arcs The first screen in an irregular pocket event will define the beginning point and some of its general parameters The last event of the irregular pocket must end at the same point as defined in the first event X Begin is the X dimension of the beginning of the pocket Y Begin is the Y dimension of the beginning of the pocket Fin Cut is the width of the finish cut If 0 is input there will be no finish cut Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 up to 3800 for model SLV 64 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Fin Feedrate is the finish cut milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 up to 3800 for model SLV Tool is the tool number you assign When the initial screen is complete you will define the perimeter of the pocket with a series of A G E Mills and A G E Arcs Programming with the Auto Geometry Engine is explained in Section 10 0 No islands may exist in an irregular pocket 8 5 4 Tool Path in Pocket Events In Program Run the ProtoTRAK SMX will first direct the cutter along a path to rough out all the material inside of the perimeter and then will do a rough cut along the inside of the perimeter which leaves the amount of material programmed in the FIN CUT prom
178. press the SYS hardkey on the ProtoTRAK SMX then press the Config Net softkey See Figure 15 12 5 above Change IP Address gives you access to the Internet Protocol Properties screen The default of the ProtoTRAK SMX is to obtain addresses automatically from the DHCP server See Figure 15 12 7 Figure 15 12 7 TCP IP Properties Add User Password allows you to establish different users or passwords for the ProtoTRAK SMX This is not recommended because it means that the ProtoTRAK SMX will need to have a keyboard plugged in each time it is turned on This may not be desirable in a shop environment Share Drive Folder allows you to share resources on the optional USB Thumb Drive flash memory Map Network Drive is covered above in Section 15 12 2 under On the ProtoTRAK SMX for the basic peer to peer network 15 12 5 Network Description Of The ProtoTRAK SMX The following data may be useful to Network Administrators or advanced users in setting up a more advanced network Operating System Windows XP Embedded w SP2 Processor Celeron 400 i01135 146 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Memory RAM 256MB Disk Optional 256MB or higher USB Thumb Drive flash Floppy drive yes Network 10 100 base T Ethernet Ports available LPT1 USB1 and 2 PS2 for keyboard System software not accessible to the user Default password ADMIN Defaul
179. pt This will be followed by a finish pass if FIN CUT was not zero along the inside of the perimeter at the Finish Feedrate Whether the cuts to clear the interior material of the irregular pocket are along the X or Y axis depends on if there are hidden areas of the pocket The ProtoTRAK SMX CNC always looks to cut along the X axis first If there are areas that are hidden to the X axis it will machine along the Y axis If there are hidden areas that cannot be machined continuously in the X or Y axis the pocket will be machined in two or more steps When a step is completed the ProtoTRAK SMX will prompt CHECK Z at which time you should raise your quill out of the pocket Press GO and the tool will move at rapid to the beginning of the next step and then there will be a prompt for you to SET Z for you to position the tool for the depth you want In the Set Up Mode you may check your tool path for hidden areas The yellow X s show points where you will receive a prompt to move the quill The red dashed lines show the rapid moves 8 5 5 Conrad in Pocket Events A conrad may be added to the last event of an Irregular Pocket The conrad will be inserted between the end of the last event and the beginning of the next event 8 6 Islands Advanced Features Option Islands programming is available as part of the Advanced Features Option See Section 3 1 2 Within the Pocket event choices you may also select a circular rectangular or irregu
180. py Event 88 8 12 Thread Mill Event 89 8 13 Pause Event 90 8 14 Engrave Event 90 8 15 Finish Teach Event 91 10 0 AGE Programming 10 1 Starting the AGE 93 10 2 AGE Mill Prompts 94 10 3 AGE Arc Prompts 95 10 4 Skipping Over Prompts 95 10 5 The OK Not OK Flag 95 10 6 Ending AGE 95 10 7 Guessing Data 96 10 8 Look and Guess 96 10 9 Calculated Data 98 10 10 Arcs and Conrads 98 10 11 Tangency 98 11 0 Edit Mode 11 1 Delete Events 99 ii XYZ Turret Mill ProtoTRAK SMX CNC Safety Programming Operating and Care Manual 11 2 Spreadsheet Editing 99 11 3 Erase Program 103 11 4 Clipboard 103 11 5 G Code Editing 104 12 0 Set Up Mode 12 1 The Tool Table 107 12 2 Tool Path 112 12 3 Reference Position 113 12 4 Fixture Offsets 114 12 5 Service Codes 114 13 0 Run Mode 13 1 Run Mode Screen 107 13 2 2 vs 3 axis Programming 107 13 3 Starting a Run 108 13 4 Program Run 118 13 5 TRAKing 119 13 6 Program Run Messages 120 13 7 Stop 120 13 8 Feedrate and Speed Override 120 13 9 Trial Run 120 13 10 Data Errors 121 13 11 Fault Messages 121 14 0 Basic Progran In Out Mode 14 1 Entering Program In Out Mode 123 14 2 What is on the Screen 123 14 3 Basic Navigation 124 14 4 Opening a File 124 14 5 Saving a File 124 14 6 Deleting a File 124 14 7 Renaming or Copying a File 125 14 8 Backing Up 125 14 9 Additional Topics 125 15 0 Program In Out Mode wit
181. r one corner of the rectangular pocket that surrounds the island Y1 POCKET Y dimension for one corner of the rectangular pocket that surrounds the island X3 POCKET X dimension for the opposite corner of the rectangular pocket that surrounds the island Y3 POCKET Y dimension for the opposite corner of the rectangular pocket that surrounds the island CONRAD PCKT the value of the tangential radius in the corners of the rectangular pocket that surrounds the island FIN CUT PCKT finish cut along the perimeter of the pocket If 0 is input there will be no finish cut See the previous section for a bottom finish cut RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is active FIN RPM is the spindle RPM for the finish cut FIN RPM pro gramming is available only if the Programmable Electronic Head Option is active Z FEEDRATE is the Z feedrate from Z rapid to Z end 83 XYZ Machine Tools Ltd XYZ Machine Tools Ltd and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual XYZ FEEDRATE the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 FIN FEEDRATE the finish milling feedrate for both the island and pocket finish cuts TOOL is the tool number you assign When the initial screen is complete you will define the perimeter of the island with a series of A G E Mills
182. ree 4 2 3 Raising Lowering the Knee For models 1500 and 2000 the knee is raised and lowered using the hand crank located on the left front of the knee Clockwise rotation moves the knee up while counterclockwise rotation moves the knee down For models 3000 and SLV the knee is raised by the power rise fall Turn the button located on the switch box to the left of the SMX display A clockwise turn raises the table a counterclockwise turn lowers it Be sure the knee is unclamped before raising or lowering 4 2 4 Spindle Brake A pneumatic air cylinder activates an automatic spindle brake when the spindle motor is turned off The brake disengages when the spindle is started 4 2 5 Draw Bar The draw bar holds the R8 or 40 ISO tool holders into the spindle taper The bar has a 5 8 unc right hand thread and should be tightened with a 23mm wrench from the top of the head When tightening it is necessary to activate the spindle brake See 4 2 4 above If the tool holder does not release from the spindle lightly tap on the top of the bar to dislodge the tool 4 2 6 High Low Neutral Level For both the standard head and the Programmable Electronic Head Option the range selection is made through the High Low Neutral Lever Figure 4 2 6 36 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Safety Programming Operating amp Care Manual CAUTION Never attempt to change the range selection through the High Lo
183. rgizes the relay that is tripped when the E Stop button is pressed To reset the system after an E Stop press first reset the E Stop button by rotating it until it returns to its out position After the E Stop is reset press and release the Reset button on the right side of the pendant 3 3 Mill Specifications See Figures 3 3 1 and 3 3 2 Note Machine shown above is in the two axis CNC configuration 24 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Two and three axis CNC Turret Mill Specifications SMX 1500 SMX2 2 Axis CNC 3 Axis DRO SMX 2000 SMX2 2 Axis CNC 3 Axis DRO SMX 3000 SMX2 2 Axis CNC 3 Axis DRO SMX SLV SMX2 2 Axis CNC 3 Axis DRO SMX1500 SMX3 3 Axis CNC 3 Axis DRO SMX2000 SMX3 3 Axis CNC 3 Axis DRO SMX3000 SMX3 3 Axis CNC 3 Axis DRO SMX SLV SMX3 3 Axis CNC 3 Axis DRO Table Size 1066 x 228 1270 x 254 1371 x 305 1473 x 305 T Slots 3 3 3 3 Table Travel 660 762 813 1016 Saddle Travel 330 406 431 431 Knee Travel 406 406 406 406 Ram Travel 330 450 450 450 FIGURE 3 3 2 The XYZ Turret Mill back view 25 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Maximum Quill Travel 2 axis CNC 127 127 127 127 Maximum Quill Travel 3 axis CNC 115 115 115 115 Quill Diameter 86 86 105 105
184. rn on the multiple fixtures offset Answering Yes will cause a prompt to appear at each event asking which fixture the event was referenced from If you select Yes the Data Input Line will ask you to enter a fixture default number from one to six The fixture default number is the fixture that will be applied to all the events in current memory when Multiple Fixtures is turned on or when a new event is programmed without another event being specified Enter the default fixture or leave the number unchanged and press SET Multiple Fixtures are explained more fully in Section 7 5 This function is part of the Advanced Features Option Dimension Definition The ProtoTRAK SMX CNC gives you a choice in programming either tool path or geometry Part Geometry programming allows you to define the geometry you want your part to have and then the CNC does the difficult job of calculating tool path for you automatically This is a great benefit for most parts most of the time because it means that the CNC is doing the hard work of determining tool position 52 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual One restriction to part geometry programming is that for events to be connective they must lay on the same plane see Section 5 3 for a definition of planes For this reason the ProtoTRAK SMX CNC gives you the option of entering your own tool path If you wish to program the pa
185. rom the center to the center of the holes Angle is the angle from the positive X axes that is 3 o clock to any hole positive angle is measured counterclockwise from 0 000 to 359 999 degrees negative angles measured clockwise Tool is the tool number you assign 8 3 MILL Events This event allows you to mill in a straight line from any one XYZ point to another including at a diagonal in space It may be programmed with a CONRAD if it is connective with the next event Prompts for the Mill event X Begin is the X dimension to the beginning of the mill cut Y Begin is the Y dimension to the beginning of the mill cut X End is the X dimension to the end of the mill cut incremental is X Begin Y End is the Y dimension to the end of the mill cut incremental is Y Begin Conrad is the dimension of a tangential radius to the next event that must lie in the same plane for part geometry programming 62 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Tool Offset is the selection of the tool offset to right input 1 offset to left input 2 or tool center no offset input 0 relative to the programmed edge and direction of tool cutter movement and as projected in the XY plane Feedrate is the milling feedrate from Begin to End in in min from 1 to 100 or mm min from 5 to 2540 up to 3800 for model SLV Tool is the tool number you assign C
186. rt by defining tool path yourself you may choose the TOOL PATH softkey Otherwise Part Geometry programming is assumed Tool Path operates under the same rules as standard RS274 A program must be entirely written in Part Geometry or Tool Path programming you cannot combine the two methods in one program Tool Path programming is part of the Advanced Features Option 7 3 3 Program Header Softkeys The following softkeys are encountered in the Program Header Screen The first five listed below are always there The last four appear when relevant to the general programming option DATA FWD moves the highlight forward through the programming options without setting an input into the program DATA BACK moves the highlight backward through the programming options without setting an input into the program GO TO BEGIN puts the Program Header on the left side of the screen and the first event on the right side GO TO END puts the last programmed event on the left side of the screen and the next event to be programmed on the right side GO TO enter the event number you wish to go to and then press SET Puts the requested event number on the right side of the screen and the previous event number on the left Note for a new program that has no Events all the GO TO selections will take you to the beginning with the program header information summarized on the left as Event 0 and the Select an Event options for Event 1 on the right
187. s on 01823 674200 or contact your Area Sales Manager to make arrangements for an authorized technician to install the electronic handwheels For three axis CNC models the Go To dimensions for the Z axis are a part of the base product even if this option is not ordered You do not need this option for Z axis Go To dimensions 3 1 7 How To Buy Software Options If you did not buy the software options described above with your machine you may purchase them later In order to use these options a Software Activation Password is required These passwords are unique to your ProtoTRAK SMX CNC Software Options are not free You may call XYZ Machine Tools on 01823 674200 or contact your Area Sales Manager for a price quotation 17 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 1 We recommend that you install the latest version of the ProtoTRAK SMX master software before installing the newest option 2 Go to the ProtoTRAK SMX CNC on which the option is to be installed use Service Code 318 to go to the Software Options Screen 3 Highlight the option you wish to install for example A Advanced Features and press the softkey labeled INSTALL 4 A screen will appear that advises you how to purchase the option Near the bottom of the screen there will be a Hardware Key Serial Number and an Option Serial Number Write down both of these numbers 5 Call
188. s to run 3 Pulse Indexer Activates a 0 3 second electronic pulse at the beginning of the event See note below AUX END options 0 None No Auxiliary functions will turn off at the end of this event 1 Coolant Air Off Turns the coolant or air solenoid off at the end of this event 3 Pulse Indexer Activates a 0 3 second electronic pulse at the end of this event See note below 4 Spindle Turns off the spindle at the end of this event Note the spindle automatically turns off for each tool change it is not necessary to program a spindle off Coolant Air on and off is automatically programmed for tool changes If you want the air or coolant pump on while cutting the entire part you need only program the Aux begin in the first event and Aux end in the last event The coolant pump or air solenoid will turn on at the beginning of the programmed event and will turn off during tool changes The Pulse Indexer function is designed to operate with a standard indexer Programming an Aux 3 at the end of an event will cause the ProtoTRAK SMX CNC to stop machining at the end of the event and wait for a signal from the indexer or rotary table that it has finished its programmed move then it will resume machining at the next event If you want the ProtoTRAK SMX CNC to return the head to the Z retract position before moving to the next event put the Aux 3 command in a Pause event The ProtoTRAK SMX CNC will interpret the signal from the
189. se to remove the chips or clean the machine oil coolant etc 12 Stop and disconnect the machine before you change belts pulley gears 13 Keep work area well lighted Ask for additional light if needed 14 Do not lean on the machine while it is running 15 Prevent slippage Keep the work area dry and clean Remove the chips oil coolant and obstacles of any kind around the machine 12 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 16 Avoid getting pinched in places where the table saddle or spindle head create pinch points while in motion 17 Securely clamp and properly locate the workpiece in the vise on the table or in the fixture Use stop blocks to prevent objects from flying loose Use proper holding clamping attachments and position them clear of the tool path 18 Use correct cutting parameters speed feed depth and width of cut in order to prevent tool breakage 19 Use proper cutting tools for the job Pay attention to the rotation of the spindle Left hand tool for counterclockwise rota tion of spindle and right hand tool for clockwise rotation of spindle 20 Prevent damage to the workpiece or the cutting tool Never start the machine including the rotation of the spindle if the tool is in contact with the part 21 Check the direction or of movement of the table when using the jog or power feed 22
190. select Full Access On The ProtoTRAK SMX 1 Press the SYS Hardkey then the Config Net softkey The PT4SX Network Tools box appears See Figure 15 12 5 2 Pick Map Network Drive and click OK 3 In the Drive box type in E You must type in both the E and the See Figure 15 12 6 below Drive letters A through D are used by other drives 4 In the Folder box Browse for the folder on your computer that you shared following the instructions above When you click browse you may have to go through a few layers of file hierarchy before you find the folder you shared Figure 15 12 5 The PT4SX Network Tools box 144 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Figure 15 12 6 Enter E in the Drive box and Browse for the file you shared on your computer 5 Click OK The shared drive on the computer should now be accessible in the Program In Out Mode under drive E 6 Once complete you must now save all changes made To do so simply click on the Save button at the network utility window See figure 15 12 5 To connect other ProtoTRAKs on this simple network repeat the process starting with assigning a name Each ProtoTRAK must have a unique name and use the same workgroup 15 12 3 General Information For Advanced Networks The ProtoTRAK SMX CNC is a PC but for setting up a network it is more useful to think of it as a devi
191. should run a G Code or GCD program see section 15 11 The above 2 axis restriction does not mean that the ProtoTRAK is not capable of running three axis simultaneous programs written in ProtoTRAK events as some ill informed competitors would have you believe This restriction is a matter of practicality Because the ProtoTRAK allows you to program in part geometry and therefore will figure out the tool path for you the process of converting a three axis program gives the ProtoTRAK a tool position problem that it cannot resolve without a lot more data from you The other reason is that the output from a CAM systems for three axis shapes is in the form of thousands and thousands of straight line G01 moves that would convert into the equal number of ProtoTRAK Mill events This is hardly a manageable program Instead of forcing the issue in a silly way we give you the more elegant solution of running GCD files To our competitors we respectfully point out that the thread and helix milling canned cycles of the ProtoTRAK are obvious examples of three axis simultaneous interpolation Three axis program fun of non cam files is part of the Advanced Features Option In order to run a CAM program the program must be posted through a post processor that makes some adjustments to the output of the CAM software so that it is understood by the ProtoTRAK The ProtoTRAK uses a post processor that is very similar to the Fanuc 6M If you are not
192. straight down Z to the appropriate Z depth The zigzag ramp will move in a zigzag pattern to depth See the previous section for more information about the zigzag ramp FIN CUT ISL Finish cut for the Island If 0 is input there will be no finish cut See the previous section for a bottom finish cut X1 POCKET X dimension for one corner of the rectangular pocket that surrounds the island Y1 POCKET Y dimension for one corner of the rectangular pocket that surrounds the island X3 POCKET X dimension for the opposite corner of the rectangular pocket that surrounds the island Y3 POCKET Y dimension for the opposite corner of the rectangular pocket that surrounds the island CONRAD PCKT the value of the tangential radius in the corners of the rectangular pocket that surrounds the island RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is active 82 XYZ Machine Tools Ltd XYZ Machine Tools Ltd and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual FIN RPM is the spindle RPM for the finish cut FIN RPM programming is available only if the Programmable Electronic Head Option is active FIN CUT PCKT finish cut along the perimeter of the pocket If 0 is input there will be no finish cut See the previous section for a bottom finish cut Z FEEDRATE is the Z feedrate from Z rapid to Z end
193. t X will remain the same Unknown point guess Skip Skip Skip Measured CCW from 3 00 from begin to end EVENT 9 AGE MILL NOTES Tangent X End Y End Conrad Angle End Length Line Angle 2 SET 0 ABS SET 0 ABS SET PAGE FWD You should see the ALL OK flag Press the Look Key Now If all is OK press Look key again t o return to program and End the AGE 159 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual XYZ Machine Tools Ltd ProtoTRAK UK Warranty Policy Warranty ProtoTRAK products are warranted to the original purchaser to be free from defects in workmanship and materials for the following periods Product Warranty Period New ProtoTRAK 12 Months Any EXCHANGE Unit 6 Months The warranty period starts on the date of the invoice to the original purchaser from XYZ Machine Tools Ltd XYZ or their authorised distributor If a unit under warranty fails it will be repaired or exchanged at our option for a properly functioning unit in similar or better condition Such repairs or exchanges will be made carriage paid within the UK Disclaimers of Warranties This warranty is expressly in lieu of any other warranties express or implied including any implied warranty of merchantability or fitness for a particular purpose and of any other obligations or liability on the part of XYZ or any producing entity if different Warrant
194. t direction as it moves from the original shape to the mirrored shape and keep all cutting either climb or conventional Mirror Axis is the selection of the axis or axes to be mirrored inp ut X or Y or XY SET X Offset is the distance from Y absolute 0 to the Y axis line of reflection Y Offset is the distance from X absolute 0 to the X axis line of reflection 9 10 3 Rotate Press the ROTATE soft key First Event is the event number of the first event to be rotated Last Event is the event number of the last event to be rotated if only one event is to be rotated the last event is the same as the first X Center is the X absolute position of the center of rotation Y Center is the Y absolute position of the center of rotation Angle is the angle of rotation of the repeated events positive is counterclockwise negative is clockwise Repeats is the number of times events are to be rotated up to 99 9 11 COPY Events Advanced Features Option Copy Events are programmed exactly like Subroutine Events The only difference is that in Copy the events are rewritten into subsequent events If for example in event 11 you Copy Repeated events 6 7 8 9 10 with 2 repeats events 6 10 would be copied with the input offsets into events 11 15 and recopied into 16 20 Copy Events may be Repeat Mirror or Rotate Copy is very useful With Copy you can Edit the events that are being repeated mirrored or
195. t user name ADMINISTRATOR Network settings TCP IP Default protocols Net beui TCP IP Network log in Auto TCP IP set up obtain IP addre ss automatically DNS Auto Gateway Not used Wins configuration Use DHCP for wins resolution There are several command line utilities available from the CMD prompt that are useful in setting up a network The following are three utilities and an example of the information that is returned IPCONFIG all Windows IP Configuration Host Name Cray 3 Primary Dns Suffix Node Type Hybrid IP Routing Enabled No WINS Proxy Enabled No Ethernet adapter INTEL LAN 1 Connection specific DNS Suffix Description Intel R PRO 100 VE Network Physical Address 00 07 E9 BA A5 47 Dhcp Enabled Yes Autoconfiguration Enabled Yes IP Address 10 1 1 220 Subnet Mask 255 255 255 0 Default Gateway 10 1 1 1 DHCP Server 10 1 1 2 DNS Servers 207 69 188 186 24 205 1 62 Primary WINS Server 10 1 1 2 Secondary WINS Server 10 1 1 3 Lease Obtained Monday 11 21 04 Lease Expires Sunday 12 12 04 PING 10 1 1 1 Pinging 10 1 1 1 with 32 bytes of data Reply from 1
196. ted as an integer i e a whole number 5 Fractional portion is optional 6 Range metric 0 to 99999 999 inch 0 to 9999 9999 D signed coordinate word denoted lt scoord gt 1 format negative number lt coord gt positive number lt coord gt or lt coord gt 2 range metric 99999 999 to 99999 999 inch 9999 9999 to 9999 9999 E tool function denoted lt tool gt 1 format dd use 2 digit only 2 leading 0 suppression 3 range 1 to 99 F miscellaneous or M codes function number denoted lt prep func gt 1 format dd 2 leading 0 suppression 3 range 1 to 99 G feedrate values denoted lt frate gt 1 format metric ddddd inch ddd dd 2 leading 0 suppression 3 decimal point not required 4 fractional portion is optional 5 range metric 1 to 6350 inch 0 1 to 250 H RPM command 1 format dddd S1000 1000 RPM 151 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 15 13 5 G Codes That Generate Errors G Code Function G27 Reference point return check G28 Return to reference point G29 Return from reference point G30 Return to 2nd reference point G31 Skip function G33 Thread cutting G37 Tool length automatic measurement G38 Cutter radius compensation vector change G39 Cutter radius compensation corner rounding G45 Tool offset inc rease G46 Tool offset decrease
197. tered text but wish to make a change you will see a 91 XYZ Machine Tools Ltd XYZ Machine Tools Ltd and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual blue question mark appear on the lower left corner of the screen when you scroll to this field press the Help button and the alpha keys will appear RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is active Z FEEDRATE Is the feedrate from Z rapid to Z end XYZ FEEDRATE The feedrate of XYZ along the path of the text Tool is the tool number you assign Figure 9 14 The above figure shows the text and special characters available for the Engrave event Notice the field that is labeled Text Length This field will display the total length of your programmed text and will update as you enter each character 9 15 Finishing Teach Events Teach events are either POSN DRILL or MILL events that are originated in the DRO Mode see Section 6 7 The Teach events that are started in the DRO Mode must be finished in the Program Mode before running Teach events are of these different types TEACH POSN for two axis operation the Position and Drill event types are combined See Section 9 1 for a description of Position event prompts TEACH DRILL this may also be made into a bore event See Section 9 2 for a description of Drill e
198. the signal from the indexer or rotary table as a GO command and continue machining without you having to press the GO key 7 5 Multiple Fixtures This function is part of the Advanced Features Option You may run your program using up to six fixtures plus a base A fixture is a location on your machine with a defined offset from your absolute 0 When you program an event to have a fixture it will treat the offset as if it were absolute zero shift The programmed X Y and Z absolute dimensions are relative to the absolute reference for the specified fixture For example say you had two vises on the table On the first vise you established the lower left jaw as the absolute 0 At the same time you measured the distance between the absolute zero you just established and the lower left jaw of the other vise You entered that measurement as an offset from your base vise the first one and the other vise which is Fixture 2 Any events that you programmed using Fixture 2 would treat the lower left corner of that second vise like the absolute 0 for the X Y and Z dimensions in the events Fixture offsets are handy for combining different programs together to run at the same time or to make multiple parts by repeating the events with different fixtures The fixture offsets are entered in the Set up mode There is a base fixture called fixture number one We recommend that Event 1 in your program uses fixture number one It doesn t have to we j
199. the center as the reference Sets the rapid to 3mm above the part Sets the drill depth to 1 The radius of the bolt hole circle Angle of first hole from zero 0 degrees Sets 1 peck Sets Z plunge rate to 125 mmpm Selects Tool 1 as the Center drill 155 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual EVENT 2 Bolt Hole NOTES drill to final size DRILL OR BORE OF HOLES X CENTER Y CENTER Z RAPID Z END RADIUS ANGLE OF PECKS FOR DRILL Z FEEDRATE TOOL 1 SET 5 ABS SET 0 ABS SET 0 ABS SET 3 ABS SET 9 ABS SET 33 SET 45 SET 3 SET 125 SET 2 SET Drill Function Known print value Use the center as the reference Sets the rapid to 3mm above the part Sets the drill depth to 9 through The radius of the bolt hole circle Angle of first hole from zero 0 degrees Sets 3 peck Sets Z plunge rate to 125 mmpm Selects Tool 2 as the M7 drill EVENT 3 CIRC PCKT NOTES X CENTER Y CENTER Z RAPID Z END RADIUS DIRECTION OF PASSES ENTRY MODE FIN CUT Z FEEDRATE XYZ FEEDRATE FIN FEEDRATE TOOL 0 ABS SET 0 ABS SET 3 ABS SET 5 ABS SET 19 SET 2 SET 2 SET 1 SET 25 SET 100 SET 250 SET 200 SET 3 SET Sets the pocket center to X zero Sets the pocket center to Y zero Sets the Rapid Sets the pocket depth Sets radius of pocket Makes the cut direction CCW Cuts the pocket using two 2 depths Selects tool ramp into the materia
200. the events you want to copy Make sure that the dimensioned data uses Absolute references in the first event to be copied and in all events where it will be important Incremental references may be used but keep in mind where the Incremental reference will be made from See the section on Incremental Reference Position in this manual In addition you may want to modify this program in order to get all the events you want together For example if you want to copy events 2 5 and 7 12 you may want to modify the program to delete events 1 and 6 first That way you can copy the all the events as they are now numbered from 1 to 10 Remember that you can modify this program just for this purpose and it will not affect the original program unless you save it with the modifications in the Program In Out Mode When the source program is ready press the CLIPBOARD softkey A message will appear that says Copy Events Onto Clipboard and the Data Input Line will read From Event Enter the number of the first event that you want copied and press SET The Data Input Line will read To Event Enter the number of the last event you want copied and press SET The group of events that you have specified is now on the clipboard and will remain there until you replace it with something else by going through the same procedure When power is turned off to the CNC the clipboard information will also be lost The events on the clipboard are inserted into a progr
201. the job at hand See Section 4 6 for switching between two and three axis operation Programming is very similar between the two EVENT 1 BOLT HOLE EVENT 1 BOLT HOLE DRILL OR BORE HOLES HOLES X CENTER X CENTER Y CENTER Y CENTER RADIUS Z RAPID ANGLE Z END TOOL RADIUS ANGLE PECKS FOR DRILL Z REEDRATE TOOL FIGURE 7 13 Programming a Bolt Hole On the left the prompts required in programming in three axis CNC On the right the prompts required for two axis In Figure 7 13 the prompts for programming a Bolt Hole in two axis and in three axis are shown side by side Note that the difference is that the three axis requires a few additional prompts For the convenience of users who have two axis CNC models the programming will be explained in two different sections If you have a three axis CNC model we suggest you skip the two axis programming section since the programming is very similar 59 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 61 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 8 0 Two Axis Program Events This section describes the events and prompts you encounter when programming your ProtoTRAK SMX as a two axis CNC If you have a three axis XYZ Turret Mill you may want to skip this section Events are fully defined pieces of geometry
202. the left side facing of the column and plugs into a 110v outlet in the electrical cabinet 3 11 Coolant Pump The coolant pump is mounted in the back of the machine column It is plugged into the electrical cabinet and is configured to operate as commanded by the accessory key 3 12 Chip Pan The Chip Pan fits around the base of the mill to collect coolant and chips 3 13 Table Guard The Table guard provides an enclosed workspace mounted on the table The doors are switched to prevent the machine spindle starting in any mode if they are open It also prevents the operation of the CNC in Run mode with the door open While it will aid in the control of chips and coolant it is not a full waterproof enclosure Removal of these guards is prohibited by law They are fitted for the benefit of the machine operator and to comply with the current legislation removal means you are breaking the law 3 14 Z Axis Ballscrew and Motor Assembly For three axis CNC models a Z axis ballscrew and motor assembly is mounted on the head using two tramming bolts and the fine feed boss In manual and CNC operations the quill is moved by a servo motor connected by a belt to a ballscrew The ball nut of the ballscrew is attached to fork that engages the quill in the threaded hole previously used by the quill stop knob In CNC operations the motor is controlled by the CNC program In manual operations the motor is controlled by jog commands from the user
203. the screen appear once the RENAME softkey is pressed New Name When a file or folder is highlighted the name will appear here When the TAB the RENAME FILE or RENAME FOLDER softkey is pressed the highlight will move here and you will then be able to write in a new name New Extension A new extension can be given to the file picking from the ones available If the file name already contains an extension you will have to erase the old one before giving it a new one Additional softkeys RENAME FOLDER Press once a new name has been entered into the New Name and New Extension areas to change the name of the folder RENAME FILE Press once a new name has been entered into the New Name and New Extension areas to change the name of the file RETURN Returns to the Program In Out Mode screen FIGURE 15 7 Renaming a file Press the Help hard key to call up the alpha keys 133 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 15 8 Backing Up In order to protect your important programs it is a good idea to back them up regularly That way if a floppy disk or hard drive becomes unusable you will not have to re write the program To back up your files press the BACK UP softkey from the Program In Out Mode screen FIGURE 15 8 Backing up The top part of the screen shows all the items in Drive A The bottom part shows the items that have been picked for b
204. the text in this sentence and you may program up to 40 characters per event although you will only be able to see 20 characters on the prompts screen To machine text in a direction other than the X axis simply use multiple Engrave Events and place the lower left corner of the box wherever you would like The numbers and letters you program will always have a standard orientation like the letters on this page you cannot program tilted or inverted letters with the Engrave Event The letters are of the font shown in the figure and all capitals Prompts for the Engrave Event First define the lower left corner of the box that will contain your text X BEGIN The X coordinate of where you want your text to begin Y BEGIN The Y coordinate of where you want your text to begin Z RAPID The Z dimension where the Z rapid feed slows to Z program feed Z END The Z dimension to the bottom of your text HEIGHT The height of your text Each character varies in width the set height of the character will change the width in order to keep the overall size of the character proportional TEXT The text to be milled When you get to this prompt the Alpha keys will automatically pop up to allow you to enter the text Once you have finished entering text you must press End F8 and then any of the SET keys to successfully enter your text into the event The alpha keys will appear automatically if the text field is blank If you have already en
205. the tool offset to the right input 1 offset to the left input 2 or tool center no offset input 0 relative to the programmed edge and direction of the cutter movement Passes is the number of cycles to machine to the final depth spacedequally from Z Rapid to Z End hint keep Z Rapid small Fin Cut is the width of the finish cut If 0 is input there will be no finish cut RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is active FIN RPM is the spindle RPM for the finish cut FIN RPM programming is available only if the Programmable Electronic Head Option is active Z Feedrate is the Z feedrate from Z rapid to Z end XYZ Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Fin Feedrate is the milling feedrate for the finish cut if programmed Tool is the tool number you assign 9 8 3 Irregular Profile Advanced Features Option Press the IRREG PROFILE soft key if you wish to mill a profile other than a rectangle or circle The Irregular Profile event gives you the powerful Auto Geometry Engine to define a shape made up of straight lines Mills and arcs The Irregular Profile is a series of events that are programmed to machine continuously The first event of the series will be called an IRR PROFILE and it will define the beginning point of the profile and other i
206. through each event one at a time For example if you were to want to change the tool number for every milling event it may be a chore to go through each event in a long program to make the changes on that event type In order to make global changes 1 Sort the data in a way that groups together the things you want to change 2 Highlight the data value that is highest on the table nearest to the top that you want changed 3 Press the CHANGE ALL softkey All the inputs that are the same as the one you highlighted and are listed together below the data you highlighted will then be highlighted 4 Enter the new value then press set All the highlighted data will be changed to the value you just input Example The following example uses Z axis data for a three axis CNC model From the screen shown in Figure 11 2 1 we will change the Z Feed for each of the mill events in the program 1 Sort by event type to get all the Mill events together 2 Highlight the Z Feed in the first Mill event Event 8 See Figure 11 2 3 3 Press the CHANGE ALL softkey All the Z Feeds in the Mill events are highlighted See Figure 11 2 4 4 Type in the new Z Feed value and press INC SET or ABS SET See Figure 11 2 5 In this example the Z feed is changed from 5 0 to 7 0 for all the Mill Events FIGURE 11 2 3 After sorting by Event Type the highlighter is placed on the Z feed of the first Mill Event 102 XYZ Machine Tools Ltd
207. ting amp Care Manual o Circle pocket o Rectangular pocke t o Circular profile o Rectangular profile Program pause Conrad automatic corner radius Math helps with graphical interface Auto load of math solutions Tool step over adjustable for pocket routines Pocket bottom finish pass three axis CNC models Selectable ramp or plunge cutter entry three axis CNC models Subroutine repeat of programmed events Nesting Rotate about Z axis for skewing data three axis CNC models Edit Mode Features Delete events Erase program Set Up Mode Features Program diagnostics Advanced tool library Tool names Tool length offset with modifiers three axis CNC models Advanced diagnostic routines Software travel limits Tool path graphics with adjustable views Run Mode Features Trial run at rapid 3D CAM file program run three axis CNC models 3D G code file run with tool comp three axis CNC models Real time run graphics with tool icon Z Go To for two axis run on three axis CNC models Program In Out Mode Features Simple program storage to floppy CAM program converter Converter for prior generation ProtoTRAK programs 3 1 2 Advanced Features Option The Advanced Features Option may be purchased with the original order or purchased later Note the Advanced Features Option is included in the ProtoTRAK Offli
208. to YES you may edit the fixture number in the Program Mode event by event You may also use the Search Edit feature in the Edit Mode to change fixture numbers See Section 11 4 for setting up fixture offsets 7 6 Assumed Inputs The ProtoTRAK SMX CNC will automatically program the following when you simply press SET either INC SET or ABS SET Tool Offset If the first event with an offset CENTER If not the first event with an offset the same as the last event if that event was a Mill or Arc event Feedrate same as last event if that event was a Mill Arc Pocket Frame or Helix Tool same as last event or Tool 1 if the first event DRILL OR BORE Drill PECKS FOR DRILL 1 peck CONRAD 0 You may change these assumed inputs by simply inputting the desired data when the event is programmed 7 7 Z Rapid Positioning Three Axis CNC Models Between any two events the head will always move to the higher of the Z rapid of the event just completed or the Z Rapid of the next event unless the two events are connective see Section 5 9 Remember when using part geometry programming two milling events are not connective unless they lie in the same plane 55 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 7 8 Softkeys within Events Once a geometry Event such as Mill or Bolt Hole is selected the softkeys will change See Figure 7 8 PAGE FWD
209. to tell the ProtoTRAK SMX CNC what file format you want to end up with Use the Save As box to tell the ProtoTRAK SMX CNC what kind of file you want the current program in the PT4 format to be converted into In Figure 15 9 3 the file name 00254 is being saved on drive A as a mx3 file Note that although the program or part name as shown in the status line is BRKT005 the file name given for converting the file conforms to the mx3 format fewer than eight characters long and consisting of numbers 15 10 ProtoTRAK and TRAK CNC Compatibility File exchange between the ProtoTRAK SMX CNC and other ProtoTRAK and TRAK CNC s is possible because the ProtoTRAK SMX CNC is backward compatible In other words the ProtoTRAK SMX CNC can store and retrieve other ProtoTRAK and TRAK CNC files The actual transfer of the files can be accomplished by using a floppy disk USB flash memory and or Ethernet cable In order to transfer files between the ProtoTRAK SMX CNC and previous generations of ProtoTRAK and TRAK CNC you must have the MX2 and MX3 converters activated See Section 15 9 above 136 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Note Previous ProtoTRAK and TRAK CNC s allow numeric filenames of eight 8 characters or less while the ProtoTRAK SMX CNC allow alphanumeric filenames letters and numbers of up to twenty five 25 characters Be sure to use only nu
210. tract status the home locations and software limits for all axes For two axis models only the X and Y limits are shown FIGURE 12 3 Reference positions for three axis CNC models The Z Retract is not set Position the head and press a SET key 12 3 1 Z Retract Three Axis CNC Models The Z Retract is where the head will go for a tool change or at the end of running a program Programs may not be run in three axis CNC until the Z Retract is set Since the Z axis head is operated manually in two axis CNC it is not necessary to set the Z retract to run a two axis CNC part As a general rule always set your Z retract so that your longest tool is above the set up When you first enter the Reference Positions screen the Z Retract will show NOT SET and the message window will instruct you to move the quill to the desired retract position and then press SET You may have to go into the DRO Mode to move the quill to where you want it and then return to the Reference Positions screen to set this position 12 3 2 Home Positions Three Axis CNC Models X and Y home positions are where the table and saddle go when there is a tool change or at the end of the program These dimensions must always be from absolute zero Note Z home is the same as Z Retract 114 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 12 3 3 Limit Positions X and Y limit positions one for pl
211. tures feature turned to YES you may edit the fixture number in the Program Mode event by event You may also use the Search Edit feature in the Edit Mode to change fixture numbers See Section 11 4 for setting up fixture offsets 7 6 Assumed Inputs The ProtoTRAK SMX CNC will automatically program the following when you simply press SET either INC SET or ABS SET Tool Offset If the first event with an offset CENTER If not the first event with an offset the same as the last event if that event was a Mill or Arc event Feedrate same as last event if that event was a Mill Arc Pocket Frame or Helix Tool same as last event or Tool 1 if the first event DRILL OR BORE Drill PECKS FOR DRILL 1 peck CONRAD 0 You may change these assumed inputs by simply inputting the desired data when the event is programmed 7 7 Z Rapid Positioning Three Axis CNC Models Between any two events the head will always move to the higher of the Z rapid of the event just completed or the Z Rapid of the next event unless the two events are connective see Section 5 9 Remember when using part geometry programming two milling events are not connective unless they lie in the same plane 55 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 7 8 Softkeys within Events Once a geometry Event such as Mill or Bolt Hole is selected the softkeys will change See F
212. u already had a program in current memory that had 10 events when you press Teach the event counter will say EVENT 11 If there was no program the event counter will say EVENT 1 The event counter shows the event for which data is being entered You may teach in position drill and mill events only On the first Teach screen the softkeys are POSN a position move For two axis programming the POSN and DRILL events are combined DRILL a drill or bore MILL BEGIN the beginning of a straight line or MILL event END TEACH ends the teaching process and returns you to the main DRO screen If you press the POSN or DRILL key the event counter will go up by one and the screen remains the same If you press the MILL BEGIN key the event counter stays on the 48 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Safety Programming Operating amp Care Manual same number That is because you have given the beginning point of the line but not yet the end The softkey selections will change to MILL END the last point of the Mill event Press this to end the Mill event and select a POSN DRILL or new MILL event MILL CONT the last point of the current Mill event but the beginning of the next Mill event You may enter successive Mill events by pressing the MILL CONT key Pressing either of the above softkeys will cause the event counter to increase by one At any time you may exit the Teach and return to the DRO scre
213. ues Interval Time 50 min Discharge Time 5 sec Discharge Pressure Approximately 100 150psi CAUTION Failure to properly lubricate the mill will result in the premature failure of bearings and sliding surfaces CAUTION Failure to manually activate the pump at the beginning of each day or allowing the Auto Lube to run dry may cause severe damage to the m ill s way surfaces and ballscrews 26 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Head Lubrication Once Each Week 1 Fill the oil cup on the front of the head with ISO 32 oil This oil lubricates the Hi Lo range shifter 2 Fill the ball oiler located in the front lower right corner of the speed hanger housing This oil lubricates the speed changer shaft 3 Extend the quill fully and apply a coating of ISO 32 oil to the outside diameter of the quill Every Four Months Apply a good grade of general purpose grease through the grease fittings on the back of the head and on the left side of the head The grease lubricates the low range gear set and the feed change gears respectively 3 5 Servo Motors The servo motors on the table and saddle are 2 newton meters of torque Integrated into each motor is an encoder with 0 00909mm underlying resolution for models 1500 2000 and 3000 and 00075mm for model SLV 3 6 Ballscrews Precision ground ballscrews are installed in the
214. us direction one for minus will stop the program if they are exceeded during run Note that pressing the LIMIT ON OFF soft key will turn the prompted limit off or back on to its input value If the limits are turned on your program and home positions must fit within the limits you define If you turn on the limits and leave them at the default of 0 Absolute the program will not run 12 4 Fixture Offsets Advanced Features Option Fixture offsets are entered in the Set Up Mode From the screen in Figure 12 0 press the Fix Offset key The following screen will result Figure 12 4 The Fixture Offset screen Setting up fixtures is easy First establish your base by setting your X Y and Z absolute zero You can do this in the DRO Mode but the X Y and Z Absolute position dimensions are also on this screen for your reference Fixture 1 is always the base Once you set your absolute zero on the base it is simple a matter of entering the distance from the base to up to five other fixture locations You can do this one of two ways By entering the numbers with the keypad or by positioning to the next fixture putting the cursor on the correct offset value and then pressing ABS SET 12 5 Service Codes These are special codes that may be entered into the ProtoTRAK SMX CNC to call up routines used in installation setting of preferences machine checkout and service WARNING Before using service codes be aware that some of the routines
215. ust believe it is clearer that way 7 5 1 The Default Fixture In the program header screen you entered a default fixture number if you didn t it assumed fixture 1 as the default fixture If there are program events already in current memory when you change the multiple fixture from NO to YES they will all receive the default fixture number automatically When you change the default fixture number in the program header screen from one fixture to another all the events that had the previous default fixture number will be changed to the new default fixture number 54 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual If there are no program events in current memory when you change the multiple fixture feature from NO to YES the prompt will be added to the end of every event you then program The default fixture number will be assumed if you press SET without specifying a different number If you do specify a different fixture number that fixture number will become the assumed input for subsequent events when SET is pressed 7 5 2 Fixtures and Running the Program To run the program first go to the DRO mode and set absolute 0 at the base fixture Fixture 1 In the Run mode the SHOW ABS displays the absolute position relative to the fixture in the event being run that is the absolute dimension that was programmed 7 5 3 Editing Fixtures With the Multiple Fix
216. vailable only if the Programmable Electronic Head Option is active Z Feedrate is the Z feedrate from Z Rapid to Z begin XYZ Feedrate is the milling feedrate from Begin to End in in min from 1 to 100 or mm min from 5 to 2540 Tool is the tool number you assign Continue Yes or no This prompt appears when the Advanced Features Option is not active in order to program a continuous tool path without stops and eliminate repetitive prompts in the next event If the Advanced Features Option is active use the Profile event to accomplish the same thing 9 5 ARC Events This event allows you to mill with circular contouring any arc fraction of a circle that lies in the XY plane or a vertical plane see Section 5 3 Vertical plane arcs are also limited to those that are entirely concave or convex in other words if you think of the arc lying on the surface of the earth then it can t cross the equator In ARC events when X Center Y Center and Z Center are programmed incrementally they are referenced from X End Y End and Z End respectively An ARC event may be programmed with a CONRA D if it is connective with the next event this next event must lie in the same plane as the Arc event Note When an arc is a 180o arc there are several paths that all have the same beginning ending and center locations To illustrate Imagine that if you were on the earth s equator and you wanted to get to the other side of the earth you could
217. ve up to the Z Rapid position and back down unnecessarily However to be connective you m ust be certain that the X Y Z begin of the first event once offset or rotated coincides with the X Y Z end of the last event Program an event parallel to X or Y where the geometry is the easiest to describe rotate it to the desired position and then delete the original Use the Clipboard to paste previously stored events from another program into the current program After you press the Clipboard key you will enter the offset from the previous program s absolute zero to the current program s ab solute zero see figure below For information about putting events into the clipboard see Section 11 4 Figure 8 10 In the above example the offset that puts the group of holes in the desired location is X 1 50 and Y 1 00 72 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 8 11 Finishing Teach Events Teach events are either POSN DRILL or MILL events that are originated in the DRO Mode see Section 6 6 The Teach events that are started in the DRO Mode must be finished in the Program Mode before running Teach events are of these different types TEACH POSN DRILL See Section 8 1 for a description of Position Drill event prompts TEACH MILL a straight line that specifies the beginning and the end When TEACH MILL events are defined using the CONT M
218. vement G Code 2 One M Code per block 152 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 153 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 16 0 Sample Programs 16 1 Sample Program No 1 Basic 2 Axis Program This program is designed to give you practice on programming 2 axis events for 3 axis CNC programming To practice on 2 axis CNC simply ignore the Z prompts The Program All programs start by first selecting Program from the front panel softkeys You may enter in an alphanumeric program description or simply press Go to Begin to get started The following program assumes the plate is clamped to machine the bolt hole pattern After the bolt hole pattern is machined the holes are used to fix the plate to a tooling plate Where you see SET below means that either the INC SET or ABS SET key may be used 154 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Sample Drawing 1 EVENT 1 Bolt Hole NOTES center drill DRILL O R BORE OF HOLES X CENTER Y CENTER Z RAPID Z END RADIUS ANGLE OF PECKS FOR DRILL Z FEEDRATE TOOL 1 5 ABS SET 0 ABS SET 0 ABS SET 3 ABS SET 3 ABS SET 33 SET 45 SET 1 SET 125 SET 1 SET Drill Function Known print value Use
219. vent prompts TEACH MILL a straight line that specifies the beginning and the end When TEACH MILL events are defined using the CONT MILL softkey the prompts for information that cannot change will be suppressed See Section 9 4 for a description of Mill event prompts When a Teach event is unfinished the words NOT OK will appear next to the event type Once the prompts are completed the words NOT OK and Teach will disappear The event will become a normal MILL DRILL or POSN event 92 XYZ Machine Tools Ltd XYZ Machine Tools Ltd and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 93 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 10 0 Auto Geometry Engine A G E Programming This entire section deals with the Auto Geometry Engine A G E which is part of the Advanced Features Option If the Advanced Features Option is not active the Auto Geometry Engine is not available on your control If you sometimes need to program prints with data missing the Auto Geometry Engine alone is worth the price of the Advanced Features Option See Section 3 1 2 for more information about the Advanced Features Option When you program an Irregular Pocket or an Irregular Profile the A G E is automatically started The A G E is powerful software that works behind the easy to use geometry programming of the ProtoTRAK SMX CNC It is treat
220. w Neutral lever when the spindle is rotating Be certain the spindle ON OFF switch is in the Off position Rotate the spindle by hand to help engage the lever into the high or low position Note Shifting from the high to low range or low to high range changes the direction of rotation for the On Off switch See Section 4 2 1 4 2 7 Speed Changes For the standard vari speed head spindle speed may be varied by rotating the variable speed crank When the Programmable Electronic Head Option is installed the spindle speed is controlled by the ProtoTRAK SMX CNC See the instructions in the Program Mode DRO Mode and Run Mode CAUTION Do not rotate the variable speed crank when the spindle is stationary 4 2 8 Operating the Quill For two axis CNC models the quill may be moved up and down through its range with the quill feed handle The quill may be locked into position by rotating the quill lock clockwise Pull the handle out slightly to rotate it freely to a new position For three axis CNC models the quill is operated by the electronic handwheel mounted on the side of the Z Ballscrew and Motor Encoder Note sections 4 2 9 through 4 2 15 refer to two axis CNC models 4 2 9 Adjusting the Quill Stop Two Axis CNC Models The quill stop may be adjusted by rotating the micrometer dial nut It is locked in place with the knurled nut 4 2 10 Power Feed Engagement Lever Two Axis CNC Models Figure 4 2 10 The power feed is en
221. way but all inputs are treated as tool center It is your job to calculate and program the tool path Note Tool Path programming is part of the Advanced Features Option 40 XYZ Machine Tools Ltd XYZ Turret Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Programs generated by CAD CAM systems are always generated as Tool Path programs and are run as such even if the Advanced Features Option has is not active on the ProtoTRAK S MX CNC 5 3 Planes and Vertical Planes A plane is any flat surface If that surface lies flat on the table it is the XY plane That is if you move your finger along that surface or plane you are moving in the X and or Y direction but not in Z or at least not until you pick your finger up If you tilted that surface think of it as a piece of paper straight up so that it faces the front of the machine it would be in the XZ plane If you tilted it up so that it faced left or right it would be in the YZ plane A vertical plane is any plane or surface tipped up on its edge on the table see below Programming vertical planes requires the Advanced Features Option Section 3 1 2 Unlike most CNC controls the ProtoTRAK SMX CNC can machine arcs in any vertical plane rather than just XZ or YZ 5 4 Absolute amp Incremental Reference The ProtoTRAK SMX CNC may be programmed and operated in either or in a combination of absolute or incremental dimensions An abs
222. when this event begins to run 3 Pulse Indexer Activates a 0 3 second electronic pulse at the beginning of the event See note below AUX END options 0 None No Auxiliary functions will turn off at the end of this event 1 Coolant Air Off Turns the coolant or air solenoid off at the end of this event 3 Pulse Indexer Activates a 0 3 second electronic pulse at the end of this event See note below 4 Spindle Turns off the spindle at the end of this event Note the spindle automatically turns off for each tool change it is not necessary to program a spindle off Coolant Air on and off is automatically programmed for tool changes If you want the air or coolant pump on while cutting the entire part you need only program the Aux begin in the first event and Aux end in the last event The coolant pump or air solenoid will turn on at the beginning of the programmed event and will turn off during tool changes The Pulse Indexer function is designed to operate with a standard indexer Programming an Aux 3 at the end of an event will cause the ProtoTRAK SMX CNC to stop machining at the end of the event and wait for a signal from the indexer or rotary table that it has finished its programmed move then it will resume machining at the next event If you want the ProtoTRAK SMX CNC to return the head to the Z retract position before moving to the next event put the Aux 3 command in a Pause event The ProtoTRAK SMX CNC will interpret
223. xis CNC Models Whether or not the TRAKing Electronic Handwheels Option is active XYZ Turret Mills with the Z axis ballscrew and motor assembly installed for three axis CNC will have this feature enabled for manual quill operation Simply follow the instructions above If the TRAKing Electronic Handwheels Option is not active only the Z will be available for setting a Go To dimension 6 7 Teach Teach gives you the ability to enter X and Y dimensions into a program It can be a useful way of entering a few manual moves for operations like clearing out excess material or remembering a few hole locations The process of using Teach is in two parts The first part takes place in the DRO Mode This is where you start the Teach program establish the program events and enter the X and Y dimensions The second part is in the Program Mode This is where you complete the Teach events that you began in the DRO Mode by entering the rest of the data Once the data is entered the Teach events become just like the other events that make up a program 6 7 1 Entering Teach Data From the DRO screen press Teach On the top of the screen you will see the message Teach and an event counter When you enter Teach you are actually programming events If there is already a program in current memory Teaching will add events to the end of the program If there is not already a program in current memory Teaching will start a new program For example if yo
224. xt but wish to make a change you will see a blue question mark appear on the lower left corner of the screen when you scroll to this field press the Help button and the alpha keys will appear FEEDRATE The feedrate of XYZ along the path of the text Tool is the tool number you assign 69 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual FIGURE 8 8 The above figureshows the text and special characters available for the Engrave event Notice the field that is labeled Text Length This field will display the total length of your programmed text and will update as you enter each character 8 9 Subroutine Events The Subroutine Events are used for manipulating previously programmed geometry within the XY plane The Subroutine Event is divided into three options Repeat Mirror and Rotate Repeat and Rotate may be connective As long as the rules of connectivity are satisfied see Section 5 9 the ProtoTRAK SMX CNC will continue milling between preceding and subsequent events REPEAT allows you to repeat an event or a grou p of events up to 99 times with an offset in X and or Y This can be useful for drilling a series of evenly spaced holes duplicating some machined shapes or even repeating an entire program with an offset for a second fixture Repeat events may be nested That is you can repeat a repeat event of a repeat event of some programmed
225. xtures offset Answering Yes will cause a prompt to appear at each event asking which fixture the event was referenced from If you select Yes the Data Input Line will ask you to enter a fixture default number from one to six The fixture default number is the fixture that will be applied to all the events in current memory when Multiple Fixtures is turned on or when a new event is programmed without another event being specified Enter the default fixture or leave the number unchanged and press SET Multiple Fixtures are explained more fully in Section 7 5 This function is part of the Advanced Features Option Dimension Definition The ProtoTRAK SMX CNC gives you a choice in programming either tool path or geometry Part Geometry programming allows you to define the geometry you want your part to have and then the CNC does the difficult job of calculating tool path for you automatically This is a great benefit for most parts most of the time because it means that the CNC is doing the hard work of determining tool position 52 XYZ Machine Tools Ltd XYZ Turret Mill and ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual One restriction to part geometry programming is that for events to be connective they must lay on the same plane see Section 5 3 for a definition of planes For this reason the ProtoTRAK SMX CNC gives you the option of entering your own tool path If you wish to program the part by defining tool p
226. y repairs exchanges do not cover incidental costs such as installation labour freight etc XYZ is not responsible for consequential damages from use or misuse of any of its products ProtoTRAK products are precision mechanical electromechanical measurement systems and must be given the reasonable care that these types of instruments require Replacement of slideway wipers and covers is the responsibility of the customer Consequently the warranty does not apply if chips or coolant have been allowed to enter the mechanism Accidental damage beyond the control of XYZ is not covered by the warranty Thus the warranty does not apply if an instrument has been abused dropped hit disassembled or opened Improper installation by or at the direction of the customer in such a way that the product consequently fails is considered to be beyond the control of the manufacturer and outside the scope of the warranty

XYZ Turret Mill ProtoTRAK SMX CNC

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