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Operating Manual - Clark Science Center

1. Southwestern Industries Inc TRAK SX Knee Mill amp Proto TRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 16 17 18 19 20 21 22 23 24 25 26 27 Avoid getting pinched in places where the table saddle or spindle head create pinch points while in motion 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 Use correct cutting parameters speed feed depth and width of cut in order to prevent tool breakage Use proper cutting tools for the job Pay attention to the rotation of the spindle Left hand tool for counterclockwise rotation of spindle and right hand tool for clockwise rotation of spindle 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 Check the direction or of movement of the table when using the jog or power feed 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 Large overhang on cutting tools when not required result in accidents and damaged parts Prevent fires When machining certain materials magnesi
2. 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 Models The ProtoTRAK EMX CNC is featured in the following products Model Description Retrofits PTEMX Two axis CNC retrofit to your knee mill Knee Mill TRAK KEMX Two axis CNC 33 x 15 5 3 HP Non Current Knee Mills TRAK K2 EMX Two axis CNC 33 x 12 3 HP TRAK K3 EMX Two axis CNC 32 x 16 3 HP TRAK K4 EMX Two axis CNC 32 x 16 5 5 HP 1 2 Manual Organization Notes This manual covers the operation of the retrofit and TRAK K Mill products that use the ProtoTRAK EMX CNC Some Sections do not apply to all users For example if you own a ProtoTRAK retrofit you should skip the sections that cover the description and operation of TRAK K Mills 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 1 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 2 0 Safety The safe operation of your knee mill depends on its proper use and the precautions taken by each operator 2 1 2 2 Read and study this manual Be certai
3. 4 0 Basic Operation 7 7 Incremental Reference Position 4 1 ProtoTRAK EMX Basic Operation 18 7 8 Finish Cuts 4 1 1 Switching the control on amp off 18 7 9 Look 4 1 2 Screen Saver 18 7 10 A Sample Program 4 1 3 Modes 18 4 1 4 Emergency Stop 19 jo Machine Operation 19 8 0 Changing or Correcting Programs 4 2 1 Spindle Forward Off Reverse 4 2 2 Table Saddle Knee Clamps 4 2 3 Raising Lowering the Knee 4 2 4 Spindle Brake 4 2 5 Draw Bar 4 2 6 High Low Neutral Level 4 2 7 Speed Changes 4 2 8 Operating the Quill 4 2 9 Adjusting the Quill Stop 4 2 10 Power Feed Engagement Lever 4 2 11 Fine Feed Direction Shaft 4 2 12 Quill Feed Selector 4 2 13 Feed Trip Lever 4 2 14 Fine Hand Quill Feed 4 2 15 Fine Automatic Quill Feed CoOwwoe ow ow NOUBRWNES Deleting a Partially Programmed Event Editing Data while Programming an Event Editing Previously Programmed Events Changing the Feedrate Changing a Part Number Copy a Program Saving Changes to a Program Erasing an Entire Program Making Parts with the CNC Setting Up Starting Up Display Messages in Program Run Program Run Prompts Stop Feedrate Override Trial Run TRAK EMX Knee Mill and ProtoTRAK EMX CNC Safety Programming Operating and Care Manual Data Errors 45 Fault Messages 45 OO 10 0 Math Help 10 1 Procedure 46 10 2 Math Help Types 48 11 0 Program Memory and Storage 11 1 Cautions About Opening amp Deleting Progs 49 11 2 Program Formats a
4. Radius Angle Tool First Event Tool 2 is a 1 4 drill Last Event X Offset Y Offset No Of Repeats Tool X Center e Tool 3 is a 1 2 end mill Y Center Radius Direction Fin Cut Feed Rate Fin Feed Rate Tool Tool Dia X Begin Y Begin X End Y End Conrad Tool Offset Feed Rate Tool Tool Dia Continue 77 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual X End Y End Conrad Continue X End Y End X Center Y Center Conrad Direction Continue X End Y End Conrad Continue 1 6445 abs 0 5990 abs 0 Yes 1 6445 abs 0 inc 0 abs 0 abs 0 CCW Yes Use Math Help Type 17 to find the tangency point of the line to the arc See math help section X End is the same value but positive because of the part s symmetry about the center point 78 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual Program 3 R 1 250 ar R 625 Z 100324 a 3 250 ag This sample part was programmed using the center of the left arc Point A as the program absolute zero The event numbers are shown in the circles e Programming Aspects Shown on This Part Profile milling Math Help to calculate arc and line tangency points e Program Notes Events 1 through 6 mill t
5. e Circle frame a circular circumference Includes finish cut e Rectangular frame a square or rectangular circumference Includes finish cut When the program is run at a Frame Event the ProtoTRAK EMX will rapid from wherever it is to 3 o clock on circular pockets and frames and X1 Y1 on rectangular pockets and frames After you set the cutter and press go it will move through the first pass and then the finish cut at the programmed feedrate and then move the cutter away from the part by the amount of the programmed finish cut The Pocket Event will rapid to the center of the circle or rectangle After you set the cutter and press GO it will move in a logical path through the material leaving the finish cut if one is 34 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual programmed using 70 of the cutter diameter After the center is cleared it will do the finish cut and ramp away from the part at the end by the amount of the programmed finish cut 7 3 5 Repeat Events This allows you to repeat an event or a group of events up to 99 times with an offset in X 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 Another use is to repeat a programmed set of drill events without offsets so you can center drill drill and
6. For some of the codes there are additional instructions 12 2 Service Code Types Code Description Notes 12 Determine feed forward Runs a routine that determines the system friction constant for setting feed forward constant Caution Do not use this code unless you understand the consequences For more details see SWI Publication No 26055 ProtoTRAK EMX Installation and Service Manual 13 Reset the default feed forward In case you ignored the warning above this resets constant the default set at the factory 15 Activate or Deactivate Z The Z axis readout should be activated if you readout installed the optional Z axis scale This may be added to your system at any time and the Z readout activated by this code 22 Turn on simulation For demo purposes the ProtoTRAK EMX may be run in simulation mode where the control operates normally but does not send commands to the motors If you use this code don t forget to restore your CNC to normal operation with Service Code 89 Simulation mode is also cancelled by turning the control on and off 33 Software ID Displays the version of software your ProtoTRAK EMX is using 54 Continuous run mode Keeps running the system through the program without stopping It is used for testing 66 Metric mode To have the ProtoTRAK EMX power up in Metric measurement 67 Inch mode To have the ProtoTRAK EMX power up in Inch measurement 79 Turn on beeper Fa
7. Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual Manual Operation Now press the DRO soft key from the Select Mode screen above The screen will once again show DRO INCH JOG X 0 000005 E Y 0 0000 rcs Z 0 00005 CODES 101284 Do the following l Press X ABS SET Y ABS SET X INC SET Y INC SET This will zero or reset the absolute and incremental readouts Press the INC ABS key Notice that the ABS on the screen changes to INC Manually crank the X handwheel so that the table moves left Move the table so that the readout is X 1 0000 INC Manually crank the Y handwheel so that the saddle moves away from you Move the saddle so that the readout is Y 1 0000 INC Press X INC SET and Y INC SET to reset the X and Y incremental readout to zero Move X another inch to 1 0000 INC and Y another inch to 1 0000 INC Press the INC ABS function key to show your absolute position That is how far you have moved from Step 1 above where you set absolute X should read 2 0000 ABS and Y 2 0000 ABS Press X ABS SET Y ABS SET to reset absolute to the position you re at now 64 Southwestern Industries Inc TRAK EMX Knee Mill amp Proto TRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual JOG Do the following 1 Fold up the X and Y handwheels pull out then fold up WARNI NG Never ope
8. Tool Dia 25 INC or ABS SET Note We want to visit the same two holes in the same place with a different tool to do the final drilling Look at what you have programmed Press the LOOK key You will see two marks on opposite sides of the screen to show where the holes have been programmed Press RETURN to get back to the programming Program the slot 40 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual Prompt You push these keys Event 4 SELECT EVENT MILL X Begin 4 25 ABS SET or 2 5 INC SET Y Begin 8 ABS SET X End INC SET Y End 1 3 INC SET Conrad INC SET Tool Offset 0 INC or ABS SET Feedrate 7 5 INC or ABS SET Continue 2 INC or ABS SET Tool 3 INC or ABS SET Tool Dia 375 INC or ABS SET 10 Look at the program again If all went well you should now see the two holes and slot tool path in the same proportion as they appear on the print If not check your inputs and try again When you machine the part you will probably want to use a drill to open up a hole at the beginning of the slot for your milling tool To do that you can either e program a position event for the drill or e when the ProtoTRAK EMX positions at the beginning of the slot center drill and drill first then put in your mill If you have a lot of parts to do it is worth your while to
9. 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 Repeat event the event numbers will increase by one as when you insert another kind of event DELETE EVENT this will delete the event on the right side of the screen 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 PROG EVENT 0 EVENT 1 DRILL PROGRAM NAME ARC POCKET FRAME REPEAT i01281 33 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 7 3 Programming Events The following events are found in the ProtoTRAK EMX 7 3 1 Posn Drill This will position the table and saddle to the location you define This event is used for drilling holes and other positioning moves When you press the POSN DRILL key you choose between e One a single position Bolt Hole a series of positions spaced evenly around a circle When the program is run at a Posn Drill Event the ProtoTRAK EMX will servo at rapid or as modified by you to each location defined and will wait for you to finish the operation e g drill the hole and press the GO key before movin
10. A C Inlet To plug in the incoming 110v power The on off switch is located directly below this inlet 3 2 3 Servo Motors Amplifiers The ProtoTRAK EMX servomotor and amplifier have been combined into a single integrated package on each axis The motors are rated 280 in oz maximum continuous torque that is sufficient for the heaviest cuts 3 2 4 The Z Scale In order to have the Z axis digital readout it is necessary to have the optional Z axis scale The Z readout may be activated or deactivated with Special Code 15 3 2 5 Ballscrews Precision ballscrews are installed in the table and saddle to ensure smooth traverse and positive control for manual and CNC machining 11 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 3 3 TRAK Knee Mill Specifications See Figures 3 3 1 and 3 3 2 This section describes the TRAK Knee Milling machines it does not apply to ProtoTRAK EMX retrofits SPINDLE MOTOR SPINDLE BRAKE X AXIS MOTOR ASSEMBLY QUILL HANDLE X AXIS HANDWHEEL Y AXIS HANDWHEEL NOTES i01270 Y AXIS 1 BOX WAY MACHINE MOTOR SHOWN ABOVE ASSEMBLY FIGURE 3 3 1 The TRAK Knee Mill Machine Overview 12 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual COOLANT PUMP ACCESS 101272 FIGURE 3 3 2 The TRAK Knee Mill bac
11. EMX internal storage do the following Plug the Thumb Drive into the ProtoTRAK EMX USB port Go to the DRO Mode Press Serv Codes Under group A Software Service Codes select code 341 Copy Files from USB Drive to Control 5 All the programs saved in the folder Programs on the thumb drive will also be saved on the ProtoTRAK EMX internal storage Sade If there are programs with the same name in the destination location you will be asked by the ProtoTRAK EMX if you want to overwrite the existing file Programs of different names on the destination location will not be affected In keeping with our philosophy to make the ProtoTRAK EMX as simple as possible we have elected the simplest possible program storage routines File transfers between the ProtoTRAK EMX and thumb drive will move all programs between the two This eliminates the complexity of adding file management to the ProtoTRAK EMX system Files may be managed on the thumb drive with your offline computer 11 5 CAM G Code files The ProtoTRAK EMX allows you to open CAM G Code files and convert them into the Prototrak EMX programming format First you must transfer the programs into the Prototrak s internal memory as described in section 11 4 The filename must be numeric no more than 8 digits long and have a CAM file extension The supported G Code format is identical to that of any of our past 2 axis controls that had the CAM option 51 Southwestern I
12. SPINDLE Feed Rate l PRESS GO FOR CNC RUN Svewide TIo i01282 The part number appears in the status line To start the program select between START and START EVENT e START starts running the program from the beginning e START EVENT starts running the program from an event in the middle If you press this key you will be prompted to enter the event number for where to start 9 3 Display Messages in Program Run IN POSITION appears in the status line when the program has come to a pause EVENT and type This is the current or next event to be run REPEAT the number of the repeat for repeat events FEEDRATE the actual table feedrate OVERRIDE the feedrate override controlled by pressing the up or down arrow keys above and below the soft keys 44 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 9 4 Program Run Prompts During Program Run messages that direct you will appear in a green box The ProtoTRAK EMX will wait until you press Go before moving the servo motors What you need to do is obvious in most cases Below is some supplemental information Check Z Means to make sure the quill is properly retracted because the next move will be rapid Press GO to continue Set Z Means to drill and retract the quill for a drilling operation or set and lock the quill to the proper depth for a milling cut Press GO to
13. Tool You input 2 SET because we re calling the 3 8 end mill tool number 2 e Tool Dia Your press 375 SET e Continue You input No SET because this is not continuous path milling wait to Sample Part 2 Event 5 The Lower Left Radius e Select Event You input soft key ARC for Event 5 e X Begin You input 0 ABS SET because we re going to start at the top and mill down and right e Y Begin You input 5 ABS SET e X End You input 5 ABS SET e Y End You input 0 ABS SET e X Center You input 5 ABS SET or we could have input 0 INC SET since the X Center is the same as the X End e Y Center You input 5 ABS SET e CONRAD You input 0 SET e Direction You input 2 SET because we are milling in a counterclockwise direction e Tool Offset You input 1 SET because looking from beginning towards end the direction of the tool cut the tool is to the right of the work piece Think about this to be sure you understand e Feedrate You input 5 SET e Tool You input 2 SET because that s still our tool e Tool Dia You input 375 SET or ONC SET e Continue You input No SET because this is not a continuous milling path Event 6 The Circular Pocket e Select Event You press POCKET FRAME soft key for Event 6 e Select You press CIRCLE POCKET soft key because our pocket is circular e X C
14. and press SET 5 Program the first hole 39 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 9 Notes Event 1 Prompt You push these keys SELECT EVENT POSN DRILL SELECT ONE X 715 ABS SET Y 2 ABS SET Tool 1 INC or ABS SET Tool Dia 1 INC or ABS SET e For the non referenced data either SET key will do e This first tool is a center drill For the Position Drill Event the program will run without a tool diameter but one may be entered as a reminder Program the second hole Prompt You push these keys Event2 ELECT EVENT POSN DRILL SELECT ONE X 1 INCSET Y INC SET Tool INC SET Tool Dia INC SET Notes e For the dimensions it was handy to read these right off the print and put them in as incremental moves from the previous hole We could have also programmed using X 1 75 ABS SET and Y 2 0 ABS SET e The INC SET entry for Y was taken as a 0 incremental move you do not have to press 0 e The INC SET for the Tool and Tool Diameter were taken as use the data from the previous event Repeat the holes to drill to size Prompt You push these keys SELECT EVENT REPEAT Event 3 First Event 1 INC or ABS SET Last event 2 INC or ABS SET X offset INC SET Y offset INC SET No of Repeats 1 INC or ABS SET Tool 2 INC or ABS SET
15. answer the questions that define the geometry 66 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual Our plan for this part is 1 2 3 8 The lower left corner of the part will be our absolute zero or absolute reference Drill the left most hole in the row using a Drill Event Drill the next 3 holes using a Repeat Event Drill the 8 hole bolt circle pattern using a Bolt Hole Event Mill the diagonal in the upper left corner using a Mill Event Mill the arc in the lower left corner using an Arc Event Mill the circular pocket with a Pocket Event Mill the through rectangle with a Frame Event Making and I nputting the Program Press MODE and then press PROG soft key to enter the Program Mode The Program Part Number The conversation display says Program Name You input 123 SET INC SET or ABS SET Event 1 The First Hole Conversation says Select Event You press POSN DRILL soft key Now press ONE to select the single hole The right side of the information area shows that Event 1 is a Position Drill and it lists what data is required But keep your eye on the conversation line Conversation says X You press 2 75 ABS SET Remember the lower left corner is our Absolute zero Y You press 75 ABS SET TOOL Your press 1 SET Tool number 1 is the 1 4 drill so press 25 SET
16. continue Run Over Means that the program run is complete If you are running a second part that will be fixtured clamped in the exact same position as the first part you do not need to relocate the absolute 0 and restart Instead press the NEXT PART softkey when the conversation line states Run Over and the system will proceed directly to Event 1 9 5 Stop At any time pressing the STOP key will halt the program This freezes the program at that point To continue press the GO key 9 6 Feedrate Override The run feedrate may be changed at any time by pressing the up and down arrow keys to the right of the LCD screen Each press changes the programmed feedrate as well as the rapid feedrate in 10 increments The maximum overrides are from 10 to 150 of programmed feedrates 9 7 Trial Run Before cutting material it is recommended that you do a trial run by keeping the quill up while the program runs through Verify that the absolute reference is set correctly 9 8 Data Errors A program must make sense geometrically For example you can t machine a 250 inch diameter circular pocket using a 500 inch end mill Data errors will nearly always be detected when the ProtoTRAK EMX runs through a program either as a trial run or on an actual part run The Error message displays the error number not necessarily important to you and the event where the error was detected This is not necessarily the event that is in error since the s
17. counterbore without reprogramming the second and third operations Repeat events may be nested up to five deep That is you can repeat a Repeat Event of a Repeat Event of a Repeat Event of some programmed event s One new tool number may be assigned for each Repeat Event 7 3 6 Subroutine Events The Subroutine Events are used for manipulating previously programmed geometry within the XY plane The Subroutine Event is divided into two options Repeat and Rotate Repeat and Rotate may be connective As long as the rules of connectivity are satisfied see Section 5 5 the ProtoTRAK EMX 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 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 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
18. data forward data back to move through the data in an event Middle five keys These keys are called software programmable or soft keys A description of the function or use of each of these keys will be shown on the LCD screen next to each key If at any time there is no description above a key that key will not operate Emergency Stop Switch The emergency stop E stop switch kills all power to the ProtoTRAK s servomotors The computer and pendant remain powered The Liquid Crystal Display LCD The display of the ProtoTRAK EMX is a 7 active matrix color LCD The information displayed on the LCD screen is nearly always divided into 4 sections or areas The top line or status line shows the system s current status This includes the mode inch or mm measurement and part numbers Beneath the status line and filling most of the screen is the information area Position data program data and graphics are shown here In addition message windows will be here in the information area Beneath the information area is a single conversation line When numeric data is required the conversation line will appear for you to see the numbers you enter before they are set into the system On the right side of the LCD are boxes describing the current function or use of each soft keys located next to them 9 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care
19. 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 4 Tool Diameter Compensation Tool diameter compensation allows the machined edges shown directly on the workpiece to be programmed instead of the center the tool The ProtoTRAK EMX then automatically compensates for the programmed geometry so that the desired results are obtained If the cutter in the sketch above is moving from left to right from point X1 Y1 to X2 Y2 and on to X3 Y3 these actual points can be programmed instead of the center of the cutter X Or the actual desired circle with radius R can be programmed instead of the radius of the center of the cutter Rc Tool cutter compensation is always specified as the tool either right or left of the workpiece while looking in the direction of the tool motion 26 Southwestern Industries Inc TRAK EMX Knee Mill amp Proto TRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual Examples of tool right are Examples of tool left are PrE go R Tool center means no compensation either right or left That is the centerline of the tool will be moved to the programmed points 5 5 Connective Events Connective events occur between two milling eve
20. e given X Y Center e 2 points on the arc 28 Sides and angles of a right triangle e at least one side and another side or an angle 48 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 11 0 Program Memory amp Storage The ProtoTRAK EMX can only have one program at a time in current memory This is the program you see when you enter the program mode and is the one that is available to run Programs may be stored for future use on the ProtoTRAK EMX internal storage Part programs are saved to storage or opened from storage in the Program In Out Mode When programs are transferred back and forth from current memory and storage they stay in both locations unless erased or cleared In other words opening a program from internal storage into the current memory does not remove it from the internal storage Only deleting the program will remove it 11 1 Cautions About Opening and Deleting Programs Care must be taken to keep from losing a program you wish to keep This can happen two ways First whenever a program is opened it is loaded into the ProtoTRAK EMX s computer program memory When this happens your existing current program is erased Therefore if your current program is one you want to keep be certain to store it before you retrieve another program Second to store a program it must have a part number so that the ProtoTRAK EMX can fi
21. even without power until you intentionally erase it Do the following 1 Press MODE and select the PROG IN OUT soft key 2 The conversation line says Part Number 123 If you wanted to change the part number you could just put in a new one at this time You press SAVE soft key and wait a few seconds until it s complete Notice your new part number 123 is now in the list Program Run Preparation Set Up the Workpiece If you want to make the part take a piece of 6 x4 x 25 aluminum and lock it into the vise as shown below Use step jaws or parallels Use step jaws or parallels Make sure the material sticks out to the left of the vise by about 1 1 2 inch Set the part zero 1 Press MODE and select DRO soft key 2 Use your edge finder to position the spindle over the bottom left corner of the part Remember this was our program absolute zero 3 Press INC ABS to be sure the display reads the absolute position ABS 71 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 4 Press X ABS SET Y ABS SET to reset the ProtoTRAK absolute zero to the same position as the program absolute zero This is how we tell the ProtoTRAK where the part is Program Run This is where we make the part Do the following Enter the Run Mode e Press MODE and select RUN soft key e The conversation line says Select Press START soft ke
22. labels on the machine are orange in color CAUTION Hazards or unsafe practices that cou d 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 2 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual TN S O SOUTH WESTERN INDUSTRIES VF j 2615 HOMESTEAD PLACE RANCHO DOMINGUEZ CA 90220 MODEL S ELECTRICAL RATINGS OUTS SS IAPS 3 PHASE 60_ Hz FLA OF LARGEST MOTOR AMPS SHORT CIRCUIT INTERRUPT AMPS ELECTRICAL DRAWING 20508 1 CNC CONTROL ELECTRICAL RATINGS IF APPLICABLE VOLTS 8 JAMPS T PHASE o Hz MACHINE ONLY MADE IN 00000 tf i00902 O Safety amp Information Labels Used On The TRAK Knee Mills It is forbidden by OSHA regulations and by law to deface destroy or remove any of these labels Retrofit customers please see the manual that came with your machine for information about safety and information labels 3 Southwestern Industries Inc TRAK SX Knee Mill amp Proto TRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual HIGH VOLTAGE 220 440 VOLTS WARNING IMPROPER INSTALLATION OR OPERATION OF THIS MOTOR MAY CAUSE INJURY TO PERSONNEL OR MOTOR FAILURE READ OPERATING INSTRUCTIONS MOTOR MUS
23. other line e angle between the lines 12 Intersection of two lines e 2 points on one line e 1 point on the other line e a radius tangent to both lines when one of the points on the two points known line is also on the radius 13 Intersection of a line and an arc e 2 points on the line e arc center e arc radius 14 Intersection of a line and an arc e 2 points on the line e 2 points on the arc e arc radius 15 Intersection of two arcs e center of each arc e radius of each arc 16 Intersection of a line tangent to two arcs e center of each arc line does not cross arc centers e radius of each arc 17 Intersection of a line tangent to an arc e one point on the line e center of the arc e radius of the arc 18 Intersection of a line tangent to two arcs e center of each arc line crosses arc centers e radius of each arc 19 Center and points of intersection of an arc e 2 of the arc centers tangent to two arcs e all 3 radii 20 Center of an arc e 2 points on the arc e radius of the arc 21 Point on an arc e center of the arc e another point on the arc e angle between known and unknown points 22 Radius of an arc or circle e 1 point on the arc e center of the arc 23 Center of an arc or circle e 2 points on the arc e angle between the 2 points 24 Center and radius of an arc or circle e 3 different points on the arc 25 Cartesian X and Y location e polar R and angle coordinates 26 Angle in decimal e angle degrees minutes and seconds 27 Accurate X Y Center
24. raise the tool Mill the Lower Left Radius e Press GO The tool will rapid to the beginning position for the Arc cut e Set Z Lower the tool to the correct depth and lock the quill 72 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual Press GO The tool will move at 5 ipm and cut the arc Check Z You should raise the tool Mill the Circular Pocket Press GO The tool will rapid to about the center of the pocket Set Z Bring the tool down or the knee up to 100 below the top of the part and lock the quill Press GO The tool will move at 8 ipm to machine the pocket Press the T and J keys while cutting the pocket to see how you can adjust the speed while you re cutting When the pocket is hogged out a little undersized the cutter will automatically make the program 020 finish cut Check Z You should raise the tool Mill the Through Rectangle Press GO The tool will rapid to the beginning point to machine the rectangular frame thru Set Z Move the quill down so that the tool is slightly below the bottom of the plate Lock the quill Press GO The tool will move at 5 ipm if you left the feedrate override at 100 when you adjusted T and 4 to machine the rectangle and make the finish pass Run Over The part is finished If you were making a second part and could locate it in the vise in the
25. screen will show three choices for finding the intersection of a line with different information given 46 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual If the information you know about the line and arc correspond to Type 13 then select the 13 softkey The screen will then show MATH INCH TYPE 13 0 0000 0 0000 2 0000 0 0000 0 2500 0 2500 moe DATA UP DATA DOWN RETURN R1 ny i01280 Input the known data in the same way you would program an event When all of the data is entered the solution or solutions if there are more than one will be shown on the left side of the information area There are often multiple solutions for geometry problems For example in the Type 13 example above a line will often intersect an arc or circle in two places In these cases all possible solutions will be calculated and displayed In most cases a careful inspection of the print and some common sense will tell you which solution applies to your problem 47 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 10 2 Math Help Types Type What you need What you know 10 Intersection of two lines e 2 points on each line 11 Intersection of two lines e 2 points on one line e 1 point on the
26. the next event Since this is not always completely clear there are some sensible rules for what the ProtoTRAK EMX looks at in the previous event when the first dimensioned data is entered as an INC SET For events such as Mill that have an X Y beginning and an X Y end the second set of data is always referenced from the first 25 Southwestern Industries Inc TRAK EMX Knee Mill amp Proto TRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual If the event is a e DRILL then an incremental move is from the X Y programmed in that previous event e BOLT HOLE then an incremental move is from the X CENTER Y CENTER programmed in that event e MILL then an incremental move is from the X END Y END programmed in that event e ARC then an incremental move is from the X END Y END programmed in that event e CIRCLE POCKET or FRAME then an incremental move is from the X CENTER Y CENTER programmed in that event e RECTANGLE POCKET or FRAME then an incremental move is from the first or X1 Y1 corner programmed in that event e REPEAT then an incremental move is the same as for the event types shown above but shifted by the programmed OFFSET 5 3 Referenced and Non Referenced Data Data is always loaded into the ProtoTRAK EMX 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
27. to make sure you re not at zero 3 Press the RETURN ABS 0 soft key 4 Press GO System prompts to Check Z press GO again The table and saddle will automatically move to the absolute zero you set earlier 65 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 13 3 Programming Sample Part 1 The purpose of this sample is to demonstrate most of the various event types or canned geometry s that can be programmed Also to give you practice inputting data and running an actual part If you don t want to machine the part just follow along with the instructions for how to use the ProtoTRAK EMX Pocket 100 deep 1 4 holes thru 12 places i00686 Preparation If you want to make this part you will need the following 1 A vise if the vise does not have step jaws you will also need parallels 2 A1 4 drill 3 A 3 8 2 flute bottom cutting end mill 4 An edge finder or wiggler 5 A piece of 6 x 4 x 250 aluminum Program Strategy Before programming a part take a moment to figure out what you want to do and what order you want to do it The strategy for programming a ProtoTRAK EMX is pretty straightforward e identify the geometry you want to machine from the print and the order you want to machine it what to machine first second etc e select each geometry event on the control one at a time e
28. 0 MX2 8 105004 Mx2 B 140004 Mx2 3 18 MX2 105005 MxX2 A 140005 Mx2 5 2 MX2 DELETE 105006 MX2 5 140006 Mx2 5 22222 MX2 105007 MxX2 5 140007 MX2 33051 MX2 105008 MX2 5 140008 Mx2 333 MX2 amp 105009 Mx2 amp 140009 Mx2 3 333 MX2 ERASE 344MX2 S 140010 MX2 5 4 MX2 PROG 8 111291 Mx2 5 140011 Mx2 54051 MX2 5 140013 MX2 545 MX2 PAGE Program Name fi FWD i01280 A view of Program In Out Mode with a few programs saved e All part numbers in the ProtoTRAK EMX internal storage are listed in the Information Area e The part number of the current program in current memory is shown in the conversation line You may change the part number at this screen by entering a new number and pressing SAVE e OPEN will write a program from the internal storage to current memory First input the part number and then press the OPEN key Then you will have the option of either opening as an MX2 or CAM file type For more on CAM files and G Code see section 11 5 e SAVE will write the program in current memory to the internal storage You will see the program added to the list in the information area after it is stored e DELETE will erase a program from the internal storage First input the program number and then press the DELETE key e ERASE PROG will erase the program from current memory You do this to clear current memory in order to write a new program e The PAGE FWD Forward softkey will continue the part number list if there are too m
29. 100 inches per minute A message will flash to warn you that J OG is activated Press to reverse direction The feedrate box will change to 100 Press again to go back to JOG the is not shown Press the down arrow key to the right of the LCD screen to reduce the jog speed in 10 percent increments The feedrate and override boxes will show these adjustments Press the up arrow key to increase the speed The range is between 10 and 150 Press and hold X or Y to jog that axis Release the key to stop To jog at a given rate for example 25 inches per minute simply press 25 while the jog message is flashing This number will appear in the feedrate box When you press X or Y you will jog at this rate Press the up or down arrow keys to adjust In metric this number represents the percent of the maximum or 2540 mm min Press RETURN soft key to return to manual DRO operation 6 4 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 softkey When you do the conversation line will read Ready to begin Press Go when ready Make sure your tool is clear and press the GO key When you do the servos will turn on 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 5 Power Feed The servomotors can be used as a power fee
30. Event 2 The Next 3 Holes Select Event You press the REPEAT soft key for Event 2 to make the next 3 holes in the row Event 2 is a Repeat Event and the data needed is shown on the right of the information area Notice Event 1 has shifted to the left First Event You press 1 SET because we want to repeat Event 1 Last Event You press 1 SET because the only event we want to repeat is Event 1 67 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual e X Offset You press 75 INC SET because that s the distance between the holes in the X direction e Y Offset Your press 0 INC SET because the other holes are not shifted in the Y direction e Repeats Your press 3 SET because we want 3 more holes each offset by 75 inch e Tool You press 1 SET because we re using the same tool Event 3 The Bolt Hole Pattern e Select Event You press POSN DRILL then the BOLT HOLE soft key for Event 3 e Event 2 has shifted to the left and the data you need to input is shown on the right e Holes You press 8 SET because there are 8 holes e X CENTER You press 1 5 ABS SET e Y CENTER You press 2 5 ABS SET e Radius You press 1 SET because the radius of the bolt hole pattern is 1 000 inch e Angle You press 90 SET This is the angle measured in the counterclo
31. LL BEGIN key the event counter stays on the 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 screen and return to the DRO screen The events you have defined with their X and Y dimensions are finished in the Program Mode See Section 7 3 6 31 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 7 0 Programming The ProtoTRAK EMX can be easily programmed to for a wide variety of parts in two axes A program is one or a series of events t can either be a complete part a set of operations on a side or only a small number of cuts It is necessary to create a program when you want the CNC to machine the part for you 7 1 Enter Program Mode and Assign a Program Name To start programming press MODE and select PROGRAM softkey For a new program to be written there cannot already be a program in the active or current program memory When you first enter Program Mode y
32. Manual 3 2 2 Pendant Back Panel PORTS TABLE GUARD FAN ASSY AIR IN AIR EXIT X MOTOR ACCESS TO Y MOTOR DIAGNOSTIC LED S GND Z SCALE MOUNTING BRACKET AC ON OFF 101273 Motor The X and Y motor cables are plugged in here Warning Never plug or unplug motor cables with the power on This will destroy the computer Z Scale Plug in the Z scale cable Table Guard For plugging in the interlock switch that is part of the optional table guard Not available with retrofits The USB Ports There are two USB ports use only one at a time for an optional thumb drive for program storage transferring programs between ProtoTRAKs and computers and for program backup Software updates will be through the USB port The ports are USB1 1 compliant The thumb drives listed below proved to be compatible with the ProtoTRAK EMX CNC at the time of this writing We can t guarantee that the brands won t change in some way that makes them incompatible but they work now PNY Memorex Lexar Microadvantage Delkin E Film The one we supply will definitely work so the way to be sure is to order the USB MEM from us 10 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual Test port Used by the factory for testing only Grd Ground We recommend that you ground the ProtoTRAK display to an earth ground such as a cold water pipe
33. ProtoTRAK EMX Installation and Service Manual 141 Load parameters Will take parameters from USB thumb drive 142 Save control parameters Save parameters to the USB thumb drive 316 Update software Used to update to the latest software version from the USB thumb drive 340 Back up programs Copy all the programs on the internal storage to the USB thumb drive 341 Load programs Copy all the programs on the USB thumb drive to the internal storage 54 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 13 0 ProtoTRAK EMX Tutorial The purpose of this tutorial is to help you to learn the operation and programming of the ProtoTRAK EMX We ve repeated some of the information found elsewhere in this manual so that you could go through this tutorial without flipping back and forth between pages We will not cover all the operations of the ProtoTRAK EMX just enough to get you comfortably started If you have been running a knee mill with a DRO the ProtoTRAK EMX is about to make your life a lot easier J ust stay with this program for a couple of hours and you ll be making more parts with less effort in no time We assume you know how to run a knee mill know how to read a blueprint and have at least a little experience inputting information into a box like a digital readout or a computer We told you this would be easy 13 1 Working with Definitions
34. T BE INSTALLED AND GROUNDED PER LOCAL AND NATIONAL ELECTRICAL CODES TO REDUCE POTENTIAL OF ELECTRICAL SHOCK DISCONNECT ALL POWER SOURCES BEFORE INITIATING ANY MAINTENANCE OR REPAIRS KEEP FINGERS AND FOREIGN OBJECTS AWAY FROM VENTILATION AND OTHER OPENINGS KEEP AIR PASSAGES CLEAR EYEBOLTS OR LIFTING HOOKS WHEN SUPPLIED ARE INTENDED FOR LIFTING THE PRODUCT ONLY AND MUST NOT BE USED TO LIFT ADDITIONAL WEIGHT USE ONLY GRADE 5 SHOULDER EYEBOLTS WITH MINIMUM THREAD LENGTH OF 1 1 2 TIMES DIAMETER Safety amp Information Labels Used On The ProtoTRAK EMX CNC It is forbidden by OSHA regulations and by law to deface destroy or remove any of these labels 4 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 2 3 10 11 12 13 14 15 Safety Precautions Do not operate this machine before the ProtoTRAK EMX CNC Safety Installation Maintenance Service and Parts List Manual and the Safety Programming Operating amp Care Manual have been studied and understood Do not run this machine without knowing the function of every control key button knob or handle Ask your supervisor or a qualified instructor for help when needed Protect your eyes Wear approved safety glasses with side shields at all times Don t get caught in moving parts Before operating this machine remove all jewelry including watches and rings neckti
35. TRAK EMX KNEE MILLS ProtoTRAK EMX CNC Safety Programming Operating and Care Manual Document P N 26056 Version 050611 Covers Cunent Models y ProtoTRAK EMX Retrofits y TRAK K3EMX Non C urrent Models y TRAK K2 EMX TRAK KEMX Y TRAK K4 EMX Southwestern Industries Inc 2615 Homestead Place Rancho Dominguez CA 90220 5610 USA T 800 421 6875 F 310 764 2668 Service Department 800 367 3165 e mail sales southwestemindustries com service southwestemindustries com web southwestemindustries c om Copyright 2010 Southwestern Industries Inc All rights are reserved No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means mechanical photocopying recording or otherwise without the prior written permission of Southwestern Industries Inc While every effort has been made to include all the information required for the purposes of this guide Southwestern Industries Inc assumes no responsibility for inaccuracies or omission and accepts no liability for damages resulting from the use of the information contained in this guide All brand names and products are trademarks or registered trademarks of their respective holders Southwestern Industries Inc 2615 Homestead Place Rancho Dominguez CA 90220 Phone 310 608 4422 u Fax 310 764 2668 Service Department Phone 800 367 3165 u Fax 310 886 8029 Table of Contents 1 0 Introductio
36. Terms and Conventions This first section contains some paper and pencil exercises to help get you warmed up and to clear up some stuff that may trip you up later It isn t hard to just take the twenty minutes or so you need to get through it X Y Plus Minus The ProtoTRAK EMX works in the Cartesian Coordinate System This is the common number line system that we can use to plot the location of a point in two dimensions X and Y Any given point may be located exactly by plotting its position on the X and Y axes For example the point A below is at point X 2 Y 1 or 2 1 Y PLUS X MINUS X PLUS i00679 Y MINUS 55 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual The point where the X line and the Y line cross is the 0 0 point This is known as Absolute 0 To the right of the Absolute 0 is the X plus To the left is X minus That is true for points whether or not they are actually on the X line or not Above the Absolute 0 is Y plus below is Y minus Again that is true whether the point is actually on the Y line or not Quiz 1 Answer these questions about what you ve just read Check your answers at the end of this section 1 Absolute 0 is the point where 2 Left of the Absolute 0 point is X or Y minus 3 Above the Absolute 0 point is X or Y plus 4 True or false Any point in two dimensions can be plott
37. Yes 1 4884 abs 2 1196 abs 0 25 Yes 2 0701 abs 1 5566 abs 0 abs 0 abs 0 25 CCW Yes Use Math Help Type 13 to find intersection of Events 8 and 9 Find the second point on the line by using right triangle math help or Use Math Help Type 15 to find the intersection of arc s 9 and 10 Use Math Help Type 13 to find the intersection of Events 10 and 11 This mill event was added to allow a Conrad to be used at the end of Event 11 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual Program 5 100327 3 250 This sample part was programmed using the lower left corner Point A as the program absolute zero The event numbers are shown in the circles e Programming Aspects Shown on This Part Profile milling Math Help to calculate arc and line intersection points e Program Notes Events 1 through 3 mill the profile of the part Eventi MN X Begin e Tool 1 isay end mill Y Begin X End Y End Conrad Tool Offset Feed Rate Tool Tool Dia Continue X End 2 0313 abs Use Math Help Type 17 to find the Y End 0 9758 abs intersection of Events 2 and 3 Conrad Continue X End Y End X Center Y Center Conrad Direction Continue 84 Southwestern Industries Inc TRAK EMX Knee Mill amp Proto TRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual TRAK Warranty Polic
38. a straight line from A to C tell the control when it asks that you have a CONRAD equal to R and then program another straight line from C to E The ProtoTRAK will automatically blend the connecting radius CONRAD R between the two straight lines with no additional input For Rectangular Pockets or Frames CONRAD stands for corner radius You may input any value that makes sense considering the size of the pocket and the diameter of the tool Quiz Answers 1 Absolute 0 is the point where the X and Y lines cross 2 Left of the Absolute 0 point is X minus 3 Above the Absolute 0 point is Y plus 4 S True Any point in two dimensions CAN be plotted with the Cartesian Coordinate ystem 60 Southwestern Industries Inc TRAK EMX Knee Mill amp Proto TRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual Quiz 3 DRAR SS ee ee eae 0 inc B 0 2 00 FromEtoF 150 0 6 00 2 00 FromDtoF 3 00 O FromLtoB 0 4 00 4 00 1 00 FromGtoM 2 00 0 1 50 H 3 00 o FromktoK o 0 Fo 2 00 1 a 6 00 2 00 0 2 00 M Quiz 4 61 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 13 2 Basic Operation Now that we have that paper and pencil stuff finished lets go to the machine Turn the ProtoTRAK EMX On On the back of the control is an on off togg
39. add the drill into the program but probably not if you only have one or two The great thing about the ProtoTRAK EMX is you don t have to make it part of the program It still does the positioning for you and you have the flexibility to do the drill operations before you press the GO button for the milling 41 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 8 0 Changing or Correcting Programs In the Program Mode you can easily correct mistakes or make changes to the program 8 1 Deleting a Partially Programmed Event If you wish to not program an event or start over after you have started to program press the DELETE EVENT softkey and the screen will revert to the Select Event prompt 8 2 Editing Data 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 RESTORE Then input the correct number and press SET If incorrect data has been entered and SET you may correct it as you are still programming that same event by pressing the arrow up or arrow down keys to the right of the LCD screen until the incorrect data is highlighted and shown in the conversation line Enter the correct number and SET The ProtoTRAK EMX will not allow you to skip past prompts by pressing an arrow ke
40. any to be shown on the screen 50 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 11 4 File Transfer and Backup A USB port is provided and an optional USB Thumb drive offered as a convenient way to transfer and backup part programs If you buy the optional thumb drive from Southwestern Industries it will already be configured correctly If you get your own thumb drive please read the following Please refer to page 12 for the list of thumb drives we have verified will work Other brands such as Sandisk do not work at this time This includes unfortunately Sandisk thumb drives that worked in previous ProtoTRAK models Before you can transfer programs from the thumb drive to the ProtoTRAK EMX you must put the files in a folder named Programs To move files from the ProtoTRAK EMX internal storage to a thumb drive do the following 1 Plug the Thumb Drive into the ProtoTRAK EMX USB port 2 Goto the DRO Mode 3 Press Serv Codes 4 Under group A Software Service Codes select code 340 Copy Files from Control to USB Drive 5 The ProtoTRAK EMX will place a folder on the thumb drive named Programs if one doesn t exist already and write the programs saved in the internal storage of the ProtoTRAK EMX to the USB Thumb Drive The programs will now be saved in both places To move files from a thumb drive to the ProtoTRAK
41. causes the program to be ejected from current memory 8 7 Erasing an Entire Program To erase an entire program from current memory go to the Program In Out Mode and press ERASE PROG You will be prompted Are you sure you want to erase this program You may want to store the program before you clear it from current memory If it is not stored pressing YES will permanently erase the program To erase an entire program from the internal storage input the part number and then press DELETE Programs in current memory will not be affected by this operation You could erase a part number on the internal storage and the program in current memory will remain in current memory even if it has the same part number as the one just erased Programs in current memory will automatically be erased when another program is retrieved from storage 43 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 9 0 Making Parts with the CNC 9 1 Setting Up Before you can run your program you must set your absolute position in the DRO Mode The CNC will use this absolute position as a reference for running your program 9 2 Starting After setting up in the DRO Mode go into the Run Mode You will see this screen RUN P N 0 INCH Event 4 MILL i Repeat 0 X 0 0000 ass Y 0 0000 xs ANANN Z LOAD TOOL 1 0 2500 DIA ABS START
42. ckwise direction from 3 00 o clock to the first hole you want to drill We could have input 0 and then we would drill the right most hole first e Tool You press SET We re still using tool number 1 but notice we didn t press the 1 If you don t input a number the ProtoTRAK assumes the last tool is used again e Tool Dia You press SET Event 4 The Upper Left Diagonal e Select Event You press MILL soft key for Event 4 e X Begin You press 0 ABS SET to define the beginning of the milling cut at its lower left point on the diagonal e Y Begin You press 3 25 ABS SET to define the beginning of the milling cut e X End You press 5 ABS SET to define the end of the milling cut e Y End You press 75 INC SET to define the end of the milling cut Notice we defined this as an incremental change of 75 inch from the beginning We could have also input 4 0 ABS SET to also define the end point Think about this and make sure you understand e CONRAD You press SET because we don t want to blend this mill cut into another cut e Tool Offset You press 2 SET because you re selecting that the tool is to the left of the work piece as it moves from beginning to end 68 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual e Feedrate You press 5 SET to mill at 5 inches per minute e
43. ctory setting 80 Turn off beeper For stealthy machining 81 Keyboard test For testing the front panel buttons 89 Cancel simulation Cancel the Service Code 22 simulation 53 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual Code Description Notes 97 Axis configuration To orient the motor encoder This should not need to be done except in a service situation 100 Axis open loop test Runs selected axis at rapid for one second and displays values Caution The machine will move Be sure you understand the consequences before you use this code See SWI Publication No 26055 ProtoTRAK EMX Installation and Service Manual 122 Calibration offset Use this to modify your calibration factor Cut part measure follow the instructions on the screen 123 Calibration of each axis of Detailed instructions are found in SWI Publication measurement No 26055 ProtoTRAK EMX Installation and Service Manual 125 Display calibration factors See SWI Publication No 26055 ProtoTRAK EMX Installation and Service Manual 127 Single encoder backlash Used to calculate a backlash value for entering in calibration Code 128 See SWI Publication No 26055 ProtoTRAK EMX Installation and Service Manual 128 Enter backlash value Used to enter the backlash value calculated using Code 127 See SWI Publication No 26055
44. d for the table or saddle or both 1 2 3 Press the POWER FEED soft key A message box will appear that shows the power feed dimensions All power feedmoves are entered as incremental moves from the current position to the next position 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 2 00 of the table in the negative direction you would enter X 2 INC SET Initiate the power feed move by pressing GO The feedrate is automatically set to 10 ipm or 254 mm per min Press the up or down arrow key to the right of the LCD screen to adjust the feedrate from 1 ipm to 100 ipm or 254 to 2540 mmpm Press STOP to halt power feed Press GO to resume Repeat the process beginning at 3 above as often as you wish Press RETURN soft key to return to manual DRO operation 6 6 Service Codes 30 Southwestern Industries Inc TRAK EMX Knee Mill amp Proto TRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual Service codes are accessed from the DRO screen Please see Section 10 for a detailed explanation of Service Codes 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 i
45. e Feedrate the milling feedrate in in min from 1 to 99 9 or in mm min from 5 to 2500 Fin cut for a pocket or frame the width of the finish cut If 0 is input there will be no finish cut Radius the radius of the bolt hole pattern arc or circle Tool the number you assign to identify the tool Tool Diameter the diameter of the tool See the note on finish cuts later in this section Tool offset the selection of the tool offset right left or center relative to the programmed edge and tool movement X or Y the X or Y dimension may be defined in absolute or incremental reference X Begin or Y Begin the X or Y beginning point of the line or arc X Center or Y Center the X or Y dimension of the center of the bolt hole pattern arc or circle X End or Y End the X or Y ending point of the line or arc X1 Y1 and X3 Y3 the X and Y dimensions for the opposite corners on a rectangular pocket or frame Prompts unique to the Repeat event First Event the first event to be repeated Last Event the last event to be repeated If only one event is to be repeated the First and Last events will be the same number X Offset the incremental X offset from the event to be repeated Y Offset the incremental Y offset from the event to be repeated Repeats the number of times the events are to be repeated up to 99 37 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofi
46. e Repeat Events are run the same cutter will be positioned correctly to do the final pass to size 7 9 Look You can look at part graphics while in the Program Mode At any time an event is finished programming and the Select Event prompt appears in the conversation line simply press the LOOK hard key The programmed events are automatically sized so that everything fits on the screen To return to the programming press the RETURN softkey The part graphics are useful for checking what you have programmed so far Certain kinds of programming mistakes are not caught by the graphics These will surface when running the program 7 10 ASample Program This simple part will be used to illustrate the process of programming P 75 ma 00 ml 250 l Steps 1 Decide the order of machining This part can be held in a vise First we will drill the two holes and then we will mill the slot 2 Decide the Absolute reference In this case we will use the lower left corner as our 0 location for X and Y 3 Enter the Program Mode If there is already a program in the current memory go into the Program In Out Mode and press the CLEAR CURRENT softkey You may want to store the program in current memory first 4 Assign a part number When there is no program in the current memory the system will prompt for a program part number as soon as it goes into Program Mode Enter a numeric part number or not if you don t want one
47. ed with the Cartesian Coordinate System Tip if you have any problem with this part take this manual out to your machine and put the drawing under the spindle so that the 0 0 point is lined up with the center of the spindle Zero out the DRO on your display and crank the table different directions Watch the DRO measurement count up and down turning from positive to negative as you pass the 0 0 points Quiz 2 Write down the X and Y dimensions including the or sign of points A through H in the figure above Check your answers at the back of this section Absolute ABS and I ncremental I NC In the previous section we saw that the absolute dimension is the point at which both X and Y are 0 Every part we make with a ProtoTRAK EMX will have an absolute zero that you 56 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual give it We want to put the Absolute 0 where it will make it easy to define the other points we need to machine so a corner or the center of a circular pattern are usually the best When we program we need to tell the ProtoTRAK EMX what the reference point is for the numbers we put in When your reference point is the 0 0 we call that an Absolute Reference That means that the number you put in is measured from 0 0 There is another way to define a point and that is with Incremental dimensions Incremental dimensions are s
48. eful if you have a new part to do that is similar to a part that you already have programmed Make a copy of the program by saving it under a new part number and then make the changes 42 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual You can rename a part program in three ways Press the PAGE BACK key past the first event until you are at Event 0 and the prompt for Program Part Number Enter the new part number and press SET Exit the Program Mode by pressing Mode and then re enter it You will have an opportunity to rename it then Rename it in the Program In Out Mode After pressing the PROG IN OUT key simply enter the new part number and press SAVE If the previous part program is already stored on the system internal storage it will remain in storage under the previous part number with the same information it had the last time it was stored 8 6 Saving Changes to a Program If a program is opened from storage and changes are made the program must be stored again in Prog In Out Mode for the changes to be preserved in the stored copy Programs in current memory may be changed and run with the changes but unless they are saved again the changes made will be lost when the program is cleared from current memory If you intend to keep the changes made to your program it is a good practice to store the program occasionally in case a power loss
49. ehind the tool as it moves away from you is the tool to the right tool right of the work piece or to the left tool left of the work piece Examples of tool right are 58 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual Examples of tool left are OSS r Tool center means no compensation either right or left That is the centerline of the tool will be moved directly over the points or line that is programmed Quiz 4 For the part tool and direction shown indicate whether the compensation is Right Left or Center Check your answers at the back of this manual B oa c E Q F H A A O oY War i00683 59 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual Conrad Connecting or Corner Radius Conrad is another really nice feature of the ProtoTRAK EMX In the example below you could machine a straight line from Point A to B then an ARC with radius R from B to D then another straight line from D to E E D N Aa che ee c A B 100684 The problem is that the arc is not easy to program because you often don t know where point D or B or the center of R is located However you may know where Point C is or you may be able to figure it out easily In that case you can program the above part by programming
50. ent type geometry and then follow all instructions in the conversation line When an event is selected all the prompts will be shown on the right side of the information area The first prompt will be highlighted and also shown in the conversation 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 32 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual As data is being entered it will show in the conversation line If you make a mistake for example you press the wrong number key you can clear the input by pressing RESTORE When SET the data will be transferred to the information area and the next prompt will be shown in the conversation line From the event data screen you may press the up arrow key to the upper right of the LCD screen to go back to edit any data within an event Options within an event include PAGE FWD moves forward through the programmed events PAGE BACK moves backwards through the programmed events 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
51. enter You press 1 5 POCKET ABS SET e Y Center You press 2 5 ABS SET 69 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual e Radius Your press 75 SET defining the radius of the pocket e Direction You press 1 SET to select clockwise tool motion We could have just as easily selected counterclockwise e Fin Cut You press 02 SET to select a finish cut of 020 inches When machining the program will hog out the pocket 020 undersized then make a finish cut pass to the proper size e Feedrate You press 8 SET e Fin Feedrate You press 5 SET e Tool You press SET e Tool Dia You press SET Event 7 The Through Rectangle e Select Event You press POCKET FRAME soft key for Event 7 e Select You press RECT PROFILE soft key for the rectangular frame e XI You press 3 75 ABS SET which is the distance to corner number 1 which we will say is the lower left corner of the frame e YI You press 1 75 ABS SET e X3 You press 1 5 INC SET because corner number 3 is the diagonal corner and it is 1 5 inches in the plus X direction from X1 e Y3 You press 1 25 INC SET e CONRAD You press 3 SET because the corner radius of the frame is 300 inch e Direction You press 2 SET to choose counterclockwise e Tool Offset You pr
52. erence Position When X and Y 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 event POSITION DRILL X and Y programmed BOLT HOLE X CENTER and Y CENTER programmed MILL X END and Y END programmed ARC X END and Y END programmed CIRCLE POCKET or FRAME X CENTER and Y CENTER programmed RECTANGLE POCKET or FRAME X1 and Y1 corner programmed position REPEAT The appropriate reference position for the event prior to the first event that was repeated 38 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 7 8 Finish Cuts The Pocket and Frame events are designed with built in finish cut routines because they are complete stand alone pieces of geometry Shapes machined with a series of Mill or Arc events don t have an automatic routine for making finish cuts Instead it is very easy to get a finish pass by overstating the size of the tool for the events in the initial pass and then using a Repeat Event and programming a new tool with the actual size of the tool For the first pass the cutter will be positioned away from the final cut half the amount of the difference between the actual size of the cutter and the diameter you put in When th
53. es and any loose fitting clothing Keep your hair away from moving parts Wear adequate safety headgear Protect your feet Wear safety shoes with oil resistant anti skid soles and steel toes Take off gloves before you start the machine Gloves are easily caught in moving parts Remove all tools wrenches check keys etc from the machine before you start Loose items can become dangerous flying projectiles Never operate a milling machine after consuming alcoholic beverages or taking strong medication or while using non prescription drugs Protect your hands Stop the machine spindle and ensure that the CNC control is in the stop mode e Before changing tools e Before changing parts e Before you clear away the chips oil or coolant Always use a chip scraper or brush e Before you make an adjustment to the part fixture coolant nozzle or take measurements e Before you open safeguards protective shields etc Never reach for the part tool or fixture around a safeguard Protect your eyes and the machine as well Don t use a compressed air hose to remove the chips or clean the machine oil coolant etc Stop and disconnect the machine before you change belts pulley gears Keep work area well lighted Ask for additional light if needed Do not lean on the machine while it is running Prevent slippage Keep the work area dry and clean Remove the chips oil coolant and obstacles of any kind around the machine 5
54. ess 2 SET because when the tool moves counterclockwise around the inside of the rectangle frame it is to the left of the work piece e Fin Cut You press 03 SET to select a 030 inch finish cut e Feedrate You press 5 SET e Fin Feedrate You press 2 SET e Tool You press because we re still using tool number 2 e Tool Dia You press SET 70 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual Look at the Program e Press the LOOK hard key to see what your program looks like You don t have to finish the programming to see what you ve done so far Any time you see the SELECT EVENT prompt in the Program Mode you can look at the part graphics The drawn part should look like this Dashed lines are for reference only on this enn diagram They are not shown on the screen because they are not programmed Tip i00687 If your part draw doesn t look like this don t panic See if you can figure what piece of geometry and therefore what event looks wrong Go back to that part of your program and check your inputs against these instructions e Press RETURN The program is complete Program I n Out Mode Now that we have a good program we want to save it If you turn the ProtoTRAK off now the program will be lost To prevent this we will save it in the system s internal storage where it will stay
55. g on 7 3 2 Mill Event Use this to machine a straight line in any direction The prompts you answer in this event will allow the ProtoTRAK EMX to calculate the complete tool path including the starting position and tool offsets It is not necessary to program a rapid move to the beginning position of the Mill Event When the program is run at a Mill Event the ProtoTRAK EMX will rapid to the beginning position prompt you to set the quill Z depth move through the Mill Event at the speed you program and end at the ending position See the discussion on Continue below for the variation in tool motion if the event is connective 7 3 3 Arc Event This is any part of a circle Like the Mill Event the prompts you answer will allow the ProtoTRAK EMX to calculate the complete tool path When the program is run at an Arc Event the ProtoTRAK EMX will rapid to the beginning position prompt you to set the quill Z depth move through the Arc Event at the speed you program and end at the ending position See the discussion on Continue below for the variation in tool motion if the event is connective 7 3 4 Pocket Frame Event Use this event to machine a pocket or frame with a minimal amount of programming When you press the Pocket Frame key you choose between the following e Circle pocket a circle and all the material in the center Includes finish cut e Rectangular pocket a rectangle and all the material in the middle Includes finish cut
56. he profile of the part pEvent DM X Begin The first mill event was used to Y Begin ramp into the part starting at Point X End B Y End Tool 1 is a 1 2 end mill Conrad Tool Offset Feed Rate Tool Tool Dia Continue 79 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual X End Y End X Center Y Center Conrad Direction Continue X End Y End Conrad Continue X End Y End X Center Y Center Conrad Direction Continue X End Y End Conrad Continue X End Y End X Center Y Center Conrad Direction Continue 0 2404 abs 1 2267 abs 0 abs 0 abs CCW 3 3702 abs 0 6133 abs 0 Yes 0 inc 0 6133 abs 3 25 abs 0 abs 0 CCW Yes 0 2404 abs 1 2267 abs 0 Yes 80 Use Math Help Type 16 to solve for intersection points See Math Help section Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual Program 4 4 R 2 TYP 2 61 N o 175 20 DP a 2 0 7 2 59 R 66 8 R _ 6237 10 R 2 59 a N 4 4 1 15 J A Dr DP gt A 3 85 98 1 A 7 38 2 4 6 l h l B 1 42 ANI fe i R 1 8 100374 ARL R 38 a 2 59 m an 2 59 This sample part was programmed using the center arc Point A as the program absolute zero The event numbers are show
57. if the Hi Lo Neutral lever is in the high position e Turn the Spindle switch straight ahead for off 19 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual a CTRAK K3 3 K3 9 vay re 2 CHANGE HANDWHEEL i SPINDLE BRAKE c QUILL HI NEUTRAL STOP LOW LEVER QUILL FEED SELECTOR e POWER ENGAGMENT FINE FEED HANDWHEEL La QUILL a n FEED HANDLE FINE INS FEED DIRECTION k F p SHAFT iz mu i FEED TRIP k N Be 7 MICROMETER QUILL ADJUSTMENT LOCK 100906 LOCK amp NUT Figure 4 2 0 TRAK K3 Mill head front view Shown without the standard quill glass scale 20 Southwestern Industries Inc TRAK EMX Knee Mill amp Proto TRAK EMX CNC Retrofit 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 Rotate clockwise 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 EMX program unless the table and saddle clamps are free 4 2 3 Raising Lowering the Knee The knee is raised and lowered using the hand crank located on the left fr
58. imply dimensions measured from the previous point Consider the print below If we say the bottom left corner is absolute zero ABS 0 then the dimensions are absolute or incremental as shown ABS i00680 ABS Quiz 3 Absolute Zero at Point A 6 00 i00681 57 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual What are the incremental dimensions ree ee a ee a T ee a a ee ea i a a eT FromLtoB FromGtom FromHtoM oT f FrmMtoH ad L FromKtoK CT Check your answers at the back of this section Tool Compensation One of the things that makes the ProtoTRAK EMX so easy to use is that you get to program the dimensions of the finished work piece that are right on the print instead of the centerline of the tool Let s say you programmed the square shape below shown as the solid line Programmed Dimension or Shape no E S E N A A i00682 The ProtoTRAK has no way of knowing whether you want to cut a pocket out of the material so you want your tool to follow Path A or if you are squaring up a block so you want your tool to follow Path B This is what tool cutter compensation or cutter comp is about Once again it is easier to think about these concepts when you imagine the tool is moving along a Stationary point The rule is Looking along the direction of tool motion imagine yourself standing b
59. is a 1 4 end mill Y Begin X End Y End Conrad Tool Offset Feed Rate Tool Tool Dia Continue X End 1 1456 abs Use Math Help Type 13 to find the Y End 0 inc intersection of the 2 parallel lines Conrad 0 187 and the arc Continue Yes X End Y End X Center Y Center Conrad Direction Continue X End Y End Conrad Continue X End e Y End is programmed past the Y End edge to ensure a good surface Conrad finish on the left side of the part Continue 75 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual Program 2 1 540 5 1 2 3 00 P 7 es 15 100375 ry ee A te x G gd N ee l l S E z A R 175 2 00 B C R 1 375 N 25 4 PLCS This sample part was programmed using the center of the circular pocket Point A as the program absolute zero The event numbers are shown in the circles e Programming Aspects Shown on This Part Bolt hole using 2 different tools Circular Pocket Profile milling Math Help to calculate arc and line tangency points 76 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual e Program Notes Events 1 and 2 drill the bolt hole pattern using 2 different tools Event1 Bolt Hole Holes e Tool 1 is a spot drill X Center Y Center
60. ition of the fine feed direction shaft IN sets the direction down OUT sets the direction up and NEUTRAL in the middle 4 2 12 Quill Feed Selector Figure 4 2 10 3 Quill Feed Selector for the K2 amp K3 Figure 4 2 10 4 Quill Feed Selector for the K4 This selector is used to set the quill feed speed 23 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 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 The Feed Trip Lever stops the quill feed motion when the quill stop knob reaches the quill micrometer dial Move the lever to the left to engage or to the right to disengage 4 2 14 Fine Hand Quill Feed 1 Disengage the Power Feed Engagement Lever 2 Set the fine feed direction shaft to the neutral position 3 Rotate the Fine Feed handwheel 4 2 15 Fine Automatic Quill Feed 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 24 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 5 0 Definitions Terms amp Concep
61. k view 13 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual TRAK KEMX TRAK K2EMX TRAK K3EMX TRAK K4EMX Table Size 50 X 10 49 X 9 50 X 10 50 X 10 Table Travel 31 33 32 32 Saddle Travel 15 5 12 16 16 Knee Travel 15 16 16 16 Ram Travel 21 12 15 19 Maximum Quill 5 5 5 De Travel Quill Diameter 3 375 3 375 3 375 3 938 Spindle Taper R8 R8 R8 NMTB 40 Spindle Speed 70 4200 RPM 60 500 600 4200 60 500 600 4200 70 500 600 3950 Vari speed head RPM RPM RPM Spindle Speed N A Two Ranges Two Ranges Two Ranges Opt E Head 40 600 300 5000 40 600 300 5000 40 600 300 5000 RPM RPM RPM Head Tilt 45 forward and 45 forward and 45 forward and 90 left and right back 90 left and right back 90 left and right back 90 left and right Quill Feeds per 0 0015 0 003 0 0015 0 003 0 0015 0 003 0 0015 0 003 Rev 0 006 0 006 0 006 0 006 Spindle Motor 3HP 3HP 3HP 5HP Power Vari speed Spindle Motor N A 3HP 3HP 5HP Opt E Head Power 110 1P 8A 110V 1P 10A 110V 1P 10A 110V 1P 10A Requirement Control Power 220 440V 3P 220 440V 3P 220 440V 3P 220 440V 3P requirements 8 5 4 25A 8 5 4 25A 8 5 4 25A 14 7A machine Maximum Weight 750 750 Ibs 750 Ibs 850 Ibs on Table Machine Weigh
62. l k x2 2 X1 Y1 Note Conrad must always be the same as or larger than the tool 00180 radius for inside corners If Conrad is less than the tool radius and an inside corner is machined the ProtoTRAK EMX will ignore the Conrad 27 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 5 7 Memory and 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 EMX holds the operating system and any part program that is ready to run In contrast storage is where the programs are saved until they are erased deliberately Programs are stored on the ProtoTRAK EMX on an internal flash drive that is capable of holding hundreds of typical programs If power is lost or turned off programs that are in current memory are lost but programs stored on the internal drive are not 28 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 6 0 Using the ProtoTRAK EMX as a DRO The ProtoTRAK EMX operates in DRO Mode as a sophisticated digital readout with jog and power feed capability 6 1 Enter DRO Mode Press MODE select DRO soft key The LCD screen will show DRO INCH JOG X 0 0000rcs we Y 0 0000 ss 2 Z 0 00005 CODES 101284 Note
63. le switch Flip it up to turn the ProtoTRAK on Each time you turn the ProtoTRAK on it must boot up or read its operating software off the built in floppy disk drive This takes about one minute so we recommend turning on in the morning and off once at the end of the day If you don t use the ProtoTRAK for 20 minutes its screen will go blank This is the screen saver Press any key or turn the X or Y handwheels and it will come on immediately Screen Organization When the system has booted and a green box appears that says select a mode Press DRO This will get you into the Digital Readout Mode the part of the control where you can work manually Before we get into that there are a couple of things to notice about the screen The STATUS line is on the top It tells you what mode of operation you are in whether you re in inch or metric if the servo motors are on etc The INFORMATION area is below and is the largest part of the screen It shows information or data depending on what you re doing In DRO operation it shows the axis readout in Programming it shows the program when you press LOOK in programming it shows a picture of your part etc The CONVERSATION line is below the information area This is where you input all the data and this is where the ProtoTRAK will prompt you for the information or activity that it wants Keyboard Organization The keyboard is made up of three sections the soft keys the data i
64. lect the Mode and then choose from the options The Modes of the ProtoTRAK EMX are e DRO Contains the DRO features for working manually or setting up to run a program This also contains the softkey for the Service Codes e PROG PROGRAM Where programs are written and edited and part graphics displayed e RUN Where programs are run to make parts e MATH HELP Routines to help you quickly and easily calculate intersections tangencies centers and more e PROG IN OUT To store and retrieve part programs from the internal storage 18 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual Dn a DRO PROG RUN MATH HELP PROG IN OUT 101283 4 1 4 Emergency Stop Press the button to shut off power to the axis motors Power is also shut off to the spindle motor for TRAK Knee Mills Rotate the switch to release 4 2 Machine Operation This section covers the operation of the TRAK Knee Mills If you purchased your ProtoTRAK EMX 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 on the left side of the milling head e Turn the Spindle switch to left to 1 for forward clockwise spindle rotation if the Hi Lo Neutral lever is in the low position e Turn the Spindle switch right to 2 for forward clockwise spindle rotation
65. n Definitions Terms amp Concepts 1 1 Models aai ProtoTRAK EMX Axis Conventions 1 2 Manual Organization Absolute amp Incremental Reference Referenced amp Non Referenced Data 2 0 Safety Tool Diameter Compensation 2 1 Safety Publications Connective Events 2 2 Danger Warning Caution and Note Conrad Labels and Notices Used in this Manual Memory amp Storage 2 3 Safety Precautions 5 oe 6 0 Using the EMX as a DRO 3 0 Description 6 1 Enter DRO Mode 3 1 Control Specifications 7 6 2 DRO Functions 3 2 Display Pendant 8 6 3 Jog 3 2 1 Pendant Front Panel 8 6 4 Return to Absolute Zero 3 2 2 Pendant Back Panel 10 6 5 Power Feed 3 2 3 Servo Motors Amplifiers 11 6 6 Service Codes 3 2 4 The Z Scale 11 6 7 Teach Service Codes 3 2 5 Ballscrews 11 3 3 Machine Specifications l 12 7 0 Program Mode 3 3 1 Manual Lubrication System 15 7 1 Enter Program Mode amp Assign Prog Name 3 3 2 Electrical Cabinet 15 7 2 Programming Strategy and Procedures 3 4 Optional Equipment 15 7 3 Programming Events 3 4 1 Power Draw Bar 15 7 3 1 Position Drill 3 4 2 Remote Stop Go Switch 16 7 3 2 Mill Event 3 4 3 Work Light 16 7 3 3 Arc Event 3 4 4 Coolant Pump 16 7 3 4 Pocket Frame Event 3 4 5 Spray Coolant 16 7 3 5 Repeat Event 3 4 6 Chip Pan Splash Shield 16 7 3 6 Subroutine Events 3 4 7 Table Guard 16 7 3 7 Finishing Teach Events 3 4 8 Auto Lubrication System 16 7 4 Prompts Used to Define Events 3 4 9 USB Thumb Drive 17 7 5 Continue F 7 7 6 Assumed Tool Offset Feedrate Tool
66. n Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual e USB thumb drive for program storage and transfer Includes a free offline EMX programming system 3 2 Display Pendant 3 2 1 Front O Blerom ne A ponam lt mn Kaa eae mmm Ricca YE i01276 Keyboard Hard Keys GO initiates motion in Run STOP halts motion during Run LOOK part graphics in Program mode INC ABS switches all or one axis between incremental and absolute INC SET loads incremental dimensions and general data ABS SET loads absolute dimensions and general data X Y Z selects axis for subsequent commands 0 9 inputs numeric data with floating 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 HELP displays information about the operation of each mode RESTORE clears an entry 8 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual Arrow Keys Between the LCD Screen and the hard keys is a column of arrow keys Up key down key these are located at the top and bottom of the column respectively They have several uses feedrate override in Run and DRO modes page forward page back to move through events in a program
67. n 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 jewelry 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 per OSHA 1910 212 Milling Machine Safety Publications Refer to and study the following publications for assistance in enhancing the safe use of this machine Safety Requirements For The Construction Care And Use of Drilling Milling and Boring Machines ANSI B11 8 2001 Available from The American National Standards Institute 1430 Broadway New York New York 10018 Concepts And Techniques Of Machine Safeguarding OSHA Publication Number 3067 Available from The Publication Office O S H A U S Department of Labor 200 Constitution Avenue NW Washington DC 20210 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 cou d result in severe personal injury and or damage to the equipment Warning
68. n in the circles e Programming Aspects Shown on This Part Profile milling Math Help to calculate arc and line intersection points 81 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual e Program Notes Events 1 through 12 mill the profile of the part X Begin Y Begin X End Y End Conrad Tool Offset Feed Rate Continue Tool Tool Dia X End Y End Conrad Continue X End Y End X Center Y Center Conrad Direction Continue X End Y End Conrad Continue X End Y End Conrad Continue X End Y End Conrad Continue 2 abs 0 38 abs 0 875 abs 0 inc 0 125 Right 0 875 abs 0 inc 0 abs 0 abs 0 CW Yes 2 59 abs 0 inc 0 38 Yes 0 inc 0 3566 abs 0 25 Yes 82 Tool 1 is a end mill The first event starts at point B Use Math Help Type 13 to find the intersection point of Events 6 and 7 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual Evet7 fre X End Y End X Center Y Center Conrad Direction Continue X End Y End Conrad Continue X End Y End X Center Y Center Conrad Direction Continue X End Y End X Center Y Center Conrad Direction Continue X End Y End Conrad Continue X End Y End Conrad Continue 2 0 abs 0 85 abs 2 61 abs 0 98 abs 0 CW
69. n 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 you already had a program in current memory that had 10 events when you press Teach the event counter will say EVENT 11 If there is 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 DRILL a position drill event 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 DRILL key the event counter will go up by one and the screen remains the same If you press the MI
70. nd Labeling 49 11 3 Saving amp Opening Programs from Internal Storage 50 11 4 File Transfer and Backup 51 11 5 CAM G Code Files 51 11 5 1 G Codes Recognized by the ProtoTRAK EMX 52 11 5 2 M Codes Supported by the ProtoTRAK EMX 52 11 5 3 Valid Characters for Word Address Sequences 52 12 0 Service Codes 12 1 Service Code Procedure 53 12 2 Service Code Types 53 13 0 ProtoTRAK EMX Tutorial 55 13 1 Working with Definition Terms Conventions 55 13 2 Basic Operation 62 13 3 Programming Sample 66 14 0 Additional Sample Programs 74 TRAK EMX Knee Mill and ProtoTRAK EMX CNC Safety Programming Operating and Care Manual 1 0 Introduction Congratulations Whether you bought the ProtoTRAK EMX CNC as a retrofit or as the CNC integrated into the TRAK Knee Mill you have an excellent toolroom machine The ProtoTRAK EMX has an easy to use interface features that make knee mill work faster and more productive Manual Machining is always available and made easier with features like power feed 100 inch per minute rapids 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 The operation of the ProtoTRAK EMX CNC has been painstakingly refined to bring you the most useful CNC technology while retaining the ease of use that has made ProtoTRAK the top brand in controls for low volume production
71. nd it when you want to open it However no two programs can have the same part number how would the system decide which to retrieve Therefore if you store a program with any particular part number it will automatically erase any other program with that same part number In both cases above the ProtoTRAK EMX will give you a warning before erasing or overwriting your program 11 2 Program Formats and Labeling The ProtoTRAK family of products has its own unique programming system one that organizes the program into events rather than codes and blocks Programs written on a two axis milling control such as the ProtoTRAK EMX will have the extension MX2 The MX2 programs created by the ProtoTRAK EMX is compatible with those created on other ProtoTRAK two axis CNCs provided that the event types of the program are found in the control that is running the program 49 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 11 3 Saving and Opening Programs from the ProtoTRAK EMX internal storage Press MODE and select the PROG IN OUT softkey The display will show 3 115001 MX2 140014 MXx2 OPEN 31 MX2 3 115002 MX2 5 140015 MX2 DIOM 2115003 MX2 amp 140016 MX2 B 1009 MX2 3123 MX2 140017 MX2 105001 MX2 S 140001 MX2 8 140018 MX2 SAVE 5 105002 Mx2 5 140002 MX2 8 140019 MX2 5 105003 MX2 5 140003 Mx2 5 14002
72. ndustries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 11 5 1 G Codes Recognized by the ProtoTRAK EMX G00 positioning rapid G01 linear interpolation feed G02 circular interpolation CW G03 circular interpolation CCW 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 G80 cancel canned cycle G81 drill canned cycle 11 5 2 M Codes Supported by the ProtoTRAK EMX MOO program stop with prompt press go to procd M01 optional stop M02 end of program no rewind M06 tool change M30 end program rewind stop 11 5 3 Valid Characters for Word Address Sequences Prepare to execute a G COMMAND Prepare to execute a M COMMAND Introduces a block number Specifies the tool number to use Specifies a feedrate Specifies the X dimension Specifies the Y dimension Specifies the Z dimension Specifies the incremental X dimension Specifies the incremental Y dimension NXT ZZO 52 Southwestern Industries Inc TRAK EMX Knee Mill amp Proto TRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 12 0 Service Codes Service codes are special codes used for set up installation or program file transfer 12 1 Service Code Procedure Go to the DRO Mode Press SERVICE CODES Input one of the codes from the list in section 12 2 Press SET
73. nee Mills only it is not available for retrofits 3 4 8 Auto Lubrication System TRAK Knee Mills Only The way and ballscrew lubrication is wired to operate while the spindle is running Factory Default Values Interval Time 60 min Discharge Time 15 sec Discharge Pressure Approximately 100 150psi To adjust the amount of Discharge Pressure displayed on the lube pump gauge loosen the jam nut and turn the adjustment screw located on the top right side of the lube pump while the lube pump is activated To activate the lube pump turn spindle on and press the Feed for continuous pumping and RST for a single programmed pump CAUTION Failure to 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 mill s way surfaces and ballscrews 16 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 3 4 9 USB Thumb Drive The USB Thumb Drive option is a Delkin Devices 256MB thumb drive It serves the following purposes Save program files for backing up or additional storage Load program files Share program files between ProtoTRAKs or computers Save system configuration files including backlash and calibration values The thumb drive comes correctly configured for P
74. nput keys and the motion control keys The SOFT KEYS are the 5 unlabeled keys directly to the right of the screen Their function is defined by the words the key is pointing to If there is nothing written then the key will not work The DATA INPUT keys are the number keys and the other keys close to them The operation of these keys is pretty obvious or will be explained in the next section One thing to note at this point is the difference between the INC SET and the ABS SET keys directly above the number keys If you are inputting an X or Y dimension it is important to set or load this into the system with the correct key If it is an absolute referenced number press ABS SET if it is an incremental number press INC SET If you are inputting any value other than an X or Y you may press either ABS SET or INC SET In this case the manual will simply say SET The MOTION CONTROL keys are the GO and STOP on the upper part of the keyboard In certain operations the J and keys will change the feed rate of automatic motion 62 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual Modes Press the MODE function key The screen will show DRO PROG RUN MATH HELP PROG IN OUT 101283 This is how you change from one mode of operation to another If you ever get confused just press MODE to get back to this beginning screen 63
75. nts 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 tool offset and tool number of both events must be the same 5 6 Conrad Conrad 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 this figure you simply program a Mill event from X1 Y1 to X2 Y2 with tool right offset and another Mill event from X2 Y2 to X3 Y3 also with tool right offset During the programming of the first Mill event the system will prompt for Conrad 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 Y1 through T1 r k T2 to X3 Y3 For this figure 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 oa a time you input the numerical value of the tangentially ra connecting radius r K3 The system will calculate the fry tangent points T1 and T2 and direct the tool cutter to pee eee aap X move continuously from X1 Y1 through OA HONI r T1 r K3 T2 to X3 Y3 Fa
76. o high range changes the direction of rotation for the On Off switch See Section 4 2 1 4 2 7 Speed Changes Spindle speed may be varied by rotating the variable speed crank CAUTION Do not rotate the variable speed crank when the spindle is stationary 4 2 8 Operating the Quill 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 4 2 9 Adjusting the Quill Stop 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 a SL aoon _ ou i00166 Figure 4 2 10 DISENGAGED ENGAGED The power feed is engaged or disengaged with this selector Pull out the knob and rotate it clockwise to disengage power feed Rotate it counterclockwise to engage power feed 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 22 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 4 2 11 Fine Feed Direction Shaft i00166 Figure 4 2 10 2 The direction of the fine feed is set by the pos
77. ont of the knee Clockwise rotation moves the knee up while counterclockwise rotation moves the knee down Be sure the knee is unclamped before raising or lowering 4 2 4 Spindle Brake The mechanical spindle break is activated pulling it down or pushing it up When the lever arm is in the horizontal position the brake is off CAUTION Be certain that the spindle brake is released before starting the motor Never attempt to activate the spindle brake when the motor is on 4 2 5 Draw Bar The draw bar holds the R8 or 40 NST tool holders into the spindle taper The bar has a 5 8 11 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 The spindle RPM range selection is made through the High Low Neutral Lever Figure 4 2 6 21 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual CAUTION Never attempt to change the range selection through the High Low 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 t
78. ou will encounter a screen that allows you to enter a program name or to enter the program at different events Event 0 is where you can enter the program name You can also get to Event 0 by pressing Page Back from Event 1 The program name is highlighted and you may enter a new program name at this point Program names are made up of up to eight numbers Note It is not necessary to enter a program name If none is entered and the INC SET or ABS SET button is pushed the system will assume the program name is 0 The ProtoTRAK EMX automatically holds all of the completed events as you program in current memory Choices at the beginning of Program Mode GO TO BEGIN puts Event 0 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 This 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 Event 0 on the left and the Select an Event options for Event 1 on the right 7 2 Programming Strategy and Procedures The ProtoTRAK EMX makes programming easy by allowing you to program the actual part geometry as defined by the print The basic strategy is to select the softkey ev
79. r 2 Fill the ball oiler located in the front lower right corner of the speed changer housing This oil lubricates the speed changer shaft 3 Extend the quill fully and apply a coating of SAE 30 or 30W 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 3 2 Electrical Cabinet TRAK Knee Mills Only TRAK Knee Mills use two electrical inputs Spindle 220 or 440V power is wired into the cabinet A cord is supplied from the cabinet to a 110V power source for running the ProtoTRAK EMX CNC 3 4 Optional Equipment 3 4 1 Power Draw Bar A manual draw bar comes standard with the machine A power draw bar option may be ordered For the TRAK K4 or other NMTB 40 machines the draw bar included in the option may be CAT or NMTB NST An NMTB NST type of draw bar is the appropriate length to fit tool holders that have a threaded tang on the top The CAT type is longer to thread into CNC tool holders that have the tool changer grip or retention knob removed 15 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 3 4 2 Remote Stop Go Switch For the convenience of operation while running the program a Remote Stop Go switch may be p
80. rate the ProtoTRAK under servo motor control unless the handles are folded into their safety position 2 Press the J OG soft key A message in red will appear that says CAUTION J OG KEYS ARE ACTIVE This means the ProtoTRAK is ready to jog in the plus X or Y direction at 100 inches per minute so if you press X or Y the machine will move 3 Press and hold X The table moves to the left at 100 ipm Release the X key to stop 4 Press and hold Y The table moves towards you Release 5 Press the key Notice the number in the Feed Rate box on the lower left of the screen changes from 100 to 100 6 Press and hold X The table now moves right Release 7 Press and hold Y The saddle now moves away Release 8 Press the J key Notice the JOG 100 ipm changes to JOG 90 ipm Press the J key several more times 9 Press and hold X Notice the table moves slower Release 10 Press the T key several times until you are back to J OG 100 ipm 11 Press number key 9 Notice that the conversation line now says FEED RATE 9 12 Press either X or Y The table or saddle now moves at 9 ipm This is the way to get low feedrates for power feeding straight cuts in X or Y 13 Press the RETN Return soft key to exit jog operation and go back to manual Return to Absolute Zero Do the following 1 Make sure the readout is displaying absolute ABS If not press the INC ABS key 2 Move the handwheels
81. rotoTRAK EMX interface and includes a copy to the PTEMX Offline Programming software for making part programs on a PC 17 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 4 0 Basic Operation Whether as a retrofit or as part of a TRAK Knee Mill the ProtoTRAK EMX 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 EMX Basic Operation 4 1 1 Switching the ProtoTRAK EMX CNC on and off Turn the ProtoTRAK EMX System on by moving the on off toggle switch located directly under the power cord When it is first turned on the system will display a series of boot up screens while the ProtoTRAK EMX system loads To turn off the system simply flip the toggle switch It is not necessary to do a shutdown routine 4 1 2 Screen saver If the system is not used either by a keystroke or by counting for 20 continuous minutes the LCD will turn itself off Press any key to bring the screen back to its previous display The key you press will be ignored except to turn the screen on 4 1 3 Modes The functions of the ProtoTRAK EMX are divided into Modes Modes are groups of activities that belong together Organizing the ProtoTRAK EMX this way makes it easy to use because you don t have to memorize how to do things Simply se
82. s readout Software Diameter Cutter Compensation allows programming of the part rather than the center of the tool path Circular interpolation makes arcs and any size hole easy to do with standard tools Linear Interpolation to machine lines at any angle Conrad provides automatic corner radius programming with one data input Incremental and Absolute programming can even be mixed within an event Error Messages to identify programming mistakes Fault Messages for system self diagnostics Parts Graphics display Look a single button press to view graphics during programming Math Help for finding points in a prompted format with graphical representation of prompts Machine Tool Error Compensation and Backlash Compensation custom set on mill after installation Selectable Inch mm measurement readout Jog of X and Y from 1 to 100 inches per minute Continue Mill to eliminate repetitive data inputs while programming Context help information provides explanations of ProtoTRAK EMX operations Programmed Canned Cycles Posn Drill single point Bolt Hole series of points evenly spaced around a circle Mill straight line in any direction Arc any portion of a circle Pocket a rectangle or circle and all the material inside includes finish cut Frame a perimeter of a rectangle or circle includes finish cut Repeat of programmed events with or without offset Options Remote Stop Go RSG switch 7 Southwester
83. same place you could now press the NEXT PART soft key and the whole program would be repeated Press MODE to exit Run Congratulations You ve Made Your First Part 73 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 14 0 Additional Sample Programs 6 PLCS Program 1 og R 1 250 100376 R 187 F 2 PLCS eT 2 lA P R 875 F E 6 b ag A 1 000 l G 7 4 sR R 125 2 PLCS 5 3 0 This sample part was programmed using the center of the bolt hole pattern Point A as the program absolute zero The event numbers are shown in the circles e Programming Aspects Shown on This Part Bolt hole using 2 different tools Profile milling Math Help to calculate arc and line intersection points e Program Notes Event 1 spot drills the bolt hole pattern and Event 2 drills the hole using Tool 2 Eventi Bolt Hole Holes e Tool 1 is a spot drill the diameter X Center doesn t matter Y Center Radius Angle Tool Tool Dia Event 2 First Event 1 e Tool 2 is a 1 4 drill Last Event 1 X Offset 0 inc Y Offset 0 inc No Of Repeats 1 Tool 2 74 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual Events 3 through 7 mill the perimeter of the part X Begin Tool 3
84. t 2820 Ibs 2200 Ibs 2816 Ibs 3630 Ibs Machine dims 71 x 59 x 87 70 x 57 x 83 71 x 59 x 84 71 x 59 x 91 lw h Max rapid feed X 1001PM 100 IPM 100 IPM 100 IPM Y Way surface type Dovetail X Y Z Dovetail X Z Y Dovetail X Z Dovetail X Square Square Y Y Z Precision 7207 CP4 spindle bearings Chrome hardened and ground quill Meehanite castings Slide ways are Turcite coated Wide way surfaces are hardened and ground 14 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 3 3 1 Manual Lubrication System Ways and Ballscrew Lubrication The TRAK Knee Mill X Y Z way surfaces and ball screws are lubricated manually with the lubrication pump located on the left side of the knee Pull the handle fully and release 4 to 6 times at the beginning of each shift and once every four hours of operation thereafter 1 At the beginning of each day check the oil level in the pump If low fill with SAE 30 or 30W oil 2 Every six months of operation apply a liberal coating of Mobile Grease MP or equivalent to the Z Axis ACME screw CAUTION Failure to manually activate the pump at the beginning of each day may cause severe damage to the TRAK Knee Mill way surfaces and ball screws Head Lubrication Once Each Week 1 Fill the oil cup on the front of the head with SAE 30 or 30W oil This oil lubricates the Hi Lo range shifte
85. t Safety Programming Operating amp Care Manual 7 5 Continue In MILL and ARC events the ProtoTRAK EMX will ask you to choose YES or NO to the continue prompt If you want the cutter to keep machining from the event you are programming to the next event without stopping you should choose YES If you want the cutter X Y motion to stop so that you can adjust Z quill position then choose NO If you choose YES then the next event must be a connective event Prompts for the X Beginning location Y Beginning location Tool Offset Feedrate and Tool will not be asked because if the events are connective this data is already known The programmed feedrate may be different for different events even when the events are connective To change the feedrate within a group of connective events finish programming the event and then use the up arrow key to get access to the feedrate prompt in previous events 7 6 Assumed Tool Offset Feedrate and Tool When the INC SET key is pressed the ProtoTRAK EMX will automatically program the following for these prompts TOOL OFFSET for a Mill or Arc Event same as the last event if that event was a Mill or Arc Event otherwise Tool Center FEEDRATE same as last event if that event was a Mill Arc Pocket or Frame TOOL same as last event or Tool 1 in the first event You may change these assumed inputs by simply inputting the correct data when the event is programmed 7 7 Incremental Ref
86. t will become a normal POSN DRILL or MILL event 7 4 Prompts Used to Define the Events The following prompts are encountered in programming the events Holes the number of holes in the bolt hole pattern Angle the location of the first hole to be machined in a Bolt Hole event It is the angle from the positive X axis that is 3 o clock to the hole The positive angle is measured counterclockwise from 0 000 to 359 999 degrees 36 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual Conrad There are two meanings to Conrad 1 The connecting radius between line or arc being programmed and the next line or arc event Simply enter the radius value at this prompt and the ProtoTRAK EMX will figure the tool path to go from one event to the next with a connecting radius If no radius is desired or if you are programming the last event enter 0 by pressing the INC SET or ABS SET key without a number value 2 The corner radius in a rectangular pocket or frame The radius is tangential Continue to tell the ProtoTRAK EMX if the event is continuous to the next event s to be programmed This saves inputs needed to define a profile If the event is programmed with a Yes for continue then X begin Y begin Tool Offset Feedrate and Tool will not be prompted in the next one Direction for an arc or circle the direction is clockwise or counterclockwis
87. the RETURN soft key is lit when in J og 6 2 DRO Functions Clear Entry Press RSTR then re enter all keys 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 e 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 e 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 e 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 29 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 6 3 Jog The servo motors can be used to jog the table 1 2 7 Press the J OG soft key The feedrate box will read 100 indicating the table will move in the X or Y positive direction at
88. times the specified events are to be rotated and repeated You may not rotate another rotate event Consider the figure below sJ YCENTER pes oae A 1 I i I 0 0 ABSOLUTE XCENTER i00840 35 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual FIGURE 7 3 Shape A programmed with 4 MILL events and Conrad s 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 SUB soft key to call up the Repeat and Rotate options 7 3 7 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 POSW 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 MILL 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 event header will appear in purple Once all the prompts are completed the word Teach will disappear The even
89. ts 5 1 ProtoTRAK EMX 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 Z Y 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 quill up Measurement up is also positive on the workpiece 5 2 Absolute amp Incremental Reference The ProtoTRAK EMX may be programmed and operated in either or in a combination of absolute or incremental dimensions An absolute 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 Absolute Dimensicns Absolute Reterence incremental Dimensions 5 2 1 Some Rules for I ncremental Reference Positions In the section above it was pretty clear what was meant by an incremental move There are times that this is not completely clear This occurs when you want to use incremental references for the first X and Y dimensioned data in a new event and the ending point of the previous event is not obvious For example with a circular pocket the ending point is not defined what does the INC SET reference mean when programming
90. um etc the chips and dust are highly flammable Obtain special instruction from your supervisor before machining these materials Prevent fires Keep flammable materials and fluids away from the machine and hot flying chips When working in manual mode not CNC make sure the computer control is switched to DRO or OFF An optional interlocked guard is available from Southwestern Industries Inc for TRAK Knee Mills if the use of the table guard is deemed necessary by the user for his application 6 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 3 0 Description 3 1 ProtoTRAK EMX CNC Specifications 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 Digital Servo Amplifiers custom designed for ProtoTRAK operation D C Servo Motors rated at 280 in oz continuous torque are twice that required Precision Ball Screws in the table and saddle Modular Design simplifies service and maximized uptime 115V 60HZ 8 amps Feedrate Override of programmed feedrate and rapid Polycarbonate Sealed Membrane Keypad to lock out contamination 7 0 Color LCD On board IDR flash memory storage for part programs USB port for interface with a storage device Rugged Industrial PC Glass Scale on quill for Z axi
91. urchased This switch is on a ten foot cable and operates like the FEED Stop and Go keys on the display 3 4 3 Work Light TRAK Knee Mills Only An optional halogen work light is available It mounts to the left side facing of the column and plugs into a 110v outlet in the electrical cabinet 3 4 4 Coolant Pump TRAK Knee Mills Only The optional coolant pump is mounted in the back of the machine column It is plugged into the electrical cabinet and may be configured to operate as commanded by the auxiliary functions or with a separate switch 3 4 5 Spray Coolant TRAK Knee Mills Only The Fog Buster spray coolant option consists of a one gallon holding tank nozzle air lines and an air regulator for attaching compressed air Coolant flow is adjusted by a needle valve at the sprayer head Air flow is adjusted at the air pressure regulator with gage Once flows are set sprayer operation is controlled by an air toggle switch or by interface with the optional Auxiliary Functions 3 4 6 Chip Pan TRAK Knee Mills Only The Chip Pan option is available for TRAK Knee Mills only not available for retrofits 3 4 7 Table Guard TRAK Knee Mills Only The Table guard option provides an enclosed workspace mounted on the table The sliding door is switched to prevent operation of the CNC Run with the door open While it will aid in the control of chips and coolant it is not a full waterproof enclosure The Table Guard is available for TRAK K
92. y Drill the Holes e Load Tool 1 Dia 250 Load the 1 4 drill in the spindle then start the spindle and adjust the RPM Note You will probably want to center drill each hole first You can run each event more than once by pressing Mode Run Start To start at the middle of the program press START EVENT e Xand Y readouts should read zero ABS Beneath them the actual feedrate now zero and the feedrate override percent now 100 are shown e Press GO The tool will move actually the table moves to the first hole in the row e Set Z You move the quill and drill the hole After every drilling operation always make sure the tool is up to clear the work piece e Press GO and drill the remaining holes and holes in the bolt hole pattern each time the conversation line says Set Z Mill the Upper Left Diagonal e When the last hole is drilled the conversation line says Load Tool 2 Dia 375 You should stop the spindle load the 3 8 end mill start the spindle and adjust the RPM e Press GO The tool will move to the upper left EMX of the part where the diagonal cut begins e Set Z You move the quill so the tool is slightly below the bottom of the plate to make the full depth cut Lock the quill at this position e Press GO The tool will move at 5 ipm and cut the diagonal e Check Z This is a warning to raise the quill because the next move will be at rapid speed 100 ipm You should
93. y Waranty TRAK products are warranted to the orginal purchaser to be free from defects in work manship and materials for the following periods Warranty Period product Materials Factory Labor New TRAK l Year l Year Any EXC HANGE 90 Days 90 Days Unit The waranty period startson the date of the invoice to the orginal purchaser from Southwestem Industries Inc SWI or their authorized distributor Ifa unit under wananty fails it will be repaired orexchanged at ouroption fora propery functioning unit in similar or better condition Such repairs or exchanges will be made FOB Factory Los Angeles or the location of our nearest factory representative orauthorized distributor Disclaimers of Wananties e This warranty is expressly in lieu of any other waranties express or implied including any implied warranty of merchantability or fitnessfora particular purpose and of any other obligations or liability on the part of SWI orany producing entity if different e Warranty repairs exchangesdo not cover incidental costs such asinstallation labor freight etc e SWlisnot responsible for consequential damages from use or misuse of any of its products e TRAK productsare precision mechanical electromechanical measurement systems and must be given the reasonable care that these typesof instruments require e Replacement of chip scrapersand wipersisthe responsibility of the customer Consequently the warrant
94. y that need to be entered to complete an event 8 3 Editing Previously Programmed Events From the Select Event screen you may press the arrow up key to the right of the LCD screen and the program will move back one event From that point you will have the following softkey options INSERT EVENT allows you to insert a new event between the two shown on the left and right side of the screen When you press INSERT EVENT the screen will revert to the Select Event screen and you may program the new added event as you would any other Subsequent events will be renumbered accordingly DELETE EVENT allows you to delete the event on the right side of the screen Subsequent events will be renumbered accordingly PAGE FWD Forward indexes the event forward by one PAGE BACK indexes the event back by one 8 4 Changing the Feedrate If the feedrate is edited in any event it will automatically be edited in every subsequent and contiguous event with the same tool number and feedrate For example let s say events 5 through 10 and 13 through 16 were all programmed with tool number 2 and 5 inches per minute feedrate If you edit the feedrate in Event 7 to 3 inches per minute it will automatically change Events 8 9 and 10 also Events 5 6 13 14 15 and 16 will not be affected 8 5 Changing a Part Number making a copy of a program You may want to rename a part program or make a copy of a program using a different name The latter may be us
95. y doesnot apply if chips have been allowed to enterthe mechanism e Accidental damage beyond the control of SWI isnot covered by the warranty Thus the warranty doesnot apply if an intrument hasbeen abused dropped hit disassembled oropened e Improperinstallation by orat the direction of the customer in such a way that the product consequently fails isconsidered to be beyond the control of the manufacturer and outside the scope of the waranty
96. ystem 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 9 9 Fault Messages The ProtoTRAK performs a number of automatic checks or self diagnostics If problems are found it will signal you through the display 45 Southwestern Industries Inc TRAK EMX Knee Mill amp ProtoTRAK EMX CNC Retrofit Safety Programming Operating amp Care Manual 10 0 Math Help Prints are unfortunately not always drawn and labeled in such a way as to provide all of the points necessary for programming To minimize this problem the ProtoTRAK EMX provides a graphic math help function which can be used to automatically calculate points of intersection centers of arcs trig functions square roots etc 10 1 Procedure To enter the Math Help Mode press MODE and select the MATH HELP soft key The screen will show MATH A Line Line Intersection B Line Arc and Arc Arc Intersection C Line Arc Tangency B D Centers Points Radius Angles of Circles E Polar Cartesian Transformation E i01279 If you already know the math help type you want see Section 10 2 press the TYPE softkey and enter the number and SET If you do not know the type select from A through E using the softkeys If for example you wish to find the intersection of a straight line and an arc or circle press the B softkey The

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