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Ultimax
Getting Started with Ultimax Manual
August, 2002 Revision A
Hurco products and services are subject to Hurco’s then current prices,
terms, and conditions, which are subject to change without notice.
The information in this document is subject to change without notice and does not
represent a commitment on the part of Hurco Companies, Inc. (Hurco). No part of this
document may be reproduced or transmitted in any form or for any purpose without the
express written permission of Hurco. However, Hurco does authorize the creation of two
electronic and two paper photocopies by the original Hurco machine tool purchaser, or
his authorized designee.
2001-2002 Hurco Companies, Inc. All rights reserved.
Many of the designations used by manufacturers and sellers to distinguish their products
are claimed as trademarks. Hurco has listed here all trademarks of which it is aware.
For more information about Hurco products and services, contact:
Caution
Important
Ensures proper operation of the machine and control.
HURCO
Troubleshooting
Steps that can be taken to solve potential problems.
Warning
The operator may be injured and the machining center
severely damaged if the described procedure is not
followed.
Sample Screens
Some sample screens in this manual were captured on a stand-alone
Ultimax system. The screens on your system may vary slightly. The Input
screen below illustrates softkeys and includes the software version (circled
below).
Programming Basics
Part Programming Setup ...................................................................................... 3-1
Part Fixturing and Tool Loading.............................................................. 3-2
Part Program Names ................................................................................ 3-2
Part Setup ................................................................................................. 3-3
Entering Part Setup Information .................................................. 3-4
Part Setup Fields .............................................................. 3-6
Part Setup Softkeys .......................................................... 3-7
Safety Work Region..................................................................... 3-8
NC Work Offsets ......................................................................... 3-9
NC Probing Part Setup............................................................... 3-10
Tool Setup.............................................................................................. 3-11
Entering Tool Setup Information ............................................... 3-12
Tool Setup Fields ........................................................... 3-16
Tool Setup Softkeys....................................................... 3-18
Automatic Feed and Speed Calculations ................................... 3-20
Entering Zero for Speed (RPM) Value .......................... 3-20
Entering Actual Speed (RPM) Value............................. 3-21
Formulas for Automatic Calculations............................ 3-21
Program Parameters ............................................................................... 3-22
General Parameters .................................................................... 3-23
Holes Parameters ....................................................................... 3-28
Milling Parameters..................................................................... 3-31
Cutter Comp Parameter.............................................................. 3-34
NC Parameters ........................................................................... 3-37
NC Configuration Parameters........................................ 3-38
M and G Code Program Numbers ................................. 3-40
NC Variables.................................................................. 3-41
Erase Functions.................................................................................................. 3-42
Erase Current Program........................................................................... 3-42
Erase Running Program ......................................................................... 3-45
Restore Functions............................................................................................... 3-46
Graphics ............................................................................................................. 3-51
Views ..................................................................................................... 3-52
Zoom ...................................................................................................... 3-54
Graphics Parameters .............................................................................. 3-54
Data Block Search.................................................................................. 3-56
Graphics Error Checking ....................................................................... 3-58
Running Part Programs ...................................................................................... 3-59
Appendix
Index
Figure 3-1. Part Zero Relative to Machine Zero Viewed Looking Down at Table3-3
Figure 3-2. Axis Motion ........................................................................................ 3-3
Figure 3-3. Part Setup Screen ................................................................................ 3-4
Figure 3-4. Safety Work Region Fields on the Part Setup Screen......................... 3-8
Figure 3-5. Work Offsets for NC Programs .......................................................... 3-9
Figure 3-6. Tool Setup Screen ............................................................................. 3-12
Figure 3-7. Cutter Compensation......................................................................... 3-14
Figure 3-8. Input Screen ...................................................................................... 3-22
Figure 3-9. General Parameters Screen ............................................................... 3-23
Figure 3-10. Positive First Peck Offset.................................................................. 3-26
Figure 3-11. Negative First Peck Offset ................................................................ 3-26
Figure 3-12. Chord Error ....................................................................................... 3-28
Figure 3-13. Holes Parameters Screen................................................................... 3-29
Figure 3-14. Milling Parameters Screen ................................................................ 3-31
Figure 3-15. Milling Parameters Screen with Insert Arc and Insert Line Softkeys3-34
Figure 3-16. Cutter Compensation Using the Insert Arc Parameter...................... 3-35
Figure 3-17. Cutter Compensation Using the Insert Line Parameter..................... 3-36
Figure 3-18. NC Parameters Screen....................................................................... 3-37
Figure 3-19. NC ParametersConfiguration Parameters Screen ......................... 3-38
Figure 3-20. NC ParametersM and G Code Program Numbers Screen ............ 3-40
Figure 3-21. Input Screen with Erase Functions Softkey ...................................... 3-42
Figure 3-22. Erase Functions ................................................................................. 3-43
Figure 3-23. Input Screen with “Do you really want to Erase?” Message ............ 3-44
Figure 3-24. Input Screen with Erase Running Program Softkey ......................... 3-45
Figure 3-25. Input Screen with Restore Functions Softkey................................... 3-46
Figure 3-26. Input Screen with Restore Functions ................................................ 3-47
Figure 3-27. Input Screen with “Do you really want to Erase?” Message ............ 3-49
Figure 3-28. Current Directory Screen After Selecting a Restore Function.......... 3-50
Figure 3-29. New Block Screen with Miscellaneous Functions............................ 3-51
Figure 3-30. Graphics Screen with Isometric View............................................... 3-52
Figure 3-31. Graphics Screen Showing All Planes................................................ 3-53
Figure 3-32. Graphics Parameters Screen.............................................................. 3-54
Figure 3-33. Identifying a Portion for the Search .................................................. 3-56
Figure 3-34. Data Block Displayed After the Search ............................................ 3-57
Figure 3-35. Graphics Screen Error Message ........................................................ 3-58
Figure 3-36. Access Code Message on Manual Screen......................................... 3-60
Figure 3-37. CE Status & Diagnostics Screen ....................................................... 3-61
Figure 3-38. Incorrect Code Message on CE Status & Diagnostics Screen .......... 3-62
Figure 3-39. Enabled Field on CE Status & Diagnostics Screen........................... 3-62
Figure 3-40. Error Message on the Auto Screen ................................................... 3-64
Figure 3-41. Input Screen with Concurrent Running Program.............................. 3-67
Figure 3-42. Input Screen with Exchange Edit/Run Programs Softkey ................ 3-68
Table 3-1. General Parameter Ranges and Default Values ................................ 3-27
Machine Components
Before using the machine, you should become familiar with its
components. Because of European Committee (CE) requirements, Hurco
machines sold in Europe differ somewhat from those sold elsewhere. The
figure below identifies some of the easily recognized components of a
machine. The console is in front of the machine, facing the operator’s
area.
Hurco machines are available with several hardware and software options.
Information about these options is available from Hurco or your Hurco
Distributor.
Consoles
The Ultimax 4 console and the Max single screen (Max) console use
Ultimax software:
The console, and the electrical components required to operate it, are
called the “control” or the “CNC” (Computer Numeric Control). Some of
the electrical components are built into a separate enclosure kept in the
machine’s electrical cabinet.
Some of the control’s internal components, such as disk drives and
memory, are like those in a PC. Disk operations, such as copying, deleting
and storing files, are also similar.
The floppy drive is located on the console’s right side panel. To protect
the drive from debris, the protective floppy drive cover should be closed,
except when inserting or removing a diskette. The floppy drive is standard
on the Ultimax 4 console, and optional on the Max console.
Hurco offers the optional Delight package for the Ultimax 4 console. The
Delight package includes a keyboard tray, document holder and print
holder. An optional keyboard tray is also available for the Max console.
A miniature PS/2 keyboard and tray package is available for the Max
console.
The Max Classic optional package for the Max console is also available
from Hurco. The Max Classic package includes touchscreen graphics,
floppy drive, memory upgrade to 64 MB RAM, hard drive upgrade to 2
GB.
Information about options is available from Hurco or your Hurco
distributor.
The Ultimax 4 console also has a power on button, emergency stop button,
and brightness control thumbwheels for the Text screen and Graphics
screen. Some consoles are also equipped with contrast control
thumbwheels.
Caution
If the Emergency Stop button is pressed during execution of a part
program, the tool must be jogged clear of the part before resuming
operation.
Programming Keyboard
Program a job at the machine while reading from a blueprint or program
worksheet. The prompts on the Text screen lead you through each element
of a part program. Enter machine operations, part dimensions, and other
parameters by selecting the appropriate screen softkeys and console
buttons.
Set up and run part programs, and manage part program files using the
following data entry keys:
Text screen data entry keys are used for entering programming
information into the Text screen’s fields. These keys are located in the
center of the console’s Programming Keypad.
Programming Mode
Programming Mode console keys are named for the screens they activate:
• Arrow keys - move the cursor from one field to the next, or
advance a part program to the next data block.
• Enter key (↵) - accept the information typed in a text field, or
move to the next field.
• Special Function keys
• C console key - Use the C console and Clear keys to delete
the value at the current cursor position.
• Delete console key - Use the F console and Delete keys
together to delete the character to the left of the cursor.
• Arrow console key - Use the F console key in combination
with the arrow keys to quickly move the graphics cursor on
the graphics screen.
Softkeys
Note
Numeric Keypad
The numeric keypad allows you to enter numbers and calculate values in
the Text screen. Perform the following operations with this keypad:
• Enter numeric data into fields on the screen.
• Perform calculations using the mathematical symbols (÷, ×,
−, +) on the keypad.
Enter part program names using the Pop-up Text Entry Window (if the
console does not have an optional computer keyboard). The Pop-up Text
Entry Window automatically appears when text is required, such as
naming a part program. The sample screen below contains this window:
3. Press the Enter key after characters are selected in the text
field (e.g., after a program name is created).
Note
You must have the Graphics option installed on the Max console to
access the Graphics screen.
Use the console trackball on the Ultimax 4 console, Select console key,
and Draw console key with the Graphics screen. Use a stylus or touch the
Max console screen in place of the console trackball.
Roll the trackball on the Ultimax 4 console with your fingers to operate it.
The trackball can be used to perform the following tasks:
The Draw console key is used to display or re-draw the graphics screen.
Unless the Graphics option is installed on the Max console, the graphics
screen will not appear when the Draw console key is pressed.
The Select console key is used with the trackball to select specific
elements on the Graphics screen.
Override Knobs
Three knobs on the upper console allow you to override the programmed
axis feedrate, rapid, and spindle speed.
Jog Unit
Use the Jog Unit to manually jog the axes. The Console Jog Unit is on the
Max console. The hand-held Remote Jog Unit can be removed from the
console and carried closer to the work piece. The Remote Jog Unit is
standard on the Ultimax console and an option on the Max console. Both
Jog Units function the same:
Important
Other than the Emergency Stop button, the Jog Unit does not affect
running programs.
• Store Position Key - record the axis’ current position in the part
program’s setup screens.
Note
Machine Control
Machine Control buttons start and stop machine operation. The buttons
function as follows:
• Power On - enables the relay control system. This button must be
illuminated to operate the machine, but may be switched off while
creating or editing a part program.
• Start Cycle - activates machine operation. When the machine is in
an active mode, the Start Cycle flashes to indicate the machine is
ready. When this button is pressed again, the light switches off.
To turn Control Power On:
Important
Never press the Start Cycle button without knowing exactly what the
machine will do.
Machine Operations
The Machine Operations console keys are needed to run part programs
and control the machine during cutting. These keys are labeled under the
Machine Mode, Spindle, Tool Changer, and Coolant groupings.
Machine Mode
Pressing the Machine Mode Auto console key displays the Auto screen.
The part program to be executed appears in the Running Part Program
field.
For Conversational part programs, the Start Block and End Block fields
display the program’s first and last data blocks. If you want to execute
only a certain portion of the program, these fields may be changed.
Identify the start and end data blocks of an NC Program by touching the
appropriate softkey.
The following softkeys are available on the Auto, Single Cycle and Test
screens:
Note
On the NC Auto monitoring screen, NC data blocks being executed
appear above the “Program Running” message. The next block to be
executed appears above the prompt.
These are the monitoring softkeys that may be available for Auto Cycle
mode:
Note
For information on the Single Cycle screen softkeys, see the “Auto
Cycle Mode Softkeys” section.
Note
During execution of the part program, you can switch between Auto and
Single Cycle operations by pressing the corresponding console key.
Caution
Standard moves are not made before executing a Single Cycle.
Examine the part program to determine the precise tool movement to
avoid interference with fixturing before executing a Single Cycle
operation.
Test Run mode is used to verify the part program and check for program
errors. For Conversational programs, you can adjust the programmed
feedrates and spindle speeds while cutting the part. The an NC Digitizing
feature for NC programs is accessed through the Test Run screen.
Press the Machine Mode Test console key to display the Test Run screen:
Caution
If the Z-Start value is set below the stock surface, the minimum Z
value must be programmed so the tool does not plunge into the part.
Note
Feedrates for Drilling and Boring operations can be adjusted using
either the Set Plunge Or Segment Feed or the Set Feed softkeys.
Using Set Plunge Or Segment Feed and Set Feed overwrites the
original values with adjusted values. When the test run is completed,
the original values are automatically erased and replaced with the
new values. The new values become effective with the next
execution of the program
• Check for Errors – See the “Auto Cycle Mode Softkeys”
section.
Manual Mode
Pressing the Machine Mode Manual console key displays the screen
shown below. The information at the top of the screen includes the current
position of each axis relative to machine absolute and part zero. Refer to
the “Part Setup” section of this manual for more information about these
functions.
Important
The Orient Spindle softkey will not function unless the enclosure
doors are completely closed.
Spindle
Tool Changer
Coolant
Communications Panel
Each Hurco machine may be connected to peripheral devices through a
communications panel located on the machine’s electrical cabinet.
Communication connectors may include two serial ports and two network
connectors. The BNC connector is used for 10Base2, thin coaxial network
cabling. The RJ45 connector is used for 10BaseT, unshielded twisted pair
network cabling. The circular plug in the center of the plate connects to
optional indexer equipment. Refer to the “Appendix” for more
information.
Power Up
The operator must perform routine checks before attempting to power up
the machine.
Machine Power
The machine’s On/Off switch supplies power to the entire machine,
including the console. The power switch is located behind the machine, on
the electrical cabinet door.
When the machine is turned on, start up and self-test information appears
on the console screen. Power must be switched off before maintenance
may be performed inside of the electrical cabinet.
Warning
High voltages inside of the electrical cabinet can cause
injury or death. Only qualified and trained maintenance
personnel are authorized to open the electrical cabinet
doors.
Before powering off the machine, refer to the “Shut Down” section.
Axes Calibration
To calibrate all axes, follow these steps:
1. Touch the Calibrate Machine softkey on the Manual screen.
The Start Cycle button begins to flash.
2. Press the flashing Start Cycle button. The Axis Limit
Switches field indicates the status of the machine’s limit
switches as each axis calibrates.
3. The Machine field for each axis displays the calibrated
position after calibration is completed.
Note
Control power must be on, and the axes must be calibrated before the
machine can be warmed up.
Important
To cancel the warm up cycle before pressing the Start Cycle button, press
any Machine Mode console key.
Each tool is inserted into a tool holder before being loaded into the
spindle. The orientation hole in the tool holder must always line up with
the orientation key in the tool changer. Tool changer stations are
numbered to identify and locate each tool.
Important
Only use tools that are dimensioned for the maximum spindle speed.
Warning
Do not manually load tools directly into the magazine.
To load the tool currently in the spindle into the ATC magazine:
The ATC Map field will indicate if the tool selected is in the
magazine, and its location.
3. Enter the tool number (of the tool you want to remove in the
magazine) into the Next Tool field.
4. Press the Tool Changer Auto console key to move the Next
Tool into the spindle.
5. Clear the tool changer area and shut the enclosure door.
Press the Start Cycle button to initiate the tool change.
6. Press the Spindle Unclamp button and manually remove the
tool from the spindle.
7. Repeat steps 2 through 6, as needed, to remove additional
tools from the ATC magazine.
Note
The ATC magazine capacity is reduced by half for tools larger than
80 mm (125 mm for some machines).
Follow these steps to load large tools into the ATC magazine:
Important
Each time you switch between large and small tools, the entire ATC
Map will be cleared and the magazine must be reloaded.
4. Touch the Yes softkey. The ATC Map will clear, then
reappear. Only the odd numbered tool pockets will be
available.
5. Reload tools into the magazine using the “Loading a Tool
into the Spindle” section.
6. Return to the default setting of Maximum Tool Diameter
XX mm or Less by using the previous procedure and
touching the Max. Tool Dia. XX mm or Less softkey.
You can view the ATC Map at any time to determine where a tool is
located in the magazine. To view the ATC Map, follow these steps:
1. Press the Machine Mode Manual console button.
2. Touch the Tool In Spindle softkey.
3. Touch the ATC Map softkey. The following screen appears:
Toggle the ATC Map field between Manual and Auto by pressing the
Tool Changer Auto console key.
Note
The default setting for ATC Map field is Manual. A qualified Hurco
Field Service Engineer can change the default setting to Auto.
If you are emptying the ATC magazine and loading new tools, you must
first clear the ATC Map:
1. Press the Machine Mode Manual console button.
2. Touch the Tool In Spindle softkey to access the Tool In
Spindle screen.
3. Touch the ATC Map softkey.
4. Touch the Reset ATC Map softkey. A message will appear
asking if you wish to continue with the procedure. Select
Yes to continue.
After clearing the ATC Map, load the first tool into the spindle as
described in the “Loading a Tool into the Spindle” section.
Shut Down
Use one of the following three shut down methods to shut power off to the
servos and stop lubrication from pumping onto the ways. Always shut
down the machine before turning off machine power.
Important
If the machine will not be used for several days, or the shop has
power surges or blackouts, turn off machine power at the main
power switch.
Warning
Emergency Stop shut down is not good for the
machine’s table, especially if the table is long and has
heavy equipment attached to one end. Before pressing
the Emergency Stop button, park the machine or center
the table.
File Management
Part programs are stored on the Computer Numeric Control (CNC) hard
drive, or on floppy diskettes. Each hard drive contains one main
directory—the root directory. An operator cannot create this directory, but
directories and subdirectories can be stored in it to enhance file
management.
Compare file management to a filing cabinet. The hard drive is the filing
cabinet. A directory is a file cabinet drawer. A subdirectory is a file folder
inside a drawer. Part programs are individual sheets of paper that are
stored “loose” on the hard drive, or filed in directories and subdirectories.
Hard Drive
(Root directory "C")
Subdirectories
Directories
Storage Functions
The Current Program screen contains softkeys that access file storage
functions such as reading and writing programs. This section explains how
to access storage functions.
Touch the Storage Functions softkey on the Auxiliary screen . The Current
Program screen appears.
The disk drive currently available is listed at the top of the screen. See the
“Select Current Storage Drive” section for information on selecting a
different drive.
Small icons that symbolize storage devices appear in the bottom left
corner of the screen. An indicator blinks on each icon when the drive it
representsis accessed. If you have installed the UltiNet option and you
have an active network connection, a network drive icon will also display.
Note
The floppy disk drive is located on the right side of the console (you
must have the Floppy Disk option installed to access the floppy disk
drive on a Max console). See the “Consoles” section in the
“Machine and Basics” chapter for information.
Note
Note
The following characters are valid for part program, directory and
subdirectory names:
Change to Directory
Change the current directory. Use the Arrow keys to highlight the
desired directory and touch the corresponding softkey. The Current
Directory screen updates to display the directory, subdirectory, and
part program names. Part programs have an .HD3 extension.
Rename Program
Delete Program
Copy Program
Program Mask
You can also use wildcards with program mask. A wildcard is a character
that can match any character or sequence of characters. Use the ? as a
wildcard for a single character, and the * as a wildcard for one more
characters.
Important
Once the NC file mask is changed, the *.FNC or *.HNC default is
lost. To return to the original defaults, delete the NCPARAMS.SET
file.
Touch the Select Current Storage Drive softkey on the Current Program
screen to store a program on the hard drive or to a floppy disk. Softkeys
allow you to choose the drive in which to store the program.
Note
Create Directory
Touch the More softkey to return to the first page of the Disk
Operations List Directory softkeys.
Delete Directory
To delete a directory:
Touch the More softkey to return to the first page of the Disk
Operations List Directory softkeys.
Touch the More softkey to return to the first page of the Disk
Operations List Directory softkeys.
Remove the tag markers from all of the tagged programs in the directory.
To untag all programs, follow these steps:
Touch the More softkey to return to the first page of the Disk
Operations List Directory softkeys.
Add or remove a tag marker from one or more part programs. To toggle
the program tag:
You cannot place a copied program into the same directory as the
original program.
Touch the More softkey to return to the first page of the Disk
Operations List Directory softkeys.
Touch the More softkey to return to the first page of the Disk
Operations List Directory softkeys.
Format Diskette
Note
You must have the Floppy Disk option installed on the Max console
to use and format a floppy diskette.
Note
Change NC Dialect
Touch the Change NC Dialect softkey on the Auxiliary screen to switch
between the Basic Numerical Control (BNC) and Industry Standard
Numerical Control (ISNC) dialect when creating NC part programs
Download/Upload
Transfer part programs between the CNC and various peripheral devices
(e.g., PC, external disk drive) with the Download/Upload softkeys on the
Auxiliary screen.
The baud rate determines how fast a single bit of information is
transferred between two serial modems. The baud rate is measured in
characters per second.
Note
Note
Conversational NC
Message Message Description
(Not Busy) The Serial Port was not
requested to transmit any data.
Waiting to (Busy Reading The Serial Port is active and
Receive… Leader) ready to receive data. Begin
sending data from the peripheral
device.
Receiving Data… (Busy Loading) The Serial Port is active and
receiving data from the
peripheral device.
Sending Data… (Busy Sending) The Serial Port is active and
sending data from the CNC.
Waiting to Send… (Waiting To The Serial Port is active and
Send) waiting for the peripheral
device to be ready to receive data.
Upload Receive
Receive a part program from peripheral devices, such as a PC. Follow the
instructions on the screen to complete the part program transfer to the
CNC. While an NC program is being uploaded, an “R” (reading) or “W”
(writing) icon appears on the screen.
Aborting an Upload
Note
Note
Follow these steps to upload a part program from a remote device into the
CNC’s memory:
1. Set up the port parameters for the appropriate port.
2. Set the Source/Dest parameter to Memory to save the part
program into the CNC’s memory.
3. Start the program loading operation by touching the Upload
Receive softkey on the Upload/Download screen.
4. Touch the appropriate softkey to select the correct port to
receive the program. If there is currently a program in
memory, a “Should the current file in memory be deleted?”
a. Touch the Yes softkey to delete the current
program from memory and continue uploading.
b. Touch the No softkey if you want to save the
current program in memory to a disk drive.
5. The Status Message appears. Initiate data transfer from the
remote device. The Status Message changes when the
upload is complete.
Note
Download Send
Download a part program from the CNC to peripheral device. During
downloading, a status message displays. When the download is complete,
a confirmation message appears.
Aborting an Download
Note
Note
Select Port
Touch the Select Port softkey on the Upload/Download screen to switch
between serial ports. The screen changes to display the other port and its
settings.
Note
Abort Operation
Touch the Abort Operation softkey to stop the current NC programming
upload/download operation.
Important
Before attempting to transmit a part program, the CNC’s serial port and
peripheral port must be identically configured.
Protocol
Refer to the Appendix for descriptions of these protocols and the reasons
to select each. An operator who wants to write communications utilities
will find this information useful. Here are the Protocol Option softkeys:
Baud Rates
Choose between seven baud rates. Select the proper baud rate for the
connected equipment using the Baud Rate field’s softkey menu.
Important
The 9600 baud is the default setting for the control. This speed is
adequate for most applications.
The baud rates for the remote device and the control must match.
Follow these steps to change Serial Port settings for each port:
1. Move the cursor to the Protocol field on the
Upload/Download screen and touch the appropriate
communication protocol softkey.
2. Move the cursor to the Baud Rate field and touch the baud
rate softkey for the port.
3. For Conversational programming Upload/Download, select
the Character Length, Stop Bits, and Parity by entering the
appropriate value in each field.
System Configuration
Access the System Configuration screen to customize console settings:
To enter today’s date into the system, move the cursor to the Month field
on the System Configuration screen, and follow these steps:
1. Type the number of the month. Press the Enter key to move
to the next portion of the field.
2. Type the number of the day. Press the Enter key.
3. Type the last two digits of the year. Press the Enter key.
Note
After 2000, the year will display as one digit, even if two digits
are entered. For example, if you enter 02 for the year 2002,
it will display as 2.
4. Touch the Set Current System Time softkey.
AutoSave Time
Use the AutoSave feature to periodically save a copy of the Conversational
part program to the hard drive in a file named saveprog.hd3. While the
part program is being saved, the system displays “Autosaving Part
Program” message.
Programming changes made after the last AutoSave are lost if the CNC is
rebooted or loses power. When the control is restored, the last AutoSave
version of the program automatically appears on the screen.
Note
Important
AutoSave does not save a program to its original programname or drive.
Refer to “Write Program to Disk” for instructions on saving a program.
Enter a time in minutes in the Screen Blank Time field on the System
Configuration screen. The screen will go blank after the entered time:
Important
To redisplay blank screens, move the trackball or press any console
key. The first keystroke is used to re-activate the blank screen. The
second keystroke begins programming input.
The DRO is viewed in the Manual or the Auto Mode screens. A status line
at the bottom of the screen indicates program units (mm or in).
You can change the DRO character size only for the Auto screen. Touch
the Toggle Display softkey to change from the standard display to the
Quad Size display. Touch the Toggle Display softkey again to change the
DRO display size back to standard.
Change the colors on the Text screen. Color bars at the bottom of each
function key show the color that will appear for each softkey selection.
The chart below lists the Text Color Parameters defaults:
Change the colors on the Graphics screen. Color bars at the bottom of
each function key show the color that will appear for each softkey
selection.
Note
The DXF color options appear on this screen only when the DXF
option is installed on the system.
Change the colors on the Storage Functions screen . Color bars at the
bottom of each function key show the color that will appear for each
softkey selection:
The Ultimax software version and options available for the machining
center are displayed on this screen.
Note
The software version and options displayed above may be different from
what is displayed on the CNC for your machining center.
Note
Change Editor
Touch the Change Editor softkey on the Auxiliary screen to switch the
program editor type between Conversational and NC.
CRT Degauss
The CRT Degauss softkey was used to remove the buildup of magnetic
fields on older monitors with cathode ray tubes (CRT). The CRT Degauss
softkey is not needed for the LCD-based Ultimax and Max consoles.
Change Language
This softkey will only appear if at least two language files are installed.
To change the language file:
Note
6. After all disks are inserted, switch off the CNC power and
switch it back on again to activate the system upgrade.
Important
Save the system upgrade diskettes in a box away from heat, debris,
and magnetic interference
Simultaneously press the F and End console keys (Ctrl and End keys for
the Max console) to highlight the message at the bottom of the page.
Touch the Write Error Log to Disk softkey to write the current log to
disk. Message text will not be saved, but can be sent to Hurco for
analysis.
Reset Master
To restart the control (reboot the system) without switching the power to
the machine off and back on again, follow these steps
1. Touch the More softkey on the Auxiliary screen.
2. Touch the Reset Master softkey. Touch the Yes softkey to
reboot the system. Touching the No softkey aborts the
reboot.
Note
Important
Be sure to save the current part program to the hard disk or a floppy
diskette before rebooting. If you do not save to the hard drive or
floppy diskette:
Programming Basics
Part Programming Setup
There are five main steps to follow before creating a part program on the
Ultimax control
1. Plan the part programming operations.
2. Perform the tool-loading and part-fixturing operations.
3. Enter the Part Setup information.
4. Enter the Tool Setup information.
5. Enter the Program Parameters information.
To perform many of the setup functions, use the axis controls to move the
table or spindle and record positions. Refer to the “Machine and Console
Basics” chapter for information about axis controls.
All machine tool operators need to plan their jobs before they begin
programming. Plan work piece placement, fixturing, and part cutting
operations before cutting a part. Then, load the tools and fixture the work
piece to the table.
Before programming the part on the Ultimax control, use the setup screens
to describe the part and the tools used to cut the part. This information is
necessary for the system to draw the part on the graphics screen.
Important
Part and Tool Setup information is saved with conversational
programs but not with NC programs. Refer to the “Restore
Functions” section of this chapter for details about restoring HD3
setup information to use with NC programs.
In order to determine the starting point (part zero) in the part, first fixture
the work piece (raw material or stock) to the machine tool table. This
process, called fixturing, can be accomplished using a variety of clamping
devices, such as vises and toe clamps. Locate the fixturing device in an
area that will not get in the way of the cutting tool.
You may want to insert a tool in the spindle to use as an edge finder when
identifying part zero. Press the Machine Mode Manual console key to
display the Manual screen. Use the Tool in Spindle field and softkey to
enter the tool number for the edge finder tool.
Part Setup
The part setup procedures establish the locations of part zero in X and Y
relative to machine absolute zero. Part zero may be located anywhere on
the fixturing or the part. During machine calibration, each axis moves to
its + or - travel limits. Machine zero, identified during machine
calibration, is the location to which each axis moves to determine a fixed
point where the X, Y, and Z axes become tangent. This value does not
change after calibration.
Figure 3-1. Part Zero Relative to Machine Zero Viewed Looking Down at Table
Program the axes to move within the coordinate system as shown below:
Begin the programming setup process with the Part Setup screen. Press the
Part Setup softkey on the Input screen. Definitions for the fields and
softkeys are in the “Part Setup Fields” and “Part Setup Softkeys” sections
that follow.
The Digital Read Out (DRO), the top left section of the screen, shows the
position of the axes and machine status. The bottom half of the screen is
the data entry area with fields for entering the values to identify part zero
and the safety work region for the part program.
There are a number of methods for entering Part Setup information. For
example, you can either manually type values into the fields, or use an
edge finder. If you use an edge finder, follow these steps:
Note
FieldsDefinitions
Part Zero Xthe X location in machine coordinates for part zero.
Ythe Y location in machine coordinates for part zero.
Offset Zthe Z dimension offset for part zero. This field is
usually left at 0 and the Tool Calibration field in Tool
Setup is used to determine each tool’s part zero.
• To store the Z values using the Store Position
button, a reference tool previously defined in Tool
Setup for this program must be in the spindle.
• Entering a value in the Offset Z field adds or
subtracts the amount of the offset to the Tool
Calibration value. For example, you can adjust all
Tool Calibration values in the Z axis and Z Start to
compensate for part thickness by changing the
Offset Z value.
Safety Work Region these fields define a part-relative safety area to
prevent the cutting tool from colliding with fixtures
or other equipment.
• The defaults are +99.0000 or -99.0000 inches
(+9999.000 or -9999.000 mm).
The remaining Part Setup fields only apply if the Part Probing option is
installed:
Probe Z the distance from Z Zero to the top of the part (i.e.,
the height, or Z Plane), with a reference tool or part
probe in the spindle. This field is used only with the
Probing option. Refer to the Probing Option Manual
for details.
Skew Angle the distance, in degrees, the part is from square
alignment with the table. This field is used only with
the Probing option.
Establish the dimensions of the Safety Work Region to prevent the cutting
tool from moving into areas where it might collide with other equipment
or the work piece and fixturing. The Safety Work Region values are
relative to Part Zero.
Figure 3-4. Safety Work Region Fields on the Part Setup Screen
To enter values into the safety work region fields, use one of these two
methods:
• Use the number keys on the keyboard to enter the
dimensional values of the safety region into the appropriate
Safety Work Region field.
Or...
• Use the axis jog functions on the jog controls to identify the
X, Y, and Z safety region. With the cursor in the appropriate
Safety Work Region field, jog each axis to the desired safety
region and press the Store Position button on the jog unit.
Touch the Exit softkey to return to the Input screen or touch the Tool
Setup softkey to describe the tools used in the part program.
NC Work Offsets
When in the NC mode, the Part Setup screen has the Work Offsets softkey
to display up to six work coordinates (G54-G59) and a set of shift offset
values. These are used to set multiple part zeroes for multiple parts
fixtured to the table and milled consecutively using the same program.
The X, Y, and Z work offset values can be entered for G54 to G59 codes.
The coordinates defining G54 are the part zero coordinates for the original
part defined on the Part Setup screen. When the G54 coordinates are
changed on this screen, the part setup is also changed.
The shift coordinates, which follow the six work coordinates on the
screen, move all of the part zero coordinates as a group. This incremental
value is useful when you place part fixtures on the table in a different
location and want to shift all of the work offsets to the newly fixtured
location. G54-G59 offset values do not change on the screen when shift
offset values are entered.
Important
Probing is used for setting up part zero for G54 only.
Tool Setup
Use the Tool Setup screen to describe the tools that will be used for the
part program. You can access this screen from either the Input screen or
the Part Setup screen by touching the Tool Setup softkey.
Each tool used in the part program must be described on the Tool Setup
screens; otherwise, the machine will not be able to cut the part when you
run the program.
• If the Tool Number, Type, and Diameter are not entered for
a tool, the system will not have enough information to draw
the part properly on the graphics screen.
Caution
You must enter data on a Tool Setup screen for each tool that will be used
in the part program. Definitions for the fields and softkeys are in the “Tool
Setup Fields” and “Tool Setup Softkeys” sections that follow.
The DRO (top left of the screen) shows the real-time position of the axes
and machine status. The fields in the bottom part of the screen describe the
tool. The Machine and Part position information in the DRO will not
appear if the machine is not calibrated, or is in concurrent programming.
To enter information for a specific tool, or to find out whether any data
already exists for that tool, type the tool number into the Tool field and
press Enter. For example, if you enter a 1 in the Tool field, the screen will
update to show existing data for tool number 1. If no data had been saved
previously for tool 1, the Type field is empty and the remaining fields
contain default values. This means that tool number 1 is currently
available to be programmed.
Note
Use the Arrow keys to move the cursor to each Tool Setup field and use
the softkeys or type in data to set up the tool descriptions for your part
program. Touching the Exit softkey displays the Input screen.
1. Enter the tool number for the tool using the number keys on
the console. If there should be no tool in the spindle, enter a
zero (0) for the tool number.
2. When you enter the tool number, the cursor is automatically
positioned in the Type field and the softkeys change to tool
type selections. Select the appropriate tool type softkey.
Note
The More softkey displays additional tool types available for this
machine (e.g., Ball Nosed End Mill, Back Spotface, Probe, and Gun
Drill).
You may also wish to consult Machinery’s Handbook or the feeds and
speeds material in the “Appendix” of this manual for more information.
Important
When a value is entered into the Speed (RPM) field, the system
ignores any data entered in the Surface Speed field. If the automatic
speed calculation is wanted, enter a value of zero (0) in the Speed
(RPM) field.
You can use the Spindle RPM dial on the front of the tool spindle
plate to override this preset speed.
The standard fields on the Tool Setup screen are defined as follows.
Fields Definitions
Tool the programmed tool number.
Type the type of tool.
Diameter the diameter of the tool’s cutting surface.
Diameter Comp applies only to BNC and corresponds to the D
code in an NC program block.
• If the program specifies the D code in a block
with a tool change (M06 with a T code), the
system uses the D code.
• If the D code is not included in the NC program,
the system uses the Diameter Compensation
value entered on this screen.
• This value is only used when cutter
compensation is On (G41 or G42 active).
• If the tool used to cut the programmed part
differs in diameter from the diameter specified
in the program (or the diameter specified in the
Diameter field), enter the difference between the
program’s tool diameter data and the diameter of
the actual tool.
• Diameter Comp = Actual Tool Diameter -
Program Tool Diameter.
Note
An actual tool that is larger than the programmed
tool results in a positive value; an actual tool that
is smaller results in a negative value. For negative
compensation, the control performs the cutter
compensation on the opposite side of the
programmed path.
The softkeys on the Tool Setup screen provide the following options:
• Delete Tool deletes all program settings for the tool number
entered in the Tool field.
• Probing accesses the probing parameters. Probing is available
only with bed mill machines.
• Part Programming accesses fields to enter the exact
description of how the part will be cut.
• Tool Offsets available only for NC programs. The tool length
offsets appear on the screen. Tool offsets are used to compensate
tool length without altering the NC program.
• Use the Positive Tool Length Compensation (G43) or
Negative Tool Length Compensation (G44) codes. A G49
code specifies tool offset cancel. An H00 also cancels an
offset.
• The G43 and G44 codes set a mode of operation within the
program that is in effect until a G49 or H00 is used. If an H
code is used without a G43 or G44, in effect, the value
stored in the tool length offset table is used as the calibrated
tool length.
• The four keyboard arrows, Page Up, and Page Down keys
scroll through the 01 to 200 offsets.
• When the Store Machine Position softkey is pressed, a
negative Z value reflecting the Z axis machine position is
entered on the screen.
• Tool offsets are not saved with the NC program.
• Part Setup returns to the Part Setup and make changes.
• Tool Home allows you to move the tool quickly away from the
part. Using this softkey after Tool Calibration is much faster than
pressing the axis jog buttons on the jog unit. Press this softkey and
then press the Start Cycle button to move the spindle to tool
change height.
• Set Tool Zero To use this softkey, carefully jog the tool in the
spindle down to the top of the part or to the fixture defined at the
Tool Calibration point and then press the softkey. The system
stores the position of the tool into the current part program and the
number appears in the Zero Calibration field on the Tool Setup
screen. This can also be accomplished by pressing the Store
Position button on the jog unit. On the screen the part display for
“Z” changes to zero.
Warning
Be certain that the tool number in the Tool in Spindle
field matches the tool being edited when the zero
calibration is stored.
• Exit exits the tool setup process and allows return to the Input
screen.
Important
The tool must be a drill, end mill, face mill, or ball nosed end mill.
The control will not automatically calculate feeds for boring and
back spotfacing.
Caution
The control uses nominal feeds and speeds for mile steel in
calculating the initial feed and speed values. The control does
not take into account material hardness and depth of cut. Be
sure to check computed feeds and speeds to ensure they are
appropriate and make any necessary adjustments.
If you enter Speed (RPM) in Tool Setup, this value is transferred to all
data blocks using this tool. The feedrates must be entered manually in the
data blocks.
Important
You can override the spindle speed in each program block. If the
Speed (RPM) field is changed in Tool Setup, the tool number must
be re-entered in the data blocks in order to force the control to
update the value. Refer to the “Changing a Part ProgramBlock
Editor” section in this chapter for information about changing
multiple blocks using the same tool.
Note
Do not enter the Surface Speed value in the Tool Setup screen if the
Speed (RPM) value is entered.
SurfaceSpeed
RPM =
Diameter∗ π
The control uses this equation to compute the milling feedrates:
Important
When using larger tools (5/8" or larger diameter), the feeds and
speeds for drilling and milling should be manually reduced by
approximately 15% to 20% based on the machinist’s experience.
Refer to the Appendix or Machinery’s Handbook for more feeds and
speeds information.
Program Parameters
Access groups of parameters with the Program Parameters softkey.
General Parameters
To display the General Parameters screen, press the console Input key to
display the Input screen. Touch the Program Parameters softkey. Then the
General Parameters screen appears:
Note
Some of the options listed on the screen above are machine specific.
You may not see these machine-specific options on the General
Parameters screen for your machine.
Chord Error maximum distance the cutter deviates from the true arc
path. This value determines the method the control uses
to generate information for executing arcs. If you enter
0.0 in this field, the control will automatically calculate
a chord error that maintains the programmed feedrate
through the arcs. This field displays 6 decimal places for
inch mode and 5 decimal places for metric mode.
Interrupt Cycle Z allows the Z axis to retract all the way up when the
Retract console Interrupt Cycle button is pressed. Selecting No
for this field means that the spindle will stay in its
current position when either the Interrupt Cycle button
or the Restart button is pressed. The default value is
Yes.
When calculating the chord error value for the General Parameters screen,
remember that the chord error for arcs is the maximum distance that the
cutter deviates from the actual arc. As shown below, the machine actually
cuts a series of very small lines when cutting an arc. However, these lines
are indistinguishable from an arc when the machining is complete.
Holes Parameters
Holes
Parameters Definitions
Bore Orient Applies only to machines with mechanical or electronic
Retract spindle orient features.
The value in this field specifies the distance the table travels
in the XY plane before the tool retracts from the part surface
• at the end of a Conversational Boring Cycle when a Bore
Orient data block is included in the part program.
• during an NC Bore Orient Cycle (Basic NC G76 or G86;
ISNC G76).
The default is 0.02 " or 0.5 mm.
Drill Dwell Controls the dwell time in seconds before the tool retracts
• at the bottom of a Conversational Drill Operation.
• during an NC Drill with Dwell, Counter Boring canned
cycle (G82).
The default value is 0.5 seconds. Many operators change this
to 0.0 seconds so that the drill will rapid out of the hole after it
is drilled.
Bore Dwell Controls the dwell time in seconds before the tool retracts
• at the bottom of a Conversational Bore operation
• during an NC Bore with Dwell canned cycle (G89), and
Bore with Manual Feed Out canned cycle (ISNC G88).
• during conversational and ISNC Non-Rigid Tapping
canned cycles (ISNC G74 and ISNC G84).
The default value is 1.0 seconds.
Milling Parameters
When the cursor is at the Cutter Comp Parameter field, Insert Arc and
Insert Lines softkeys appear:
Figure 3-15. Milling Parameters Screen with Insert Arc and Insert Line Softkeys
Touch the Insert Arc or the Insert Lines softkey, and the field connects
these milling segments as follows:
Note
Some operators find the Insert Arc method inappropriate for their
applications because the cutter remains in contact with the work
piece and may drag a chip across a sharp angle on the part. In such
circumstances, operators select the Insert Line field.
NC Parameters
From this softkey menu, you can access the NC Configuration Parameters,
NC M and G Code Program Numbers, and NC Program Variables screens.
See the NC Part Programming Manual for more information about NC
part programming.
NC Configuration Parameters
If the NCPP option is installed, from the NC Parameters screen, touch the
NC M and G Code Program Numbers softkey and this screen appears:
NC Variables
Erase Functions
While a Conversational or NC part program is being created or used, it is
stored in a temporary memory area on the control. This is not the
permanent memory where programs are stored for later access.
The erase functions do not affect the permanently stored programs. These
functions only remove copies of programs and portions of programs in
temporary memory.
Erase Current Program
Use these functions to perform the following tasks:
• Throw away changes to a copy of a program that are no
longer needed.
• Clear the entire work area to start fresh (using the Erase All
softkey).
• Clear the part program and keep the part setup and/or tool
setup to use for a new program.
Access these options by touching the Erase Functions softkey on the Input
screen:
The Input screen softkeys change to list the erase functions, as shown
below:
The erase functions will only affect the part program currently displayed
on the Input screen:
• Erase Part Setup - resets all of the Part Setup to their default
values.
• Erase Tool Setup - deletes all tool data defined for the part.
After you select one of the erase functions, the system displays the
message shown on the screen below and, therefore, allows you to confirm
the erase operation:
Figure 3-23. Input Screen with “Do you really want to Erase?” Message
The erase functions only erase program descriptions from the temporary
memory. This does not affect the stored version of the program on the
hard drive. For an explanation of permanent program storage and deletion,
refer to the “Program Storage Functions” section in the “System Basics”
chapter.
Pressing the Erase Running Program softkey causes the system to display
the “Do you really want to ERASE (Y/N)?” prompt. Touch the Yes
softkey to remove the running program from temporary memory.
Restore Functions
While a part program is being created or used, it is stored in a temporary
memory area on the control. This is not the permanent memory where
programs are stored for later access.
The restore functions copy portions of programs from the permanently
stored programs into temporary memory. Restore functions are used with
Part Setup, Tool Setup, and Program Parameters. The Restore All function
restores the part setup, tool setup, and program parameters from the
selected HD3 file into temporary storage. Operators use these functions to
perform the following tasks on HD3 files only:
• Restore particular sections from existing files into the
current part program.
• Read an entire tool setup into an existing part program file
and still retain the part program created.
• Load in different program parameter setups based on
personal preferences and retain part program and tool setup.
The Input screen softkeys change to the restore menu, as shown below:
The restore functions will only affect the part program currently displayed
on the Input screen:
• Restore Part Setup - reads the part setup from the selected HD3
file into memory.
• Restore Tool Setup - deletes all tool data defined for the part and
replaces it with the tool setup stored in the selected HD3 file.
• Restore Part & Tool Setup - restores the part and tool setup from
the selected HD3 file.
• Restore Program Parameters - restores all program parameters
from the selected HD3 file. .
• Restore Part Program - .restores the part program portion of the
selected HD3 file into memory. May be used to restore the saved
version of a part program into memory eliminating any changes
made to the current version.
• Restore All - .restores part program, program parameters, tool
setup, and part setup from the selected HD3 file.
Important
The CNC will not allow an operator to perform a restore function
from a program that was created and saved with different
measurement units than the one in memory (i.e., mm in memory and
restore program in inches, or, vice versa). An error message displays
and the restore action aborts when this type of restore is attempted.
After you select one of the restore functions, the system displays the
message shown on the screen below and allows you to confirm the restore
operation. The term “erase” is used in this message to indicate
modification of the program in temporary memory:
Figure 3-27. Input Screen with “Do you really want to Erase?” Message
The restore functions do not affect the stored version of the program on
the hard drive. For an explanation of permanent program storage and
deletion, refer to the “Program Storage Functions” section in the “System
Basics” chapter.
If you choose the Yes softkey from the previous screen, the Current
Directory screen appears with the softkeys shown below:
Choose from these functions for each of the restore functions on the
previous Input screen:
• Change to Directory - allows you to change to a different
directory.
• Rename Program - allows you to rename a program.
• Delete Program - allows you to delete a program.
• Copy Program - allows you to copy a program.
• Change Program Mask - allows you to create a directory.
• Select Current Storage Drive - allows you to choose the storage
drive.
• More- allows access to more softkeys.
• Exit - Returns to the Input screen and does not erase or modify the
sections in program memory.
Graphics
Drawing stops when a data block has incomplete (or incorrect) data and
when new data blocks are being created. Before appearing on the screen,
the scale of the part drawing is computed for the maximum that fits on the
screen. The message “Autoscaling part program” will be displayed on the
screen during this scaling process.
To switch the graphics display on and off within a part program, press the
Miscellaneous softkey on the New Block screen. The graphics softkeys
then appear as shown below:
The Graphics Off and Graphics On softkeys allow viewing selected part
features in complex programs where certain operations tend to obliterate
others such as facing and pocketing.
Pressing either the Graphics Off or Graphics On softkey stores the
selected function as a data block in the part program. The graphic drawing
of the part is turned off and turned on at the point the block is encountered
in the program.
Caution
Blocks that are hidden by Graphics Off are still cut when the
program is run.
Views
Graphics can be displayed in five views:
• XY Plane (XY projection)
• XZ Plane (XZ projection)
• YZ Plane (YZ projection)
• Isometric (three-dimensional)
• All Planes (all four of the views)
Access any of these views by positioning the crosshair cursor on the View
screen button and pressing the console Select key. Then using the same
method, select the appropriate screen button for the desired view from the
next displayed set of screen buttons.
Scaled views appear to the left and at the bottom of the screen, except
when using the isometric view. The displayed views are automatically
proportioned by the control according to the programmed dimensions of
the part.
The following is a screen showing four views (All Planes option) of a bolt
circle:
Views may be eliminated from the screen using one of the parameters
described later in this section.
Zoom
The Zoom function enlarges a selected portion of the drawing. A zoomed
screen remains in that state until the Full Scale option is selected.
Selecting the Zoom function for a plane view does not zoom the other
plane views (i.e., zoom on XY plane does not zoom the XZ plane).
Graphics Parameters
To change the graphics display parameters, position the crosshair cursor
on the Parameters screen button and press the console Select key. This
selection displays a screen with the following options:
To change the Yes/No entry for a field, move the cursor to the box in front
of the field and press the Select key until the desired response appears
after the equal sign.
4. To stop the search, move the crosshair cursor to the Exit box
and press the Select key.
5. To return to the drawing, press the console Draw key.
Important
The data block search function can only be used for the XY Plane
view and is inoperative when viewing a running part program.
After the machine is calibrated and warmed up, you can perform the
operations described in this section.
The Ultimax system has a variety of options for running programs. You
may wish to run an entire program or only a portion of it. You can also use
the test run facilities, error checking, and program run time estimate
features that are available.
Warning
When running part programs, always follow these rules:
• Do not leave the machine unattended.
• Never press the console Start Cycle button without
knowing exactly what the machine will do!
• Never start the machine when the cutter is in
contact with the work piece.
• Stand away while the machine is running a part
program.
• Never lean on the machine while the spindle is
moving.
You must work within reach of an Emergency Stop button and be able to
observe the operation of the spindle. If you are running a part program and
cannot reach an Emergency Stop button nor observe the spindle, that is
considered unattended operation and is viewed as a foreseeable misuse of
the machine.
While the doors are open, manual functions such as adjusting the fixture
can be performed. However, the jog feed is restricted. The jog feed is
limited to 80 inches per minute (2 meters per minute).
Note
A Door Open Fault can occur at the end of a program if the doors are
opened for part inspection or removal but the Tool Magazine is rotating to
the next tool in anticipation of the program restarting. To avoid this Door
Open Fault, do not engage the Manual Safety Override until all machine
movement has ceased - including movement of the Tool Magazine that
could occur at the end of a program.
Important
No spindle operation is allowed when the doors are open.
If you try to jog the axes with the doors open without enabling the safety
mode using the Access Code, this message appears on the screen:
To enable the Safety Override mode, access the CE Status & Diagnostics
screen.
1. From the Manual mode screen, touch the Manual Function
Setup softkey.
2. Touch the CE Diagnostics softkey. This screen appears:
The fields on the CE Status & Diagnostics screen are defined as follows:
Field Definition
CE Configuration displays CE logic configuration.
Door Lock Status displays status as Unlocked or Locked.
Door Switch Status displays status as Closed or Open. The switch must be
Closed when the Door Lock Status is Locked.
Limited Manual displays status as Not Enabled or Enabled. Enabled
Operations controls all movement when the chip doors are open.
Status is Enabled after using the Enter Code softkey and
entering an access code. Enabled allows limited safe
motion with the doors open.
Follow these steps to enter an access code for the first time:
Error Conditions
If the control detects an error during the execution of the program, it clears
the softkeys and stops the spindle and program execution. An error
message is displayed on the bottom of the screen as shown below:
Pressing the Enter key displays the program editor and positions the
flashing cursor at the block containing the error.
If the control is loading from a remote device while running the program
and the internal buffers become “starved,” the Z axis retracts from the part
surface by the amount specified by the Depletion Retract parameter in the
Program Parameters. The following message is displayed:
Reloading Buffer...
The Tool has been raised from the part surface. When the program
memory has been refilled, the Z axis is fed into the part and the run
resumes.
Stop Motion
If you observe a problem during the cutting process or simply want to stop
the machine to make some adjustments, you may press one of three
buttons to stop motion:
• Feed Hold - stops all axes movement (except a tapping operation
in progress), when the tool is in the programmed feedrate region.
Pressing the button a second time allows machine positioning to
resume without loss of position, provided no other button or key
has been pressed.
• Interrupt Cycle - halts machine operation during automatic
execution of a program to allow manual functions such as cleaning
the work piece. Pressing the Interrupt Cycle button performs the
following actions:
1. Stops all motion except the spindle.
2. Pulls the tool straight up and out of the part.
3. Stops the spindle.
4. Displays the manual screen on the console.
To restart the part program, press the Auto button followed by the
Start Cycle button.
Important
If any key other than the Auto button is pressed to restart the
program, the system cancels the execution of the part program.
• Emergency Stop - all motion stops and power is shut off to the
spindle, relay control, and servo systems. An emergency stop
message with recovery instructions appears at the bottom of the
text screen. To release an Emergency Stop button, twist the button
in the direction indicated by the arrows and pull the button up.
Important
After the last choice is selected, the following sequence occurs:
1. A prompt is displayed to press the Start button while the
console Start Cycle button flashes.
2. When the Start Cycle button is pressed, the program begins
running at the specified point of the Start Block.
3. When the specified End Block is reached, the display
indicates that Recovery Restart mode is complete and the
Start Cycle button flashes again.
4. If the Start Cycle button is pressed again, then the program
will re-run using the same Start and End Blocks.
To re-run the program in its entirety after a Recovery Restart, follow these
steps:
Concurrent Programming
Concurrent Programming allows you to create or edit a Conversational
part program and/or read a part program from disk into memory, while
simultaneously machining a part using a different part program.
Concurrent Programming is possible only when using the Auto screen to
run the program.
Important
Before beginning Concurrent Programming, save each program to
the hard drive or floppy diskette. If the machine power is shut off,
the control will only save the program that is in the editor. The
running program will not be restored and changes made to it prior to
beginning Concurrent Programming will not be saved by the
AutoSave feature.
The Running Part Program field identifies the program currently running.
This screen lists the program names for both the running part program and
the edit part program. The graphics screen becomes blank to prepare for
the new part program graphics. The filename of the new part program may
be entered in the Edit Part Program field. Use the part programming
features to create or change data blocks.
To run the new edit part program or to edit the running part program,
follow these steps:
1. Wait for the running program to finish, or stop this program
from being executed by pressing the console Feed Hold
button, then the Spindle Off key, followed by the Feed Hold
button. The input screen displays the Edit and Run Part
Program names.
2. Press the Input key.
3. Touch the Exchange Edit/Run Programs softkey.
4. The program names for the Edit and Running Part Programs
are switched. The program now in Edit Part Program can be
edited.
5. Touch the Exchange Edit/Run Programs softkey and the
program names are switched again.
6. Select the Auto button to run the program that was
originally running when the program was interrupted.
Important
Editing tool or program information without switching the editor
means that the changes are not being made to the running part
program. You cannot abort Auto, edit the program in Input, and
return to Auto because the control will be running the part program
in the Running Part Program field, not the Edit Part Program field.
Software Options
The Ultimax control contains software used to process data and display
screens in much the same manner that personal computers use software
programs. As with other software systems, Ultimax has additional
software options that can be purchased for the system.
Hardware handshaking physically connects the RTS and CTS pins of one
device to the CTS and RTS pins of another device via a cable. With
hardware handshaking, the receiver uses electronic signals to tell the
sender when the sender can and cannot send characters. This method
usually reacts quickly to the signals but requires that the cabling contain
enough wires to accommodate the additional signals.
CTS/RTS Protocol
The CTS/RTS protocol is described from the Ultimax control side of the
connection. The following Control As Sender section describes what
happens when the control sends a program; the Control As Receiver
section describes what happens when the control receives a program. With
this information and the knowledge of the remote device, you can adjust
the remote equipment to communicate with the control.
When the control’s ports are initialized, the TD, RTS and DTR (if
available) signals are held in the low state (from -3 to -15 volts or
disasserted). When you start a load or save operation at the control
console, the control brings the RTS and DTR lines into a high state (from
+3 to +15 volts or asserted). This tells the remote device that the control is
ready to communicate.
CTS is an input to the control. Its state depends on the state of the
handshake lines attached to it from the remote device. If the remote device
is ready to communicate, it should be high; if not, it should be low.
Control As Sender
With this method, the remote device can regulate the control’s character
flow by periodically resetting its handshake output LOW causing a LOW
control CTS input, thus suspending the flow of characters from the
control. When the remote device is able to receive characters again, the
device sets its handshake signals HIGH causing a HIGH control CTS, thus
resuming the flow of characters.
Control As Receiver
When the control is receiving a program, it signals the remote device that
it is ready to receive characters, by setting its RTS and DTR lines HIGH.
No communication can occur until the remote device is ready to transmit.
When the remote device is ready, it sets its handshake lines HIGH which
should set the control’s CTS to HIGH. The remote device will begin
transmitting when it sees that both the control and the remote device are
ready.
XON/XOFF Protocol
The XON/XOFF protocol is a software flow control method. It is the
preferred transfer protocol for NC programs. The only wires that must be
in the cable are TD, RD, SG, and the shield (PG). This method uses three
special control characters to start and stop the flow of data characters. The
characters that control the character flow follow:
Meanwhile, the receiver advertises its presence by sending XON one time
every 250 msec. The receiver continues to send XONs until it receives a
character from the sender or until the operator aborts the receiving
operation.
Once the sender begins to send the file, it continues until the receiver
sends the XOFF signal, the end of file is reached, or the operator aborts
the sending operation. If the sender receives XOFF, it stops transmission
and waits for XON before it resumes. The receiver sends XOFF if its
internal buffers are full. This buffer level is usually calculated so the
receiver sends the XOFF signal early enough for the sender to process the
message and stop transmission before the receiver’s buffers overflow.
After the receiver is able to handle more characters, it sends an XON
signal.
Between steps 3–4 and 5–6, there are time lags as the receiver sends
the control characters and the sender responds to them.
Full Handshake
As with XON/XOFF, full handshake is a software protocol differing from
XON/XOFF only in the beginning synchronization stage. Full handshake
uses the same type of cabling as XON/XOFF.
With full handshake, the sender does not have a five-second time-out.
Instead, DC2s are sent every 250 msec until the confirming that the DC1
is received, or the sender aborts the operation. Once the sender receives
the DC1, it sends the confirming DC2 and begins the file transmission.
This protocol makes it easy to start both the sender and the receiver at the
operator’s leisure and in whichever order is appropriate for the
application.
During the actual transmission of the file, XON/XOFF and full handshake
operate identically.
Free Cutting Brass and Bronze .022 .018 .013 .011 .007
Cast Iron, soft (150–180 BH) .016 .013 .009 .008 .005
Cast Iron, med. (180–220 BH) .013 .010 .007 .007 .004
Cast Iron, hard (220–300 BH) .010 .008 .006 .006 .003
A B (continued)
C (continued) C (continued)
F G
I (continued) M
M (continued) N (continued)
O (continued) P (continued)
S S (continued)
S (continued) S (continued)
T (continued) U
Tool Ultimax
broken, 3-11 software
calibration, 3-6, 3-14 options, 3-70
changer keys, 1-28 upgrade, 2-35
descriptions in the system, 3-12 Ultimax 4 and Max consoles figure, 1-2
diameter, 3-11, 3-14, 3-20, 3-21 Ultimax 4 panel groups figure, 1-3
in Spindle, 1-35 Ultimax training, 3-70
in Spindle softkey, 1-27 Unattended operation, 3-59
number, 3-11, 3-13 Untag all programs, 2-11
setup, 3-11, 3-43, 3-47 Upgrade system files, 2-35
activate coolant, 1-28 Upload from peripheral device, 2-18
checking, 3-11 Upload programs, 2-14
screen, 3-12 Upload receive, 2-17
templates, 3-11 Uploading a part program, 2-17
Setup softkey, 3-7
types, 3-11, 3-13 V
zero, 3-19
Tool, 3-16 Video hardware type, 2-27
Tool change position, 3-25, 3-27
Tool changer W
orientation key, 1-35 Warm Up Machine softkey, 1-34
Tool changers, 1-35 Warm up the machine, 1-34
Tool holder Wildcard
orientation hole, 1-35 file extension), 2-9
Tool Home Work offsets for NC programming, 3-9
softkey, 3-18 Work Offsets softkey, 3-9
Tool Length Tolerance, NC, 3-39 Work piece, 3-6
Tool loading cleaning, 3-65
machine spindle, 1-35 fixturing, 3-2
Tool Offsets, NC, 3-18 safety region, 3-8
Tool removal from ATC magazine, 1-38 Write part programs to disk, 2-5
Tool removal from spindle, 1-36
Tool Setup fields, 3-16
Tool setup screen, 3-12 Z
Tool Setup softkeys, 3-18
Tool setup with tool types, 3-13 Z Bottom parameter, 3-8
Tool Type, 3-16 Zero calibration, 3-11, 3-14, 3-19
Trackball, 1-9, 3-56 Zero Calibration, 3-17
Training classes, 3-70 Zoom, 3-54
Turning off the text entry window, 2-27 Zero calibration
Turning on the text entry window, 2-27 in NC, 87