THE MILL CAN BE A VERY DANGEROUS MACHINE IF NOT USED PROPERLY!
- Warning! This mill can hurt you!
- Don’t use this mill unless you know EXCACTLY what you are doing. Never press a button unless you know precisely what that button is supposed to do. Don’t ever experiment.
- If you are unsure about a particular procedure, read this manual and/or get another approved shop user to help you.
ONLY APPROVED AND CERTIFIED SHOP USERS MAY USE THE MILL WITHOUT SUPERVISION!
- You must take a shop class taught by an approved shop user to use the equipment in the shop without supervision.
- There are NO exception to this rule!
ALWAYS WEAR PROTECTIVE EYEWARE WHEN YOU ARE IN THE SHOP.
- This rule applies, even if you are not personally using a piece of equipment in the shop.
IF AN EMERGENCY SITUATION OCCURS WHILE USING THE MILL IN ‘JOG’ MODE, HIT THE BIG RED "EMERGENCY STOP" BUTTON ON THE MAIN CONTOL PANEL.
- See Part V for further information.
IF AN EMERGENCY SITUATION OCCURS WHILE USING THE MILL IN ‘MANUAL’ MODE, PRESS THE SQUARE "STOP-BRAKE" BUTTON ON THE MAIN CONTROL PANEL.
- When in ‘Manual’ mode, "Stop-Brake" is the ONLY way to turn off the spindle.
- Please also note: WHILE IN MANUAL MODE, THE RED "EMERGENCY STOP" BUTTON DOES NOT FUNCTION!
- See Part IV for further information.
RESTORING MILL OPERATIONAL SYSTEMS AFTER HITTING "EMERGENCY STOP"
- Pushing in the "Emergency Stop" button at any time causes the
mechanical operating systems of the mill to become un-accessible from the
main control panel. For example, the spindle will not spin and the bed will
not translate when buttons are pushed on the control panel.
- Pull out the "Emergency Stop" button.
- Press the green "Control On/Reset" button. You should hear a
click and see a "Machine ready" message.
- The mill should now be fully operational from the main control panel.
IF THE MILL IS NOT RESPONDING TO COMMANDS FROM THE CONTROL PANEL
- Press in and then pull out red "Emergency stop" button.
- Press the green "Control On/Reset" button. You should hear a
click and see a "Machine ready" message.
- The mill should now be fully operational from the main control panel
IF REPEATED EMERGENCY STOP WARNINGS APPEAR
- Press in the red "Emergency stop" button, and then click "OK"
twice.
- Look at the warning message (yellow print in a blue box) on the monitor.
Attempt to correct the problem. It is very likely that the mill was not
referenced properly or perhaps the "Emergency stop" button was
inadvertently pulled out when the machine was turned on (See Part II).
- Try pressing in and then pulling out red "Emergency stop" button.
Then press the green "Control On/Reset" button. You should hear
a click and see a "Machine ready" message.
- If the mill continues to present you with repeated emergency stop condition
warnings, shut down the mill and follow the proper startup and referencing
procedures.
IF YOU GET A "Z SOFTWARE LIMIT OVERTRAVEL" MESSAGE
- Sometimes, the mill will refuse to 'Jog' along the Z-axis. Usually a "Z
Software Limit Overtravel" message appears.
- The problem is corrected by the following steps: (1) Turn the "Mode Select"
dial to "Reference"; (2) Turn the "Axis Select" dial to "Z"; (3) Zero the
Z-axis reference by turning the "-/+ Jog" dial; (4) Click "OK" on the small
dialog box; (5) Turn the "Mode Select" dial to "Jog"; (6) Turn the "-/+
Jog" in a direction that moves the yellow Z-axis reference mark on the spindle
support structure closer to the stationary yellow reference mark on main
body of the mill; (7) Jog the spindle the Z-direction until another "Z Software
Limit Overtravel" message appears.
- Repeat steps (1) through (7) until the Z-axis reference marks are lined
up. Perform one last Z referencing procedure to zero the mill at the reference
point.
Part II: GENERAL STARTUP PROCEDURES
TURN OFF THE MILL
- Press the red "Control Off" button on the main control panel.
- The computer monitor will go blank.
TURN ON THE MILL
- Make sure no disks are in the disk drive mounted on the far right rear
of the mill support structure.
- Make sure that the big red "Emergency stop" button is pushed
in.
- Turn on mill by pressing the green "Control On/Reset" button.
The mill will now boot up.
- You should immediately get the "MICROPATH Series 40" window
on the computer monitor. The "Program position" and "Distance
to go" coordinates should be clearly displayed.
- Pull out red "Emergency stop" button.
- Press the green "Control On/Reset" button again. This step is
crucial! You should hear a click and receive a "Machine Ready"
message. Now the machine is up and running.
- If you get an "Emergency Stop Condition" warning, the proper
startup procedure was probably not followed. The "Emergency Stop"
button probably pulled out when the mill was turned on. Push in the "Emergency
Stop" button, turn off the machine, and start again.
REFERENCING THE MILL UPON STARTUP (Necessary every time you boot up!)
- This procedure needs to be done whenever the mill is started up.
- Set "Mode Select" dial to "Jog".
- Pull out "Emergency Stop" button.
- Use "Axis Select" knob and "-/+" jog dial to position
all axes of the machine so that yellow tick marks on the gantry of each
axis are lined up with the stationary yellow tick marks on the main body
of the milling machine. All stationary yellow marks are to the right of
middle of the machine.
- Set "Mode Select" dial to "Reference".
- Turn "Axis Select" dial to "A" for all axes.
- Rotate "-/+" jog clockwise or counter-clockwise. Click "OK"
in the "Axis Reference" window. Machine will move a little, so
stand back! Coordinates for all axes should be zeroed.
- If you repeated get "Emergency Stop Condition" warnings when
conducting this referencing procedure, press the red "Control Off"
button. Then follow the mill startup procedure.
- Press green "Spindle Forward" button. Spindle will not spin
just yet.
- A box with a "Is spindle gear currently LOW?" message appears.
Look on the right side of the spindle support structure to determine the
speed range: Hi, Neutral, or Low. Generally, the lever is parked in ‘Hi’.
So usually you need to click on "No".
- Press the green "Spindle Forward" button again. The spindle
will now be spinning so be careful.
- While the spindle is spinning, turn the crank on the spindle support structure
to adjust the spindle speed. Generally, a setting of 700 to 800 RPM is appropriate
for aluminum cutting. The Hi and Low speed ranges are indicated on the large
red and silver dial.
- Press the red "Stop-Brake" button to stop the spindle.
IF REPEATED EMERGENCY STOP WARNINGS APPEAR
- Press in the red "Emergency stop" button, and then click "OK"
twice.
- Look at the warning message (yellow print in a blue box) on the monitor.
Attempt to correct the problem.
- Try pressing in and then pulling out red "Emergency stop" button.
Then press the green "Control On/Reset" button. You should hear
a click and see a "Machine ready" message.
- If the mill continues to present you with repeated emergency stop condition
warnings, shut down the mill and follow the proper startup and referencing
procedures.
IF YOU GET A "Z SOFTWARE LIMIT OVERTRAVEL" MESSAGE
- Sometimes, the mill will refuse to 'Jog' along the Z-axis. Usually a "Z
Sftware Limit Overtravel" message appears.
- The problem is corrected by the following steps: (1) Turn the "Mode Select"
dial to "Reference"; (2) Turn the "Axis Select" dial to "Z"; (3) Zero the
Z-axis reference by turning the "-/+ Jog" dial; (4) Click "OK" on the small
dialog box; (5) Turn the "Mode Select" dial to "Jog"; (6) Turn the "-/+
Jog" in a direction that moves the yellow Z-axis reference mark on the spindle
support structure closer to the stationary yellow reference mark on main
body of the mill; (7) Jog the spindle the Z-direction until another "Z Software
Limit Overtravel" message appears.
- Repeat steps (1) through (7) until the Z-axis reference marks are lined
up. Perform one last Z referencing procedure to zero the mill at the reference
point.
Part III: SPINDLE PREPARATION AND OPERATIONS
LOADING AND UNLOADING THE MILLING TOOL
- Release the small one inch long lever just to the right and above the
mill spindle. This unlocks the spindle for ‘Z’ axis adjustment of spindle
position.
- Use the large lever on the right side of the spindle support structure
to raise the spindle to its highest position. Tightly lock the one inch
long lever down.
- Select the desired milling tool and secure it to an appropriate collet.
- Insert the collet up into the spindle and press the "Tool In"
button. A loud pneumatic jack grabs and secures the collet. Watch your fingers!
If you hear a grinding sound, but the spindle does not grab the collet,
the spindle has not been raised to its highest position, the one inch lever
is not locked down, or both.
- The collet can be removed from the spindle by pressing the "Tool
Out" button. Use your left hand to catch the released collet.
USING THE SPINDLE
- Turn on the spindle by pressing the green "Spindle Forward"
button.
- Adjust spindle speed while the spindle is spinning using the spindle speed
adjustment crank on the front of the spindle support structure. In general,
for aluminum, spindle speeds should range between 700 and 800 RPM.
- As required, turn off the spindle by pressing the red "Stop-Brake"
button.
- If you are in electronic ‘Jog’ mode and something goes wrong, press the
red "Emergency Stop" button.
- If you are in ‘Manual’ mode and something goes wrong, press the "Stop-Brake"
button to stop the spindle. Note: When in ‘Manual’ mode, this is the ONLY
way to turn off the spindle (besides turning the mill off). Please also
note: WHILE IN MANUAL MODE, THE RED "EMERGENCY STOP" BUTTON DOES
NOT FUNCTION!
- As a general rule, never mill out more than about 0.1" of material
(in depth) in a single milling pass when using an end mill tool insert.
Part IV: USING THE MILL IN ‘MANUAL’ MODE
POSITIONING THE MILL BED IN ‘MANUAL’ MODE
- First, push in the red "Emergency Stop" button. Now the mechanical
operating systems of the mill are un-accessible from the main control panel.
- Turn "Mode Select" dial to "MDI". A "MDI mode
selected" message should appear on the monitor.
- Select "Manual" (F9). A "Manual mode enabled" message
should appear. You should also hear a soft click. Now the spindle can be
turned on and off using the control panel. If you get a "Manual mode
disabled" message, just hit "Manual" (F9) again.
- The X and Y translation cranks are now unlocked and can be turned by hand
for both general bed positioning and milling operations. X and Y coordinates
are presented on the computer monitor.
- Please note that the large plunge crank on the spindle head support structure
is used for Z-axis positioning of the spindle. However, moving the plunge
crank does not cause the Z-axis coordinates to change on the computer monitor.
Be sure that the small one inch long plunge release lever is locked down
after positioning operations are completed.
- Also note that before the milling operation can begin, electronic ‘Jog’
mode may be required to position the spindle close to the workpiece along
the Z-axis if plunge depth provided by the plunge lever is not adequate.
SPECIAL NOTES FOR MILLING OPERATIONS WHILE IN ‘MANUAL’ MODE
- If you are in ‘Manual’ mode and something goes wrong, press the "Stop-Brake"
button to stop the spindle.
- When in ‘Manual’ mode, "Stop-Brake" is the ONLY way to turn
off the spindle (besides turning the mill off).
- Please also note: WHILE IN MANUAL MODE, THE RED "EMERGENCY STOP"
BUTTON DOES NOT FUNCTION!
Part V: USING THE MILL IN ELECTRONIC ‘JOG’ MODE
POSITIONING THE MILL BED IN ELECTRONIC ‘JOG’ MODE
- Pull out red "Emergency Stop" button.
- Turn the "Mode Select" dial to "Jog". A "Jog
mode selected" message should appear.
- Select the desired axis with the "Axis Select" dial.
- Turn the "-/+" Jog dial to activate translation of the bed to
the desired direction.
- Use "Feedrate Override" and "Jog Select" dials to
control the speed of translation.
- Discrete translation steps can be made by using the 1.0, 0.1, 0.01, etc.
options on the "Jog Select" dial. Steps of 1.0 inch are to be
avoided to prevent accidents.
- Jog mode will cease to function if the red "Emergency Stop"
button is ever pushed in. Remedy the situation by pulling out the "Emergency
Stop" button and pressing the green "Control On/Reset" button.
You should here a click. Jog mode is now enabled.
IF YOU GET A "Z SOFTWARE LIMIT OVERTRAVEL" MESSAGE
- Sometimes, the mill will refuse to 'Jog' along the Z-axis. Usually a "Z
Sftware Limit Overtravel" message appears.
- The problem is corrected by the following steps: (1) Turn the "Mode Select"
dial to "Reference"; (2) Turn the "Axis Select" dial to "Z"; (3) Zero the
Z-axis reference by turning the "-/+ Jog" dial; (4) Click "OK" on the small
dialog box; (5) Turn the "Mode Select" dial to "Jog"; (6) Turn the "-/+
Jog" in a direction that moves the yellow Z-axis reference mark on the spindle
support structure closer to the stationary yellow reference mark on main
body of the mill; (7) Jog the spindle the Z-direction until another "Z Software
Limit Overtravel" message appears.
- Repeat steps (1) through (7) until the Z-axis reference marks are lined
up. Perform one last Z referencing procedure to zero the mill at the reference
point.
Part VI: RUNNING THE MILL USING G-CODE INSTRUCTIONS
ENTERING A G-CODE INSTRUCTION SET INTO THE MILL BY HAND
- On keyboard, press function key for "Files" (F2). Click "Edit"
(F3). Click "New" (F3).
- A blinking cursor appears on the white dialog box.
- Enter one G-code command per line.
- To save, select "Save As" (F6).
- Enter the desired file name and press return. Be sure that file is saved
in the "C:\nc\" folder.
- Press "Files" (F2), then "Edit" (F3), and then "Close"
(F8).
- Make sure that the file name is correct and click "OK". Click
"Yes" in response to the "Replace existing file?" message
box.
- An "Edit File: Saved" message should appear in yellow.
LOADING A G-CODE FILE INTO THE MILL FROM A FLOPPY DISK
- Before saving your G-code to disk, make sure that you have an extra dummy
command line at the end. Like an extra Z-axis translation, for example.
The dummy line never gets executed by the mill, but it is required to prevent
the mill from ending the CNC program prematurely on the second-to-last command
line.
- Insert the 3 ½" floppy disk into the disk drive located at the far
right-hand corner of the main body of the mill.
- Select "Files" (2) and then "Copy" (F5).
- A "Copy" window appears. Click on the "File to Copy" box. Select the "a:\"
drive and make sure that the "List Files of Type" box shows "All Files *.*".
Select the desired file.
- Now Click on the "New File Name" box. Select the "c:\" drive and manually
type in the file name, but now be sure to manually add a ".nc" extension
to the file name. For example, "myjob.nc" is an appropriate file name.
- The file is now copied from the floppy disk to the "c:\" drive of the
mill.
VISUALIZING THE TOOL PATH FOR A SAVED FILE IN A GRAPHICS WINDOW
- Please note that this visualization software will only generate a toolpath
window for G-code files that are less than 32 Kb in size. No visualization
capability is available for files that are larger than 32 Kb.
- Open the desired file by selecting "Files" (F2), then "Active"
(F2), and then "Open (STD)" (F2). If you get an error message
at this point, your file is larger than 32 Kb and not tool path visualization
window is available.
- Select the appropriate file name and click "OK".
- A tool path visualization graphics window appears.
- An error or warning window may appear first; selecting "Yes"
will result in a tool path generation up to the piece of code that caused
the error. Note: the G-Code cannot be edited at this time (See instructions,
below).
- Pull down menus within the graphics window allow you to choose various
views for the tool path (isometric, etc.). After choosing a view, click
on "Options" and select "Redraw" to see the new view.
- Close the file by selecting "Files" (F2), then "Active"
(F2), then "Close" (F2), then "Files" (F2), then "Edit"
(F3), and then again choose "Close" (F8).
- Click "OK" in the "Save Editor" box.
- Click "Yes" when prompted by the "Replace existing file?"
window.
- Now G-code lines should have disappeared from the white dialog box.
- Remove the graphics window by selecting "Exit" from the pulldown
menu and pressing "Return".
EXECUTING SINGLE LINES OF G-CODE (for debugging purposes)
- This mode enables you to type and execute a single line of G-Code.
- Set "Mode Select" to "MDI".
- Select "MDI" (F7).
- A new window should appear.
- Enter G-code commands in "NC Code" entry box.
- Stand back and click "Execute". The machine will now be activated
and running under its own power.
- Keep a hand on the "Feedrate Override" dial to control milling
speed.
- If something goes wrong, press the big red "Emergency Stop"
button.
RUNNING A G-CODE FILE IN AIR AS A TRIAL RUN
- Using parallel bars (if required), securely mount the workpiece in the
vice on the milling bed. Make sure that the top surface of the workpiece
sticks up above the top surface of the vice.
- To reset the system, push in and then pull out the "Emergency Stop"
button. Then press the green "Control On/Reset" button. You should
hear a click and see a "Machine ready" message.
- Turn on the spindle by pressing the green "Spindle Forward" button.
- Use electronic ‘Jog’ mode or ‘Manual’ mode to position the end of the
milling tool about 2 inches above the work piece. The milling tool should
be positioned above an appropriate starting X and Y position. See Part IV
and Part V of this guide for instructions on positioning the milling bed
and spindle while in Jog and Manual modes.
- Turn off the spindle by pressing the red "Stop-Brake" button.
- Turn the "Mode Select" dial to "Set Zero", and turn
the "Axis select" dial to "A" for all axes. Turn the
"-/+" jog dial clockwise or counter-clockwise to zero the position
for all three axes at once.
- Turn the "Mode Select" dial to "Auto". This is a very important step.
- Open a desired file by selecting "Files" (F2), then "Active"
(F2), and then "Open (STD)" (F2).
- Select the appropriate file name and click "OK".
- If the G-code file is less than 32 Kb in size, a tool path visualization
graphics window appears. The full G-code is also presented.
- If a "NC file too large for STD Mode, Use DNC Mode" message appears, then
your G-code is greater than 32 Kb. First click "OK", then select "Files"
(F2), then select "Active" (F2), and finally select "Open (DNC)" (F3).
- If the G-code has been accepted by the mill, no error windows should appear.
If error windows do appear, just acknowledge them by clicking on "OK". But
do take note of them and take the time to figure out why those particular
G-code commands were not accepted by the mill.
- Turn "Feedrate Override" dial nearly all the way to the left
(slow). Keep your hand on this dial.
- To start the CNC file run, press green "Cycle Start" button.
Machine will now be activated and motion begins. Keep a hand on the "Feedrate
Override" dial to control speed at which the machine completes the
CNC commands. If the mill is not translating, you may need to turn up the
"Feedrate Override" dial.
- If the G-code file is less than 32 Kb in size, the progress of the mill
during the CNC operation can be monitored in the tool path visualization
graphics window.
- As the CNC program progresses, make sure that the spindle does not make
undesirable translations. It's very important that you watch the monitor
to make sure that the depth of cut along the Z-axis is never more than 0.1
inches per pass. Also, watch for sudden or jerky movements (especially plunging
motions). Also make sure that the entire tool path is kept within the boundaries
of the workpiece.
- Note: When machine is moving under its own power with a G-Code instruction
set, the spindle should always be spinning. That way, if the machine should
suddenly plunge, the tool can cut through the workpiece without breaking
the tool and the mill.
- If something goes wrong and you want to stop everything (including the
spindle), press the big red "Emergency Stop" button.
- When the CNC program is complete, close the file by selecting "Files"
(F2), "Active" (F2), then "Close" (F2), then "Files"
(F2), then "Edit" (F3), and then finally "Close" (F8).
- Click "OK" in the "Save Editor" box.
- Click "Yes" when prompted by the "Replace existing file?"
window. The white dialog box should now be clear.
- If present, remove the toolpath graphics window by selecting "Exit"
from the pulldown menu and pressing "Enter".
- Note: When running a file in "Open (DNC)" mode, pressing "Emergency Stop"
while the program is running make cause a system crash. There is no remedy
for this. You must reboot, re-reference, and re-zero the mill and start
over. However, sometimes you get lucky and pulling out "Emergency Stop"
and pressing "Control/On Reset" is all that is required.
INTERRUPTING A PROGRAM WHILE USING DNC MODE (this tip added 11/6/2000 by Zach
Kramer)
This is useful if you don't want to wait through the whole air cutting program,
or if you need to interrupt the program and then continue working without losing
your zeroes.