“ALPHA” MODE TUTORIAL

ALPHA “ALPHA” MODE TUTORIAL

THIS SIMPLE PROGRAMME OF WORK HAS BEEN DESIGNED AS A
FAMILIARISATION EXERCISE FOR FIRST TIME USERS IN THE SET UP AND OPERATION
OF THIS MACHINE IN THE ‘ALPHA’ MODE OF OPERATION

IT IS ESSENTIAL THAT THE OPERATOR HAS APPROPRIATE SKILL

AND EXPERIENCE IN THE USE OF A CONVENTIONAL CENTRE LATHE, AND IS
FAMILIAR WITH THE MACHINE OPERATORS MANUAL, IN PARTICULAR THE
SAFETY NOTES.
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Contents
Operator Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Power On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Power On Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Start/stop the spindle rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Foward/reverse & high/low gear selection . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Manual Feed rate selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Manual feedrate override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hand wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Tool Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Tool Selection - Optional Turrets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tool Setting / Tool Setting : Tool Status Flags . . . . . . . . . . . . . . . . . . . . . . . 10
Tool Setting : Tool Status Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Tool Setting : Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Tool Setting : Tool Nose Radius Compensation(T.N.R.C.) . . . . . . . . . 20
Resize key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Work Shift key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Setting the Maximum rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Setting the Constant Surface Speed (CSS) . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Switching the CSS on / off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Operation and Data Input Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Manual mode screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Operation Review screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Edit screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
CAM menu screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Diagonostic screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Inch / Metric conversion screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Operation Review Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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System Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Operation - External Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
To activate the operation - External Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Operation notes - External Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Operation - Internal Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Important Note: Using ‘Stops’ during Grooving or Drilling Ops . 47
To activate the operation - Internal Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Operation Notes - Internal Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Box cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Area Clear - Rectilinear Box Cycle with radius & chamfer . . . . . . . . . 56
Finish Pass - Rectilinear Box Cycle with radius & chamfer . . . . . . . . . 56
Operation - Straight Box Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
To activate the operation - Box Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Operation Notes - Box Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Tapers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Operation - External Tapers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
To activate the operation - External Tapers . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Operation - Internal Tapers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
To activate the operation - Internal Tapers . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Operation Notes - Tapers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Taper Box Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Area Clearance - Taper Box Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Finish Pass - Taper Box Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Operation - Taper Box Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
To activate the operation - Taper Box Cycles . . . . . . . . . . . . . . . . . . . . . . . . 80
Operation Notes - Taper Box Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
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Threading Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Operation - External right hand parallel thread . . . . . . . . . . . . . . . . . . . . . 83
To activate operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Operation Notes - Threading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Operation - Other Taper Threads (Internal/Taper threads) . . . . . . . . 91
Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Operation - ACME parallel thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
To activate the operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Operation Notes - Threading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Thread Chasing (Repair) Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Thread Chamfer Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Drilling Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Example - using Drilling Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
To activate the operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Tapping Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Example - using Tapping Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
To activate the operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Grooving Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Example - using Grooving Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
To activate the operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Edit Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
SAVE Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
RESTORE Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
DELETE Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
CAM Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
CAM Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Using Programs from other ALPHALINK Versions . . . . . . . . . . . . . . . . . . . 144
Running the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Exiting during a program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Starting the machine in the middle of a program . . . . . . . . . . . . . . . . . . 147
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Operator Control Station
Please see section 2 of the main manual for an overview of the Operators console.

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Powering Up the Machine / Operation Mode Selection.
Switch on mains isolator (this is situated on the electrical cabinet at the headstock end)
Press the “Power On” button, the loading screen will appear, please wait until the “Home Screen”
appears.

Figure 2.8 - Left - Loading screen, Right - Home screen

Press, then release, the “Emergency Stop” button and press the “Power On” button again.

Press the “Fanuc CNC” touch screen key.

Please wait as machine loads MGI and Alpha modes, after which, dependent on the position of
the operation mode select key, the machine will now display either the “CNC mode - absolute
position” screen or will the “Alpha Mode” screen. Switch Key between positions to switch between
these two modes.
To enter “MGI mode”, ensure the key switch is set so the “CNC Mode” is active, then press the
“Manual Guide” key, followed by the “EDIT” key, machine will now switch to “MGI mode”
Please see relevant machine tutorial for operation of machine in these various modes.

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Power On Screen (Manual mode)

This screen displays the following Touch screen keys and register, along with the graphic
representation of the X & Z hand wheels depicting the machine is in the hand wheel operation
The screen also displays the current slide position, selected tool and spindle speed

This screen can be returned to from any other by pressing the manual screen key.

The machine can be powered up in either a Metric (mm) or Imperial (inch) measuring system.
3 figures behind the decimal point on the read out indicates metric measuring system.
4 figures behind the decimal point indicates inch measuring system.
See page 33 of this manual for details of how to change the measurement system of the machine

Touch screen keys to set tool offsets.

Touch screen key to access the tool selection page.

Touch screen key to access the spindle set up page for: High/Medium/Low
Speed Ranges, Spindle Forward/Reverse and Constant surface speed.

The smaller character to the right of the S signifies which speed range the machine is in
4

(H= High range, M= High range and L=Low range)

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Touch screen key to turn CSS On/Off.

Touch screen key to Increase  / decrease manual feed rate.



Touch screen keys to select x1 x10 x100 hand wheel increment.

(Selected increment appears in yellow)

Touch screen key to access Operation page.

Touch screen key to access CAM menu page.

Touch screen key to access the Edit pages for loading/downloading to and from the
machine / computer and deleting information from the machine memory

Touch screen key to access the Diagnostics, Alarm pages

Touch screen key to turn Coolant On/Off

Battery Status Warnimg

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“ALPHA” MODE TUTORIAL
Machine Operation
(practical examples in using the machine)

Emergency Stop
Pressing the Emergency stop at any time will close down
the machine immediately.

Start/stop the spindle rotating

i) Lift the spindle stop/start lever to start the Spindle
lower the lever to stop the spindle
ii) Turn the spindle speed potentiometer clockwise.
The rpm will register at the side of the S screen key.

Forward / Reverse and High / Low gear range selection

Spindle Direction

Reverse Forwards

Speed Range

Low Medium High

i) Press the S touch screen key on the to display the secondary spindle screen.
ii) Press the relevant touch screen keys for: - Forward / reverse and high / medium / low range to
activate the options. The keys shown in yellow are the ones which are active
iii) Rotate the spindle speed potentiometer in a clockwise direction to increase the rpm.
This will register on the screen at the side of the S key
iv) Press either the manual screen key to return to Manual mode screen, or alternatively the
operation screen key to return to the Operations page.
Note: the constant surface speed (CSS) can only be set correctly after the tool offsets are set
correctly. (see the separate section 'setting the CSS' on page 26)
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Manual feed rate selection
The feed rate touch screen key
has a range of feeds from 0.03 to
0.6mm (0.003inch to 0.024inch)
and is a two way key for
Increasing / decreasing the feed /
revolution the actual tool feed rate
is displayed on the screen along
with selected feed rate and %
override.

Manual feed rate override

The feedrate override control has a range of 0 to 120% in varying
increments. This is recorded on screen by rotating the selector clockwise
(cw) or counter clockwise (ccw).
This will alter the feed rate on the screen accordingly and register the
actual feed rate reading,along with the selected feed rate and %
override.

Hand wheels
The hand wheels control the Cross Slide and Saddle
movement which are designated
i) X axis (Cross Slide)
ii) Z axis (Saddle)
In the UK and Europe the left hand wheel is the Cross
slide and the Right hand wheel is the Saddle
In the USA the hand wheel configuration is reversed.
iii) Winding the X axis hand wheel (cross-slide) clockwise will advance the slide towards the centre
line of the machine
iv) Winding the X axis hand wheel counter clockwise will reverse the direction of the movement
v) Winding the Z axis hand wheel (Saddle) counter clockwise will advance the slide towards the
chuck
vi) Winding the Z axis hand wheel (Saddle) clockwise will move the slide away from the chuck.
v) Individual pressing the x1 x10 x100 screen keys will reverse video the key altering the hand
wheel increment and slide movement from 0.001mm, 0.010mm, 0.100mm
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Tool Selection
i) Press the tool select key.

ii) This will display the tool selection menu:

Enter the tool number required (11 to 32) and

press the input key, on the keypad, to confirm the
selection and automatically return to the manual
screen.
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Tool Selection - Optional Turrets
The Alpha 1000 series machines have the option of automatic turrets. The method of indexing this
turret is dependant on the control software currently selected by the operator. (Alpha mode, Manual
Guide mode or C.N.C. mode.)
Turret Index Operation in ALPHA Mode.
In Alpha mode tool selection on screen will automatically index the turret to the tool number
selected. The turret will take the shortest route CW or CCW from the current tool to the tool
selected.
Note: Only tool numbers between 1 and 8 are available on turret machines.
Press the tool number key:

Type the number required

using the keypad:

Now press (INPUT) on the keypad and the turret will index to the tool selected.

Note: The turret is bi-directional and will take the shortest path the tool number requested.
(Clockwise or Counter-Clockwise).
Note: The saddle guard must always be closed to allow turret index.

CAM Mode (ALPHA System).

When running a CAM program in the ALPHA mode, selection of the first tool requires following the
procedure outlined above.
When running in SINGLE STEP each tool change is performed using the above method.
When running in AUTO CYCLE the tool will automatically change when required within the
program.
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Tool Setting
In general the tool setting method used in the Alpha system may be considered as the same as that
employed when using a standard digital readout on a conventional centre lathe.
The Z 0.000 will be the front of the billet to be machined, with movements towards the chuck
being a ‘-- Z’ (MINUS) amount .
The X axis figure will be a diameter value of the component being turned.

Note: In addition to the X axis and Z axis figures used for tool setting, a Radius value (tool tip
radius) and tip direction (Left hand, Right hand, Internal ,External) should also be added to the tool
information. This will allow the system to use Tool Nose Radius Compensation (T.N.R.C.) when
running machining cycles on the Alpha control.(See ‘Selection of Radius Values and Tool Direction’
page 21 to 22).

Important:
It should be remembered however that the Alpha U allows three individual methods of operation
Alpha / Manual Guide / I.S.O. (C.N.C.) and for convenience tool setting on the Alpha system will
write this tool position and tip radius information to the other systems.

Note: Manual Guide and I.S.O. (C.N.C.) both use the standard Offset / Workshift method of tool
setting. See Manual Guide and I.S.O. (C.N.C.) manuals for full information.
Because of this some general rules must be observed when setting the tools on the alpha system to
comply with the requirements of the other two systems. (See ‘Tool Setting Example’ page 14 to 20).

Tool Setting : Tool Status Flags

To allow an inexperienced operator see (at a glance) the status of each tool, several warning flags
(or symbols) have been added to the tool setting sections of the control screen.
These are as follows:

This Indicates the tool is selected as the Datum Tool.

This Indicates the tool has been set since the last change of the Datum Tool.

This Indicates that the tool requires re-setting due to a change of Datum Tool.

The above flags may be used in the tool information box of the control screen in the following
ways:
1. The tool information box indicates that tool number 1 has been
selected as datum tool.

2. The tool information box above indicates that tool number 2 is no

longer correctly set due to a change of datum tool.

3. The tool information box above indicates that tool number 2 has
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been reset correctly to the new datum tool.

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Tool Setting : Tool Status Table
In addition to the on screen tool status box seen while operating the machine (see previous page)
a screen showing the status of all 32 tools, Tool Status Table, is available to the operator.

This is automatically offered for selection if any alterations to the tool offsets have been made while
using the other systems available on the machine: Manual Guide or I.S.O. (C.N.C.).
If the machine has been used in these other formats and alterations made to the tooling , the
following message / screen will be seen when re-powering in the Alpha system.

In addition to this automatic request to view the tool status page as noted above, an operator may
select this tool status table at any time by:
1. From the Manual Mode Screen:

i) Press the question mark touch screen

key

ii) Selecting the Tool Status option from

11

the menu

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2. From the Tool Setting screen:

i) Pressing the tool status touch screen key

This will display the Tool Status table:

For each tool number (1 to 32) the tool status table displays the following:
1. The number of the tool set as the datum tool;
Indicated by the symbol ‘ ’ in the STATUS column.
2. Tools correctly set in Z relative to the datum tool;
’, in the STATUS column, (tools incorrectly set display a ‘X’ symbol).
Indicated by a tick, ‘
3. Tools changed while not operating in the Alpha system mode (i.e. Manual guide or CNC
modes) that require re-checking are indicated by a ‘?’ in the OFFSET column, this column will
then also indicate what was altered while not operating in the Alpha system mode, ‘X’ or ‘Z’
for an axis change or an ‘R’ if the tool radius value was changed.
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Example: In the Tool Status table shown on page 12 then for the first column, tools 1 to 13 :

Tool 1;
Is set as the datum tool.

Tools 2 and 3;
Are set correctly relative to the datum tool (tool 1).

Tools 4, 7, 8, 10, 11, 12 and 13;

Are out of position to the datum tool (tool 1) and will require re-setting before being used.

Tool 5;
Was not set to the datum tool (tool 1) but was run in Manual Guide or I.S.O. (C.N.C.) modes,
where the radius value of the tool was changed. Re-entering the R amount while in the Alpha
’, in the Offset column.
system mode will add a tick, ‘
Note: Z must be set to the datum position to add a tick, ‘
’, in the status column.

Tool 6;
Was set to the datum tool, (tool 1) but an alteration was made in X while the machine was being
used in Manual Guide or I.S.O. (C.N.C.) modes. It is advisable to re-check the X size prior to
using in the Alpha system mode.
Note: in this example it may be safe to run this tool as only the X value has been altered. (This may
be due to a small alteration in size when running in I.S.O.) It is generally advisable however to
have both columns showing the a tick, ‘ ’, prior to running the tool.

Tool 9;
Was not set to tool 1 (Datum) but was used and set in X and Z while the machine was being used
in Manual Guide or I.S.O. (C.N.C.) modes. Checking the size in X and Z and re-entering the X
and Z amounts while in the Alpha system will add a tick,‘
’, in the Offset and Status columns.

Notes:
The tool status table is designed as an aid to a inexperienced operator and is not available when
tool setting in the Manual Guide or I.S.O. (C.N.C.) operating systems.

Tool setting may be performed in the Alpha system mode prior to switching to Manual Guide or
I.S.O. (C.N.C.) modes, if this is found to be preferable by the operator.

To exit the tool status screen and return to the previously viewed screen press the arrow key:
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Tool Setting : Example
The following example covers the setting of three tools to machine a component.
The example also presumes the use of a new datum tool (tool number 1 to be used) in the setting
procedure. To achieve this start point in the procedure you must clear tool number 1 of the datum
flag (if this is set as datum on your machine). To do this, follow the procedure below.
If, however, any tool other than tool 1 is flagged as datum move straight to the tool setting
instructions on page 16.

To clear tool number 1 of the Datum flag

i) Select any other tool number (e.g.tool 5) as per the instructions on page 8.

ii) Press the Z position setting key:

To display the Z axis tool setting screen:

iii) Press the Datum tool selection key.

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iv) Press the tick box to confirm:

This will now have selected tool number 5 as the datum tool, the tool number box should show the
following information:
Indicates tool set as datum tool

You are now ready to follow the tool setting example on the following pages:
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Tool Setting : Example - Setting three external tools:
In the following example three tools will be set ready for use on the machine. For the purposes of
this example these will be:
Tool No.1 - Roughing. (also set as Datum tool).
Tool No.2 - Finishing.
Tool No.3 - Threading.

Setting tool offsets and datum tool (using cut and measure)
1. Load the material into the chuck (e.g.a billet 50 dia. x 100 prodtruding from jaws) and mount
tool number 1 (roughing tool) in tool holder.
2. Select tool number 1 (see page 8)

Setting tool number 1 Z0.000

Set Z Position and Datum for tool number 1
3. Manually face front of billet to clean

4. Move tool clear of billet in X axis only.

3
DO NOT move away in the Z axis.

5. To set this front face as the datum, Z0.000

i) Press the Z position setting key:

To display the Z axis tool setting screen:

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ii) Type 0
iii) To set this tool as the datum tool press the datum select key:
iv) Confirm by pressing the ‘tick’ touch screen key:

The Z axis position should now read Z0.000 and the tool number box should be as shown below:

Indicates tool set as datum tool Indicates tool set correctly

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Set X Position (Diameter) for tool number 1
6. Manually turn outside diameter of billet to clean.

Measure

7 3

7. Move tool clear of billet in Z axis only. DO NOT move tool in the X axis.
8. Measure turned diameter.
9. To enter X diameter value:
i) Select X position setting key:

To display the X axis tool setting screen:

ii) Enter measured diameter value and press input

Tool Number 1 is now set in the X and Z axis

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Setting tool number 2
10. Mount tool number 2 (finishing tool) in toolpost.
11. Select tool number 2
i) Press tool select key

ii) Type 2 and press input on the keypad.

Set Z axis offset

12. Touch tool on front of billet (machined face)

Z0.000
13. To enter Z0 value
i) Select Z position setting key:

To display the Z axis tool setting screen.

ii) Type 0 and press input on the keypad:

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Set X axis (Diameter value) offset
14. Touch tool on machined diamter (or re-cut).

Measure

15. To enter X diameter value

i) Select X position setting key:

To display the X axis tool setting screen.

ii) Use the keypad to enter the measured X diameter value and press input.

Tool Number 2 is now set in the X and Z axis

Setting tool number 3

To set tool number 3 (threading tool etc.) repeat steps 10 to 15 from the previous section.
Note: After setting the three tools, these may be checked by using the tool status table.
(See page 11).

Tool Setting : Tool Nose Radius Compensation (T.N.R.C.)

Selection of Radius values and Tool direction
It is possible for the machine to compensate for the radius found on the end of standard turning
tools.

For this to operate correctly two values must also be added to the tool information after setting the
X and Z positional amounts.
X Axis Contact Point
These values are:
a) The size of the radius: R R

Centre of Tip Radius

Z Axis Contact Point

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b) The type (Direction) of the tool being used.
As may be seen from the tool direction list shown left (and
present on the actual control) all tool types are covered
including internal, external, left hand and right hand.
-X

-Z +Z

+X

To select the Direction and Radius value required:

Call tool number required:
i) Press tool select key
ii) Type in tool number required and press input.
Then re-select tool page by pressing the tool select key again:
i)
Select the direction of tool being
used as this number, in this
example; External, right hand
(direction 3)
Note: the selected key will change
to yellow indicated it has been
selected.

ii)
Press the radius setting touch
screen key, enter the size of the
tool tip radius using the numerical
keypad and press Input
The Direction of the tool and the tool tip radius value are now set.
Note: The radius value is now shown in the tool info block:

Note: Tool Nose Radius Compensation only operates on the finish pass cycles of 'Stops' and 'Taper'
modes.
Important: The tool direction of the tool being used must be set correctly for the direction of cut for
any given operation (Towards/away from Chuck, External/Internal).
Failure to do so will result in the component been produced to the incorrect size.
21

Note: Setting of a Radius value of 0.000 for any given tool will allow a finishing cycle without Tool
Nose Radius Compensation
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Tool Nose Radius Compensation: Tool Direction Examples
External Straight Finish Cycle External Straight Finish Cycle Internal Straight Finish Cycle

External Taper Finish Cycle External Taper Finish Cycle Internal Taper Finish Cycle

Where using T.N.R.C with any of the programming examples in this manual be sure that the correct
tool direction has been set.

Start Points for Box & Taper Box Cycles

Both the roughing & finishing cycle have a fixed start position.
This is 0.500mm or 0.2000 ".
This stand off distance from the actual programmed sizes
is standard for all cycles and is the start and return
position for the tool.
Any cycle will work to these positions unless a tool nose
value has been input for the tool being used.
If a tool nose value is included, this value is added to the
standard value.
e.g. If a cycle start was programmed as X70.000, Z0.000
the start position with no tool radius value would be
X71.000, Z0.500.
If a Radius value of 0.800mm was set for the tool being
used the start position would change to X72.600, Z1.300
(X71.000+ [0.800x2], Z0.500+0.800).
Note: This addition occurs in Roughing and Finishing
22

cycles, but the tool compensation is only active in

Finishing cycles.
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Resize key

The resize key is a simple way of altering the X or Z tool offset by a known amount.

Example:
After a test cut the diameter/size sisplayed is 55.000 mm and it actually measures 55.010.
Press the X screen key to display the cut and measure screen.

With the tool readout at X55.000 position Type - 0.010 and press the Resize key.
This will result in adding 0.010 on to the X offset. Therefore correcting the error at the read out
and returning the screen to the manual mode.

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Work Shift key
The work shift key is a simple way of altering all Z axis tool offsets without
independently calling each tool to screen.

Example:
Position the tool to the old Z zero position.
Press the Z screen key to display the cut and measure screen.

Type in the direction (plus or minus) and the Numerical amount of Work shift required,
e.g. -103.148
Press the Work shift key to return the screen to the manual screen. Resetting all the tools Z axis
offsets by the same amount (-103.148). Thus displacing the Zero position of the component.
24

Note: A minus figure will move the zero datum of the component towards the Tailstock A positive
figure will move the zero datum of the component towards the chuck.

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Setting the maximum rpm
Max rpm is only applies when CSS is active - See pages 26 to 29.
Press the S touch screen key to display the spindle setting screen.

i)
Press the forward or reverse
touch screen key to activate the
direction of the spindle rotation.
Selection is acknowledged by
the key turning yellow.

ii)
Press the speed range selection
touch screen key for high or low
clutch selection.
Selection is acknowledged by
the key turning yellow.

iii) Turn the spindle speed potentiometer in a clockwise direction to increase the spindle rpm,
until the maximum speed required for the particular component is achieved, e.g.1800 rpm

iv) Press the Max rpm screen key to confirm the speed and record it on the screen:

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Setting the Constant Surface Speed (CSS)
Definition of CSS: for any constant feed rate set in the X-axis.The spindle rpm will increase or
decrease, relative to the diametrical position of the tool and the specified surface speed in metres
or feet per minute.
The spindle setting page can be accessed from the S touch screen key and exited to the Manual
mode page, Sequence operations mode page or Cam mode page by pressing the appropriate key.

It is possible to set a different CSS for any number of tools. The only common denominator
required is the maximum rpm for the component. Before setting up the constant surface speed(s) all
tool offsets must be set.
The CSS can be switched on/off in the Manual Mode, Operations mode and CAM program
screens.

CSS Off CSS On

To Start/Restart CSS, at any time, press the CSS touch screen key

To cancel CSS, press the CSS touch screen key.

Note: the spindle speed potentiometer must be fully turned off (i.e. Counter -clockwise).

IMPORTANT: To prevent unintentionally high (and therefore unsafe) spindle speeds, CSS cutting
must always be preceded by a physical speed rpm capping process. That is the maximum rpm for
any particular work piece, taking into consideration the cutting speeds, component weight, work
holding and tool combination).

IMPORTANT: Before setting up the CSS the tool offsets for all Tools in question must be set.
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Setting the CSS for tool number 01
Tool cutting data
Tool 01 to cut the component at 250 metres per minute i.e. Equal to 796 rpm at 100 mm diameter
Switch off the CSS (if necessary) by rotating counter clockwise the spindle speed potentiometer to
the completely off position and pressing the CSS touch screen key.
i) Press the T touch screen key and type in the tool number 01

ii) Press the input key on the keypad to register it to the screen.
iii) Press the S touch screen key to access the spindle setting screen.
iv) Start the spindle and increase speed,using the spindle speed potentiometer, until 250 m/min is
shown as below:

v) Press the CSS enter touch screen key to establish CSS for Tool 01
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To check the CSS, wind the tool in an -X or +X direction and the spindle speed should respond
accordingly.

To exit the page and return to the manual mode screen press the manual screen key

The CSS touch screen key should now register on:

Setting the CSS for tool number 02

Cancel the CSS option as follows: (this will operate with the spindle running or stationary.)
Rotate the spindle speed potentiometer counter clockwise to the completely off position and
press the CSS touch screen key.

Tool cutting data

Tool 02 to cut the component at 150 metres per minute i.e. Equal to 478 rpm at 100 mm diameter
i) Press the T screen key and type in tool number 02
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ii) Press the input key on the numerical keypad.
iii) Press the S touch screen key to access the spindle setting screen.
iv) Start the spindle and increase speed,using the spindle speed potentiometer, until 150 m/min is
shown as below:

v) Press CSS enter touch screen key to establish the CSS for tool 02

To check the CSS, wind the tool in an -X or +X direction the spindle speed should respond
accordingly.

To exit the page and return to the manual mode screen press the manual screen key

The CSS touch screen key should now register on:

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Switching the CSS on
To start/re-start the CSS option at any time:
i) Press the CSS touch screen key

(Off) (On)

Switching the CSS off

To cancel the CSS option at any time:
i) Rotate the spindle speed potentiometer to the OFF position (fully counter-clockwise)
ii) Press the CSS touch screen key.

(On) (Off)
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Operation and Data Input Screens
Manual mode screen (H
Hand wheel operation)

Press the Manual mode screen key to return to the manual mode (hand wheel) screen.

The Manual screen is the key to the system. It allows all the operation of the machine described on
pages 4 to 30.
The bottom row of touch screen keys allows access to:-

Operation review screen

CAM menu screen

Edit mode screen

Diagnostics screen

Coolant On / Off

Operation Review screen

Press the Operation touch screen key to display the Operation review screen and
operation selection keys For Stops ,Taper, Threads and Box cycles. (see page 34)

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Edit screen
Press the Edit touch screen key to call the edit page to screen which gives the option of
deleting operations from the machine memory and loading / saving operations between
the machine and PC. (see page 130 to 138)

CAM menu screen

Press the CAM touch screen key to call the CAM menu to screen which gives the option
of running the file in single block and full automatic cycles along with a step through
programme facility and loading to the machine from PC. (see pages 139 to 148)
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Diagnostic screen
Press the Diagnostic touch screen key to call the diagnostic pages to screen.

Inch / Metric conversion screen

Press the Diagnostic touch screen key to call the diagnostic pages to screen.
Press the relevant option touch screen key to select the ‘Inch/Metric Convert’ option screen.
Press the screen key to change measurment units.
WAIT” followed by the instruction to “P
This will be followed by the message “W POWER OFF /
POWER ON” Using the Red and Green pushbuttons.
Press the touch screen key to cancel and return to the manual mode screen.

Important:
i) After changing the measuring
system from inch to metric or
vice-versa. All Tool offsets will
be invalid and must all be
re-set
ii) The machine is not a dual
purpose co-ordinated system
it is either set up in an Inch
or Metric system at power
up. Inorder to machine an
inch thread in a metric
co-ordinated system the
thread data must be
converted to metric.
33

Metric read outs have up to 3 figures before and 3 figures behind the decimal point, i.e. 123.456
Inch read outs have up to 2 figures before and 4 figures behind he decimal point, i.e. 12.34567
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Operations Review Screen
Accessed from the Manual page,
Press the Operation screen key to call to screen the;

Operations review screen

The review screen also displays:
i ii
i) X & Z positional read outs

ii) T & S touch screen keys

iii) Cursor Keys (for scrolling

through review screens)

iv) CSS on/off touch screen key

v) x1 x10 x100 hand wheel

increment keys

vi) Option keys (bottom row)

- see page 35.

vii) Operation review window

- see below

iii vi iv v vii

Operation review window

The Operation review window displays:
i iii ii iv
i) Operation number

ii) Tool number

iii) Type of operation being used

(shown graphically)

iv) A summary of the relative

data for the operation.

Special Feature of the Review screen

The review screen has a special HIDDEN feature.
Pressing the icon on the left hand side of the review window acts as a quick entry to the current
Data Input page
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Option keys
Manual depicted by the hand symbol
(Returns you to Manual mode screen - see page 4)

Stops and Box cycles depicted by the cross symbol

(see pages 38 to 61)

Taper and Taper Box cycles depicted by the cone symbol

(see pages 62 to 82)

Threading, Drilling and Tapping depicted by the screw symbol

(see pages 83 to 110 - Threading, Thread Chasing and Thread Chamfer)
(see pages 111 to 115 - Drilling Cycles)
(see pages 116 to 120 - Tapping Cycles)

Grooving cycles depicted by the ‘H’ symbol

(see pages 121 to 129)

Press to turn Coolant on /off

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System Warning Messages
When using the Stops / Box Cycles (pages 38 to 61), Tapers / Taper Box Cycles (pages 62 to 82)
and Threading (pages 83 to 100), warning messages have been included to assist in the correct
operation of these functions.
These are as follows:

1. Wrong Direction Key Selected


 

Note: In the above example one of the direction keys shown in red was accidentally selected on the
keypad. This warning then appears to show, in green, the directions available for this operation.

These direction options will change depending on the type of stop / taper or thread is selected:

 
   
 
2. Option Not Available
36

Note: In the above example the operation programmed is not possible in any direction.

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3. Incorrect Tool Position

If the tool is incorrectly positioned when pressing a direction key to engage the chosen cycle the
warning shown will be similar to those shown above.

Example: External stop of X 50.000 Z -50.000. Positioning the tool manually to X 48.000 (below
the finish position in X) will result in the warning shown above left.

Note: In the above illustrations, the area relative to the stop point of the cycle, the area the tool
should be positioned in, is shown as the blank area.

4. Wrong Tool Selected

(i) If the tool selected does not correspond with the tool programmed in the cycle, the tool
select key will be turn red.

(ii) If a direction key is selected with the control in the above condition the wrong tool warning
will be displayed on screen.

37

Note: To clear any of the above warnings from screen, press the ‘ ‘ key.
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Stops
The Stops operation sets up the limits the Cross Slide
(X axis) and the Saddle (Z axis) are allowed to travel
within a working quadrant. It makes provision to include
radius R or chamfer C at the intersection of the two
paths (XX and Z)
Please see also the Important note on page 48 if a
drilling or grooving operation is been programmed.

Operation - External Stops

i) Press the Stops touch screen key to display the screen giving the choice of either
External or Internal operation

ii)
Press External touch screen key to
change the screen to the Data
Input screen, showing the relative
Diagram, Symbols and Touch
keys.

Internal touch screen key

External touch screen key

iii)
Systematically press the
individual touch screen Data
Input keys for T, X, Z, R (or C)
and F and type in the relative
data from the numerical keypad
and confirm each individual entry
by pressing the Input key.

Touch screen Data Input keys

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iv)
Pressing the
radius/chamfer
touch screen key
alternates the diagrammatic keys
for chamfer or radius direction.
This will automatically change
the radius or chamfer data key
to the correct designation R or C
Press the appropriate screen key
to register the type of chamfer or
radius required.
If there is no requirement for a
radius or chamfer type in the
figure 0.000

Chamfer Select Keys

Radius Select Keys

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Example:

Tool = T 01
Feed = F 0.20

{ Radius
Type of Radius
=
=
R 5.000

Diameter = X 40.000
Length = Z -60.000

Step-by-step Data Input:

Tool = T 01
Press the T touch screen key to
change display to Tool Data
Input screen
Input Tool number 01 using the
numerical keypad
Press Input key on the keypad to
register tool number and change
display back to main Data Input
screen

Diameter = X 40.000
Press the X touch screen key to
change display to Diameter
(X Axis) Data Input screen
Input Diameter 40.000 using the
numerical keypad
Press Enter key on the keypad to
register tool number and change
display back to main Data Input
screen.
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Length = Z -60.000
Press the Z touch screen key to
change display to Lenght (Z Axis)
Data Input screen
Input Diameter -60.000 using the
numerical keypad
Press Enter key on the keypad to
register tool number and change
display back to main Data
Input screen

Radius = R 5.000
This example requires a radius so
ensure the radius / chamfer data
key is set to R (radius) by pressing
the radius/chamfer touch screen
key as required.
Press the R touch screen key to
change display to Radius Data
Input screen
Input Radius 5.000 using the
numerical keypad
Press Input key on the keypad to
register tool number and change
display back to main Data
Input screen
Select Radius type required by
pressing relevant screen touch
key from the selection shown

Feed = F 0.20
Press the F touch screen key to
change display to Feed Data
Input screen
Input Feed required 0.20 using
the numerical keypad
Press Input key on the keypad to
register tool number and change
display back to main Data
Input screen
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Once all data has been input

Press the screen key ‘ to confirm all the data input and return to the Operation review screen
with the new data registered to memory:
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To activate the operation - External Stops
i) Using the hand wheels wind
the tool onto the correct
quadrant.

ii) Press the -Z feed direction key

to activate the stops (the Op
No. box on the review window
turns yellow, signifying the
operation is active).
This will prevent the slides
travelling past the co-ordinates
set in the X & Z data page.

iii) Start the spindle, turn the

spindle speed potentiometer
clockwise to select the desired
rpm.

iv) If the CSS has been set up and is required:

Press the CSS touch screen key to turn ON the
constant surface speed.

v) Wind the hand wheels to position the slides for

the first cut.
X STOP
vi) Engage the feed lever to release the hand
wheels drives and commence the feed
F movement of the Z axis slide.
When the slide reaches the figure set in Z the
0.2mm slide will retract in both X and Z by 0.2mm
(0.008"). (See note on page 48).
Z STOP
The hand wheels drives will become active
again, wind the tool back in the +Z direction
to the start of the next cut.
Feed direction Keys Alternatively use the slide rapid key option,
-Z for internal and external cycles feeding
see page 2.
the tool towards the chuck.
+Z for external cycles feeding the tool vii) Apply depths of cut systematically and repeat
away from the chuck. the full operation until the sizes set in set in X is
achieved. When the slide reaches the point set
-X for facing cycles feeding the tool
in the X data the X axis hand wheel drive will
towards the centre line of the chuck.
release preventing you from been able to wind
+X for internal facing cycles feeding the the cross-slide any further in that direction,
tool away from the centre line of the indicating finish position is reached. Engage
chuck. the feed lever to activate the feed for the final
cut.
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viii) To clean up the uneven face left by the tool form.
Wind the tool clear of the outside diameter. Press the
+X direction key to activate the stop, wind the tool
to the Z stop position. At this point the Z axis hand
wheel drive will release, preventing you from winding
the cross-slide any further in that direction, indicating
that the finish position has been reached.
X STOP
ix) Engage the feed lever to commence the feed in the
0.2mm X direction. The slide will completing the operation
including the radius contour and retract by 0.2 mm
(0.008") in both the X and Z directions.
F
(See note on page 48)

Z STOP
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Operation Notes - External Stops
Pressing the relative Directional keys on the console
Z
illuminates the light on that directional key and turns the
Op No. display yellow, signifying the Stops are active.
This will only happen providing the tool is in the correct
ØX working quadrant.
R or C X STOP The Stops operation is capable of feeding in both the X
F and Z direction for external data. The directions are
Working
F dependent on the working quadrant.
Quadrant
Z STOP T For an external Stops operation, there are two working
quadrants:

The first is when the tool is feeding in the -Z or -X

direction. For this operation only the -Z and -X direction
keys are capable of activating the Stops.

Z
The second is when the tool is feeding in the +Z or -X
direction For this operation only the +Z and -X direction
keys are capable of activating the Stops
ØX
X STOP
Working
Quadrant
F If a direction key is pressed and it does not Illuminate
F and the Op No. box does not turn yellow, the tool is at
Z STOP
the wrong quadrant (wrong side of one or both the
programmed stops).

D) is put on by manually turning the

The depth of cut (D
hand wheel and is selected at random by the operator.

X STOP When in the feed condition, the slide will follow a

recta-linear cycle retracting by 0.2mm (0.008") in both
X and Z when it reaches the set X & Z limit. When the
F
tool enters the radius area it will then follow the radial
D
contour

0.2mm Only the X & Z slide limits will respond when using the
Z STOP hand wheels manually. When manually wound slides will
not obey or follow the radius or chamfer data

Pressing the icon on the left hand side of the review

45

window acts as a quick entry to the current Data Input

page
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HANDS ON TUTORIAL - “ALPHA”

MODE
Operation - Internal Stopsi
i) Press the Stops touch screen key to display the screen giving the choice of either
External or Internal operation

ii)
Press Internal touch screen key
to change the screen to the Data
Input screen, showing the
relative Diagram, Symbols and
Touch keys.

Internal touch screen key

External touch screen key

Example:
Tool = T 01
Feed = F 0.20

R5
Ø40
{ Radius
Type of Radius
=
=
R 5.000

X STOP Diameter = X 40.000

Length = Z -60.000
60
Z STOP

iii)
Systematically press the individual
touch screen Data Input keys for
T, X, Z, R (or C) and F to and
type in the relative data from
the numerical keypad and
confirm each individual entry by
pressing the numerical keypad
Input key.

Touch screen Data Input keys

46

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iv)
Pressing the
radius/chamfer
touch screen key
alternates the diagrammatic keys
for chamfer or radius direction.
This will automatically change the
radius or chamfer data key to the
correct designation R or C
Press the appropriate screen key
to register the type of chamfer /
radius required.
Selected Radius/Chamfer type is
displayed to the left of the
selection keys. (For Internal Stops
only 1style of chamfer is
available)
Radius Select Keys
If there is no requirement for a
radius or chamfer type in the
figure 0.000

Chamfer Select Key

Once all data has been input

Press the screen key ‘ to confirm all the data input and return to the Operation review screen
with the new data registered to memory:

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Important Note: Using ‘Stops’ during Grooving or Drilling operations
Omission of automatic Tool Retract
For certain operations it is necessary to omit one of the automatic tool retraction moves (0.2mm
in X and Z axis) e.g. When Grooving or Drilling

This is possible by using the following procedure:

Set the stop positions using the set up procedure outlined in the Stops section of this manual see
pages 38 to 42 but set the Radius as a ( - ) minus value.
Any value may be programmed as a radius but it must include the minus ( - ) prefix.
Adding this minus ( - ) value as a radius will cause the tool to retract by the standard 0.2 mm
only in the direction of feed.

Example:
To drill a hole set the X Stop to X 0.000 and Z to the Depth of the hole required (e.g. Z-50.000)
To prevent auto tool retract in the X axis, which would break the drill, enter a minus value into
the radius section of the set up page.
In this example, as the drill is
feeding in the Z axis, the tool
will feed to Z-50.000, stop
and retract to Z-49.800.
(X will remain at 0.000)

If feed had occured in X axis, e.g. grooving, retract would only occur in the X axis.
48

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To activate the operation - Internal Stops
i) Using the hand wheels wind
the tool onto the correct
quadrant.

ii) Press the -Z feed direction key

to activate the stops (the Op
No. box on the review window
turns yellow, signifying the
operation is active).
This will prevent the slides
travelling past the co-ordinates
set in the X & Z data page.

iii) Start the spindle, turn the

spindle speed potentiometer
clockwise to select the desired
rpm.

iv) If the CSS has been set up and is required:

Press the CSS touch screen key to turn ON the
constant surface speed.

v) Wind the hand wheels to position the slides for

the first cut.
0.2mm
vi) Engage the feed lever to release the hand
wheels drives and commence the feed
movement of the Z axis slide.
When the slide reaches the figure set in Z the
F slide will retract in both X and Z by 0.2mm
(0.008"). (See note on page 48).
X STOP The hand wheels drives will become active
Z STOP again, wind the tool back in the +Z direction
to the start of the next cut.
Alternatively use the slide rapid key option,
Feed direction Keys see page 2.
-Z for internal and external cycles feeding
the tool towards the chuck. vii) Apply depths of cut systematically and repeat
+Z for external cycles feeding the tool the full operation until the sizes set in set in X is
away from the chuck. achieved. When the slide reaches the point set
in the X data the X axis hand wheel drive will
-X for facing cycles feeding the tool release preventing you from been able to wind
towards the centre line of the chuck. the cross-slide any further in that direction,
+X for internal facing cycles feeding the indicating finish position is reached. Engage
tool away from the centre line of the the feed lever to activate the feed for the final
chuck. cut.
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viii) To clean up the uneven face left by the tool form.
Wind the tool clear of the outside diameter. Press the
+X direction key to activate the stop, wind the tool
to the Z stop position. At this point the Z axis hand
wheel drive will release, preventing you from winding
the cross-slide any further in that direction, indicating
that the finish position has been reached.

ix) Engage the feed lever to commence the feed in the

X direction. The slide will completing the operation
including the radius contour and retract by 0.2 mm
F (0.008") in both the X and Z directions.
0.2mm (See note on page 48)
X STOP
Z STOP
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Operation Notes - Internal Stopsi
Pressing the relative Directional keys on the console
illuminates the light on that directional key and turns the
Op No. display yellow, signifying the Stops are active.
This will only happen providing the tool is in the correct
ØX working quadrant.
F
Working
Quadrant The Stops operation is capable of feeding in both the X
X STOP and Z direction for external data. The directions are
Z dependent on the working quadrant.
Z STOP

For an Internal Stops Operation there is only one

working quadrant, when the tool is feeding in either the
-Z or +X direction and for this operation only the -Z and
+X direction keys are capable of activating the Stops.

If a direction key is pressed and it does not Illuminate

and the Op No. box does not turn yellow, the tool is at
the wrong quadrant (wrong side of one or both the
programmed stops).

0.2mm D) is put on by manually turning the

The depth of cut (D
hand wheel and is selected at random by the operator.

When in the feed condition, the slide will follow a

F recta-linear cycle retracting by 0.2mm (0.008") in both
X and Z when it reaches the set X & Z limit. When the
tool enters the radius area it will then follow the radial
X STOP
contour
D
Z STOP

Only the X & Z slide limits will respond when using the
hand wheels manually. When manually wound slides will
not obey or follow the radius or chamfer data.

Pressing the icon on the left hand side of the review

window acts as a quick entry to the current Data Input
page
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Example : External Stop

60

R5
Ø40

X STOP
F
2

F 1
Z STOP

1 2

Example : External Stop

60

R5
Ø40

X STOP
F
2

F 1
Z STOP

1 2
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Example : External Stop

R5
Ø40

X STOP
F
1

F
10
2
Z STOP

1 2

Example : External Stop

R5
Ø40

X STOP
F
1

F
10
2
Z STOP

1 2
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Example : External Stop

R0.8

R10 X STOP
F

1
Z STOP F

1 2
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Example : Internal Stop

1
Ø40
F
2
F
X STOP
60
Z STOP

1 2

Example : Internal Stop

1
Ø40
F
2
F
X STOP
60
Z STOP

1 2
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Box Cycles
The box cycle is dual purpose function.
It can be used as an Area Clearance or as Finish pass.

Longitudinal Box Area Clear - Rectilinear Box cycle with radius and chamfer
Cycle The Area clearance cycle can be either a longitudinal
cycle or facing cycle
X STOP

The cycle sets up the limits that the tool can travel in
X and Z direction within a working quadrant, taking into
consideration the optional internal /external, radius or
chamfer at the intersection of X and Z limits.
Z STOP F A depth of cut, feed per revolution, a finishing allowance
for a both X and Z axis, a combination of the option of
Roughing and /or Finishing cycle along, with the option
of a separate Tool change and feed rate for the finishing
Facing Box Cycle pass.

X STOP

Z STOP

Finish Pass - Rectilinear Box Cycle with radius and chamfer

Finish Box Cycle The Finish cycle follows the full contour taking into
consideration the optional Internal / External, radius or
X STOP chamfer, X and Z starts and stops positions, Tool change
and separate feed rate

The X and Z stop positions can be approached from -X, -Z

and +Z direction when active
Z STOP

Note:
The data pages used in the Box Cycles set up are the
Standard Stops pages plus an extra Data page to input the
extra information

To access the second Data page. Input all the information

56

on the Stops page and then press the Box cycle screen key
as shown on following page.

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Start Position Start Points for Box Cycles
Both the roughing & finishing cycle have a fixed start position.
This is 0.500mm or 0.2000 ".
This stand off distance from the actual programmed sizes
is standard for all cycles and is the start and return
position for the tool.
Any cycle will work to these positions unless a tool nose
value has been input for the tool being used.
If a tool nose value is included, this value is added to the
standard value.
e.g. If a cycle start was programmed as X70.000, Z0.000
the start position with no tool radius value would be
X71.000, Z0.500.
If a Radius value of 0.800mm was set for the tool being
used the start position would change to X72.600, Z1.300
(X71.000+ [0.800x2], Z0.500+0.800).
Note: This addition occurs in Roughing and Finishing
cycles, but the tool compensation is only active in
Finishing cycles.

Operation - Straight Box Cycles

Follow the procedure for setting Stops as explained in detail on pages 40 to 42, but do not press
the key to confirm the data.

Example :
60 Tool = T 01
R5 10 Feed = F 0.25

Ø60 Ø40
{ Radius
Type of Radius
=
=
R 5.000

Diameter = X 40.000
X STOP
Length = Z -60.000

Z STOP
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Press the Box cycle key to change the screen to the Box cycle screen.
Two slightly different versions of this screen are available dependent on whether a
Roughing or Finishing cycle is selected:

1. Roughing Cycle
Press the Roughing cycle screen key to select roughing cycle.

Systematically press the individual touch screen data input keys for X1, Z1, D, U and W and type in
the relative data from the numerical keypad and confirm each individual entry by pressing the Input
key on the keypad.

Example :
Maximum Diameter = X1 60.000
Cut Depth = D 2.5
Z Axis start position* = Z1 -10.000
Finish allowance in X = U 1.0
Finish allowance in Z = W 0.1

Roughing cycle key (selected)

‘Back’ Key
This key returns you back
to the main stops input
screen.
* The machine automatically includes a clearance value when the machining cycle is engaged so
as not to strike the workpiece prior to metal cutting commencing

2. Finish Cycle
Press the Finish cycle screen key to select the finish pass cycle only and calls to screen, 2 new keys
T2 and F2 giving the option of a separate Tool and Feed for the finish pass.

Example :
Finish Tool = T 2 04
Finish Feed = F2 0.15

Finish cycle key (selected)

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Once all data has been input
Important: Select the roughing cycle again, before confirming data input, this will ensure
the roughing cycle is the first cycle selected when activating the inputted data.
Press the screen key ‘ to confirm all the data input and return to the Operation review screen
with the new data registered to memory:

Roughing cycle

Finish cycle

To activate the operation - Box Cycles

The box cycle operation will only
commence when the tool is in a
5mm window of the start point.

i) Using the hand wheels wind

the tool into the correct
quadrant

ii) Start the spindle, turn the

spindle speed potentiometer
clockwise to the rpm required

iii) If the CSS has been set up and

is required:
59

Press the CSS touch screen key

to turn ON the constant
surface speed.
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iv) Press the -Z feed directional key to activate the
box cycle (the Op No. box on the review
window turns yellow, signifying the operation is
active).
The message:
WIND TOOL TO START POSITION X60.000
“W
Z-10.000”
X STOP
will appear on screen
X1,Z1
iv) Using the hand wheel wind the slides towards
Z STOP the cycle start position, (X1, Z1). When the tool
enters a 5mm window adjacent to (X1, Z1) the
hand wheels will release their drives and the
slides will cease to move, indicating the
machine is ready to commence the cycle.
Feed direction Keys The machine automatically includes a
-Z for internal and external cycles feeding clearance value when the machining cycle is
the tool towards the chuck. engaged so as not to strike the workpiece prior
+Z for external cycles feeding the tool to metal cutting commencing
away from the chuck.
-X for facing cycles feeding the tool v) Engage the feed lever to commence the cycle
towards the centre line of the chuck.
+X for internal facing cycles feeding the
tool away from the centre line of the
chuck.

Operation Notes - Box Cycles

During a cutting cycle, de-activating the feed directional key or disengaging the feed lever, at any
time will stop the feed, returning the machine to hand wheel operation. The slide can then be
wound away manually and returned to 5mm cycle start window position X1, Z1. Re-activating the
feed direction key and engaging the feed lever will recommence the box cycle from the start.

Altering the X1 start position to the diameter which was last being cut will allow the allow the slide
to commence at the start of the last cut.

Pressing the icon on the left hand side of the review window acts as a
quick entry to the current Data Input page
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Straight Roughing Box Cycles - External Straight Finish Box Cycles - External
F
F

F F

F
F

F F

F
F

F F

F
F

F F

Straight Roughing Box Cycles - Internal Straight Finish Box Cycles - Internal

F
F F

F
F

F F
61

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Tapers
Z The taper operation sets up the limits that the cross-slide
(XX) and saddle (Z
Z) are allowed to travel within the
working quadrant, taking into consideration the angle.
ØX α).
The feed direction follows the angle (α

a X STOP

Z STOP

Operation - External Tapers

i) Press the taper key to display the screen, giving the choice of either external or internal
operation

ii)
Press External touch screen key to
change the screen to the Data
Input screen, showing the relative
Diagram, Symbols and Touch
screen keys.

Internal touch screen key

External touch screen key

Example: Tool = T 01
40
Feed = F 0.20
10 Diameter = X 30.000
Length = Z -40.000
Ø40 Ø30
Taper Direction =
a X STOP Angle* = α {unknown see (v) page 63}

* The angle of the taper can be inserted directly if

Z STOP known or calculated via the calculator key
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iii) Systematically press the
individual touch screen Data
Input keys for T, F, X & Z.
Type in the relative data
from the numerical keypad
and confirm each input
by pressing the Input key, to
register them to the memory

Touch screen Data Input keys

iv) Select the direction of the taper by pressing the direction symbol key.
To signify which direction is active, the selected taper key will turn yellow.

v) Press the Calculator key to access the angle co-ordinate page:

vi) Systematically press the

individual touch screen data
input keys for X1, Z1, X2 and
Z2 . Type the relative data with
the numerical keypad and
confirm each input by
pressing the Input key to
register them to the memory:
X1 = 30.000
Z1 = -10.000
X2 = 40.000
Z2 = -40.000

vii) Press the key to

calculate the angle and
return to the data input
screen.
‘Back’ Key The angle will be registered
This key returns you back α) key.
against the angle (α
to the main stops input
screen.
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Once all data has been input

Press the screen key ‘ to confirm all the data input and return to the Operation review screen
with the new data registered to memory:
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To activate the operation - External Tapers
i) Using the hand wheels wind
the tool onto the correct
quadrant.

ii) Press the -Z feed direction key

to activate the stops (the Op
No. box on the review window
turns yellow, signifying the
operation is active).
This will prevent the slides
travelling past the co-ordinates
set in the X & Z data page.

iii) Start the spindle, turn the

spindle speed potentiometer
clockwise to select the desired
rpm.

iv) If the CSS has been set up and is required:

Press the CSS touch screen key to turn ON the
constant surface speed.

Z
v) Wind the hand wheels to position the slides for
the first cut.

ØX vi) Engage the feed lever to release the hand

X STOP wheels drives and commence the feed
a movement of the Z axis slide.
F

Working When in the feed condition, the tool will follow

Quadrant
Z STOP the compound angle retracting by 0.2mm
(0.008") in either X and Z or in some
conditions both, when it reaches the X or Z
Feed direction Keys limit. At this point the hand wheels drives will
-Z for internal and external cycles feeding become active again, wind the tool back in the
the tool towards the chuck. +Z direction to the start of the next cut.
Alternatively use the slide rapid key option see
+Z for external cycles feeding the tool page 2.
away from the chuck.
-X for facing cycles feeding the tool
towards the centre line of the chuck.
+X for internal facing cycles feeding the
tool away from the centre line of the
chuck.
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vii) Apply depths of cut systematically and repeat
Alternate Working Quadrant
the full operation until the sizes set in set in X is
achieved.

For the final cut the start point of the feed

should be accurately positioned.
Z
For this example X30.000, Z-10.000
(see diagram on page 62).
When the slide reaches the point set in the X
ØX data. Engage the feed lever to activate the feed
X STOP for the final cut.
a
F
When winding the hand wheels manually, only
Working the X & Z slide limits will respond. The slides
Quadrant will not follow the taper.
Z STOP
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Operation - Internal Tapers
i) Press the taper key to display the screen, giving the choice of either external or internal
operation

ii)
Press Internal touch screen key to
change the screen to the Data
Input screen, showing the relative
Diagram, Symbols and Touch
screen keys.

Internal touch screen key

External touch screen key

Example: 40 Tool = T 01
Feed = F 0.20
Diameter = X 40.000
10 Length = Z -40.000
Ø30 Ø40 Taper Direction =
a Angle* = α {unknown see (v) page 68}
Z STOP X STOP * The angle of the taper can be inserted directly if
known or calculated via the calculator key

iii)
Systematically press the
individual touch screen data
input keys for T, F, X & Z. Type in
the relative data from the
numerical keypad and confirm
each input by pressing the Input
key, to register them to the
memory.

iv)
Select the direction of the taper
by pressing the direction symbol
key. To signify which direction is
67

active, the selected taper key will

turn yellow.
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v) Press the Calculator key to access the angle co-ordinate page:

vi) Systematically press the

individual touch screen data
input keys for X1, Z1, X2 and
Z2 . Type the relative data with
the numerical keypad and
confirm each input by
pressing the Input key to
register them to the memory:
X1 = 40.000
Z1 = -10.000
X2 = 30.000
Z2 = -40.000

vii) Press the key to

calculate the angle and
return to the data input
screen.
‘Back’ Key The angle will be registered
This key returns you back α) key.
against the angle (α
to the main stops input
screen.
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Once all data has been input
Press the screen key ‘ to confirm all the data input and return to the Operation review screen
with the new data registered to memory:

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To activate the operation - Internal Tapers
i) Using the hand wheels wind
the tool onto the correct
quadrant.

ii) Press the -Z feed direction key

to activate the stops (the Op
No. box on the review window
turns yellow, signifying the
operation is active).
This will prevent the slides
travelling past the co-ordinates
set in the X & Z data page.

iii) Start the spindle, turn the

spindle speed potentiometer
clockwise to select the desired
rpm.

iv) If the CSS has been set up and is required:

Press the CSS touch screen key to turn ON the
constant surface speed.

v) Wind the hand wheels to position the slides for

the first cut.
Z STOP Z
Working
Quadrant vi) Engage the feed lever to release the hand
wheels drives and commence the feed
a movement of the Z axis slide.
ØX
F When in the feed condition, the tool will follow
the compound angle retracting by 0.2mm
X STOP (0.008") in either X and Z or in some
conditions both, when it reaches the X or Z
limit. At this point the hand wheels drives will
become active again, wind the tool back in the
Feed direction Keys +Z direction to the start of the next cut.
-Z for internal and external cycles feeding Alternatively use the slide rapid key option see
the tool towards the chuck. page 2.
+Z for external cycles feeding the tool
away from the chuck.
-X for facing cycles feeding the tool
towards the centre line of the chuck.
+X for internal facing cycles feeding the
tool away from the centre line of the
chuck.
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vii) Apply depths of cut systematically and repeat the full
Alternate Working Quadrant
operation until the sizes set in set in X is achieved.
Z STOP Z
Working
Quadrant For the final cut the start point of the feed should be
accurately positioned. For this example X40.000
a Z-10.000 (see diagram on page 67). When the slide
ØX
reaches the point set in the X data. Engage the feed
F lever to activate the feed for the final cut.

X STOP When winding the hand wheels manually, only the

X & Z slide limits will respond. The slides will not
follow the taper.

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Operation Notes - Tapers
The Operation can only be activated if the Tool is in the
Z correct working quadrant (at the correct side ofthe stops
for the active directional key)

ØX The Taper operation will operate anywhere in the active

X STOP
a quadrant.
F
D) is put on by manually turning the
The depth of cut (D
hand wheel and is selected at random by the operator.
Z STOP D

Z STOP Z When in the feed condition, the slide will follow a the
compound angle, retracting by 0.2mm (0.008") in either
X and Z, when it reaches the set X & Z limit. This is
D dependent on the direction of the taper or whether its
internal or external.
ØX
F
a
When winding the hand wheels manually only, the X & Z
X STOP slide limits will respond. The slides will not follow the
Taper.

The Taper operation will only function under a Feed

ondition, it does not function under Hand wheel control

There are no negative angles only (+) positive angles

direction
but dependent on the type of angle selected (d
symbol screen key) the angle can climb or descend.

Pressing the icon on the left hand side of the review

window acts as a quick entry to the current Data Input
page
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Example : External taper

40
10

Ø40 Ø30

.
9462º
F X STOP

Z STOP

Example : External taper

40
10

Ø40 Ø30

.
9462º
X STOP

F Z STOP
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Example : External taper

40

10

Ø30 Ø40

.
9462º
X STOP

Z STOP F

Example : External taper

40

10

Ø30 Ø40

.
9462º
X STOP

Z STOP
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Example : Internal taper

40
10

.
9462º
Ø40
Ø30
F
X STOP

Z STOP

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Example : Internal taper

40
10

.
9462º
Ø40
Ø50
F
X STOP

Z STOP

Example : Internal taper

40
10

.
9462º

Ø50 Ø40
F
X STOP

Z STOP
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Taper Box Cycles
The Taper Box Cycle has a automatic Dual purpose
function. It can be used as a Taper Area Clearance or
a Finish Pass

Area Clearance - Taper box cycle

The Area clearance cycle can be either a longitudinal or
a facing cycle
a a D
The cycle sets up the limits that the tool can travel in the
X & Z directions within a working quadrant, taking into
F F
consideration the angle of the taper, internal / external,
depth of cut, feed per revolution of the spindle, a finish
allowance for both X and Z, a combination of Roughing
a
NOT AVAILABLE AS
and / or Finishing cycle.
F
A BOX CYCLE

Finish Pass - Taper box cycle

The Finish cycle follows the full contour taking into
consideration the options of the limits the angle, choice
a a of Internal / External , X & Z starts and stops Positions,
F F Tool Change and separate feed Rate if required.

a
NOT AVAILABLE AS
A BOX CYCLE F

Note:
The data pages used in the Taper box cycles set up are
the Standard Taper page plus an extra Data page to
input the extra information
To access the second Data page. Input all the
information on the Taper page and then press the
77

Box Cycle screen key.

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Start Position Start Points for Taper Box Cycles
Both the roughing & finishing cycle have a fixed start position.
This is 0.500mm or 0.2000 ".
This stand off distance from the actual programmed sizes
is standard for all cycles and is the start and return
position for the tool.
Any cycle will work to these positions unless a tool nose
value has been input for the tool being used.
If a tool nose value is included, this value is added to the
standard value.
e.g. If a cycle start was programmed as X70.000, Z0.000
the start position with no tool radius value would be
X71.000, Z0.500.
If a Radius value of 0.800mm was set for the tool being
used the start position would change to X72.600, Z1.300
(X71.000+ [0.800x2], Z0.500+0.800).
Note: This addition occurs in Roughing and Finishing
cycles, but the tool compensation is only active in
Finishing cycles.

Operation - Taper Box Cycles

Follow the procedure for setting Tapers as explained in detail on pages 62 to 64, but do not press
the key to confirm the data.

Example :
Tool = T 01
Feed = F 0.20
Angle = α 30.000
Ø70 Ø30 Diameter = X 30.000
X STOP
30°a Length = Z -30.000

10
Z STOP 30
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Press the Box cycle key to change the screen to the Box cycle screen.
Two slightly different versions of this screen are available dependent on whether a
Roughing or Finishing cycle is selected:

1. Roughing Cycle
Press the Roughing cycle screen key to select roughing cycle.

Systematically press the individual touch screen data input keys for X1, Z1, D, U and W and type in
the relative data from the numerical keypad and confirm each individual entry by pressing the Input
key on the keypad.

Example :
Maximum Diameter = X1 70.000
Cut Depth = D 2.5
Z Axis start position* = Z1 -10.000
Finish allowance in X = U 1.0
Finish allowance in Z = W 0.1

Roughing cycle key (selected)

‘Back’ Key
This key returns you back
to the main stops input
screen.
* The machine automatically includes a clearance value when the machining cycle is engaged so
as not to strike the workpiece prior to metal cutting commencing

2. Finish Cycle
Press the Finish cycle screen key to select the finish pass cycle only and calls to screen, 2 new keys
T2 and F2 giving the option of a separate Tool and Feed for the finish pass.

Example :
Finish Tool = T 2 02
Finish Feed = F2 0.1

Finish cycle key (selected)

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Once all data has been input
Press the screen key ‘ to confirm all the data input and return to the Operation review screen
with the new data registered to memory:
Roughing cycle

Finish cycle

To activate the operation - Taper Box Cycles

The box cycle operation will only
commence when the tool is in a
5mm window of the start point.

i) Using the hand wheels wind

the tool into the correct
quadrant

ii) Start the spindle, turn the

spindle speed potentiometer
clockwise to the rpm required

iii) If the CSS has been set up and

is required:
Press the CSS touch screen key
80

to turn ON the constant

surface speed.

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iv) Press the -Z feed directional key to activate the
box cycle (the Op No. box on the review
window turns yellow, signifying the operation is
active).
The message:
WIND TOOL TO START POSITION X70.000
“W
X STOP Z-10.000”
will appear on screen
X1,Z1
iv) Using the hand wheel wind the slides towards
Z STOP the cycle start position, (X1, Z1). When the tool
enters a 5mm window adjacent to (X1, Z1) the
hand wheels will release their drives and the
slides will cease to move, indicating the
machine is ready to commence the cycle.
Feed direction Keys The machine automatically includes a
-Z for internal and external cycles feeding clearance value when the machining cycle is
the tool towards the chuck. engaged so as not to strike the workpiece prior
+Z for external cycles feeding the tool to metal cutting commencing
away from the chuck.
-X for facing cycles feeding the tool v) Engage the feed lever to commence the cycle
towards the centre line of the chuck.
+X for internal facing cycles feeding the
tool away from the centre line of the
chuck.

Operation Notes - Taper Box Cycles

During a cutting cycle, de-activating the feed directional key or disengaging the feed lever, at any
time will stop the feed, returning the machine to hand wheel operation. The slide can then be
wound away manually and returned to 5mm cycle start window position X1, Z1. Re-activating the
feed direction key and engaging the feed lever will recommence the box cycle from the start.

Altering the X1 start position to the diameter which was last being cut will allow the allow the slide
to commence at the start of the last cut.

Pressing the icon on the left hand side of the review window acts as a
quick entry to the current Data Input page
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Taper Roughing Box Cycles - External Taper Finish Box Cycles - External
F
F F
F

F
F

F F

F F
F

F
F

F
F
F

Taper Roughing Box Cycles - Internal Taper Finish Box Cycles - Internal
F

F F
F F

F F
F
F
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Threading Cycles
Z
The thread operation sets-up the thread data to produce
L
External, Internal, Parallel, Taper, Metric, Inch, Right
hand, Left hand, MOD, DP and ACME threads.
ØX1 ØX2
(Root Dia.)

X STOP
P
Z STOP

3 x P (max 5mm)
Tool start position

Operation - External right hand parallel thread

i) Press the Thread key to display the screen giving the choice of either external or internal
thread operation (The other two options are for drilling and tapping and are covered in
later in this manual.)

ii)
Press the External screen key
to change the screen to the
selection for parallel right hand,
parallel left hand, taper right
hand or taper left hand threads.
Internal touch screen key

External touch screen key

iii)
Press the Parallel right hand
thread touch screen key to call
the Data Input page to screen
Parallel - Left hand
Parallel - Right hand
Note:
This touch screen activates the
Thread Chasing option, see
page 101 for details.

Taper - Right hand

83

Taper - Left hand

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iv)
Systematically press the individual
touch screen data Input keys for
T, P (see notes on this function
key below), X 1, X2, etc. to
activate and type in the relative
data from the numerical keypad
and confirm each individual entry
by pressing the keypad Input key.

Thread Chamfer On/Off

(See page 110)

Multiple Function Key P (TPI / MOD / DP)

Pressing this touch screen key access’s the touch keys to select the type of thread required.
The types of threads available are:-
Pitch, M O D (mm selection)
T P I , DP (inch selection)
A C M E option (mm / inch selection)
Press the required thread type
touch key from the selection
shown in the top left of the
screen, the selected thread type
will be displayed on the Data
input screen function key
(currently yellow).

The touch screen key will

display P, TPI, MOD or DP
dependant on thread type
selected

If the ACME option is also required in conjunction with thread type then selecting this option
will also ‘light’ the ACME select key (see pages 96 to 100)

Note:
When the machine is using the metric measurement system. All dimensions for X1, X2, Z and L
should all be inserted in metric measurement even if it is an inch thread is being cut. However the
84

TPI (threads per inch) and DP figures can be inserted directly, the machine system will automatically
in the background convert TPI and DP to the equivalent pitch.
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Example:
30 Tool = T 04
20 Thread Type - Pitch = P 1.5
Outside Diameter = X 1 40.000
Root Diameter = X2 38.166
Ø38.166
Ø40 (Root Dia.) Angle of Thread form = A 60.000
Thread Length = L 20.000
X STOP Thread Stop Position = Z -30.000
1.5 No. of Thread Starts = NS 1
Z STOP No. of Passes = NP 10.2
4.5mm
Tool start position

Step-by-step Data Input:

Tool = T 04
Press the T touch screen key to
change display to Tool data input
screen
Input Tool number 04 using
numerical keypad
Press Input key on keypad to
register tool number and change
display back to main Data
Input screen

Thread Length = L 20.000

Press the L touch screen key to
change display to Thread Lenght
data input screen
Input Thread lenght dimension
20.000 using numerical keypad
Thread lenght is always entered
as a positive value
Press Input key on keypad to
register thread lenght and
change display back to main
Data Input screen
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Thread Stop Position = Z -30.000

Press the Z touch screen key to
change display to Position Where
Thread Stops Relative to Z Zero
data input screen
Input Thread Stop Position
-30.000 using numerical keypad
Press Input key on keypad to
register thread stop position and
change display back to main
Data Input screen

Outside Diameter = X1 40.000

Press the X1 touch screen key to
change display to Outside
Diameter of Thread data input
screen
Input Outside diameter
dimension 40.000 using
numerical keypad
Press Input key on keypad to
register outside diameter and
change display back to main
Data Input screen

Root Diameter = X 1 40.000

Press the X2 touch screen key to
change display to Root Diameter
of Thread data input screen
Input Root diameter dimension
38.166 using numerical keypad
Press Input key on keypad to
register root diameter and
change display back to main
Data Input screen
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Thread Type - Pitch = P 1.5
Press the P touch screen key to
change display to Thread type
data input screen
Press the P touch screen key from
the thread type options to set
Pitch as the thread option, (This
must be done even if the main
screen key already displays P to
confirm choice) and Input
pitch value 1.5 using numerical
keypad.
Press Input key on keypad to
register pitch and change display
back to main Data Input screen.

Angle of Thread = A 60.000

Press the A touch screen key to
change display to Inclusive Angle
of Thread Form data input screen
Input Angle dimension 60.000
using numerical keypad
Press Enter key on keypad to
register thread form angle value
and change display back to main
Data Input screen

No. of Thread Starts = NS 1

Press the NS touch screen key to
change display to Number of
Thread Starts data input screen
Input Number of Starts 1 using
numerical keypad
Press Input key on keypad to
register number of thread starts
and change display back to
main Data Input screen
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No. of Passes = NP 10.2
Press the NP touch screen key to
change display to Number of
Passes including Spring Passes
data input screen
Input Number of Passes 10.2
(where 10 is the number of
passes and .2 is the spring
passes) using numerical keypad
Press Input key on keypad to
register number of passes and
change display back to main
Data Input screen

Once all data has been input

Press the screen key ‘ to confirm all the data input and return to the Operation review screen
with the new data registered to memory:
The arrow under the icon on the
left hand side of the review
window indicates whether a left
hand thread (arrow pointing right)
or right hand thread (arrow
pointing left) is currently selected.
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To activate the operation
i) Using the hand wheels wind
the tool onto the correct
quadrant.

ii) Start the spindle, turn the

spindle speed potentiometer
clockwise to select the desired
rpm.

iii) Press the -Z feed direction key to lock in the

spindle speed, activate the stops (the Op No.
box on the review window turns yellow,
signifying the operation is active).
DO NOT ALTER THE SPINDLE SPEED
POTENTIOMETER POSITION

iv) The message:

X STOP
WIND TOOL TO START POSITION X40.000
“W
Z-4.500”
Z STOP
will appear on screen
Using the hand wheels wind the tool to the
thread start position co-ordinates shown on
Feed direction Keys screen.
-Z for internal and external cycles feeding
In the X axis the start co-ordinate is the
the tool towards the chuck.
diameter of the thread
+Z for external cycles feeding the tool
In the Z axis the start co-ordinate is (3 x
away from the chuck.
pitch P). Unless (3 x pitch P) is greater than
-X for facing cycles feeding the tool 5mm. In which case there is a default start
towards the centre line of the chuck. figure of 5mm
+X for internal facing cycles feeding the The hand wheels will disengage once the tool
tool away from the centre line of the is within a 5mm window of the start position.
chuck.
v) Engage the Feed Lever to commence the
continuous thread cycle.
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Operation Notes - Threading
At the end of the cycle the Feed direction key can be
pressed to de-activated the operation and to re-engage
the Hand wheel drives, allowing the Tool to be moved
away from the component in order to check the thread,
At this point the tool offset can also be changed.

DO NOT ALTER THE SPINDLE SPEED POTENTIOMETER

POSITION - USE SPINDLE START/STOP LEVER ONLY

Pressing the Feed direction key will re-activate the cycle,

X STOP
and pick up the previous RPM so the thread can be
re-cut.

Z STOP The pull off at the end of each pass is:-

In X to 0.2mm clear of the thread diameter.
In Z it will retract over the last half a pitch at the
thread flank angle.

TO ENSURE THE TOOL REMAINS IN PITCH. DO NOT

FOR ANY REASON CHANGE THE SPINDLE SPEED
POTENTIOMETER SETTING
CHANGING A SPINDLE SPEED BEFORE THE THREAD
IS COMPLETE WILL RESULT IN LOSING THE
SYNCHRONISATION OF THE PITCH.

If the Op No. on the review screen will not ‘light up’

yellow then the tool is not in the correct working
quadrant. Use the hand wheels to correct the position
of the tool

The arrow under the icon on the left hand side of the
review window indicates whether a left hand thread
(arrow pointing right) or right hand thread (arrow
pointing left) is currently selected.
Also, pressing this icon acts as a quick entry to the
current Data Input page.

It is not possible to switch from a left hand to a right

hand thread (and vice versa) from the data input screen.
If the wrong hand thread has been set up the operation
will have to be deleted and completly re-input from the
beginning.

In threading mode pressing the cursor touch key to

advance to next sequence will cause the message
90

“TTURN POT TO ZERO” to appear on screen.

Turn the spindle speed potentiometer to Zero and
repress the cursor key to advance to the next Op No.
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Operation - Other Taper Threads
External Taper Threads
If a Taper thread had been
selected (see iii, page 83) then a
variation of the main thread data
input screen appears.
In addition to touch screen keys
defined on pages 83 to 86, this
screen also contains an addition
touch screen key to define the
Taper of the thread:

Taper ot the Thread = α (0-15°)

Press the α touch screen key to
change display to Thread Taper
Angle data input screen
Input Thread Taper angle value,
this can only be a value from 0°
upto a 15° maximum, using the
numerical keypad
Press Input key on keypad to
register angle and change display
back to main Data Input screen.
Internal Parallel / Taper Threads
If a Internal thread had been selected (see ii, page 81) then the following thread types are available:
The thread data input screens that
appear for these options are
similar to those shown on pages
52 to 56 and above, dependant
on thread type chosen, with data
entry as previously described.

Parallel - Left hand

Parallel - Right hand

Taper - Right hand

Taper - Left hand

Important Note on the following thread examples :

As the tool performs a ‘pull off’ as it approaches the end of each pass, it is, in order to ensure a
91

full form thread over the required length, advisable to have each pass end beyond the actual
required length. In the following examples a 5mm ‘run out’ has been included. This will affect the
L and Z values. [e.g. In the first example: L = 25 + 5 = 25 and Z = (-30) + (-5) = -35]
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Example : External parallel right hand thread

End Point of
thread cycle
5 30
20

Ø40 Ø38.166
(Root Dia.)

1.5

Example : External parallel left hand thread

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Example : Internal parallel right hand thread

End Point of
thread cycle
5 45
30

1.5
Ø30 Ø28.2
(Root Dia.)

Example : Internal parallel left hand thread

45
30

1.5
Ø30 Ø28.2
(Root Dia.)

5
End Point of
thread cycle
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Example : External taper right hand thread

End Point of
thread cycle
5 30
Ø28.160
(Root Dia.)
α
a
Ø40 Ø30

1.5
αa = 9.462°

Example : External taper left hand thread

30
Ø28.160
(Root Dia.)
aα
Ø40 Ø30

1.5 Ø28.333*
αa = 9.462° Ø26.493*
(Root Dia.)
5
End Point of
thread cycle
(*Must be calculated)
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Example : Internal taper right hand thread

End Point of
thread cycle

5 35

2
αa
Ø41.125
(Root Dia.)
Ø43.587

α
a = 5°

Example : Internal taper left hand thread

35

2
αa
(Root Dia.)

(Root Dia.)
Ø43.587
Ø44.450
Ø41.125

Ø42.000

aα= 5°
5
End Point of
thread cycle
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Operation - ACME parallel thread
The ACME thread cycle has a special 2 sequences of
Z SHIFT metal removal per individual pass of the thread.

The first pass removes the rear portion of the thread.

The tool then does a Z axis datum shift to the correct
width of the thread. The second pass removes the
forward portion of the thread.

The system will then advance to the next depth of cut

pass taking into consideration the flank angle. This
L means that the Z shift reduces with each depth of cut
A and the amount of metal removal get less. Until on the
final pass the full form of the tool is in contact with
ØX2 metal.
ØX1 (Root Dia.)

X STOP
Note:
When the machine is using the metric measurement
Z system. All dimensions for X1, X2, Z, and L should all
Z STOP be inserted in metric measurement even if it is an inch
thread is being cut. However the TPI (threads per inch)
and DP figures can be inserted directly, the machine
system will automatically in the background convert TPI
and DP to the equivalent pitch.
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Example : External right hand ACME parallel thread
i) Press the Thread key to display the screen giving the choice of either external or internal
thread operation

ii)
Press the External screen key to
change the screen to the selection
for parallel right hand, parallel
left hand, taper right hand or
taper left hand threads.

iii)
Press the Parallel right hand
thread touch screen key to call
the Data Input page to screen

2" Tool = T 04
29° Thread Type = TPI (ACME) 5
Outside Diameter = X 1 25.400 (1”)
Ø1" ؾ" Root Diameter = X 2 19.050 (0.75”)
(Root Dia.)
Angle of Thread form = A 29.000
X STOP Thread Length = L 50.800 (2”)
Thread Stop Position = Z -63.500 (2.5”)
2½" No. of Thread Starts = NS 1
Z STOP No. of Passes = NP 20.1

iv)
Systematically press the individual
touch screen data input keys and
input relevant data.

v)
Press P (pitch) screen key to
access the window keys
97

for type of thread available,

P / TPI / MOD / DP / ACME
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vi)
Press the window key TPI to
confirm that threads per inch is
the option to be used and type in
the data required.
TPI will also be displayed in place
of P on the screen touch key

vii)
Press the ACME window key,
which will turn yellow,
confirming the ACME thread
form is required along with the
TPI option.

viii)
Press Input on the keypad to
return the screen to the new
ACME data page.

The TPI key is now displayed in

place of the P key, indicating that
TPI threading is selected, with the
TPI data recorded to screen.

ix)
Systematically press the other
remaining individual touch
screen data input keys and input
relevant data.
Once all data has been input
Press the screen key ‘ to confirm all the data input and return to the Operation review screen
with the new data registered to memory:
The arrow under the icon on the
left hand side of the review
window indicates whether a left
hand thread (arrow pointing
right) or right hand thread (arrow
pointing left) is currently selected.
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To activate the operation
i) Using the hand wheels wind
the tool onto the correct
quadrant.

ii) Start the spindle, turn the

spindle speed potentiometer
clockwise to select the desired
rpm.

iii) Press the -Z feed direction key to lock in the

spindle speed, activate the stops (the Op No.
box on the review window turns yellow,
signifying the operation is active).
DO NOT ALTER THE SPINDLE SPEED
POTENTIOMETER POSITION

iv) The message:

WIND TOOL TO START POSITION X25.000
“W
X STOP Z5.000”
will appear on screen
Z STOP Using the hand wheels wind the tool to the
thread start position co-ordinates shown on
screen.
Feed direction Keys In the X axis the start co-ordinate is the
-Z for internal and external cycles feeding diameter of the thread
the tool towards the chuck.
In the Z axis the start co-ordinate is (3 x
+Z for external cycles feeding the tool pitch P). Unless (3 x pitch P) is greater than
away from the chuck. 5mm. In which case there is a default start
-X for facing cycles feeding the tool figure of 5mm
towards the centre line of the chuck. The hand wheels will disengage once the tool
+X for internal facing cycles feeding the is within a 5mm window of the start position.
tool away from the centre line of the
chuck. v) Engage the Feed Lever to commence the
continuous thread cycle.
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Operation Notes - Threading
At the end of the cycle the Feed direction key can be
pressed to de-activated the operation and to re-engage
the Hand wheel drives, allowing the Tool to be moved
away from the component in order to check the thread,
At this point the tool offset can also be changed.

DO NOT ALTER THE SPINDLE SPEED POTENTIOMETER

POSITION - USE SPINDLE START/STOP LEVER ONLY

Pressing the Feed Direction Key will re-activate the cycle,

and pick up the previous RPM so the thread can be
X STOP
re-cut.

The pull off at the end of each pass is:-

Z STOP
In X to 0.2mm clear of the thread diameter.
In Z it will retract over the last half a pitch at the
thread flank angle.

TO ENSURE THE TOOL REMAINS IN PITCH. DO NOT

FOR ANY REASON CHANGE THE SPINDLE SPEED
POTENTIOMETER SETTING
CHANGING A SPINDLE SPEED BEFORE THE THREAD
IS COMPLETE WILL RESULT IN LOOSING THE
SYNCHRONISATION OF THE PITCH.

If the Op No. on the review screen will not ‘light up’

yellow then the tool is not in the correct working
quadrant. Use the hand wheels to correct the position
of the tool

The arrow under the icon on the left hand side of the
review window indicates whether a left hand thread
(arrow pointing right) or right hand thread (arrow
pointing left) is currently selected.
Also, pressing this icon acts as a quick entry to the
current Data Input page.

It is not possible to switch from a left hand to a right

hand thread (and vice versa) from the data input screen.
If the wrong hand thread has been set up the operation
will have to be deleted and completly re-input from the
beginning.

In threading mode pressing the cursor touch key to

advance to next sequence will cause the message
100

“TTURN POT TO ZERO” to appear on screen.

Turn the spindle speed potentiometer to Zero and
repress the cursor key to advance to the next Op No.
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Thread Chase (Repair) Function
The thread chase function allows previously machined thread forms to be re loaded to the machine
for repair. Unlike standard threading, the pitch form position may be re attained with the tool to be
used.

Example - Using Thread Chase

Tool = T 03
Thread Type - Pitch = P 1.5
Outside Diameter = X 1 51.000
Thread Length = L 180.000
Thread Stop Position = Z -180.000

Press the Thread key to display the screen giving the choice of either external or internal
thread operation

Press the External screen key

to change the screen to the
selection for parallel right hand,
parallel left hand, taper right
hand or taper left hand threads.

Internal touch screen key

External touch screen key

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Press the Thread Chase Option
touch screen key.
Note: The key will ‘light’ yellow
to confirm selection

Thread Chase

Select the Thread Direction and

Type required.

Parallel - Left hand

Parallel - Right hand

Taper - Right hand

Taper - Left hand

This will causes this page to be

displayed:

Thread Chamfer On/Off

102

(See page 110)

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Tool = T3
Press the T touch screen key to
change display to Tool data input
screen
Input Tool number 3 using
numerical keypad
Press Input key on keypad to
register tool number and change
display back to main Data
Input screen

Outer Pass Diameter Value =

X1 51.000
Press the X1 touch screen key to
change display to Outer Pass
Diameter data input screen
Input Outside pass diameter
dimension 51.000 using
numerical keypad
Press Input key on keypad to
register outside diameter and
change display back to main
Data Input screen
IMPORTANT! This should be clear of the actual diameter of the thread. (X 51.000 in this case).
this will be the diameter the threading tool passes over the material at the initial pass, allowing the
operator to gauge the thread tool position in the existing form.

Thread Length = L 50.000

Press the L touch screen key to
change display to Thread Length
data input screen
Input Thread length dimension
50 using numerical keypad
Thread length is always entered
as a positive value
Press Input key on keypad to
register thread length and
103

change display back to main

Data Input screen
IMPORTANT! This should be shorter than the finished length of the thread for two reasons.
See following page.
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IMPORTANT! - continued.
i. This reduces the cycle time for each pass required to establish correct tool to thread form
position.
ii. If moving the tool position towards the chuck during tool movement, this will take the tool past
the selected Z stop position (Z - 180.000 in this case) by the moved amount on that move only.
(recalculation of the Z stop cannot be achieved while the tool is in motion).

Direction of Tool Shift

NOTE: the full length of thread may be entered after correct tool position in X has been established

Thread Stop Position = Z -50.000

Press the Z touch screen key to
change display to Position Where
Thread Stops Relative to Z Zero
data input screen
Input Thread Stop Position
-50 using numerical keypad
Press Input key on keypad to
register thread stop position and
change display back to main
Data Input screen

Thread Type - Pitch = P 1.5

Press the P touch screen key to
change display to Thread type
data input screen
X Press the P touch screen key from
the thread type options to set
Pitch as the thread option, (This
must be done even if the main
screen key already displays P to
confirm choice) and Input
pitch value 1.5 using numerical
keypad.
Press Input key on keypad to register pitch and change display back to main Data Input screen.

IMPORTANT! PITCH, T.P.I, MOD and DP may all be used to define the thread form.
104

ACME is not required as this defines the tool movement when running an auto thread cycle and
when thread chasing the tool is to be positioned manually.

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Once all data has been input
Press the screen key ‘ to confirm all the data input and return to the Operation review screen
with the new data registered to memory:
The arrow under the icon on the
left hand side of the review
window indicates whether a left
hand thread (arrow pointing right)
or right hand thread (arrow
pointing left) is currently selected.

To activate the operation

Set the spindle speed and engage the cycle using the direction key:

IMPORTANT! It is recommended that a slow spindle speed is used for thread chase (150/200 RPM)
as this will give time during tool travel to view and approximately position the tool in pitch.

The following screen will now appear:

Wind the tool to the position
shown. When in position the run
screen will reappear.
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Engage the feed lever to start the
cycle.

NOTE: During the running of the cycle the following messages will appear:
HOLD RAPID KEY ENGAGE FEED LEVER

Follow these instructions when required in the cycle.

The tool will now cycle over the material at X 51.000.

Using the X axis handwheel position the tool into approximate pitch.

NOTE: This may be performed while the tool is moving along the material or shifted by a required
amount prior to engaging the feed.

NOTE: The amount of shift is

registered in the tool shift section
of the screen:
106

IMPORTANT! When in thread

chase mode only X10 and X1
handwheel movements may be
selected.
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Continue to run the pass (single passes) and use the X or Z axis handwheels to position the tool in
pitch and to depth.

IMPORTANT! Time should be taken in correctly position the tool in the existing form. Never move
the tool in large amounts on each pass. In the X axis the tool should never be moved into the
material by more than the retract value of the cycle (0.500 mm / 0.0200") while the tool is in
motion. Moving the tool more than these amounts will prevent full retraction above the outside
diameter of the thread form on that pass, and cause a groove to be formed around the material.
(Re running the pass will recalculate the retract and pull out correctly).
If large X axis infeeds are required these should be input with the handwheel prior to engaging the
cycle. This allows recalculation of the retract position prior to tool feed.

After correct pitch and thread depth has been achieved the cut length may be altered to the full
thread length.

Disengage the cycle by pressing the direction key:

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Alter the thread length and Z stop values:
Thread Length = L 180.000
Press the L touch screen key to
change display to Thread Length
data input screen
Input Thread length dimension
180 using numerical keypad
Thread length is always entered
as a positive value
Press Input key on keypad to
register thread length and
change display back to main
Data Input screen

Thread Stop Position = Z -180.00

Press the Z touch screen key to
change display to Position Where
Thread Stops Relative to Z Zero
data input screen
Input Thread Stop Position
-180 using numerical keypad
Press Input key on keypad to
register thread stop position and
change display back to main
Data Input screen

Once all data has been input

Press the screen key ‘ to confirm all the data input and return to the Operation review screen
with the new data registered to memory:
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Engage the cycle using the direction key:

Cut the thread to the full length.

Disengage the cycle by deselecting the direction key:

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Thread Chamfer
When programming a thread cycle, it is possible to select thread chamfering on / off.
This selection is made during the programming of the thread pitch / size information.

Using Thread Chamfer

Press the Thread key to select the thread option and program the thread information in
the usual way.

Select thread chamfering on/off.:

Thread Chamfer On/Off

Thread chamfer ON

Thread chamfer OFF

IMPORTANT! Using Thread chamfer OFF will produce a groove around the end point of the thread
110

and is intended for use when machining into undercuts and / or close to end faces.

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Drilling Cycle
Press the Thread key to display the screen giving allowing access to the Drilling operation

Press the Drilling Cycle screen

key to acess the drilling data
input screen.

Drilling Cycle touch screen key

Example - Using Drilling Cycle

Tool = T 02
Drill Stop Position = Z -30.000
Peck Depth = d 5.0
Hole Length = L 30.000
Feed Rate = F 0.100
Dwell 1 = D 1 2.000
Dwell 2 = D2 1.000

Tool = T2
Press the T touch screen key to
change display to Tool data input
screen
Input Tool number 2 using
numerical keypad
Press Input key on keypad to
register tool number and change
display back to main Data
Input screen
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Drill Stop Position = Z -30.000
Press the Z touch screen key to
change display to Drill Stop
Position data input screen
Input Drill Stop Position -30
This is always a minus (-) value.
Press Input key on keypad to
register Drill stop position and
change display back to main
Data Input screen
NOTE! This is the total distance from the front of the component (datum point) to the finish point
of the drill cycle and is always a – (minus) value.
Peck Depth = d 5.000
Press the d touch screen key to
change display to Peck Depth
data input screen
Input Peck value 5
Press Input key on keypad to
register peck depth and change
display back to main Data Input
screen

NOTE! Pecking is always full retract. After each peck the drill rapids back to the start point, dwells
(if set) and then rapids back to 2mm clear of the previous cut.
Hole Length = L 30.000
Press the L touch screen key to
change display to Hole length
data input screen
Input Hole length 30
This is always a positive (+)
value.
Press Input key on keypad to
register thread Hole length and
change display back to main
Data Input screen

IMPORTANT! When the Hole starts on the end face

of the material, as per the example we are following,
the numerical part of the L value is the same as the Z
value. (i.e. Z -30.000 and L 30.000)
112

However the Hole Length value L may be different

from the Z Drill stop value allowing the cycle to
commence inside a previously drilled hole as per the
diagram shown right. (i.e. Z -40.000 and L 20.000) L 20.000
Z- 40.000
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Feed Rate = F 0.100
Press the F touch screen key to
change display to Feed Rate data
input screen
Input Feed rate 0.100
Feedrate is always mm/rev.
Press Input key on keypad to
register Feed rate and change
display back to main Data Input
screen

Dwell 1 = D1 2.000
Press the D1 touch screen key to
change display to Dwell 1 data
input screen
Input Dwell 1 value 2.000
The dwell value is in seconds
Press Input key on keypad to
register Dwell 1 value and
change display back to main
Data Input screen

NOTE! The dwell value is in seconds.

Dwell 1 takes place following the retract to the start point after each peck. This allows the coolant
to clear the hole at the end of each peck.

Dwell 2 = D2 1.000
Press the D2 touch screen key to
change display to Dwell 2 data
input screen
Input Dwell 2 value 1.000
The dwell value is in seconds
Press Input key on keypad to
register Dwell 2 value and
change display back to main
Data Input screen

NOTE! The dwell value is in seconds.

Dwell 2 takes place when the tool achieves full hole depth.
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Once all data has been input

Press the screen key ‘ to confirm all the data input and return to the Operation review screen
with the new data registered to memory:
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To activate the operation
Start the spindle and set the spindle speed required.
Select the -Z key to activate the cycle:

The following screen will now appear:

Wind the tool towards the

position shown on screen.

NOTE: The cycle will engage

within a + / - 5mm area of the
actual start point.

When in position the run screen

will reappear.

Engage the feed lever to start the

cycle.

The tool will rapid from the safe start window

position to the exact cycle start point of X 0.000
Z 2.000 and complete the drilling moves.
115

NOTE: CONTROL FEED / RAPID SPEED WITH

OVERRIDE.

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Tapping Cycle
Press the Thread key to display the screen giving allowing access to the tapping operation

Press the Tapping Cycle screen

key to acess the drilling data
input screen.

Taping Cycle touch screen key

Example - Using Tapping Cycle

Tool = T 02
Tap Stop Position = Z -25.000
Hole Length = L 25.000
Pitch = P 2.000
Dwell = D 1.000

Tool = T2
Press the T touch screen key to
change display to Tool data input
screen
Input Tool number 2 using
numerical keypad
Press Input key on keypad to
register tool number and change
display back to main Data
Input screen
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Hole Length = L 25.000
Press the L touch screen key to
change display to Hole length
data input screen
Input Hole length 25.000
This is always a positive (+)
value.
Press Input key on keypad to
register Hle length and change
display back to main Data Input
screen

IMPORTANT! When the Hole starts on the end face

of the material, as per the example we are following,
the numerical part of the L value is the same as the Z
value. (i.e. Z -25.000 and L 25.000)
However the Hole Length value L may be different
from the Z Tap stop value allowing the cycle to
commence inside a previously drilled hole as per the
diagram shown right. (i.e. Z -40.000 and L 20.000) L 20.000
Z- 40.000

Tap Stop Position = Z -25.000

Press the Z touch screen key to
change display to Tap Stop
Position data input screen
Input Tap Stop Position -30
This is always a minus (-) value.
Press Input key on keypad to
register Drill stop position and
change display back to main
Data Input screen

NOTE! This is the total distance from the front of the component (datum point) to the finish point
of the drill cycle. This is always a – (minus) value.
Pitch = F 2.000
Press the P touch screen key to
change display to Pitch data
input screen
Input Pitch value 2.000
117

2mm
2 mm

Press Input key on keypad to

register Pitch and change display
back to main Data Input screen
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Dwell = D 1.000
Press the D1 touch screen key to
change display to Dwell data
input screen
Input Dwell value 1.000
The dwell value is in seconds
Press Input key on keypad to
register Dwell value and change
display back to main Data Input
screen

NOTE! The dwell value is in seconds.

Dwell takes place when the tool achieves full hole depth.

Once all data has been input

Press the screen key ‘ to confirm all the data input and return to the Operation review screen
with the new data registered to memory:
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To activate the operation
Start the spindle and set the spindle speed required.
Select the -Z key to activate the cycle:

IMPORTANT! There is a fix maximum taping spindle speed in each gear range. These are:
HIGH GEAR: 600 r.p.m.
MED GEAR: 300 r.p.m.
LOW GEAR: 100 r.p.m.
If these maximum values are exceeded the following warning graphic will appear.

Clear the graphic by pressing

and set a permitted speed.

Then reselect the -Z key to

activate the cycle:

With the cycle selected the following screen will now appear:
NOTE: The spindle speed now
locks at the selected r.p.m.

Wind the tool towards the

position shown on screen.
119

NOTE: The cycle will engage

within a + / - 5mm area of the
actual start point.

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When in position the run screen
will reappear.

Engage the feed lever to start the

cycle.

The tool will rapid from the safe

start window position to the exact
cycle start point of X 0.000 Z
5.000 and complete the tapping
cycle.

NOTE: CONTROL INITIAL RAPID SPEED WITH

OVERRIDE

Tapping Cycle:
1. Tap rapids to start point and feeds to depth
2. Dwell
3. Spindle reverses and tap feeds out
4. Cycle complete - spindle reverts to running
forwards

X
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Grooving Cycle
Press the Grooving key to display the screen giving allowing access to the Grooving
operation

Press the O/D Grooving Cycle

screen key to acess the grooving
data input screen.

O/D (outside diameter)

Grooving Cycle touch screen
key

Example - Using Grooving Cycle

Tool = T 05 Groove Top Width = W T 30.000

Feed Rate = F 0.150 Groove Bottom Width = W B 30.000
Tool Width = Tw 4.000 Groove Height 2 = H2 5.000
X Start Point = X 50.000 Groove Height 1 = H1 5.000
Z Start Point = Z -50.000 Groove Top - Radius = Rt 5.000
Groove Bottom - Chamfer = Cb 3.000
121

Finish Allowance = fa 0.100

Peck Depth = P d 2.000

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Tool = T5
Press the T touch screen key to
change display to Tool data input
screen
Input Tool number 5 using
numerical keypad
Press Input key on keypad to
register tool number and change
display back to main Data
Input screen

Feed Rate = F 0.150

Press the F touch screen key to
change display to Feed Rate data
input screen
Input Feed rate 0.150
Feedrate is always mm/rev.
Press Input key on keypad to
register Feed rate and change
display back to main Data Input
screen
Tool Width = Tw 4.000
Press the Tw touch screen key to
change display to Tool Width
data input screen
Input Tool Width 4
Press Input key on keypad to
register Tool width and change
display back to main Data Input
screen

X Start Point = X 5.000

Press the d touch screen key to
change display to X start point
data input screen
Input X start point 50.000
Press Input key on keypad to
register X start point and change
122

display back to main Data Input

screen

NOTE! The X Start Point is always a diameter value and does not include any Chamfer or Radius
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Z Start Point = Z -50.000
Press the Z touch screen key to
change display to Z Start Point
data input screen
Input Z start point -50.000
This is always a minus (-) value.
Press Input key on keypad to
register thread Z start point and
change display back to main
Data Input screen

NOTE! The Z start point is always a (-) minus value take from the component datum and does not
include any Chamfer or Radius values added latter in the programming.

Width of Groove at Top

= WT 30.000
Press the WT touch screen key to
change display to Top Groove
Width data input screen
Input Top Goove Width 30.000
Press Input key on keypad to
register top groove width and
change display back to main
Data Input screen

Width of Groove at Bottom

= WT 20.000
Press the WT touch screen key to
change display to Bottom Groove
Width data input screen
Input Bottom Goove Width
30.000
Press Input key on keypad to
register bottom groove width and
change display back to main
Data Input screen

NOTE! The bottom width of the groove is always equal-distant about the top width.
123

WB

WT

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Groove Height 2 = H 2 5.000
Press the H2 touch screen key to
change display to Groove Height
2 data input screen
Input Goove Height 2 5.000
Groove Height 2 is always to the
RIGHT of the groove form.
Press Input key on keypad to
register groove height 2 and
change display back to main
Data Input screen
NOTE! Two heights are possible to allow grooves to be produced on a stepped component.
When producing a standard groove the H2 and H1 (see below) should contain the same value.

H2
H1 H1 H2

Groove Height 1 = H 1 5.000

Press the H1 touch screen key to
change display to Groove Height
2 data input screen
Input Goove Height 1 5.000
Groove Height 1 is always to the
LEFT of the groove form.
Press Input key on keypad to
register groove height 1 and
change display back to main
Data Input screen
With all the data on this screen complete, Press (TAB) to move to the next Data Input Page:
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Top of Groove
Select or (Radius or Chamfer) prior to inputting the values:

Selecting R or C defines the first

screen data input key.
Selcting R sets the key as Rt

NOTE: Different values / form

types cannot be selected for
each side of the top of the
groove.

Groove Top - Radius = Rt 5.000

Press the Rt touch screen key to
change display to Goove top -
Radius data input screen
Input Radius 5.000
Press Input key on keypad to
register Radius and change
display back to the Data Input
screen

Bottom of Groove
Select or (Radius or Chamfer) prior to inputting the values:

Selecting R or C defines the

second screen data input key.
Selecting C sets the key as Cb

NOTE: Different values / form

types cannot be selected for
each side of the top of the
groove.

Groove Bottom - Chamfer

= Cb 3.000
Press the Cb touch screen key to
change display to Goove bottom
- Chamfer data input screen
Input Chamfer 5.000
125

Press Input key on keypad to

register Radius and change
display back to the Data Input
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Finish Allowance = fa 0.100
Press the fa touch screen key to
change display to Finish
allowance data input screen
Input finish allowance 0.100
The finish allowance is a constant
value around each section of the
groove form.
Press Input key on keypad to
register finish allowance and
change display back to the Data
Input screen

Peck Depth = Pd 2.000

Press the Pd touch screen key to
change display to Peck Depth
data input screen
Input Peck Depth 2.000
Press Input key on keypad to
register peck depth and change
display back to the Data Input
screen

With all the data on this screen complete, Press to return to the mainData Input Page.

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Once all data has been input
Press the screen key ‘ to confirm all the data input and return to the Operation review screen
with the new data registered to memory:

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To activate the operation
Start the spindle and set the spindle speed required.
Select the -X key to activate the cycle:

The following screen will now appear:

Wind the tool towards the

position shown on screen.

NOTE: The cycle will engage

within a + / - 5mm area of the
actual start point.

When in position the run screen

will reappear.

Engage the feed lever to start the

cycle.

NOTE: There will be a 5 second

dwell (calculation time) between
engagement of the feed lever and
commencement of the cycle.

The tool will rapid from the safe start window position to the
exact cycle start point and complete the grooving moves.

NOTE: CONTROL FEED / RAPID SPEED WITH OVERRIDE.

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IMPORTANT! For correct operation of the grooving cycle the tool must be set as follows:
Tool Radius = 0.000
Tool Vector = 3.

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Edit Mode
This option is used for saving and loading operation
to and from the machine's memory, via the RS232
interface and the Alpha Link CAD/CAM system.

It is also used for deleting all or individual operations

from the machine memory.

Edit Mode can only be accessed from the

Manual mode screen

Ensure that the RS232 cable is firmly connected to

the machine and the PC “WWaiting for data... “

“OP SAVE/RESTORE”
SAVE Operation
Setting the PC to receive data from the machine.

Click on the Alpha Link Folder Icon to call the Alpha Link options to screen.

Click the Alpha Utilities icon to display the communication page.

i) Click on to the F1 (File Type) Button...

...to display the directory menu:

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Click on ‘Alpha-Lathe : Man Ops’ - this will hightlight the line:

Then click on ‘OK’ to activate that directory and record it to the window in the top left hand of
the screen:

ii) Click to the F3 ( Receive ) Button to display the Receive File menu

Enter the name of the file to be received into the box:

Then click OK to receive the file.

Receiving... [filename].MOP’ will appear:
The message ‘R
131

The PC is now ready to recieve the file from the Machine...

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Setting up the machine to send data to the PC.
i) Press the Manual screen key to display
the Manual mode screen.

ii) Press the Edit screen key to display the

Edit screen.

OP. SAVE/RESTORE” touch screen key

iii) Press the “O
to change he screen to the communication
direction selection.

iv) Press the ‘Save from machine’ operation arrow

key to open the communications channel
and commence transmission. The arrow key turn
yellow whilst each Op No is tranfered to the PC.

During transmission the message on the screen

will change from “SSAVING OP. 01“,
“SSAVING OP 02“, “SSAVING OP 03“ etc. as
each operation transfer is completed.
After all 25 Op’s have been saved the screen will
revert to the Manual mode screen.
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During transmission the PC will display the transmission as it is recieved and the status bar in the
bottom right will indicate progress as a percentage:

At 100% the message: ‘Receiving... [filename].MOP’ will vanish, leaving just the program on
screen
Exit the page in the normal way by pressing the cross in the top right hand side of the page or
alternatively Click on File(top left hand corner) and EXIT.

RESTORE Operation
Setting up the machine to send data to the PC.
i) Press the Manual screen key to display
the Manual mode screen.

ii) Press the Edit screen key to display the

Edit screen.

OP. SAVE/RESTORE” touch screen key

iii) Press the “O
to change he screen to the communication
direction selection.

iv) Press the ‘Load to machine’ operation arrow key

to open the communications channel
The arrow key will turn yellow indicating the
machine is ready to receive data.
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Set the PC up to send file the file to the machine.

Click on the Alpha Link Folder Icon to call the Alpha Link options to screen.

Click the Alpha Utilities icon to display the communication page.

i) Click on to the F1 (File Type) Button...

...to display the directory menu:

Click on ‘Alpha-Lathe : Man Ops’ - this will hightlight the line:

Then click on ‘OK’ to activate that directory and record it to the window in the top left hand of
the screen:
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ii) Click to the F2 ( Send ) Button to display the full list of the files available.

Click on the file to send - this will hightlight the File name:

Then click OK to send the file.

The file will be seen on screen as it is transmitted and the message ‘SSending... [filename].MOP’
will appear:

At 100% the message: ‘Sending... [filename].MOP’ will vanish, leaving just the program on
screen.
Exit the page in the normal way by pressing the cross in the top right hand side of the page or
alternatively Click on File(top left hand corner) and EXIT.
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During transmission the touch screen will will
display a message that will change from
“LLOADING OP 01“, “LLOADING OP 02“,
“LLOADING OP 03“ etc. as each operation
transfer is completed, until all 25 Op's are
loaded.
After all 25 Op’s have been loaded the screen
will revert to the Manual mode screen

DELETE Operation
Is used to delete data from the Operation memory of
the machine. It can delete:-
i) Individual Operation No's data
ii) All 25 Operations No's data

“DELETE CURRENT OP.”

To delete any individual Operation.
i) Press the Manual screen key

ii) Press the Op's screen key

iii) Cursor to the individual Review screen of the

operation to be deleted.
(For this example - OP. 14)

iv) Press the Manual screen key to return to

the Manual mode screen
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v) Press the Edit screen key to display the
Edit screen.

DELETE CURRENT OP.” touch screen

v) Press the “D
DELETE
key to display the on screen message “D
OP. 14” and display the touch screen keys:

- to confirm deletion.

- to cancel deletion.

vi) Press the ‘tick’ key to return to the Op’s page to

witness the data being deleted from the
operation review box leaving it blank.

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“DELETE ALL OPS.”
To delete all Operations.
i) Press the Manual screen key to return to
the Manual mode screen

ii) Press the Edit screen key to display the

Edit screen.

DELETE ALL OPS.” touch screen key to

iii) Press the “D
DELETE ALL
display the on screen message “D
OPS.” and display the touch screen keys:

- to confirm deletion.

- to cancel deletion.

vi) Press the ‘tick’ key to return to the Op’s page to

witness the data being deleted from the
operation review boxes leaving them blank.
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CAM Mode
The CAM option of the machine gives an alternative
method of producing components. It can produce:-
i) A simple components without using the Stops,
Tapers, box cycles and threads.
ii) A more complex component which otherwise
could not be produced using Stops, Tapers,
Threads, etc.
CAM Menu can only be accessed from the
Manual mode screen

The following instructions only cover how to load and

run the CAM File.

CAM operation
Set up the machine to receive the CAM File Program.

Ensure the RS232 cable is firmly connected to the

machine and the PC

CAUTION
Damage can occur if a serial cable longer than
the one supplied is used to connect the machine
control to a remote computer. The serial interface
used is the industry standard RS-232 and the
specified maximum recommended length of cable
is 15 metres or 50 feet. However with longer lines
and connections between devices that may be on
different electrical busses, there is a much greater
risk of ground loops. These resultant ground loops
can slowly heat the circuits and eventually cause
failure in the remote computer or the machine
ontrol. It is recommended that the ports are
optically isolated if long cables cannot be avoided.
RS-232 optical isolation devices are commercially
available.
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i) Press the Manual screen key to return to
the Manual mode screen

ii) Press the CAM screen key to display the

CAM menu screen.

iii) Press the “LLOAD CAM FILE” touch screen key to

display the communication screen.

iv) Press the arrow key to commence transmission.

Once pressed and during transmission the arrow
key will turn yellow.

Note:
Pressing the ‘Abort’ key (the arrow key in the
bottom left hand side of the screen) will revert the
screen to the CAM Menu Page.

IMPORTANT NOTE:
LOADING MUST BE COMPLETED ONCE STARTED
The ‘Abort’ Key Must Not Be Pressed Once The Arrow
Key has been pressed (turned yellow).
The transmission once started must be completed.
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Set the PC up to send file the file to the machine.

Click on the Alpha Link Folder Icon to call the Alpha Link options to screen.

Click the Alpha Utilities icon to display the communication page.

i) Click on to the F1 (File Type) Button...

...to display the directory menu:

Click on ‘Alpha-Lathe : CAM Progs’ - this will hightlight the line:

Then click on ‘OK’ to activate that directory and record it to the window in the top left hand of
the screen:
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ii) Click to the F2 ( Send ) Button to display the full list of the files available.

Click on the file to send - this will hightlight the File name:

CAUTION - Customers can cause corruption of the software in the Alpha machines:
In every case this is the result of downloading A CAM program, which was not created using the
Alphalink software supplied with the machine.
(If you also own one of the other types of Alpha machines using the Fanuc 21It control, loading
a program from the Alphalink supplied with these machines will also corrupt the macros of this
Alpha machine).
USE ONLY THE PROGRAMS GENERATED ON THE VERSION OF THE ALPHALINK SOFTWARE
WITH THIS ALPHA MACHINE.
(See note on page 144 if you have programs on other versions of the ALPHALINK software that
you wish to use)

Then click OK to send the file.

The file will be seen on screen as it is transmitted and the message ‘SSending... [filename].PRG’
will appear:
142

At 100% the message: ‘Sending... [filename].PRG’ will vanish, leaving just the program on
screen.
Exit the page in the normal way by pressing the cross in the top right hand side of the page or
alternatively Click on File(top left hand corner) and EXIT.
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iii) At the end of the transmission the machine will
revert the CAM menu screen.

Important:
If you attempt to load a inch CAM program into the
machine set in metric values (or metric program to
inch machine) attempting to run this CAM program
will result in the alarm key being shown over the
CAM page.

Pressing this key will result in the alarm screen being

shown, which will display the message:
CAM PROGRAM INCH / METRIC MISMATCH”
”C

i) To clear this alarm switch the machine OFF/ON

ii) The machine must now be changed into the

correct units to run the program, see page 33.

iii) After following the inch/metric change procedure,

the program may now be loaded in the usual
manner.
Important: Changing from inch to metric or metric to
inch will clear all the tool values. All tools must be
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Using Programs from Other ALPHALINK Versions
If you currently own one of the other versions of the ALPHA MACHINES (ALPHA T or early S & U
versions), and have CAM programs you wish to produce on this ALPHA, these files must be
transferred from the ALPHALINK CAD/CAM software supplied with these machines to the
ALPHALINK version supplied with this machine.
This file must then be RESAVED on the relevant ALPHALINK version to produce the CORRECT
PROGRAM FORMAT FOR LOADING TO THE CONTROL FITTED TO THIS MACHINE.

Procedure.
1. Open ALPHALINK version for other machine. (ALPHA T, or early S & U ).
2. Copy To/From Floppy Disc‘ and then
From the Menu Options select ‘C
Copy Drawings from Hard Disc to Floppy Disc’ to transfer the file to floppy disc.
‘C
3. Exit to Dos’)
Close this version of the ALPHALINK. (‘E
4. Open the version of the ALPHALINK software for this machine.
5. Copy To/From Floppy Disc‘ and then
From the Menu Options select ‘C
Copy Drawings from Floppy Disc to Hard Disc’ to transfer the file to Hard disc.
‘C
6. From the Menu Options select ‘A ALPHA CAM Module’, option 1, and use
Retrieve a drawing’ to open the drawing you have just transferred.
‘R
(See your ALPHALINK manual)
7. The drawing will now be viewed on screen.
EXIT DRAWING’ function from the CAM menu.
Resave this drawing using the ‘E
(See your ALPHALINK manual)

Re-saving on this ALPHALINK version of the CAM system has now produced the correct program
format type for use on this machine.
FAILURE TO RESAVE THIS PROGRAM TO THE CORRECT FORMAT TYPE PRIOR TO LOADING
TO THIS MACHINE WILL CAUSE CORRUPTION OF THE MACHINE CONTROL MACROS.
If this occurs the Macros will need to be restored as detailed in your ALPHALINK manual.
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Running the machine
Press the CAM screen key to display the
CAM menu screen.

There are 2 methods of running the machine

1. “ RUN EXISTING FILE SINGLE OP.”
In this mode the slide will stops after each block
of information, rapid move or feed move. With
the message “PPRESS RAPID TO CONTINUE” or
ENGAGE FEED TO CONTINUE”. This mode is
“E
used for checking out a cycle component.

2. “ RUN EXISTING FILE AUTO CYCLE“

Where the slide moves in full automatic cycle. It
will only stop when it sees a Tool Change.

i) Select option 1 or 2 as required

by pressing the relevant touch
screen key.
The display will change to show
the CAM program screen.

Follow the sequence of

instructions and messages
displayed on the screen.

ii)
The cycle will progress through
the program until it sees a tool
change, the program will then
stop. The T key will turn yellow
and the screen will display the
messages:
“PPRESS ENTER TO RE-RUN”
and
ENGAGE FEED TO CONTINUE“
“E

Note:
145

Pressing the Reset key will revert

the program to the beginning of
the program.

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iv) Physically change the Tool and Press the T key.
Type in the new Tool number and press Enter
on the numerical keypad to confirm to the
selection.

v)
The message:
HOLD RAPID KEY” will appear.
“H
Press and hold the Axis Rapid Key
down to advance the slides forward
to the component.
The Feedrate Override can be used
to control the speed of the slide
movement)
The message:
ENGAGE FEED LEVER” will
“E
appear.
Engage the Feed lever to continue
the cycle.

iv) At the end of the complete cycle the screen will

display the messages:
END OF CAM FILE. PRESS RESET TO RERUN“
“E
OR ARROW BACK TO CAM MENU“
“O

Exiting during a program

Press the Reset key on the keypad.
Wait 5 seconds and then press the arrow key in the
bottom left corner of the screen.
This will return the machine to the CAM menu
screen.
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Starting the machine in the middle of a program
In the event of a tool breakage during a machining
operation it is an advantage to recommence the
machining operation at the nearest convenient point
to where the tool stopped cutting, ie. the start of that
particular pass.

i) Return the machine to the CAM menu screen.

(see page 139 if currently still in CAM program
screen.)

Important:
A step through procedure can be performed at
any time. Before commencing a step through
procedure, first select the Tool which is to be
used at that position.

ii) Press the Manual screen key to display

the Manual mode screen.

iii) Press T and select the tool number required at

the restart position.
(Physically change the Tool if necessary at this
point)

iv) Press the CAM key again to display the

CAM menu screen.

Press the screen key:

SELECT PASS (SELECT TOOL 1ST)
This will turn the button yellow confirming the
selection is active.
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vi) Press the screen key:
RUN EXISTING FILE AUTO CYCLE
To display the CAM program screen along with
the messages:
“PPRESS ENTER TO STEP THROUGH“
and
“EENGAGE FEED TO START PROGRAM“

vii)
Press the Input key on the
numerical keypad to advance
through the program. At each press
of the Input key the program will
scroll forward updating the display
for each pass.

On reaching the recommencement point required:

viii) Close the sliding guard
ix) Engage the feed lever to
recommence the cycle
and follow the on-screen messages:
If the tool is already within it’s ‘start
window’
HOLD RAPID KEY“
“H
Or if the tool is not within it’s ‘start
window’
WIND TOOL TO START POSITION”
“W
followed by
HOLD RAPID KEY“
“H
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x) The cycle will now recommence from the

selected point.
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