WinCNC_V1.12_V8 Operating manual.pdf

OPERATING MANUAL

FOR eWinCNC V1.12

------------------------------------------------------------------- ------------------------------------------------------------------- REGD. OFFICE : WORKS : MARKETED BY ELECTRONICA MACHINE ELECTRONICA MACHINE ELECTRONICA MACHINE TOOLS LTD. TOOLS LTD., TOOLS LTD., ELEKTRA HOUSE, 691/1 A, SASWAD, ELEKTRA CHAMBERS,44, PUNE SATARA ROAD, TAL. : PURANDHAR MUKUND NAGAR, PUNE - 411037 (INDIA) DIST. : PUNE - 412301 (INDIA) PUNE -411037. (INDIA.)

D:01:278:05:08INDEX

eWinCNC Help Index Menu Page No

1. Operations 1.1 2. Manual Operation Modes 2.1- 2.7 3. Automatic Operation Modes 3.1-3.5

4. Programming Instructions 4.1-4.7 5. List Of Messages 5.1-5.10

6. Short Keys 6.1- 6.3

7. Terms 7.1

8. Installation Procedure 8.1- 8.5

9. Machine ID generation procedure 9.1-9.6 10. Annexture

This Manual provides guidance in brief for the operations of eWinCNC. It should be used in conjuction with eWinCNC Help. For detailed operational instructions please refer to ON-line or Off-line eWinCNC Help.

ELECTRONICA MACHINE TOOLS LTD. PAGE : 1 - 1

CHAPTER 1

Operations This chapter introduces you to the controller of ELEKTRA Wire EDM machine. You can interact with the machine either through the Machine Control Panel or through keyboard & mouse attached with the controller. The machine will interact with you with the help of the display. The display is situated at the top of the interface panel. It shows the status of all the operations taking place on the Machine tool.

It Contains topics such as

1. Getting Started

2. Screen Layout

The entire screen is divided into following areas.

Menu & Toolbar Many operations can be performed using them. Status Display Area Displays status parameters, position & flags. Profile Display Area Profile display is the area where user can get the

profile of currently downloaded program to controller.

Block display (Optional) Display executing block while running the program Message & alarm Here controller will display the messages, warnings, and errors Function key panel To perform function on cnc operations. Status Bar Status bar is the bottommost area of the screen.

Display few status information & tool tips

ELECTRONICA MACHINE TOOLS LTD. PAGE: 2 - 1

CHAPTER 2

Manual Operation Modes operation modes are the first available modes after loading the

application. operations give you the functions required to perform machine

commands of jogging, machine referencing, switching ON/OFF conditions, etc.

Following modes come under manual operations:

2-1 Main mode

2-2 JobSet mode

2-3 DrySpk mode

2-4 Coord mode

2.1 Main mode: (Alt + F1)

Main mode includes function key set as follows

Function Key Set :

Buzzer (F1): This key is used to toggle [Buzzer] flag ON/OFF.

Contact (F2): This key is used to toggle [Contact] option ON/OFF.

Cut (F3): This key is used to cut the wire.

Thread (F4): This key is used to thread the wire.

S-AWT (F5): This key is used to thread the wire manually through workpiece

and lower wire sense position.

AWT (F6): This key is used to enable/disable the Auto Wire Threading

operation .

FillTnk (F7): This key is applicable only for Submerge M/c to fill the tank with

coolant.

DrnTnk (F8): This key is applicable only for M/c with submerge facility to

remove the coolant from tank.

Flush (F9): This key is used to switch the flushing system ON/OFF.

WFWT (F10): This key is used to switch the Wire feed and Wire tension

ON/OFF.


Halt (F11): This key halts the current operation.

In Main mode, Jog Mode dialog is displayed as shown below.

From this dialog user can do the Jogging, Machine referencing, Jog Zero &

Prejog operations.

2.2 JobSet Mode ( Alt + F4 ) Workpiece used in manufacturing has to be referred either from an edge or from

center of a hole. Function of mode is to find the edge of the workpiece or

the center of the hole. stands for EDGE FIND and CENTER FIND

Operation Before machining, one also needs to make the Wire exactly vertical. Auto

Wire Verticality facility (abbreviated as [AWV]) is also provided in the same mode.

This mode also provides Workpiece Rotation angle calculation mode.(as AlignEF,

AlignCF)

2.2.1 EF Mode

2.2.2 CF Mode


2.2.3 3PtCF Mode

2.2.4. Align

2.2.4.1 AlignEF Mode

2.2.4.2 AlignCF Mode

2.2.5 AWV Mode

2.2.6 EFVolt

2.2.7 SLimit

2.2.1 EF Mode(F1)

EF Function Key Set: EF (F1) To find Edge along the path in the direction of selected angle.

SetHalf (F7) This function key is used for HALF FUNCTION. This key is used

to make axis coordinates half of their current value.

Set (F8) To set the coordinates of current WCS to any value.

Zero (F9) To set the coordinates of current WCS to zero.

Prmtr (F10) This key pops up a dialog that lets you to set the edge find Mode

(Fast / Slow).

Halt (F11) To stop the Edge Find (EF) operation.

Prev (F12) This key is used to switch to the JobSet mode key set.

2.2.2 CF Mode(F2)

CF Function Key Set:

CF (F1) To find center along the direction and angle selected in Center

Find Angle selection dialog.





(Fast / Slow).

Halt (F11) To stop the Edge Find (CF) operation.


2.2.3 3 PTCF Mode(F3)

3 Pt.Center Find Function Key Set:

EF1 (F1) To find Edge-1 along the path in the direction of selected angle.



GoCntr (F4) Jog to the calculated center find position.




(Fast / Slow).

Halt (F11) To stop the 3Point Center Find (CF) operation.


2.2.4 Align Mode This mode is used to calculate work piece rotation angle. Screen shows Align point

1, Align point 2, Calc. WCS Align angle, distance between two points (Align point 1 &

Align point 2) & Set Align angle. When you are out of this mode (Align mode) after

carrying out Align point 1 or Align point 2 or both operation earlier, then while

entering in to this mode again it will ask you whether to clear previous readings.

Align Mode is divided in two parts

2.2.4.1 AlignEF Mode

2.2.4.2 AlignCF Mode


2.2.4.1 AlignEF Mode(F4)

AlignEF Function Key Set:



ALIGN (F4) To make the Align ON / OFF.

DIAL (F6) Use to find the Align angle by using Dial without doing edge find

operation.



Prmtr (F10) This key pops up a dialog that lets you to set the Align Angle &

Mode Parameters.

Halt (F11) To stop the AlignEF operation.


2.2.4.2 AlignCF Mode(F5)

AlignCF Function Key Set:

CF1 (F1) To find Center-1 along the path in the direction of selected

angle.

CF2 (F2) To find Center-2 along the path in the direction of selected

angle.

ALIGN (F4) To make the Align ON / OFF.

DIAL (F6) Use to find the Align angle by using Dial without doing edge find

operation.



Prmtr (F10) This key pops up a dialog that lets you to set the Align Angle &


Mode Parameters.

Halt (F11) To stop the AlignCF operation.


2.2.5 AWV Mode (F6) A dialog has been displayed for AWV mode, which contains mode selection for

following three operations

AWV Mode: To make the wire vertical

AWV-Jig: To make the wire vertical

Guide Span and Worktable Height CalculationTo calculate the Guide

span & Worktable height.

2.2.6 EFVolt (F7)

EFVOLT key is used to select high or low voltage for spark during JobSet &

Dryspark Operation.

2.2.7 SLimit (Soft Limit) (F9)

SLIMIT is used to set software over travel limits for X & Y axis.

2.3 Dry Spk mode: (Alt + F5)

This mode is used for making the wire vertical with the help of verticality block so

that during cutting the sparking will be uniform along the workpiece height. If required

you can also make wire parallel to workpiece surface.

Dry spark mode includes function key set as follows

Function Key Set:

X+ (F1) To find edge on X -axis in positive direction.

X- (F2) To find edge on X -axis in negative direction.

Y+ (F3) To find edge on Y -axis in positive direction.

Y- (F4) To find edge on Y -axis in negative direction.

U+ (F5) To move U-axis in positive direction.


U- (F6) To move U-axis in negative direction.

V+ (F7) To move V-axis in positive direction.

V- (F8) To move V-axis in negative direction.

Prmtr (F9) This key pops up a dialog that lets you to set the WF, WT

& Jstep parameters.

EFVolt (F10) EFVOLT key is used to select high or low voltage for

spark during JobSet & Dryspark Operation.

Halt (F11) To stop the Dry spark operation.

2.4 Coord Mode ( Alt + F6 )

Coord mode includes function key set as follows

Function Key Set:

G54 (F1)

G55 (F2)

G56 (F3)

G57 (F4)

G58 (F5)

G59 (F6)

To select one of the six WCS (Work Co-ordinate Systems).

G92 (F7) To set global offset, so that ORIGIN Point for all WCS can be

shifted from its current position by that offset.

SET (F8) To set the coordinates of current position to any value for

selected WCS.

ZERO (F9) To set the coordinates of current position as Zero position for

selected WCS.

Halt (F11) To Halt operation.


CHAPTER 3

Automatic Operation Modes

3.1 Set M/c mode

3.2 Run mode

3.3 Status mode

3.4 Setup mode


3.1 Set M/c Mode (Alt + F7)

Set M/c mode includes following options as follows

TON Pulse ON time setting

TOFF Pulse OFF time setting.

IP Fine Pulse & Power Pulse setting

VP To set Pulse peak voltage.

WP To set Programmable Submerge mode & Dielectric pressure.

WF To set Wire Feed Rate

WT To set Wire tension

SV To set Spark gap reference voltage.

SF To set Servo Feed Rate.

CS % To set cutting speed override.

CC% To set Corner control

CDwell To set Corner dwell

SC To set the Conductivity value.


3.2 Run Mode (Alt + F8).

Run mode is used to check the loaded profile by Dry run facility and to cut the profile.

Run mode includes two-function key set as follows

Function Key Set 1:

Start (F1) : To start the cutting or Dry run of the programmed job.

Dry (F2) : To switch the Dry run facility ON/OFF.

Step (F3) : To switch the STEP Mode ON/OFF.

Hold (F4) : To hold all the axes that are moving.

MidStart (F5) : To switch the Midstart mode ON/OFF.

PreSpk (F6) : To switch the PreSpk mode ON/OFF.

MDI (F7) : To execute single line program.

Abort (F8) : To stop the sparking & execution of program.

Noman (F9) : To switch on Noman level.

Goto Start Point (F10): Move to the start point of cavity.

Halt (F11) : To halt running program.

More (F12) : To go to function key set 2.

Function Key Set 2 :

Skip / (F1) : To switch the Skip facility ON/OFF.

OStop (F2) : To switch the program stop functionality ON/OFF at M01.

F% (F3) : To override the Dry run feed in terms of percentage.

Set (F4) : To set the origin of active WCS.

Zero (F5) : To set the selected WCS to ZERO & switch OFF all

transformations.

Timerst (F6) : To reset the timer which counts the machining time.

Align (F7) : To switch Align Mode ON/OFF

Halt (F11) : To halt running program.

Prev (F12) : To go to function key set 1.


3.3 Status Mode (Alt + F9)

This mode displays the current status that includes various flags, G and M codes that are

active while the program is running. Status mode includes function key set as follows

Function Key Set:

GMCODE (F1) This screen displays all the G and M codes. Currently active or

executing codes are highlighted and all others are displayed in

normal intensity. This helps user to note the status of various

codes at a glance.

FLAGS (F2) The flag status screen displays ON/OFF state & values of

various controls, functions & parameters

IOSTAT (F3) The Input and Output line status is displayed portwise in this

screen. This is used mainly for the diagnostic and

troubleshooting purpose.

DIAG (F4) DIAG screen describes the current position in terms of

ABSOLUTE MACHINE coordinates. It displays the Global (G92)

offset and origin of currently active WCS. It also displays the

actual coordinates of all axes and commanded and goto

coordinates of X, Y, U, V and Z-axes. In addition it shows

Following Error and Velocities of X, Y, U, V, Z and W axes.

Maintain (F5) Maintain screen displays routine maintenance required for

P.F.Unit.

CONSUM (F6) CONSUMABLES screen shows Total & Remaining life of

consumable components of the M/c.


3.4 Setup mode (Alt+F10)

The Setup mode allows you to set various machine related parameters.

Setup mode includes function key set as follows

Function Key Set:

USER (F1)

Fact. (F2)

PERR (F5) This is the table provided for setting the values, which can

be used for Pitch Error compensation.

Pass. (F6) To set the password. (Refer chapter Machine ID generation

procedure while setting password)

Default (F7) Load the default parameter given from Factory. After pressing

this key all user parameter gets overwrite.

Factory setup contains the parameters, which are set in Factory. User is not allowed to

change these parameters.

User Setup and factory setup contains following key set :

MOTOR (F1) Motor setup values are factory set, and they should not be

changed unless there is a change in hardware or any other major

modifications. User is not supposed to change these values.

MCH (F2) This mode is to set the values concerned with machine tool.

FLAGS (F3) This mode is used to set the Flag in machine.

AWT (F4) This mode is used to AWT related parameters.


CHAPTER 4

Programming Instructions

1] G Code Programming Instructions

G0---G9

G20---G29

G40---G49

G50---G59

G70---G79

G90---G99

G100---G103

2] M Code Programming Instructions

M0---M9

M20---M29

M90---M99


PROGRAMMING INSTRUCTIONS

This chapter explains the CODES (or COMMANDS) used in creating the NC

Program with their applications and examples. It explains all the necessary terms

and definitions that are frequently used in connection with a NC program.

MOTION PROGRAM FOR A CNC MACHINE

Computerized Numerical Control (abbreviated as CNC) machine understands a

group of commands, which are called motion codes or simply G-Codes and M-

Codes. The sequence of these commands in a particular syntax is called NC

PROGRAM. This NC PROGRAM changes with the size and shape of a Part to be

cut. Hence it is also called PART PROGRAM. The codes and commands of the NC

PROGRAM are converted into machine movements and/or settings inside the

controller, which in turn produces the component according to the NC PROGRAM.

As the major function of this NC Program is to maneuver the machine table

movements it is also called MOTION PROGRAM. In this manual the terms NC

PROGRAM, PART PROGRAM and MOTION PROGRAM are used interchangeably.

This Manual explains all the G, M and E codes used in ELPULS-50 controller

Mastering these codes and formats will help you to exploit the power of the machine

to the fullest extent.

Structure of a NC Program

Any NC Program is divided into number of Blocks. A BLOCK is further divided into

number of Words. A WORD is an ADDRESS (an ALPHABET from A to Z) followed

by a EXPRESSION or a VALUE (positive or negative) associated with it. A WORD

can be classified as CODE (or COMMAND) and PARAMETER. Any WORD with

ADDRESS 'G' or 'M' or 'E' is treated specially as CODE. All other Words are treated

as Parameters and are used along with the Codes. Codes with similar functions are

associated to form a GROUP. A block cannot have two Codes from a same GROUP.

In such a condition Group Clash occurs and Error is generated. Some codes are

STAND ALONE type of codes. Any Block can Contain one and only one Stand Alone

code in it.

Two characters are treated very specially by the controller. They are '/' and ';'. Block

beginning with '/'will be skipped by the controller if the SKIP b lock feature is turned

ON. Any Text after ';' in a Block is always ignored by the controller, so that you can

write your own notes, comments after this. Part of a NC Program is shown below as


an Example:

Program for cutting Die plate

G54 G0 X0 Y0 G1 Y5 X5 Y10 X-5 Table 4.1 : List of valid addresses. ADDRES

S USED IN

RANGE

REMARKS

A G51,G52 0-360

Taper Angle

G26 0-360 Rotation angle

B G74 0-Top height Height where Bottom Profile is defined.

D Expr,G41,G42 0-9

Wire comp. Offset value

E ECodes 1-9999

Machining Cond,ECode

G GCodes 0-103

Preparatory Code

H Expressions 0-99

Scratch Pad variable

I G2,G3 -99999.9999

Offset of centerpoint from current position

J G2,G3 +99999.9999 Offset of center point from current position

L M98 1-99 Subroutine Loop count

M Motion Prog 0-99

Machine Codes

N All Blocks 1-9999

Block number

P M98 1-999 Subroutine Program number P G102,G103 -99999.9999

Offset of center point from current position.

Q G102,G103 +99999.9999 Offset of center point from current position.

R G48,G1,G2,G3 0.005-99999.9 0.005-99999.9

MODALCorner radius rounding Corner radius for rounding at the end of the block

T

G4 0-99 Dwell in seconds

G74 Not Applicable

Height where Top profile is defined.


ADDRESS USED IN

RANGE

REMARKS

U V

G0, G100, G101, G102,G103

-99999.9999 +99999.9999

Coordinates of the end point to be reached.

G29 -99999.9999 +99999.9999

Coordinates of Ref. point

G92 -99999.9999 +99999.9999

Global offset

G92-G54to G92-G59

-99999.9999 +99999.9999

Change the WCS Origin so that current point has specified coord.

W

G51,G52 0-Z Position

Programmed height

X Y

G0, G1, G2, G3

-99999.9999 +99999.9999

Coordinates of the end point to be reached.

G26 -99999.9999 +99999.9999

Coordinates of the point about which to rotate

G29 -99999.9999 +99999.9999

Coordinates of Ref. point

G92 -99999.9999 +99999.9999

Global offset

G92-G54 to G92-G59

-99999.9999 +99999.9999

Change the WCS Origin so that current point has specified coord.

Z

G51, G52, G74 0 - 99999.99

Z Height


Table 4.2 : List of G Codes, Short Summary GCODE PARAMETERS EFFECT, STAND

ALONE?

GROUP

APPLICATION

0 X Y U V Modal, NOT STAND ALONE

A Rapid Traverse

1 X Y R Modal, NOT STAND ALONE

Linear interpolation

2 X Y I J R NonModal, NOT STAND ALONE

CW circular interpolation

3 X Y I J R NonModal, NOT STAND ALONE

CCW circular interpolation

5 NONE Modal, STAND ALONE B X Mirror

6 NONE Modal, STAND ALONE Y Mirror

8 NONE Modal, STAND ALONE X-Y Exchange

9 NONE Modal, STAND ALONE Cancel all Mirror or Exchanges

95 NONE Modal, STAND ALONE Simultaneous X-Y Mirror

96 NONE Modal, STAND ALONE Cancel all Mirror or Exchanges

13 NONE Modal, STAND ALONE

C Ref. return ON


Ref. return OFF


Stored stroke Limits ON.


Stored stroke Limits OFF.

26 X Y A Modal, STAND ALONE

D Pattern rotation ON


Pattern rotation OFF


E Reference point return

29 X Y U V Modal, STAND ALONE Remember Ref. point

40 NONE

Modal, STAND ALONE F W.D.Comp. OFF

41 D Modal, STAND ALONE W.D.Comp. LEFT

42 D Modal, STAND ALONE W.D.Comp. RIGHT

48 R Modal, STAND ALONE G Const. Corner radius ON


GCODE PARAMETERS EFFECT, STAND

ALONE? GROUP APPLICATION

49 NONE Modal, STAND ALONE G Const. Corner radius

OFF

50 NONE Modal, STAND ALONE H Taper cutting mode OFF

51 A W Z Modal, STAND ALONE Taper cutting mode (LEFT) ON

52 A W Z Modal, STAND ALONE Taper cutting mode (RIGHT) ON

53 G Modal, NOT STAND ALONE

I Absolute M/c Ref.


Activate WCS or Define WCS origin









59 G Modal,NOT STAND ALONE


70 NONE Modal,STAND ALONE J Dimensions in mm

71 NONE Modal, STAND ALONE Dimensions in Inch

74 B T Z Modal, STAND ALONE K Complex machining mode ON

75 NONE Modal, STAND ALONE Complex machining mode OFF

90 NONE Modal, STAND ALONE L Absolute program mode

91 NONE Modal, STAND ALONE Incremental program mode

92 X Y U V Modal, NOT STAND ALONE

M Def.Global offset

100 U V Modal, STAND ALONE Rapid traverse for UV table, Complex cutting mode


101 U V Modal,STAND ALONE N Linear interpolation for

UV table, Complex cut. Mode

102 U V P Q Modal, STAND ALONE N CW Circular interpolation for UV table,Complex cutting mode

103 U V P Q Modal, STAND ALONE CCW Circular interpolation for UV table,Complex cutting mode

4 T NonModal, STAND ALONE

O Dwell in seconds

46 NONE MODAL , STAND ALONE P CRK Enable

47 NONE MODAL , STAND ALONE CRK Disable

Table 4.3 : List of M Codes, short summary MCODE PARAMETERS

APPLICATION

0 None

Program stop

1 None

Optional stop

2 None

Program end

6 None

Index the Rotary Table

20 None

Cut the Wire

21 None

Thread the wire

98 P,L

Call subprogram

99 None

End sub-program


CHAPTER 5

List of messages

LIST OF CONTROLLER MESSAGES :

List of Simulator's Messages.

McCond Table Not Found.

The specified machining condition given by E code does not exist .It has to be

set, saved and then can be used.

Const.R in arc-invalid.

Code not allowed in MDI.

Error in Z / W / B / T.

Error Start Corner Rad.

Error End Corner Radius.

Error (CT xxxx).

Corner Rad. too Small.

Complex Not Intersect.

Addnl.Block Insert Fail.

Error!!!

This error displays in following cases.

1. If stroke limit error occurs.

2. If Guide Span + Z height is less than or equal to worktable height for

complex & taper programs.

Lxxx : CRK distorted original profile

Where Lxxx specifies the line number in which the error has occurred.

List of Controller's General Messages

Controller SYSTEM Software Checksum Failed.

Switch off the Machine and Download System again using key 2/3.

Controller PROM 1.15E version required. Switch off machine, Change PROM

Chip. Download System again Using 2/3

Controller not Found !

Controller hardware problem, Contact EMTL.

Communication Link Failure (mode latter)..


Internal system communication error.

Controller Software version old.

Controller FIRMWARE checksum failed. Contact ELECTRONICA

Missing GLib and/or MLib at PMAC.

Terminating CNC...

Pitch error table MISSING, press key to Download....

1000 Sparking hours! It's Time for Preventive maintenance.

This is a warning that 1000 sparking hours completed.

Time for preventive maintenance.

1. Cleaning of filter housed in panel cooler.

2. Check that all Fans are working.

3. All fuses, connectors are tight enough.

4. Clean head of floppy disk drive by head cleaning diskette.

5. Greasing of all L-M guides.

Can't do. Program is running.

CRK has distorted original profile, Press key.

This message appears when selected Program is downloaded to the

controller in which, because of application of Radius correction (CRK) factor

profile distortion is occurred.

Reading Downloaded Program ...

After power up the previously downloaded NC program is being read in the

controller's memory

Wire Break...Press any Key.

Wire break encountered at the M/c tool. Acknowledge the same with a key

press at the controller keyboard.

Servo overload, RESET Drive.

Servo Drive Fault has encountered, cannot continue unless the RESET

operation is done.

X Positive Software Limit Reached..

X Negative Software Limit Reached..

Y Positive Software Limit Reached..

Y Negative Software Limit Reached..

U Positive Software Limit Reached..


U Negative Software Limit Reached..

V Positive Software Limit Reached..

V Negative Software Limit Reached..

The axis has crossed the Software Stroke Limit set in the SETUP mode;

Software stroke limits can be disabled giving G23 code from MDI

Program aborted and rewound..

Running program halted, spark off, and program rewound so program will

start from the beginning.

M/c Referencing in progress...

Selected axis Homing is in progress

Program Halted.

Program stopped and can be continued from the same position.

Program Hold.

System is in hold condition; the operation can be continued with Start key

Step Mode - Program Halted..

Program halted in single step mode, can be continued with Start key

Electrode Workpiece Short! Press Key.

EW short detected when contact sensing enabled.

Running..

Currently loaded program is running at the machine

Program End ..

Program end has encountered and Program is automatically rewound and

actions like spark off, flushing off, wire feed/tension off, table movements

stop are taken. Start key restarts the operation from beginning of program.

X Axis Negative Travel Limit Reached..

X Axis Positive Travel Limit Reached..

Y Axis Negative Travel Limit Reached..

Y Axis Positive Travel Limit Reached..

U Axis Negative Travel Limit Reached..

U Axis Positive Travel Limit Reached..

V Axis Negative Travel Limit Reached..

V Axis Positive Travel Limit Reached..

Z Axis Positive Travel Limit Reached..


Axis travel limit is reached, move the axis in opposite direction to get out of

this.

DWELL in Progress......

The system is in dwell status for specified time

Downloading program, Please wait !!!

Selected program is downloading to the controller, please wait

No Program Downloaded! Press Key.

Start key is pressed without downloading the NC program; no start operation

can be done.

Running program is going to be KILLED.

Please download running program again.

Due to some changes made in the machine parameters the downloaded

program becomes invalid and it is being erased from the system.

AL723SYS.PMC File Not Found..

AL723FLX.PMC File Not Found..

Very important system software file is corrupted, install software and then

operation should be continued.

Unable to open pitch error file.

Pitch error compensation file corrupted.

Can not PreSpark.

Prespark is allowed only after program halt due to M0.

PreSpark Mode can NOT be turned OFF.

Once machine is forced in prespark mode by user, prespark cannot be turned

off. The only way to turn prespark off is to abort program.

Restoring conditions

This message indicates 'E' code execution is over.

Power Disturbance ...Program Hold.

It is an indication of a power supply fluctuation. Machine momentarily waits

and resumes if normal power conditions are restored.

Program Buffer Full...Press Key

Controller is out of memory because program is too large.

PMACRSET.DAT File NOT Found..

PMACIFLX.DAT File NOT Found..


PMACINIT.DAT File NOT Found..

Very important system file is corrupted.

M/c Reference related messages:

1. Message Do M/c Ref for ... ... Axes, Press Key as specific axis related

message, eg. Do M/c Ref for X, Y, Z Press key... depending on which

axes require referencing.

2. Message ...axis M/c Ref Fail, set Limit-ABS dist, Press key... as specific

axis related message, eg. X axis M/c Ref Fail, set Limit-ABS dist....

In reference, table sense limit & try to find ABS, if it gets ABS between 1

mm.to 4mm. from limit then only M/C reference is successful.

PROGRAM NUMBER LOST...

PROGRAM ABSENT, (Err595)...

Program number internally stored is lost or misreported. Re-cycle power

supply and recheck, if the condition persists, report EMTL.

WARNING : Negative radius

The taper cut in the circular block is causing XY table and UV table to move in

opposite direction. This is due to higher taper angle. You may use constant

radius to solve this problem if it is allowed in the application.

MCP Not Found

If ELC-304 card is not present or faulty.

WCS Origin inconsistent, Press key...

If stored data of WCS is corrupted.

Table NOT In-Pos. Set/Zero failed.

If table is moving & operator tries to set co-ordinates. It is not allowed.

Program will be aborted, if exists.

Servo Trip, RESET Drive...

Due to over speed, servo trips, reset it.

Prejog all axes before START, Press key.

If operator halts a program & moves the table from it's programmed path and

presses Start key.

Z Axis Position incorrect, Press Key.

In case of tapered and complex profiles if difference between Z axis position

and Z axis GOTO position is greater than Z tolerance specified in SETUP.


Reseting NOMAN mode...

On selecting NOMAN mode if a program is running and wire breaks or limit is

sensed, key sense for 3 minutes, if within these three minutes operator press

a key NOMAN mode gets reset.

M/cRef aborted, Lift Quill, press key.

In 7** series M/C, it is a software interlock to prevent quill accident. When

this limit operates then only referencing is possible.

NOMAN active, Press key to continue..

It is an indication of activated NOMAN mode & after 3 minutes M/C will be

turned OFF.

Enable pitch error table?

This indicates the operator that the pitch error table is disabled. It also asks

whether it should be enabled. It should normally be enabled. It can be

enabled or disabled from the SETUP.

Exprn. evaluation error.

The entered expression is not proper or is evaluated to a wrong value that is

not allowed.

Run Time Error, Halt! Press Key.

Program is halted due to some runtime error.

Please wait, Confirming program absence

Save pitch error table?

Download pitch error table?

Start M/C Ref ?

PERR downloading FAILED, press key.

Downloading pitch error compensation.

Battery voltage low !!!!

Filter life over , change it and reset life in status

Resin life over, change it and reset life in status

Wire guides life over , change it and reset life in status

E-W Short, Operation Aborted ! Press Key.

Safety Cover Open, press key.

Program Halt, Wire Brake in Outlet, Press Key.

Program halt by Flush Off, Press Key.


Program Halted due to Gap Short.

NIR Temp. High.

Filter Pressure Crossed Limit, Replace It.

Entering deadlock.

Power recovered.

Bringing axes in closed loop.

All PLCs enabled.

Bringing all axes in closed loop.

All axes are in closed loop.

Start command issued.

Do M/cRef for Axes.

Is Wire Normally vertical?

Axes at PreSpark target position?

Kill program?

Abort Current Run Program?

Reset time?

Program not downloaded.

Switching OFF Machine.

Currentpickup life over, change it and reset life in status

Installation completed successfully !!!

Power fail position not saved.

Initializing System Transformation..Wait

WCS Orgin inconsistent.

Machine Stop.

Clear previous 3pt center find settings?

Set calculated WCS angle ?

Angle Calculation Error ! Aln Pt1 & Aln Pt2 angles are different.

Edge find failed,clean workpiece, press key.

Clear Previous Settings ?

Messages related to AWT operation:

Clamp miss Error

This message is displayed if the wire clamp fails to hold the wire properly


before cutting the wire.

Failed to cut the wire.

If cutter failed to cut the wire, this message gets displayed

Cutting over.

Indicates the wire cutting operation is over.

Retracing sparking path.

After threading the wire through wireguides and work-piece after wire break

condition, wire traces the path upto the position where wire had broken.

During this operation this message is displayed.

Failed to thread upto upper guide.

Wire failed to reach upto upper wire guide within specified time (First insertion

time) due to some obstacle.

Failed to thread upto lower sense.

Wire failed to reach upto lower assembly within specified time (Third insertion

time) due to some obstacle.

Failed to thread upto workpiece.

Wire failed to reach upto workpiece within specified time due to some

obstacle.

Wire blocked in outlet.

Wire stucked in between lower assembly and bin sense.

Threading Successful.

Wire threading completed successfully.

Moving to jet vertical.

Z axis is moving towards the jet so that Z-axis will be vertically aligned above

the jet.

Wire spool empty, prog halt, press key.

This message is displayed if the wire bobbin becomes empty.

Lower Sense, Wire blocked in outlet.

There is wire in the lower assembly.

Wire stucked in outlet OR Water conductivity high.

Wire is blocked in the lower assembly or water conductivity is increased.

Wire idling in progress.

After cutting the wire, the wire remained between lower assembly and bin


sense is being pulled out of assembly.

Wire Blocked at Cutter, Program Halted! Press Key.

Wire is blocked in spring or near Cutter.

Program Halt, Threading Retries Over, Press Key.

As Threading Reties are over & as Handling retry over is not selected from

AWT Setup Program is halted.

Messages related to large program downloading :

Loading program, please wait

While downloading program to controller.

Prog aborted due to previous load failure.

While loading program, if power failure occurs, & loading is not

completed.

Program downloading aborted.

Program downloading canceled by user.

Reading program, please wait

While downloading program to controller.

Prespark disabled due to large cavity program

Prespark will be disabled for single large cavity in program, which

occupies PROG memory more than 60KB approximately

Aborting load, Memory insufficient at Block No. XXXXX .

.If size of program in from G0 to G0 for Non AWT or M21 to M21for

AWT is greater than controller memory then program will not be

downloaded. If program contains single G0 or single M21 & program size

is grater than controller memory then program will not be downloaded.

XXXXX stands for cavity no.

Messages related to rotary axis:

Rotary table program not rewound.

This message is displayed if referencing (Home Zero Position) of rotary axis is

not done.

Rotary table indexing error.

This message is displayed if there is any error while indexing rotary axis.

Messages related with floppy and floppy drive faults


Messages related to Submerge:

Tank door open, Prog halt, Press key.

Backwash / Clean filter / PF unit fault, Prog halt, Press key.

Tank door open, Fill disabled.

Work tank water level low.

Quill level high.

Water level low not reached.

PF unit fault, Prog halt, Press key.

Filter pressure high, Prog halt, Press key.

Float switch fault, Prog halt, Press key.

MCP WFWT/ Flush Off Program halt, Press Key.

Messages related to password during password setting:

Password successfully set.

This message indicates password is set successfully.

Invalid password

This message is displayed whenever there is mismatch in Machine ID of

machine & that of password.

Invalid password, Mismatch in expiry dates.

This message occurs due to the mismatch in password expiry date and CNC

expiry date.

Invalid password, Mismatch in dates.

This message occurs due to the mismatch in password generation date and

current date of machine.

Same Password already present.

Messages related to password at the time of initialization:

Unable to run eWinCNC application, Contact Service Engineer.

This message occurs due to the mismatch in machine date.

Password expired, Contact Service Engineer

The validity period for Password expired, Contact service engineer to get the

new password or to activate the machine.


CHAPTER 6

Short Keys

The list of keyboard commands available in eWinCNC is as follows -

Command Short key

Open Ctrl + O

XY layer Alt + X

UV layer Alt + U

Top layer Alt + T

ProgHeight layer Alt + P

DrawHeight layer Alt + D

Wirepath layer Alt + W

ReDraw Alt + R

FullGraphics Alt + G

Pan Alt + N

3D profile view Alt + 3

AutoPan Alt + A

Main Mode Alt + F1

Jog Mode Alt + F2

M/cReference Mode Alt + F3

JobSet Mode Alt + F4

DrySpark Mode Alt + F5

Coord Mode Alt + F6

Set Machine Mode Alt + F7

Run Mode Alt + F8

Status Mode Alt + F9

Setup Mode Alt + F10

Reset Alt + F12

File Menu Alt + F

View Menu Alt + V

Parameter Menu Alt + M

Serial Menu Alt + S


Install Menu Alt + I

Help Menu Alt + H

The list of keyboard commands available in MidStart mode is as follows

Previous Block Up Arrow

Next Block Down Arrow

Goto Start Block Ctrl+PgUp

Goto End Block Ctrl+PgDn

Previous G0 Block PgUp

Next G0 Block PgDn

Mark Start Block Ctrl+S

Mark End Block Ctrl+E

Find Text Ctrl+F

Clear Settings Ctrl+L

OK Ctrl+Y

Cancel Ctrl+N

The list of Symbols used in eWinCNC is as follows

Main Mode

JobSet Mode

Coordinate Mode

Set Machine Mode

Run Mode

Setup Mode

Start

DryRun

Step

Hold


Manual Data Input (MDI)

Abort

Noman

Goto start point

Halt

Skip

Ostop

TimeReset

Goto next key set

Goto previous key set

Buzzer

Cut the Wire

Thread the wire

Semi Auto wire threading

Fill tank

Drain tank

Flush

WFWT

Motor Reset


CHAPTER 7

Terms

XY layer :

Layer drawn at XY guide level.

UV layer :

Layer drawn at UV guide level.

Top layer :

Layer drawn at the height of workpiece from worktable height.

ProgHeight layer :

Height at which profile is programmed.

DrawHeight layer :

Height at which user wishes to view the profile. It is user settable parameter.

Wirepath layer :

Connecting lines between XY and UV layers.

Ecode :

Technology used for cutting workpiece.

Guide Span :

Distance between UV and XY guides. When Z = 0.

WorkTable Height :

Distance between top surface of worktable & lower(XY) guide.


CHAPTER 8

Installation Procedure

Installing FirstTime On System

Following steps to be followed to install a eWinCNC Software first time on

your system from CD-Rom

- Insert CD into CD drive

- Explore the contents of CD

- Double click on Setup.exe file

- Follow the instructions displayed by application.

Install from CD-Rom Following steps to be followed to install a eWinCNC from CD-Rom

- Insert CD into CD drive

- Select Install from CD option from Install menu


Install from System Following steps to be followed to install a eWinCNC from System

- Select Install from PC option from Install menu


Above given both procedures will ask for Insert disk to drive & press OK to

take backup of setup.cnc & perr.dat file.

After that it will ask for Model, Drive/Motor, Feedback, Technology &

Language selection. Select the appropriate option. Now eWinCNC will get

installed on your system at path C:\eWinCNC.


Installation Steps 1. From list of machine models select the current machine model. The selection dialog looks like


2. From list of drives select the appropriate drive. The selection dialog looks like


3.From list of feedback select the appropriate option. The selection dialog looks like

4.Select the appropriate option for technology. The selection dialog looks like


5. From list of languages select the language in which software to be installed. The selection dialog looks like

6. In above 5 steps as you go on selecting the previous selected options is displayed at the top of dialog. If your selection is correct then at last setup shows following message.


CHAPTER 9

How to get and send Machine ID and Machine number Method 1:

Get Machine ID from Command Prompt During Initialization of eWinCNC application Press F4 (Function Key), So that application closes and brings Desktop. Now go to the command prompt using command as shown in Figure 1 Or cmd as shown in Figure 2 Figure 1

Figure 2


DOS command prompt is displayed as shown in Figure 3 Figure 3

Now Type command D:\>ipconfig/all in command prompt as shown in Figure 4 Encircled in yellow. Note: If physical address is not displayed then check the network configuration. After executing above command following Information is displayed on screen as Shown in Figure 4 Look for Physical Address encircled in Blue and note down the number (Address) Displayed in front of it encircled in Red e.g. 00-01-53-82-43-96 Send this Address with the Machine No. Figure 4


Method 2:

Machine ID from eWinCNC application Step1:

Install eWinCNC V 1.08 s/w or higher ver in the machine.

Step2: How to Save Machine No in Machine Setup

After installing eWinCNC V1.08, enter the Machine No in Machine

Setup and save it.

Figure1

Step3: How to send Machine ID and Machine number

Press Password key in SETUP mode, Password dialog will be displayed

Send Machine Number and Machine ID displayed on the Password Dialog

Machine Number: 010607

Machine ID: 00-01-53-82-43-96

Note: First check that the Machine number & Machine ID is displayed on the screen. If Machine number is not displayed fill machine number in setup. If Machine ID is not displayed then check the network configuration.


Figure2

OR Send Password Site ID file generated from Backup option.

(Parameter-> Backup -> SAVE -> Password file.)

Figure3

Select drive to store generated Site ID file.

Name of Generated (site ID) file is IMID-xx-xx-xx-xx-xx-xx.dat IMID followed by

Machine ID No e.g IMID-00-01-53-82-43-96.dat


Figure4

Figure5


Step3: How to Set Password to eWinCNC

After sending the site ID file or Machine ID, password or password file for that

Machine ID will be provided. Load this file from Password dialog using

LoadFromFile button (by specifying path of the file) or enter the key / Password

in New password: box & press set password button.

Name of Password file is OMID-xx-xx-xx-xx-xx-xx.dat IMID followed by Machine

ID e.g OMID-00-01-53-82-43-96.dat

Figure6

SiteID and Password File description:

Generated (Site ID) file is IMID-xx-xx-xx-xx-xx-xx.dat :

Password file is OMID-xx-xx-xx-xx-xx-xx.dat :

Example:

For Machine ID: 00-01-53-82-43-96

Files will be

Generated (site ID) file is: IMID-00-01-53-82-43-96.dat

Password file is: OMID-00-01-53-82-43-96.dat

ANNEXTURE eWinCNC S/W Version 1.12 UPDATES from Version 1.11

1) Ecodes changed to 8 digits, to accommodate more job thickness and

wire material etc.

2) Improper shutdown of machine detected and registered in history.

3) On Communication Link Failure, If Communication Link Failure is not

recovered in approximate 1minute then, Windows is Shut Down with

msg "Unrecoverable CommunicationLink Failure ShuttingDown

Windows Switch OFF UPS Manually,Press Key!!"

4) Retained backup of history for 1 year in folder C:\eHistory.

5) WC program can be loaded from CD.

6) On wire break during AWT, retained modified technology parameters,

also during GotoStart operation.

7) Default value of Wire Removal Feed in AWT setup changed from 13 to

8 as per the Export feedback for Diale Assembly.

8) Now in AWT Kept W axis at same position as before reverse motion

for cut detection.

9) Note :- Its necessary to Install Dot Net Framework on machine

from eWinCNC s/w CD Located at DotNet_Framework folder

else s/w wont work properly!!
Operating Manual eWINCNC V1.11INDEXOperationsManual operation modesAutomatic operation modesProgramming instructionsList of messagesShort keysTermsInstallation procedureHow to get and send M/CID & M/C No.Annexure

Documents

WinCNC_V1.12_V8 Operating manual.pdf