® NCT 100T NCT® 990T ® NCT 2000T Controls for Lathes Operator`s Manual Valid from software version x.
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Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1 Operator’s Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.1 The NC Control Panel: Display Unit and Data Input Keyboard . . . . . . . . . . . . . . . . . 8 1.1.1 Data Input Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1.1.
.1 Structure of Part Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Division of EDIT Screen during Editing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 Basic Editing Functions: Typing, Cursor Moving, Delete, Insert, Select . . . . . . . . . . 4.4 Editor Action Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 File Actions: Save, Save as . . . . . . . . . . . . . . . . . .
12.1 Single Block Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 12.2 Dry Run (All Feedrates at High Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 12.3 Machine Lock Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 12.4 Other Locking Possibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 12.5 Test Run . . . . . . . . . . .
© Copyright NCT March 18, 2003 The Publisher reserves all rights for the contents of this Manual. No reprinting, even in extracts, is permissible unless our written consent is obtained. The text of this Manual has been compiled and checked with utmost care, yet we assume no liability for possible errors or spurious data and for consequential losses or damages.
Introduction Introduction Dear User, Thank you for having opted for one of our NCT100T, NCT990T, or NCT2000T control systems. It is hoped sincerely that you will be always satisfied in your work with its facilities. It should be remembered that the skill of operating the machine can only be learnt in the possession of the part programming fundamentals. Similarly, no programming is feasible unless the skills of machine operation are acquired.
1 Operator’s Panel 1 Operator’s Panel 1.1 The NC Control Panel: Display Unit and Data Input Keyboard The NC control panel employs the display unit (monitor), the softkeys beneath, and the data input keyboard. The NCT100T, NCT990T and the NCT 2000T control panels are available in different versions. The monitor can be 9" monochrome, or 15" color.
1 Operator’s Panel Operator’s panel with 15" color monitor and with optional Machine control board 9
1 Operator’s Panel 1.1.1 Data Input Keyboard In case of a 9" monitor directly beneath the screen are five softkeys, in case of a 15" monitor ten softkeys built together with the screen. In both cases the meaning of these softkeys can be read in the menu bars found in the bottom line of screen, therefore their meanings may alter. However it is likely, that in some right-side menu bar there are no captions. This can only mean, that in that situation the softkeys have no function at all.
1 Operator’s Panel Keys PgUp and PgDn are used for turning pages within the text. Keys INS and DEL serve for inserting and deleting characters. The above listed units (monitor and keyboard) constitute the permanent part of NC and are transported together with the control in any case of configuration. The NC keyboard is fitted with repeater-type keys.
1 Operator’s Panel 3 Functional State of Automatic and Manual Data Input – NSCH: block search – INTD: automatic execution interrupted – STRT: start state – STOP: stop state 4 Program Manipulation State – LOAD: loading program from external device – SAVE: saving program to external device – SORT: sorting programs in directory is in progress – EDIT: long-lasting edit operation – WFTG: waiting for trigger – TRGD: triggered – Exch: change between general displaying areas is in progress – BURN: burning into FLA
1 Operator’s Panel the operator’s messages of PLC are displayed. The date and time display can also be found in this line. In the third line the name of the active general displaying area and behind the number of programs indicated for running can be read. In case of manual data input mode, the number of programs belonging to the manual data input can be seen here, otherwise the number of programs indicated for automatic mode is displayed. 1.1.
1 Operator’s Panel Optional machine control board Bel ow the operating items of machine control board delivered by NCT are described. The lighting state of LED in the top left corner of buttons shows, that the function indicated by the key is active. Emergency stop. By its depressing the NC registers the emergency stop state, shuts down all movements, and cuts its outputs off the machine. It can be undone by rotating the head of the button in the direction of the arrow.
1 Operator’s Panel Automatic Manual data input Increment selectors: Selecting 1, 10, 100, 1000 increment size. Override switches: Feedrate override switch. By affecting it the programmed feedrate can be changed in the 0-120% range. Rapid traverse override value can be influenced by four optionally supplied buttons. Spindle speed override buttons. By affecting <–> the programmed revolution is reduced, by affecting <+> it is increased by 10% in the 50-150% range.
1 Operator’s Panel Block restart Block return Function lock Movement, start and stop buttons Start button. Details of its functioning are discussed in the forthcoming chapters of the Manual. Stop button. Details of its functioning are discussed in the forthcoming chapters of the Manual. Jog buttons. Operators of jogging and incrementing. In case of running to reference point they serve for selecting axes. The arrangement of buttons can vary for machine types. Spindle start and stop buttons.
2 General Operating Knowledge 2 General Operating Knowledge 2.1 Screen Menu After turning the power on among the captions interpreting the softkeys the screen menu is active. On a color screen the default background color of the menu bar of the screen menu is light grey. In order to switch over from another menu to this, the screen menu key must be pressed. The different screens can be selected in the screen menu by pressing the softkey with the appropriate caption. Actions (e.g.
2 General Operating Knowledge further items after Service screen menu, those would be shown by pressing the screen menu key , until the first part of screen menu is returned. The number seen in the bottom right corner of menu field indicates the softkey number of the appropriate menu field and not the line number of the menu within the screen menu (for more see parameter SFNUMB ). By pressing the softkey of the active screen menu, its menu appears.
2 General Operating Knowledge Setting #1#100#500Timer / Tool pot PLC ta- User’s Security #33 1 #199 2 #599 3 counter 4 5 ble 6 params7 8 Service Param PLC Test 2 I/O 1 Logic Test 3 anal 4 mes Scope 5 Errors 6 7 Version 8 9 0 9 0 Summary: The screen menus are in two levels. The first level has eight screen menus. On the first level the screens can be switched over within the active menu field by means of Page softkey.
2 General Operating Knowledge – The digit entered is interpreted as an integer or as a decimal digit before or after the decimal point has been pressed, respectively. – It is not necessary to enter the right-hand insignificant zeros behind the decimal point or the decimal point (in the case of an integer value). – The data input can be started with decimal point when the integer part of a number is zero.
3 General Displaying Areas and Actions Executed on Them 3 General Displaying Areas and Actions Executed on Them Each general displaying area is accessible any time, independent of the current operation mode or other states of control. However actions belonging to the given display cannot be executed any time, the execution can depend on the mode or other states of control.
3.1 POSITION Screens 3.1 POSITION Screens There can be five types of POSITION screens. The first four screens displays the selected position with big-size characters, meanwhile on the fifth screen all position displays as well as in case of six or fewer axes the feed and revolution values are also displayed with normal characters. In case of an oriented spindle when the loop is closed (state M19) the screen shows the angle position of the spindle instead of the revolution.
3.1 POSITION Screens CARTESIAN POSITION Screen: In the state of polar coordinate interpolation on (G12.1) it indicates the tool position in the programmed Cartesian coordinate system. In the state of polar coordinate interpolation off (G13.1) positions indicated here are the same as on the screen ABSOLUTE.
3.2 CHECK Screens 3.2 CHECK Screens This screen serves for displaying running programs and their states. 3.2.1 PROGRAM TEXT Screen, Listing of Running Program In the lower part of general displaying area the list of the running program can be seen. One block on the list is highlighted; This is the block under execution. In the middle part of general displaying areas of feed and revolution can be seen (provided the number of displayed axes is not more than six).
3.2 CHECK Screens 3.2.3 LAST and ACTIVE screens. G Codes and Compensations. On the LAST and ACTIVE screens the active G codes and compensations under block display (LAST) and program execution (ACTIVE) can be seen. The LAST screen corresponds to the values of #4000..., #4100... macro variables, while the ACTIVE screen to that of #4200..., #4300... . The current tool position is displayed on the upper part of general displaying area.
3.2 CHECK Screens Action I can be used for input of incremental operator. Action Block Delete clears the whole block in buffer. 3.2.4 OPERATOR’S PANEL Screen The general display area of OPERATOR’S PANEL shows a view on the state of the most essential machine control items. The controllability of different item groups from softkeys is permitted by the PLC program. The illustration shows the general displaying area of the control panel.
3.2 CHECK Screens Operation Modes Actions (Modes) The following modes can be selected: Edit Auto 1 Mdi 2 Jog 3 Incr 4 Handle Ref 5 6 7 8 9 0 Axes Actions In the menu bar all axes of the machine tool are listed. Here the axis, with which an action must be done, can be selected. This action is necessary for example if an axis is to be moved by means of a manual handle.
3.2 CHECK Screens Clear Relative Position Actions (Clear Relpnt) The relative coordinate displays can be zeroed by means of action keys. Relative position setting by axes is discussed in the chapter 3.4.5. 3.2.5 MESSAGES Screen In this general displaying area the momentary messages in waiting state can be seen.
3.3 PROGRAM Screens 3.3 PROGRAM Screens Screens of actions executed on part programs. 3.3.1 DIRECTORY Screen In the top line of general displaying area the number of programs in memory and the free memory in bytes can be seen. The programs in memory are listed in the middle part. The control records the programs according to their code; These numbers can be read in the first column.
3.3 PROGRAM Screens New Action: When pressing the softkey a window opens in the bottom left part of general displaying area, where the program number can be typed in. The input can be terminated by any arrow key. In this case a new program occurs with the number entered, or an error message is displayed, if there is already a program with the same number or if there is no room in the memory.
3.3 PROGRAM Screens DNC contact working on the basis of DNC protocol can be implemented. The Chart action is only effective in Edit mode. By pressing it, provided program No. T (tool pot table) or P (PLC table) is highlighted, the file containing the selected chart is loaded to the appropriate chart. See the chapter 3.6.5 “TOOL POT TABLE” and the chapter 3.6.6 “PLC TABLE”. Using key DNC FEW programs can be executed from PC optionally integrated into the control.
3.3 PROGRAM Screens Last Action: When pressing the key the highlighting bar goes to the last block of the program. Check Action: When pressing the key control brings the highlighting bar to the last block of the program, meanwhile it reads the entire program and examines its check sum. This way it checks if the program in memory is damaged (the program can be damaged for example due to storage or operation in too low temperature).
3.3 PROGRAM Screens 3.3.4 BLOCK INPUT Screen In the upper part of general displaying area the current position can be seen. It is possible to enter single block as well as to re-execute or to modify a block entered earlier on by pressing action menu key . A sing- le block is to be entered similarly to that of a program block, however in the address chain of the single block the address letters, of which the entering would be here senseless are automatically not specified.
3.4 OFFSETS Screens 3.4 OFFSETS Screens Screens of actions executed on zero point and offset registers. 3.4.1 WORK OFFSETS Screen In the general displaying area are offset values of G54, ..., G58, common zero point offsets, as well as of offsets programmed by means of commands G52 and G92. The coordinate values belonging to one zero point form a group.
3.4 OFFSETS Screens activated by pressing action menu key Clear Clear group 1 all I 2 /2 3 : Save 4 5 6 7 8 9 0 Clear Group Action Menu: When pressing the key the question CLEAR G5x? (G5x according to current coordinate system) appears in the bottom left part of general displaying area, together with Exec and Cancel actions in menu bar, the meaning of which is the usual.
3.4 OFFSETS Screens keys and . This bar selects the offset register to be modified. Actions of TOOL OFFSETS Screen Actions executed on TOOL OFFSETS screen overwrite offset registers instantly, however it is registered by the program under execution only if the program has been started from the beginning or the program execution is interrupted (INTD state) and restarted.
3.4 OFFSETS Screens On the figures below the interpretation of the imaginary tool nose number (Q) can be seen.
3.4 OFFSETS Screens 3.4.3 WORK OFFSET MEASURE Screen In the upper part of general displaying area the current tool position can be seen. The first column always shows the machine position, the middle column the position in the selected coordinate system, while the last one the distance to go position. The following information can be seen in the lower part of general displaying area going downwards. In line Nnn the length offset values of the indicated offset group can be seen for each axis.
3.4 OFFSETS Screens For detailed description of work offset measure see the chapter 7.2.1 “Work Offset Measure” on the page 76. 3.4.4 TOOL LENGTH OFFSET MEASURE Screen In the upper part of general displaying area the position display can be seen. The following information can be seen in the lower part of general displaying area going downwards. In line Nnn the length offset values of the indicated offset group can be seen for each axis.
3.4 OFFSETS Screens For detailed description of work offset measure see the chapter 7.2.2 “Tool Length Offset Measure inside the Machine” on the page 79. 3.4.5 RELATIVE POSITION OFFSETS Screen In the general displaying area below the current tool position are the values of relative position offsets. An inverse bar can be moved on axis addresses by means of keys and . This bar enables to select the offset register to be modified.
3.5 GRAPHIC POSITION Screens 3.5 GRAPHIC POSITION Screens In automatic operation mode the graphic position display shows the path of the imaginary tool nose. In the case of graphic position display the tool nose path stored in a buffer is drawn on the screen. As the buffer (which is a part of the control memory) is finite, it is possible, that in case of complex and long programs the entire path might not be stored. 3.5.
3.5 GRAPHIC POSITION Screens In case the value of the auto erase is other than zero, when starting the automatic program execution both the drawing area and the buffer are cleared. If the value of the path color is 0 rapid traverse is drawn with red, feed with green, while thread cutting with yellow color. If the value is not zero, the rapid traverse movements are not drawn.
3.5 GRAPHIC POSITION Screens 3.5.2 DRAW Screen In the drawing area in the middle of screen the current tool center is shown by a cross. The following information can be read in the top right corner of the screen: Current feed, spindle revolution and the number of the current tool. Further on in the column the position display of axes can be seen as selected on the POSITION DISPLAYS screen. (see the chapter 3.1 on the page 22).
3.5 GRAPHIC POSITION Screens Down (PgDn). By means of softkeys, as well as the page keys the drawing area can be halved or doubled. As the effect of Full Sceen action the centre of the screen automatically adjusted to the middle of the tool path and scaling is set that the tool path covers the whole screen. Graphic Action Menu: After pushing the softkey the following actions appear: Auto Erase, G40, G53, Dotted. Using Auto Erase the item with the same title in graphic parameters table can be set or reset.
3.6 SETTING Screens 3.6 SETTING Screens The following screens can be found in this menu; LOCAL MACRO VARIABLES #1–#33, COMMON MACRO VARIABLES #100–#199 and #500–#599, TIMER and COUNTER, TOOL POSITION TABLE, PLC TABLE, TOOL WEAR TABLE, USER’S PARAMETERS and SECURITY SETTINGS. Contents of variables, timers, counters and tables are preserved upon power-off. 3.6.1 Screen of LOCAL MACRO VARIABLES #1–#33 In the general displaying area the local macro variables and their values can be seen.
3.6 SETTING Screens 3.6.2 Screen of COMMON MACRO VARIABLES #100–#199 In the general displaying area common macro variables #100–#199 and their values can be seen. Variables #120–#199 are vacated upon power-off and when resetting automatic mode (RESET) Variables #100–#119 are also vacated in case of value 1 of parameter CLCV, otherwise their values are preserved. A highlighting bar can be moved along the macro variables by means of arrow keys up and down.
3.6 SETTING Screens 3.6.3 Screen of COMMON MACRO VARIABLES #500–#599 In the general displaying area common macro variables #500–#599 and their values can be seen. These variables are not vacated upon power-off or when restoring automatic mode (RESET), on the other hand by switching to parameters, when saving parameters they are saved to the external device, and when loading parameters the original values are overwritten.
3.6 SETTING Screens 3.6.4 TIMER AND COUNTER Screen In the general displaying area the different timers and counters can be seen. The highlighting bar can be moved to the timer or counter to be modified by means of arrow keys. Apart from the operating time the values are free to overwrite.
3.6 SETTING Screens The length of the tool pot table can be set in parameter MAGAZINE No. 0061. In parameter MAGAZINE the number of tool pots in the magazine is to be entered. Line 0 of table shows the code of the tool in spindle, i.e., the spindle is pot No. 0. In the first column of the table the number of tool position or pot, in the second column the under address T the number of the tool in pot, while in the third one under address L the width code of the tool can be found.
3.6 SETTING Screens actions in the menu bar, the meaning of which is the usual. With Exec in effect the selected line is cleared. Save Action: When pressing the key the program number can be entered into the bottom data input line. In case the input is terminated by any of the keys or program can also be named there. As the effect of keys and , the values are saved in the appropriate macro variable. It is registered in the directory not under program number O, but under address T.
3.6 SETTING Screens program can also be named there. As the effect of keys and values are saved in the appropriate macro variable. It is registered in the directory not under program number O, but under address T. Restoring values of the table is discussed in the chapter 3.3.1 on the page 30 “DIRECTORY Screen” Run action menu Table action. 3.6.7 USER’S PARAMETERS Screen (User’s Params) In the general displaying area a restricted part - that can also be set by the user - of the parameters can be seen.
3.6 SETTING Screens 3.6.8 SECURITY PANEL Screen The control provides wide-range data security service. The picture shows the SECURITY PANEL screen. When the general security gate is open the other security gates have no significant role, thus all actions listed on the screen can be executed even if the symbol . is displayed beside the action. If however the general security gate is locked, i.e., the symbol . is seen beside the caption the actions, beside the name of which lock symbol .
3.
3.6 SETTING Screens is entered the data input can be closed by means of button and the function is enabled. Close action: If a function is to be locked move symbol = (cursor) to the function. Press Close button. The selected function is locked independent of the state of the general security gate.
4 Editing part programs 4 Editing Part Programs 4.1 Structure of Part Program The part program is made up of blocks. A block consists of words. Word: Address and Data A word is formed by two components: Address and data (e.g., X127.064 or Z#103). The address may comprise one or more characters (X, Z in the example), while the data may be: SQ a number that may have integer and decimal number as well (127.
4 Editing part programs Beginning and end of program The program begins and ends with character %. As a new program is loaded with the help of NEW action on DIRECTORY screen string %Onnnns% is formed automatically. In the course of editing a part program on the CNC the opening and closing % characters and the program number (Onnnn) do not appear in the program list and edit field therefore they can not be altered. If one edits a part program on an external device e.g.
4 Editing part programs 4.2 Division of EDIT Screen during Editing 19 lines are kept for editing in the middle of screen. The division of these is as follows: Lines ranging from No. 1 to No. 16: program list and edit field. In the first column only character > representing a new block, i.e., code s may appear. The first character of the block occurs in the second column. Otherwise if a new line must be opened on screen for the block does not have enough room in one line, the first column remains empty.
4 Editing part programs 4.3 Basic Editing Functions: Typing, Cursor Moving, Delete, Insert, Select The editing gets started as the effect of action menu key . Basic editing functions are implemented with the help of the following keys: – characters: , , ... . By their use capital letters can be typed in. – Shift button: . In case the key is kept pressed down and another key is pushed meanwhile, the second character indicated on the key is entered.
4 Editing part programs If value of parameter 0567 N STEP is other than 0, the block number is increased by the value given at the parameter for each push of the key and this is automatically inserted to the beginning of the new block at address N. If for example the value of parameter is 10 the block numbers are increased by ten: N10, N20, N30, ... Moving the cursor As the effect of right key the cursor goes to the next character.
4 Editing part programs As the effect of backspace key the character before the cursor is deleted and the characters behind step forward. Regarding logic lines (blocks) the same rearrangements are in force as those referring to delete key . Insert When opening, the editor accepts insert mode indicated by caption INSERT on the right side of the 18th line of screen.. After pressing key OVERWRITE.
4 Editing part programs 4.4 Editor Action Menu The following actions as well as action groups are available for editing, when action menu key is pressed: File Edit 1 Insert Insert Insert Insert Window Change Help 2 misc 3 cond 4 operat 5 funct 6 7 wind 8 9 0 4.5 File Actions: Save, Save as Edit File 1 Insert Insert Insert Insert Window Change Help 2 misc 3 cond 4 operat 5 funct 6 7 wind 8 9 0 The following actions are accessible by selecting File action group F1. Save 1 2 3 Save 4 as...
4 Editing part programs Copy Action: By pressing the key the text selected earlier on is put to the clipboard and the original text remains at its position. Paste Action: By pressing the key the content of the clipboard is inserted starting from the position next to the cursor. In case the clipboard is empty, the caption of the key is dark, otherwise it is light. Select All Action: By pressing the key the entire program is selected. Find/Replace Action: By pressing the key it remains pressed down.
4 Editing part programs found string. If no text is given after the caption REPLACE, Replace action is equivalent to the deleting of the found text. Undo action can also be applied after Replace action. 4.7 Insert Actions File Edit 1 Insert Insert Insert Insert Window Change Help 2 misc 3 cond 4 operat 5 funct 6 7 wind 8 9 0 The following actions are accessible by selecting action groups F3, ...
4 Editing part programs screen. By returning to the EDIT screen the other program can be seen in the window active when exiting. The active window as well as the program numbers shown in the windows are indicated in the 18th status line. The cursor is seen in the active window, and this is also the place where editing actions may be executed.
5 Switching Over Operation Modes 5 Switching Over Operation Modes With the help of the data input keyboard the state of operation modes, switches, etc., displayed on the OPERATOR’S PANEL screen can be changed by means of softkeys after action menu key has been pressed. The above switches are available not only on the OPERATOR’S PANEL screen, but also on POSITION screens. These are discussed in details in the chapters of the appropriate screen.
6.1 Manual Reference Point Return Mode 6 Manual Operation Modes The manual operation modes are as follows: Manual reference point return Manual handle feed Incremental jog Jog 6.1 Manual Reference Point Return Mode Reference point can be returned only upon power-on state of the machine, i.e. when there is no EMG (emergency stop) state in the rightmost field (general NC state) of status bar.
6.1 Manual Reference Point Return Mode happened yet, symbol !! can be seen beside the position. In case the reference point has been returned on all axes REF, i.e., the caption indicating lack of reference position is cleared from the general NC state field. LNote: By different machine tools return to the reference point may function contrary to the abovementioned process.
6.2 Jog Mode 6.2 Jog Mode Jogging can only be done upon power-on state of the machine, i.e. when there is no EMG (emergency stop) state in the rightmost field (general NC state) of status bar. After selecting the operation mode in the 2nd field of status bar caption JOG appears. If the machine is mounted with NCT machine control board the jog mode can be switched on by pressing the button.
6.2 Jog Mode LNote: The above discussed cases are the basic cases of jog mode. By different machines functions contrary to these may be created by the machine tool builder. It is common, for example, if pressing of a jog button is followed by the pressing of the START button, than the jog button is not to be held down any longer. This way the movement on the selected axis is carried on until the STOP button is pressed. For details turn to the machine tool builder for an information material.
6.3 Incremental Jog Mode 6.3 Incremental Jog Mode Incremental jogging can only be done upon power-on state of the machine, i.e. when there is no EMG (emergency stop) state in the rightmost field (general NC state) of status bar. After selecting the operation mode in the 2nd field of status bar caption INCR appears. If the machine is mounted with NCT machine control board the incremental jog mode can be switched on by pressing the button.
6.
6.4 Manual Handle Mode 6.4 Manual Handle Mode Moving by the use of manual handle can only be done upon power-on state of the machine, i.e. when there is no EMG (emergency stop) state in the rightmost field (general NC state) of status bar. After selecting the operation mode in the 2nd field of status bar caption HNDL appears. If the machine is mounted with NCT machine control board the manual handle mode can be switched on by pressing the button.
6.4 Manual Handle Mode Speed In case of moving by the use of the manual handle the speed of the axis depends upon the selected increment size and upon the speed of the rotation of the handle. The movement is started by acceleration and finished by deceleration. The pulse number rotated is always executed, if parameter 1373 HNDLFEED is 0 therefore, if the selected axis cannot follow the pulses coming from the manual handle those are buffered and are moved after the rotation has been stopped.
7 Actions Executed in Manual Operation Modes 7 Actions Executed in Manual Operation Modes 7.1 Single Block Operation A single block can be entered by selecting BLOCK INPUT screen of the PROGRAM screen menu and pressing the action menu key. This action can be used only in jog, incremental jog and manual handle modes. The data input is discussed in the chapter 3.3.4 “SINGLE BLOCK Screen” on the page 34. Only a program block not referring to previous or following blocks can be entered, i.e.
7.2.1 Work Zero Point Offset Measurement 7.2.1 Work Zero Point Offset Measurement If work offset is to be measured inside the machine, select F3 W. OFFS MEASURE (work offset measurement) screen of OFFSETS screen menu and press the action menu key. The coordinate system to be measured can be selected after pressing softkey F1 WORK COORDNT. (Work coordinate system), than the appropriate softkey F1 G54, F2 G55, ...
7.2.1 Work Zero Point Offset Measurement Work Zero Point Offset Measurement, if Tool Length Equals to Tool Overhang If tool length equals to the Xand Z-direction tool overhang (because for example tool offset measuring was executed on an external measuring device) the work offset (work zero point) must always be measured.
7.2.1 Work Zero Point Offset Measurement Work Zero Point Offset Measurement, if Tool Length Equals to Coordinate Shift If tool lengths are measured so that they also contain the offsets of the work zero point (see tool length measurement) work offsets do not have to be measured. An exception to this if the offset needs to be compensated, as well as if another work coordinate system is to be used. This is needed, for the tool length is calculated in relation to a given work coordinate system.
7.2.2 Tool Length Offset Measurement inside the Machine 7.2.2 Tool Length Offset Measurement inside the Machine Tool length can be measured also inside the machine. For this softkey F4 T. LENG MEASUR (tool length measurement) of F5 OFFSETS action menu must be selected. Select the tool length offset register, in which the tool length to be stored. In order to do this softkey F3 OFS NO SEARCH (offset number search) must be pressed.
7.2.2 Tool Length Offset Measurement inside the Machine If No Work Zero Point Offset Measurement had Taken Place Previously If no work zero point offset had taken place previously, the appropriate work offset of the selected coordinate system is zero (Mx=0, Mz=0). The coordinate values measured after cutting and entered to control at addresses X and Z: x0, z0. The control calculates the tool length with the help of the relation, discussed for work zero point offsets.
7.2.3 Automatic Tool Length Offset Measurement 7.2.3 Automatic Tool Length Offset Measurement Tool length offsets can also be measured automatically, provided the machine is mounted with a tool offset sensor. Select screen F4 T LENG MEASURE (tool length measurement) in screen menu of F5 OFFSETS. Switch control to JOG mode, than change the tool to be measured. Move the tool tip near to the tool sensor by the use of jog buttons.
7.2.4 Calibrating Tool Offset Sensor 7.2.4 Calibrating Tool Offset Sensor The tool offset sensor calibration means the definition and storage of button positions at parameters CONTACT. The sensor can be calibrated in two ways. The first possibility is that the button positions of the sensor are defined in a coordinate system set by the user, e.g., a coordinate system fixed to the chuck. In this case the values of tool length offsets contain the zero point offset according to the reference point.
7.2.4 Calibrating Tool Offset Sensor Calibrating the Sensor to the Coordinate System of Chuck The enclosed diagram beside shows the interpretation of CONTACT parameters. Calibrating in X direction Turn an optional workpiece, leave the workpiece in Z direction and read the machine position of X axis, indicated with Xworkp on the diagram below. Measure the workpiece diameter indicated with D on the figure. Execute an automatic tool length measure as discussed in the previous chapter in X– direction.
7.2.4 Calibrating Tool Offset Sensor Calibrating the Sensor to Reference Point The figure beside shows the interpretation of CONTACT parameters. Let us examine the following example. Place a tool, the overhang of which is known in the tool holder. The tool overhang is indicated with XT, ZT on the diagram below. Execute an automatic tool length measurement as discussed in the previous chapter. On the diagram it is in directions X–, Z–.
8.1 Automatic Mode 8 Modes of Automatic Operation The modes of automatic operation are: Automatic Edit Manual Data Input 8.1 Automatic Mode Program execution in automatic mode can only be done upon power-on state of the machine, i.e. when there is no EMG (emergency stop) state in the rightmost field (general NC state) of status bar. If the machine is mounted with NCT machine control board the automatic mode can be switched on by pressing button.
8.1 Automatic Mode executed on the transmitter side. Program dnc-plus.exe can be executed on IBM PC or on a compatible computer. It ensures connection between transmitter and receiver with protocol. Its advantage over simple DNC connection is that it calculates the checksum by each program block and sends it to control. If the receiver detects an error, it asks for repetition and the transmitter sends the block again. Of this, the operator notices nothing what so ever, for it proceeds automatically.
8.2 Edit Mode 8.2 Edit Mode In case there is no PLC program or PLC program or parameter area is damaged in control, edit mode is activated after turning the power on. . Edit mode is indicated by caption EDIT in the leftmost field of the status bar.
8.3 Manual Data Input Mode 8.3 Manual Data Input Mode Program execution in manual data input mode can only be done upon power-on state of the machine, i.e. when there is no EMG (emergency stop) state in the rightmost field (general NC state) of status bar. If the machine is mounted with NCT machine control board the manual data input mode can be switched on by pressing the button. In manual data input mode all part programs in control memory, that is not selected for automatic execution can be executed.
8.3 Manual Data Input Mode In manual data input mode, during program execution, the operation of the following functions corresponds to that in automatic mode: – Single block execution – Conditional STOP – Conditional block – Dry run – Locking possibilities.
9 Override Switches 9 Override Switches The control can operate three override switches: – the feedrate, – the rapid traverse, and – the spindle speed override switches. 9.1 Feedrate Override Switch The feedrate override switch has 16 positions. The feedrate switch determines, by how many percent of the programmed feedrate (F) should the axes be moved. The diagram beside shows the position of the switch and the percentage belonging to the position.
9 Override Switches 9.2 Rapid Traverse Override Switch The rapid traverse override switch determines, by how many percent of the rapid traverse rate defined in the parameter should the axes be moved. The diagram beside contains the switch positions and the percentages belonging to the positions. switch state F0 is a percentage fixed at parameter 1204 RAPOVER. Its practical value is 10% or less.
9 Override Switches pressing the button the control restores the programmed 100% rate. During thread cutting G33, G34, G76, G78 and tapping cycles G84.1, G84 the spindle speed override switch is ineffective. The control registers 100% independent of the switch position.
10 Program Execution Start and Stop 10 Program Execution Start and Stop The program execution is started by the use of the START button. The program execution can be stopped by means of the following functions and keys: – with the STOP button, – with the RESET key, – at the end of block execution in the single block mode , – after executing programmed stop command M00, – as the effect of conditional stop command M01, if optional stop switch is on, – after executing program end commands M02, M30.
10 Program Execution Start and Stop At the same time some global messages are also cleared from the message field of the status bar. The PLC program (generally) stops spindle rotation and suspends operation under execution. Besides RESET key has other effects in the different modes as well. In Automatic Operation in Case There is No INTD State Yet: If RESET key is pressed in automatic operation and there is no INTD (interrupted) state yet, caption INTD is displayed in the 3rd field of status bar.
10 Program Execution Start and Stop executes block containing code M01 if switch COND. STOP assumed and the machining stops. With START button Nothing happens if switch COND. STOP is on, than STOP state is the machining is continued. is off. 10.6 End of Program: M02, M30 Codes M02, M30 indicate the end of main program. By its use the machining stops, START state is canceled.
11 Intervention in the Course of Program Execution 11 Intervention in the Course of Program Execution 11.1 Conditional Block Skip If at the beginning of block conditional block skip /n is programmed (n means the number of the conditional block switch), than – if switch No. n is on, it skips block, – if switch No. n is off, it executes block. The conditional block switch No. 1 can be reached on OPERATOR’S PANEL or POSITION screens.
11 Intervention in the Course of Program Execution 11.3 Intervention by Means of Manual Handle in Automatic Operation The manual handle operation can also be turned on parallel to the automatic operation. In this case in the leftmost field of status bar caption AUTM or AUTD indicating automatic operation can be seen, depending on where the program execution takes place from. At the same time in the 2nd field of status bar caption HNDL appears, indicating the manual handle operation.
11 Intervention in the Course of Program Execution Effect of intervention to coordinate system – The manual handle pulses are also added to the offset on the appropriate axis in the common work zero point offset registers. This way all the works and local coordinate systems are being shifted. – Naturally this does not influence the machine coordinate system. In case of G53 or G28 the axis always moves to the appropriate position.
12 Debugging Part Program 12 Debugging the Part Program The following functions help the testing, debugging of the part program: – single block execution, – dry run, – locking possibilities and – test run. These functions are not operation modes, but conditions influencing the program execution in automatic mode. 12.1 Single Block Execution Single block execution can be selected on OPERATOR’S PANEL or POSITION screens.
12 Debugging Part Program 12.3 Machine Lock Function Switch MACHINE LOCK can be reached on OPERATOR’S PANEL or POSITION screens. After pressing the action menu key F5 CONDITIONS action menu must be selected, than softkey MACHINE LOCK needs to be pressed. If NCT machine control board is used select the button. The locked state of the machine is indicated by caption LOCK in the 8th field (general NC state) of the status bar.
12 Debugging Part Program The different function and axis locking possibilities can be combined optionally. An axis, e.g. Z axis and the functions can be locked simultaneously. LNote: About the different locking possibilities turn to the machine tool builder for an information material. 12.5 Test Run Softkey TEST can be reached on OPERATOR’S PANEL or POSITION screens. After pressing the action menu key F5 CONDITIONS action menu must be selected, than softkey TEST needs to be pressed.
13 Interruption and Restart of Automatic Operation 13 Interruption and Restart of Automatic Operation In many cases the automatic operation needs to be interrupted, than later on the machining to be continued.
13 Interruption and Restart of Automatic Operation if machining is started in INTD state of automatic mode and START button is pressed, control registers STOP state and message RESTORE MODAL FUNCTIONS? Y is displayed (Y=yes). By pressing key question RESTORE MODAL FUNCTIONS? N is asked (N=no). The messages can be switched over by the use of key START . If the button is pressed, it restores the state before suspension according to the message (Y) or not (N).
13.3 Unconditional Restart of Automatic Operation 13.3 Unconditional Restart of Automatic Operation If automatic operation is started from interrupted state (INTD) unconditionally after START the control goes to the end position of the interrupted block and carries on machining from there.
13.3 Unconditional Restart of Automatic Operation 2nd case: in state G40 interrupting oblique linear interpolation Let us examine fragments of the following sample programs: Program No. 1: Program No. 2: ... N40 G90 G0 X20 Z–10 N50 X80 Z–60 N60 Z–85 ... ... N40 G90 G0 X20 Z–10 N50 G91 X60 Z–50 N60 Z–25 ... Programs No. 1 and 2 are on the same tool path, however the data specification of the former one is absolute, while that of the latter one is incremental. The interruption occurs in block N50.
13.3 Unconditional Restart of Automatic Operation If in the selected plane the address of one of the axes has not been programmed (e.g., Y) and movement has been made also in this direction, or in Z direction, the movement may be led back to the 1st case, i.e., the axes will move after pressing START in neither Y, nor Z direction.
13.3 Unconditional Restart of Automatic Operation The cases below refer to the axes in the selected plane in when offset mode is on. To interruption of axis movements outside the selected plane refer to interruption cases in state G40. 6th case: in state G41 or G42 interrupting linear interpolation parallel to axis Let us examine fragments of the following sample programs: Program No. 2: Program No. 1: G41 G18 G90 G1... ... N80 X40 N90 Z-30 ... G41 G18 G91 G1... ... N80 X45 N90 Z-20 ...
13.3 Unconditional Restart of Automatic Operation When manual movement is done to a position, which is left from the end position of the circle, according to the diagram, the control proceeds also as discussed above. However this time the arc of the variable radius circle is close to 360° because of direction G03 according to the diagram.
13.4 Automatic Operation Restart with BLOCK RESTART Condition 13.4 Automatic Operation Restart with BLOCK RESTART Condition If the condition BLOCK RESTART and than START button is switched on after returning to automatic mode is pressed, the control goes to the start position of the inter- rupted block and continues machining from there, i.e., it re-executes the interrupted block. This function is typically for the restart after tool break.
13.4 Automatic Operation Restart with BLOCK RESTART Condition 13.4.3 Cases of Return by Means of BLOCK RESTART Condition Return to Block Start Position After Interrupting Simple Movement Block 1st case: in state G40 interrupting and restarting linear interpolation The diagram shows the case, when a linear interpolation in the plane X, Z is interrupted, a manual mode is set and manual operation is used along the two axes.
13.4 Automatic Operation Restart with BLOCK RESTART Condition X=100, Y=70, Z=10. 3rd part block: Hole machining and retraction to start position (G98) or to R-point (G99). In this part block the start position is coordinate X=100, Y=70, Z=2. At the end of all three part blocks the control stops in single block mode. If the canned cycle is programmed with repetition count L the above part blocks are repeated.
13.4 Automatic Operation Restart with BLOCK RESTART Condition 5th case: Return to block start position after interrupting machining in offset mode at outside corner By the use of BLOCK RESTART condition it is set out from the offset vector on the start position of the interrupted block, the length of which is multiplied by the length of the new tool radius and divided by the old one: Afterwards the machining is continued on the tool path with the new offset value.
13.5 Automatic Mode Restart with BLOCK RETURN Condition 13.5 Automatic Mode Restart with BLOCK RETURN Condition If automatic operation has been interrupted, manual operation was used to move away from the workpiece and return is to be made to the interruption point, the BLOCK RETURN condition needs to be used. Its switch can be selected on the OPERATOR’S PANEL or POSITION screens. After pressing the action menu key action F5 CONDITIONS must be selected and the BLOCK RETURN softkey pressed.
13.5 Automatic Mode Restart with BLOCK RETURN Condition 13.5.3 Cases of Return by Means of Condition BLOCK RETURN Cases of return by means of BLOCK RETURN RESTART condition correspond to that of BLOCK condition, except for return is made not to start position of block, but to the interruption point.
13.5 Automatic Mode Restart with BLOCK RETURN Condition the canned cycle restarted by means of condition BLOCK RETURN consists of 3 part blocks: 1st part block: Positioning in the selected plane (GO X100 Y70) 2nd part block: Positioning to point R (G0 Z2) 3rd part block: Hole machining and retracting to initial level (G98) or to point R (G99). At the end of all three part blocks the control stops in single block mode.
13.5 Automatic Mode Restart with BLOCK RETURN Condition 5th case: Return to interruption point machining in offset mode at outside corner By the use of the BLOCK RETURN condition it states a perpendicular vector on the interruption point, the length of which corresponds to that of the new tool radius (supposing the radius has been changed) Afterwards the machining is continued on the tool path with the new offset value from the interruption point.
13.6 Automatic Operation Start after Block Search 13.6 Automatic Operation Start after Block Search In the course of machining there may be a need for executing the program selected for automatic mode not from the first block, but from a block within the program. For this, the appropriate block of the program has to be pointed at. On the DIRECTORY screen the program must be selected for automatic execution, than VIEW screen needs to be displayed. The control is to be switched over to automatic mode .
13.6 Automatic Operation Start after Block Search pressing key . If the number of the subprogram is not numeric, but is an arithmetic expression it will not open the subprogram. If the subprogram is called by means of repetition count (L) the cycle number from which the program is to be executed can be specified. On the keyboard key needs to be pressed, than the cycle number entered.
13.6 Automatic Operation Start after Block Search Spindle Rotation Code: M3 The command referring to the last spindle rotation is gathered, in this case M3. Coolant Code: M8 The command referring to coolant handling is gathered, in this case M8. Other Functions: M Other M functions in the program are listed in the 2nd line of the gathered information.
13.6 Automatic Operation Start after Block Search Other Intervention Possibilities Before START It is possible to change the order of execution, as well as to cancel the execution of other M codes before starting the execution of data gathered in automatic mode. The cursor can be moved along the listed commands by means of keys , . The cursor must be moved to the function or coordinate, the execution of which is to be taken out from the execution after the first START.
13.6 Automatic Operation Start after Block Search key has been pressed, BLOCK SEARCH action must be pressed on VIEW screen. By the use of INTERRUPTED softkey the control starts searching for the block, the execution of which has been interrupted. Afterwards the process corresponds to that of command F3 SEARCH.
14 Listing of Messages and their Codes 14 Listing of Messages and their Codes There may be two types of messages: Local and global. 14.1 Local Message Local messages are the ones connected to an action executed on a certain screen, and are not available on any other screen. These are for example the data input errors displayed by the control upon false input. Local messages are displayed in the bottom right corner of screen above the softkeys.
14 Listing of Messages and their Codes Messages of custom macros: – error messages programmed by the user and waiting for to be canceled, or – messages programmed by the user waiting for START. In the case of global messages the different messages are needed to be answered differently, i.e., to be canceled. Therefore, in the enclosed table after each message the method of canceling it is shown.
14.3 Listing of Global Messages 14.
14.3 Listing of Global Messages Error Code Message 60 PLC TIMEOUT 1 61 PLC TIMEOUT 2 70 124 Description Canceling and Repairing Method If either module :001 or module :002 of PLC program does not expire in the time slice reserved for it, message PLC TIMEOUT 1 or 2 is displayed. This message is generated in EMG state. This message can only be canceled by power-off of the control. In order to repair it, turn to a well-trained expert.
14.3 Listing of Global Messages Error Code Message Description Canceling and Repairing Method SHORT MON This message is displayed, if MON (Machine ON) output of control is short-circuited or overloaded. This message is generated in EMG state. This message causes EMG state and loss of reference point. It can be canceled by RESET. 1020 POSITION ERROR This message is displayed, if the position lag does not reach the value specified at parameter within 5 seconds after the interpolator has stopped.
14.3 Listing of Global Messages Error Code 1102 Message Description Canceling and Repairing Method REFERENCE POINT t3 This message is displayed, if the zero pulse has not been found after leaving the reference switch within the distance specified at parameter SWSHIFT + :ZERODIS. Value of t is the name of the axis: X, Y, Z, U, V, W, A, B, C. In the error code (1102, 1112, 1122, ...) the digit on local value 10 (0, 1, 2, ...) +1 is the physical axis number. The message is canceled by RESET key.
14.3 Listing of Global Messages Error Code 1105 Message Description Canceling and Repairing Method REFERENCE POINT t6 This message is displayed, if during reference point return in case of distance-coded measuring system the distance between two zero pulses is not in accordance with the values of parameter ZERODIS. Value of t is the name of the axis: X, Y, Z, U, V, W, A, B, C. In the error code (1105, 1115, 1125, ...) the digit on local value 10 (0, 1, 2, ...) +1 is the physical axis number.
14.3 Listing of Global Messages Error Code Message Description Canceling and Repairing Method LIMIT t+ This message is displayed, if one of the axes has run on limit switch or on overtravel position specified at a parameter in direction –. Value of t is the name of the axis: X, Y, Z, U, V, W, A, B, C. In the error code (1360, 1361, 1362, ...) the digit on local value 1 (0, 1, 2, ...) +1 is the physical axis number.
14.3 Listing of Global Messages Error Code Message Description Canceling and Repairing Method 2000 PLC ERROR 001 2001 PLC ERROR 002 2002 PLC ERROR 003 At most 152 different messages can be sent by PLC. The message texts are optional. In case no text is added by the programmer of PLC, message PLC ERROR ijk is displayed. 2150 PLC ERROR 151 For the list of messages and the description of messages turn to the machine tool builder.
14.3 Listing of Global Messages Error Code Message Description Canceling and Repairing Method 3006 VALUE EXCESS H, D, P If in tool offset selection (H) or (D) the number entered under the address exceeds the range permitted. The same error occurs in case of value P of command G10 L(10, 11, 12, 13). The message is canceled by RESET key.
14.3 Listing of Global Messages Error Code Message 3018 ,A IN G2, G3 3019 DOMINATOR STANT=0 3020 Description Canceling and Repairing Method If in circular interpolation block (G2, G3) angle (,A) has been programmed. The message is canceled by RESET key. If in 3D radius compensation calculation the value of dominator constant is 0. The message is canceled by RESET key.
14.3 Listing of Global Messages Error Code Canceling and Repairing Method Message Description 3029 GROUP NUMBER IS TOO HIGH If in block G10 L3 (filling up life time table) the number of tool groups exceeds the maximum value registered on parameter 1181 GROUPNUM. The message is canceled by RESET key. 3030 DEFINITION ERROR T If tool call is being programmed (address T) and value T is greater than 9999, or is negative. The message is canceled by RESET key.
14.3 Listing of Global Messages Error Code Message Description Canceling and Repairing Method 3040 G38 NOT IN G0, G1 If vector hold block G38 was programmed and the interpolation code is not G0 or G1. The message is canceled by RESET key. 3041 AFTER G2, G3 ILLEG. BLOCK If in offset mode (G41, G42) an offset mode cancel block (G10, G20, G21, G22, G23, G28, G29, G30, G31, G37, G52, G53, G54, ..., G59, G92) is programmed after circular interpolation block. The message is canceled by RESET key.
14.3 Listing of Global Messages Error Code Message Description Canceling and Repairing Method 3051 G22, G28, ...
14.3 Listing of Global Messages Error Code Message Description Canceling and Repairing Method 3059 3060 3061 3062 3063 3064 BAD MACRO MENT 3065 STATE- If the macro expression is syntactically incorrect. The message is canceled by RESET key. TOO LONG BLOCK If the programmed block does not have enough room in the buffer. The message is canceled by RESET key. 3066 N O I N T E RS E C T I O N POINT If there is no intersection point (eg., in case of parallel straights lines, concentric circles etc.
14.3 Listing of Global Messages Error Code Message 3073 NOT EXISTING GRAM NO. 3074 Description PRO- Canceling and Repairing Method If, in case of subprogram call (M98 P) or macro call (G65 or G66 or G66.1 P), the program number specified at address P is not in the memory, subprogram or macro call has been selected for G, M, A, B, C, S, T and the referring subprogram is not in the memory, or the program executor called the subprogram or macro, which is being edited at the moment (EDIT screen).
14.3 Listing of Global Messages Error Code Message Description Canceling and Repairing Method 3086 DEFINITION ERROR G51 If scaling axis by axis is programmed (G51 X Y Z I J K) and X and U, or Y and V, or Z and W are in one block. The message is canceled by RESET key. 3087 ILLEGAL PLANE SELECT If in G76 multiple thread cutting cycle, on lathe control, not G18 plane is selected. The message is canceled by RESET key.
14.3 Listing of Global Messages Error Code Message Description Canceling and Repairing Method 3100 3101 BLOCK NOT FOUND If the block searched for is not found and the end of program is reached (M2, M30 or %). The message is canceled by RESET key. 3102 INCORRECT G12.1 If polar coordinate interpolation is on (G12.1) and the position of the 1st axis is 0, or the position of the 2nd axis is not 0. The message is canceled by RESET key.
14.3 Listing of Global Messages Error Code Message Description Canceling and Repairing Method 3123 3124 3125 3126 3127 3500 PROGRAM EDITED This message is displayed, if program selected for automatic execution is edited in automatic mode, or if program selected for manual data input execution is edited in MDI mode, meanwhile START is pressed. The message is canceled by RESET key. The program can be started if the EDIT screen is closed after terminating editing.
14.3 Listing of Global Messages Error Code Message Description Canceling and Repairing Method 3508 NC STATUS TABLE BAD If the check sum of the memory area containing the general NC state, preserved upon power-off is false.
14.3 Listing of Global Messages Error Code Message Description Canceling and Repairing Method 3518 DIRECTORY FULL At most 254 programs can be stored, for the file manager built in control enables the registration of 254 programs in the directory. This message is displayed, if more programs are to be registered during program execution by the use of command POPEN. This does not necessarily mean, that the memory is full. The message is canceled by RESET key.
14.3 Listing of Global Messages Error Code Canceling and Repairing Method Message Description 3549 RESTORE MODAL FUNCTIONS? Y The message is canceled by RESET key. INTD state remains. 3550 RESTORE MODAL FUNCTIONS? N If AUTOMATIC operation is started from INTD status by means of START, the control registers STOP status and question RESTORE MODAL FUNCTIONS? Y is displayed (Y=yes). By pressing key question RESTORE MODAL FUNCTIONS? N is displayed (N=no).
Notes Notes 143
Alphabetical index: Access forbidden . . . . . . . . . . . . . . . . . 12 Address . . . . . . . . . . . . . . . . . . . . . . . . 56 Alphabetical keys . . . . . . . . . . . . . . . . . 10 Arrow keys . . . . . . . . . . . . . . . . . . . . . 10 Beginning of program . . . . . . . . . . . . . 57 Block . . . . . . . . . . . . . . . . . . . . . . . . . 56 CANCEL . . . . . . . . . . . . . . . . . . . . . . 10 Conflicting state . . . . . . . . . . . . . . . . . 12 Control Panel . . . . . . . . . . . . . . . . . .
