User's Manual Thank you very much for purchasing the CAMM-3 Model PNC-3100. • To ensure correct and safe usage with a full understanding of this product's performance, please be sure to read through this manual completely and store it in a safe location. • Unauthorized copying or transferral, in whole or in part, of this manual is prohibited. • The contents of this operation manual and the specifications of this product are subject to change without notice.
For the USA FEDERAL COMMUNICATIONS COMMISSION RADIO FREQUENCY INTERFERENCE STATEMENT This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment.
Table of Contents How to Read This Manual ............................................................................................. i Typographic Conventions ........................................................................................... ii To Ensure Safe Use ......................................................................................... iii Part 1 Startup 1. 2. 3. 4. 5. Conditions for Installation ..................................................................................
How to Read This Manual This manual is organized in the following format. Please use it in the way that best matches your needs. Part 1 Startup Installation, basic operation, and the procedures to follow when finished cutting are explained here. Please read this section if you are using the PNC-3100 for the first time. Part 2 User's Reference Usage of the PNC-3100’s functions, daily care, and an overview if instruction sets sent from the computer are explained here.
Typographic Conventions This manual uses certain typographic symbols, outlined below. This indicates a point requiring particular care to ensure safe use of the product. DANGER : Failure to heed this message will result in serious injury or death. WARNING : Failure to heed this message may result in serious injury or death. CAUTION : Failure to heed this message may result in minor injury. NOTICE : Indicates important information to prevent machine breakdown or malfunction and ensure correct use.
To Ensure Safe Use WARNING WARNING Keep hands away from moving spindle. Do not wear gloves, a necktie or wide-sleeved clothing. Such items may become caught in the machine. WARNING yy , À @ @ À , @ À , yy À @ , WARNING Switch off spindle before attempting to access it. Do not insert the fingers between the XY table and base or between the head and Z cover. Switch off the spindle before mounting or removing a tool, and before cleaning. Sudden movement of the spindle may occur otherwise.
WARNING WARNING @AÀÁ,yz ACÁÃz| Do not operate beyond capacity or subject the tool to undue force. Fasten the tool and material securely in place. The tool may break or fly off in a random direction. If machining operation beyond capacity is started inadvertently, immediately switch off the power. This items may come loose during cutting and fly off in a random direction. WARNING WARNING Wear dust goggles and mask during use. Do not disassemble or remodel the machine.
CAUTION CAUTION Do not block the ventilation holes. Handle the power cord with care. Blocking the ventilation holes at the rear of the controller may prevent heat radiation and cause fire. Do not step on or damage the power cord, or allow heavy objects to be placed atop it. Failure to heed this may result in electrocution or fire. Ventilation holes X Y Z Z CAUTION CAUTION Do not place anything within the moving area of the XY table.
About the Warning Labels Affixed to the Unit Four warning labels are affixed to the body of this product. The following figure describes the location and content of these warning messages. @À,y ,@Àyy,À@ @ À , y @@ ÀÀ ,, yy @@ ÀÀ ,, yy Do not insert fingers between the head and Z cover during operation. Handle tool with care. Do not insert fingers between XY table and base during operation. Do not place anything within the moving area of the XY TABLE.
To Ensure Correct Use NOTICE Never pile things up on head of the PNC-3100. This can be very dangerous because of the possibility of vibration during operation.
Part 1 1 Part Part StartUp 1. Conditions for Installation WARNING Do not install the machine in a location where it may tip over, such as at the edge of a table. NOTICE The space shown in the figure is required for installation. 150mm (5-15/16") Install the machine on a stable stand for operation. Use within a temperature range of 5 to 40°C (41 to 104°F) and within a humidity range of 35 to 80%. Avoid installing the PNC-3100 in the following locations, as this may result in damage to the machine.
Part 1 2. Removing the PNC-3100 from the Carton CAUTION Two or more people are needed to take the PNC-3100 out of the carton. The main unit weighs 52 kg (114.6 lb.), and the controller weighs 9 kg (19.8 lb.). For this reason, extreme care should be taken to avoid injury when installing. Remove all packing material, except for the packing material underneath the main unit. A securing board is attached to the unit. Use the 17 mm spanner included with the unit to remove the four bolts and detach the board.
Part 1 4.
Part 1 Power/Error LED Controller Spindle control Parallel connector Power switch Serial connector POWER OFF POWER ON Option connector (Refer to page 41.
Part 1 Switch panel X-AXIS Y-AXIS Z -AXIS JOG X Y Z ENTER REPLOT SPINDLE TEST SENSOR ON / OFF ON / OFF BUFFER Z1 Z0 Z2 HOME JOG VIEW Z CLEAR PAUSE ON X-AXIS OFF XYZ Coordinate Display This display shows the coordinate values of each axis in 1/100 mm units. For the X and Y axes, the home position coordinates (refer to page 14) are (0, 0). For the Z axis, Z0 (refer to page 15) is displayed as "0.
Part 1 PAUSE Keys When the [PAUSE ON] key is pressed while operating under the instruction of a computer, the PAUSE LED comes ON and the PNC3100 enters the temporary stop condition and all cutting operations are interrupted. When the [OFF] key is pressed, the temporary stop condition is cancelled and machine resumes cutting from the position at which operation was interrupted.
Part 1 5. Connecting to a Computer Connecting the Main Unit, Controller, and Switch Panel NOTICE Connect the cables only when the PNC-3100 and the computer power sources are OFF. Ensure that the power supply voltage is within ±10% of the machine's rated voltage. Securely connect the power cord and cables for computer input and output to prevent them from coming loose or causing poor contact during use.
Part 1 Connecting to a Computer NOTICE When connecting to a computer for the first time, be sure to perform an operation check to make sure the unit is operating correctly. Connect the PNC-3100 to the computer using the cable. The cable for computer connection is optional. Please purchase the appropriate cable for the type of computer and software used . Parallel Connection Connect the printer-use connector of the computer and the parallel connector at the rear of the controller using a parallel cable.
Part 1 Communication Protocol Setting In the PNC-3100, the interface type (Parallel or Serial) is differentiated automatically. The distinguished interface is memorized until the power is turned OFF. It can not be varied while the power is ON. When changing the differentiated interface, turn the power OFF and then ON again, then transmit data. In the case of serial connection, the controller sends and receives data under the communication protocols set using the PNC-3100 DIP switches.
Part 1 6. Workpiece Set Side WARNING Detachment of the material during operation is extremely dangerous. Follow the procedure described below to fasten the material in place securely. NOTICE Do not place anything on the XY table except material to be cut. This section is an explanation of the cutting workpiece attachment method when an optional machine vice ZV-1 is used. If employing an alternative attachment method, fix the workpiece firmly in place using the following explanation for reference.
Part 1 7. Cutting Tool Attachment WARNING When you attach the cutting tool, make sure that the SPINDLE switch is OFF. NOTICE Use the correct tool for the material to be cut and the cutting method. 1 2 Set the SPINDLE switch on the front of the PNC-3100 to OFF. LED • The LED lamp in the SPINDLE switch flashes. (When power is applied.) If a cutting tool has been installed, remove it. Use the two spanners provided to loosen the collet cap.
Part 1 If the collet chuck has not been installed, install it. Fit the collet chuck in the collet cap as shown in the figure, and tighten provisionally on the spindle. • Lightly tighten the collet cap to prevent it from falling off. • The collet chuck included with the unit has a diameter of 6 mm (1/4"). If the shank diameter of the cutting tool does not match the diameter of the chuck, replace with a chuck of matching diameter (chucks with diameters other than 6 mm (1/4") are sold separately).
Part 1 Set the SPINDLE switch to ON. 5 • The LED lamp in the SPINDLE switch lights up. (When power is applied.) 8. Power ON CAUTION Connection all cables securely. Normal operation may be impossible if the power is switched on while connections are incomplete. Press the POWER switch on the front of the controller setting the power to ON. (In the PNC-3100 after setting the power to ON, proceed to turn on power to the computer.
Part 1 9. Setting the Cutting Origin The PNC-3100 are suitable for use with a versatile range of workpiece shapes and a wide variety of tools, so determine the standard points for cutting each time a new workpiece is set. Set the home position (origin point for X an Y axes) and Z0 (Z axis origin point). (If these points can be set with your current software, they should be set using the software.
Part 1 Setting the Z0 Position With some software, Z1 (the tool-down position) and Z2 (the tool-up position) are set by commands from the software (see page 28 for an explanation of Z1 and Z2). Right after switching on the power, Z0 is set at the mechanically uppermost position. This means that if cutting data is sent from such software without setting Z0 first, the software will attempt to set Z2 at a position higher than the uppermost mechanical point, and an error will occur.
Part 1 10. Cutting Condition Setting WARNING When using a small-diameter tool, do not apply an excessive feed speed or cutting-in amount while cutting, or the tool may break or fly off. Before you begin the actual cutting process, the cutting conditions such as the revolution speed of the spindle motor and the feeding speed of each axis must be designated according to the quality of the workpiece and the type of tool used.
Part 1 Spindle Motor Revolution Speed HIGH The spindle motor revolution speed can be set by turning the spindle control knob on the controller. Monitor the speed indicated on the Spindle RPM Display while making this setting. Spindle Speed Ranges 3,000 to 8,000 rpm Cutting-in Amount The cutting-in amount is set by setting Z1. (Refer to page 28; "Setting the Tool Up/Down Position Manually.
Part 1 11. Downloading Cutting Data The PNC-3100 performs cutting after receiving cutting data from the computer (software). In this section, general matters related to data output are explained. Refer to this section when carrying out data output. For details of the cutting data output method, refer to the operation manual for the software used. Software Setting In cases where cutting is controlled by generally available application software, select PNC-3100 as the output equipment setting.
Part 1 12. Finishing 1 2 When all cutting operations are complete press the [VIEW] key for at least half a second. At least 0.5 seconds. • Raise the cutting tool, move the XY table to the outer left (close to operator) and stop it. • When the spindle is still rotating, press the [SPINDLE TEST ON/OFF] key in order to stop it. • After turning off the power, removal of the workpiece and cutting tool will be easier now that the spindle has been moved out of the way.
Part 2 Part Part 2 User's Reference 1. Cutting Area The maximum cutting area of the PNC-3100 is 250 mm × 150 mm × 150 mm (9-13/16" × 5-7/8" × 5-7/8"). Converting this into coordinate values based on the machine's step number (1 step = 1/100 mm (0.00039")), we obtain the coordinate system; (x, y, z)=(25000, 15000, 15000).
Part 2 2. Coordinate System The PNC-3100 employs three separate coordinate systems (described below) according to the application or purpose of use. Machine Coordinate Under the machine coordinate system, the coordinates are determined mechanically against the PNC-3100. This system forms the basis of the "work coordinates" and "user coordinates" which are explained later. The machine coordinate range is equivalent to the PNC3100's maximum operating range.
Part 2 3. Operating Each Function Replotting (Recutting) Pressing the [REPLOT] key calls up the cutting data stored in the PNC-3100's data buffer and executes the replotting procedure. The data buffer is the place where data received from the computer is stored temporarily. (The data in the data buffer can be erased by switching off the power or holding down the [BUFFER CLEAR] key for at least 0.5 sec.) When replotting is executed, the entire data content of the data buffer is called up.
Part 2 Feeding Speed Manual Setting At times when speed cannot be set with the software or when adjusting the speed during an ongoing cutting operation use the panel switch keys to set cutting tool movement speed. Press the [PAUSE ON] key. 1 • PAUSE LED comes ON. Press the [ENTER] key. 2 3 • The current feeding speed of each axis is displayed on the coordinate display of the switch panel. (Units are in mm/sec.) Press the Jog key ([ [ (Z)], [ (Z)]).
Part 2 Operation Check If the PNC-3100 operates abnormally, perform an operation check according to the instructions below. If, as a result of the check, no abnormality is found, check for abnormalities in the computer, software or cable. WARNING Remove the tool, workpiece and vice before beginning the operation check. 1 Turn the power ON. (If the power has already been turned on, turn it off and then back on again. • The POWER/ERROR LED will light up. Press the Jog key.
Part 2 4 5 6 Press the [SPINDLE TEST ON/OFF] key for at least 0.5 seconds. At least 0.5 seconds. • The spindle starts to rotate. Turn the Spindle Control knob to the left and right. • Rotating the control clockwise raises spindle speed (rpm). • Rotating the control counterclockwise lowers spindle speed (rpm). • Make sure that the speed indicated on the Spindle RPM Display changes. HIGH Press the [SPINDLE TEST ON/OFF] key. • Spindle rotation stops. STOP Turn the Spindle switch OFF.
Part 2 8 Press the [SPINDLE TEST ON/OFF] key for at least 0.5 seconds. At least 0.5 seconds. • The spindle does not rotate. Turn the Spindle switch ON. 9 • The spindle lights up after flashing. Turn the power OFF. 10 • The POWER/ERROR LED turns off. This completes the operation check. If no abnormalities are detected in the course of this check, the PNC-3100 is normal.
Part 2 Stopping the Cutting Process Immediately In the case that you begin cutting and then find that you have sent the wrong cutting data, perform the following operation. Press the [PAUSE ON] key. 1 2 • PAUSE LED comes ON. • The unit stops after completing the cutting operation in progress. Stop the transfer of data to the PNC-3100 by operating software of computer. Download Data • For details of the data transfer stop method, refer to the manual of the computer or software you use.
Part 2 Setting the Tool Up/Down Position Manually The cutting tool up position (Z2 point) and down position (Z1 point) are normally set with the software. If they cannot be set with your current software then set them manually using the keys on the switch panel. Setting is done by determining the cutting tool up position Z2 and down position Z1. Tool Tool up position Tool down position 1 2 3 Z2 Z0 Z1 Workpiece Move the cutting tool tip to a position near Z1 (or Z2) with the jog keys [ (Z)], [ (Z)].
Part 2 4. Maintenance WARNING When cleaning the PNC-3100, make sure that the main unit's power is OFF. Cleaning the Main Unit When the arm of the main unit (excluding the display section), controller or switch panel (excluding the display section) becomes dirty, use a cloth moistened with water or neutral detergent solution to wipe it lightly. Use a dry cloth to wipe the display section on the main unit and switch panel.
Part 2 Display of Spindle Rotation Time The PNC-3100 has a function for the displaying the total rotation time of the spindle. Because the brushes and other components of the spindle motor are parts that wear out and require inspection at periodic intervals. This display is designed to serve as a guide for such inspection. (The motor brushes require replacement approximately every 500 hours.) Turn the power ON. 1 • The POWER/ERROR LED will light up. Press the [PAUSE ON] key. 2 3 • PAUSE LED comes ON.
Part 2 5. Troubleshooting When the PNC-3100 does not work ... The following causes should be considered. PNC-3100 Main Unit Checking Item Is the PNC-3100 damaged? Is the PNC-3100 in the temporary stop condition? Is the PNC-3100's power OFF? Remedy See page 24 "Operation Check" and perform the operation check procedure. When the Pause LED is ON, the main unit is in the temporary stop condition. Press the [OFF] key to cancel the temporary stop condition. Turn the PNC-3100 power ON.
Part 2 Connecting Cable Checking Item Remedy Are the computer and machine connected with the The connection cable differs according to the type of computer and the correct cable? software employed. Different software run on the same computer may Is the cable connected correctly? Connect the cable correctly. require a different cable. Use the designated cable. When the POWER/ERROR LED Flashes The POWER/ERROR LED flashes to indicate that an error has occurred in the PNC-3100.
Part 2 6. List of CAMM-GLI Instructions A "CAMM-GL I Programmer's Manual" is available for separate purchase for those wishing to create their own programs for this machine. For further information, please contact the nearest Roland DG Corp. dealer or distributor. * 1 : -(226-1)—+(226-1) * 2 : -(226-1)—+(226-1) * 3 : -(226-1)°—+(226-1)° • mode1 Instruction @ Input Z1 & Z2 Com.
Part 2 • mode2 Instruction AA AR CA Arc Absolute Arc Relative Alternate Character Com. O O O Set CI Circle Format Parameter AA x, y, Øc(, Ød); x, y AA ∆x, ∆y, Øc(, Ød); Center angle *3 Ød Chord tolerance * 1 [5°] Character Plot [Default] Center coordinate *1 Øc Center angle *3 Ød Chord tolerance * 1 [5°] n Character set No.
Part 2 • mode2 UC Instruction User Defined Character VS Velocity Select Com. O O Format UC (c,)∆x1,∆y1(,(c,)∆x2,∆y2...
Part 2 Instruction ESC .N Format [ESC].N;;; Set Handshake Output Specifications (2) • • • • ;: Parameter P1 : Intercharacter delay data block P2—P11 Range ([ ] is default) 0—32767(msec) [0(msec)] Explanation Sets an intercharacter delay, and also an Xoff character for performing the Xon/Xoff handshake. [All 0(Sets nothing)] : Xoff character (for Xon/Xoff) Immediate response character (for ENQ/ACK) ESC .H [ESC].H;; Sets ENQ/ACK Handshake Mode1 ; • • • • ;: ESC .
Appendix APPENDIX Supplies < Tools> Name Product No. Conventional steel straight end mill End mill Specifications ZHS-100 φ1 3 l x 6d x 45L x 2NT ZHS-200 φ2 5 l x 6d x 50L x 2NT ZHS-300 φ3 8 l x 6d x 50L x 2NT ZHS-400 φ4 8 l x 6d x 60L x 2NT ZHS-500 φ5 10 l x 6d x 60L x 2NT ZHS-600 φ6 12 l x 6d x 60L x 2NT Cemented carbide steel ball end mill ZUB-150 R1.5 10 l x 3d x 65L x 2NT ZUB-200 R2.0 12 l x 4d x 65L x 2NT (superfine particle) ZUB-250 R2.
Appendix Collet chuck The collet chuck and collet cap included with the PNC-3100 are the EDC-0624 (diameter 6 mm (1/4") collet chuck) and KDP-2422 (collet cap) made by NT Tool Co., Ltd. Please see the chart below for collet chucks with diameters other than 6 mm (1/4"). < Collet chucks> (Not available from Roland DG Corporation) Name Collet chuck Name Collet cap Product No. Tool shank diameter EDC-0324 φ3.02.8 EDC-03324 φ3.33.1 EDC-03624 φ3.63.4 EDC-03924 φ3.93.7 EDC-04224 φ4.24.
Appendix Specifications PNC-3100 XY table size Max. cutting area 560 mm x 170 mm (22-1/16" x 6-11/16") 250 mm(X) x 150 mm(Y) x 150 mm(Z) (9-13/16"(X) x 5-7/8"(Y) x 5-7/8"(Z)) Software resolution 0.01 mm/step (0.00039") Mechanical resolution Feed rate 0.00125 mm/step (micro-step control) X, Y-axis : Max. 60 mm/sec. (2-3/8"/sec.) Spindle motor Z-axis : Max. 30 mm/sec. (1-3/16"/sec.
Appendix • Parallel connector NC 36 18 HIGH * 35 17 HIGH *** GND NC 34 16 GND GND 33 15 NC HIGH * 32 14 NC NC 31 13 HIGH ** 30 12 GND 29 11 BUSY 28 10 ACK 27 9 D7 26 8 D6 25 7 D5 24 6 D4 23 5 D3 22 4 D2 21 3 D1 20 2 D0 19 1 STROBE 1 18 GND *= ** = *** = +5V 3.3K Ω 19 36 +5V 1.2K Ω +5V 100 Ω • Serial connector Terminal No.
Appendix • Option connector NC GND 36 18 35 17 34 16 33 15 32 14 31 13 30 12 29 11 28 10 27 9 26 8 25 7 24 6 23 5 22 4 21 3 20 2 19 1 36 18 19 1 NC SPINDLE ON/OFF Connector : JAE Co.
Appendix Index [ ], [ ], [ ], [ ], [ (Z) ], [ ] key ......... 6, 14, 15 Cutting condition (Z) [BUFFER CLEAR] key ................................. 6, 22, 27 -(manual setting) ............................................... 16, 17 [ENTER] key ............................................ 5, 14, 15, 28 -(setting example) ................................................... 17 [HOME] key ......................................................... 5, 14 Cutting origin .................................
Appendix O U Operation check ........................................................ 24 User coordinate system ............................................. 21 Option connector ........................................................ 4 Option connector specification ................................. 41 W Origin of the machine coordinate ............................. 21 Work coordinate system ........................................... 21 Origin of the work coordinate ...............................
Appendix MEMO 44
PNC-3100 Printed in JAPAN R9-980216
