Standard. CNC Turning & Milling Machine Rev 1.0. OM5 Control Software Instruction Manual

Transcription

1 Standard CNC Turning & Milling Machine Rev 1.0 OM5 Control Software Instruction Manual Legacy Woodworking Machinery 435 W N. Springville, UT 84663

2 Standard CNC Machine 2 Content Warranty and Repair information... 3 Standard CNC photo overview... 4 OM5 Control Software Overview (Mach3) OM5 Control Software Machine Setup screen... 7 Work Offsets screen Tool Setup screen Run Machine screen Diagnostic screen Referencing Machine Setting Up Offsets - Flat Stock Turning Between Centers Tool Touch Off Methods Smart Tool Tool Offset Part Bull Nose Standard CNC Fast Start Reference Sheet Trouble Shooting OM5 Control Software Glossary G-code Reference Page... 41

3 Standard 5 Axis CNC Turning/Milling Machine Product of: Legacy Woodworking Machinery 435 W N. Springville, UT WARRANTY Legacy Woodworking Machinery warrants to the original purchaser that it s products are free from defects in material and workmanship. This warranty covers electronic control devices for one year from the date of delivery. This warranty covers the frame and mechanical devices for three years from the date of delivery. This warranty does not cover any damage to Legacy products that result from improper installation, accident abuse, misuse, natural disaster, insufficient or excessive electrical supply, abnormal mechanical or environmental conditions, or any unauthorized disassembly, repair or modification. Repairs If product repair or replacement is necessary, the Customer is responsible for all shipping charges, freight, insurance and proper packaging to prevent breakage or damage in transit. Technical Support You can contact the Legacy s technical support department at: cncsupport@legacywoodworking.com (801) (800) Legacy provides free technical support for the first 90 days to its customers worldwide. Proudly made in the USA

4 X-axis Motor Control Tower EPO Box (emergency shut off) Z-axis Motor Y-axis Motor 4

5 OM5 Control Software The OM5 Control Software is an interface to the Mach 3 program. This software is designed to allow you to take full advantage of Legacy s powerful Five Axis CNC Milling Machines. The OM5 interface is divided into five separate work screens. Each screen contains the top menu bar, a middle work section and a bottom Manual Data Impute area. The top menu bar and the bottom Manual Data Impute area are identical on each screen. TOP MENU BAR: The top menu bar contains the five work screen titles, allowing you to access any screen with a click of the mouse. These screens have been laid out in a logical working order to assist in moving through each project in the proper sequence. 5 MIDDLE WORK AREA: The middle area of each screen is the work area and differs for each screen set. These screens will be covered in detail in the following pages. THE Manual Data Impute area: This area is the same on each screen and allows for manual data input as well as listing the active mode. It also includes System Reset, Modal Reset, reference sheets for G-code and M- code and a Screen Help which will take you to the help videos that have been pre-loaded with your program. Manual Data Input: This input line allows you to manually input G-code to move the machine. This is an advanced feature which is used as you gain understanding of G-code and how G-code is used to move and orient your machine. Active Modes: Lists the active G-code modes the machine is currently running in. System Reset: This button resets the machine. You can also use this button to stop a program. When starting the OM5 Control Software for the first time each day this button will be flashing and will need to be reset. Modal Reset: This will take the machine back to the factory set modes. G-Code: This button will take you to a reference screen that lists the G-code definitions in a short at a glance format and in an extended definition format. M-code: This button will take you to a reference screen that lists the M-code definitions in a short at a glance format. Screen Help: This screen will take you to the pre-loaded training videos menu.

6 6 Machine Setup: This screen contains three main function buttons. Set Machine Coordinates Spindle Warm-up Park Spindle These buttons are used to begin machine operations at the beginning of each day and to shut down machine operations at the end of each day. Work Offsets: This screen allows you to see at a glance the Machine Home Position in reference to the Work Offset Position. This is also the screen where you can manually create Offset positions for your projects and manually drive each axis motor. Tool Setup: This screen is where you will choose to use or not use the Smart Tool feature. The left side of the work area is dedicated to the control of Smart Tool. The right side of the work screen is designed for advanced tool library setup. Run Machine: This screen is your main work screen. This is where you will load and view code. You will also start each program from this screen and are able to watch your code as the program runs Diagnostics: This screen is used by Legacy technicians during initial set up and calibration.

7 Machine Setup Screen 7 Set Machine Coordinates: The Set Machine Coordinates button is not used on Standard CNC machine. The Home position for a Standard CNC Machine is set to the current location of the spindle when the machine is powered on. If the machine was parked at the proper home position prior to shut down using the Park Spindle button, then the Home coordinates will be positioned correctly. Go to the Work Offsets screen page for instruction on setting the Reference Machine or home coordinates (page 9). Spindle Warm-up: Not used on any machines using a router This function will start the spindle into a controlled warm up sequence that will take approximately 7-11 minutes to complete. Machines with a router do not need to perform a spindle warm-up. Part Spindle: The park spindle button drives all axis motors back to the Home Machine Coordinates. It is recommended to Park Spindle at the end of the day.

8 OM5 Control Software Work Offsets Screen 8 Code Coordinates: These digital number displays show the distance between the machine Home position and the Work Offset Position. Machine Position: These digital number displays show the current spindle location in reference to the machine home position. Work Offset Position: These digital number displays show the current spindle location in reference to the home position for the work offset you are currently using. Reference Machine: This button will set your machine home coordinates at the current spindle location. To change the Machine Coordinates, move the spindle to the desired location and hit Reference Machine. This is the main Reference Machine button for Standard CNC Machine. Reference A Axis: This button is not used on a Standard CNC Machine. Go To Offset: This button positions the cutter at 0 for all axes for the Offset you are currently in. It is important to check the Z-axis clearance before using the Go To Offset button. Active Offset: This is a DRO display that shows the Offset you are currently using. Offset 1 G54 - Offset 5G58: These buttons allow you to work multiple offsets in one project, or to run duplicate parts with different 0 offset positions. A Offset 6 G59: This offset has been programmed for A-axis turning and the X,Y 0 s are automatically set during the Reference Machine sequence. Axis Jog On/Off: When highlighted, this allows you to manually move your machine using the on screen or keyboard controls. When turned off, your machine can not be jogged manually. Slow Jog %: This allows you to change the jog speed by typing in a percent of the total speed, up to 100%. Cont Jog: Represents Continuous Jog. In continuous jog mode each axis motor will move at the given speed while the corresponding screen button or keyboard key is being depressed. Step Jog: This button changes the jog mode to incremental steps. The step size is determined by which jog size button you choose ,.0100 or The Ctrl (control) key is the keyboard shortcut key for this function. While in Cont Jog mode, hold down the Ctrl button and Step Jog is activated until you release the Ctrl button. Rotation Feed Rate: This digital number screen is used when turning on the A-axis. Type in the diameter of your work piece. The system uses this information to calculate the correct A-axis spindle RPM s to maintain the feed rate specified in your program.

9 9 Work Offsets Screen When manually jogging (moving) your machine router you have the choice between the on screen or keyboard controls. You use the on screen jog controls by placing your mouse arrow over the button corresponding to the direction you need to jog your machine. The machine will move while you hold down the left mouse button in continues jog mode or will move one step when in step mode. The keyboard manual jog controls are layout as follows: X-axis - Arrows right (+) and left (-) Y-axis - Arrows up (+) and down (-) Z-axis - Page Up is up; Page Down is down A-axis - less than (<) is clockwise; greater than (>) is counter clockwise. B-axis - Left bracket is down, Right bracket is up On screen manual jog controls Keyboard manual jog controls PgUp PgDn Alt Ctrl You can change to the Step Jog function by holding down the Control (Ctrl) button while using any of the keyboard control keys.

10 Tool Setup Screen Most Standard CNC Machines operators will not use this screen. The Smart Tool optional upgrade is needed to run the Smart Tool Setup which covers the right side of the screen. The left side of the screen, the Setup Tool Offsets, is an advanced tool library and will not be covered in this manual. 10 The Tool Setup Screen is divided into two sides, On the left side you have the Smart Tool set up buttons. On the right side you have the Setup Tool Offsets for setting up a custom tool table. Smart Tool: The Smart Tool is a sensing pad that automatically sets the Z-axis origin. It eliminates the need for tool tables with height offsets or manually touching off each tool. There are two Smart Tool options, one for Flat stock projects and one for Turnings. Smart Tool Setup: This button runs a routine to measure the difference between the Smart Tool Pad and your work piece when cutting on FLAT STOCK. This routine creates a 0 Z-axis position on the surface of your work piece. You will need to place the Mobile Smart Tool pad on you work piece and position your cutter over the pad prior to activating this routine. Smart Tool On: is used to turn on Smart Tool for use on FLAT STOCK Smart Tool A On: is used to turn on Smart Tool for use with TURNINGS on the A-AXIS Smart Tool Off: turns Smart Tool off It is important to remember that your machine settings need to match the type of tool changing you set in your programs. If Smart Tool is used in the G-code design program, Smart Tool must be turned on or the machine will not calibrate bit depths correctly. If Smart Tool was not used in the G-code design program then Smart Tool must be turned off. The following buttons are the same as on the Work Offset screen: Axis Jog On/Off, Slow Jog%, Cont. Jog, Step Jog,.1000,.0100 and You can find these button definition on page 4. Smart Tool A Offset: This DRO is used to calibrate the Smart Tool when turning between centers. This is preset during manufacturing at the factory and should require no adjustment. Setup Tool Offsets: turns Smart Tool off Reference tool touch: it sets the Z-axis to 0 for the reference tool using Smart Tool Zero reference tool: it manually sets the Z-axis to 0 for the reference tool. Tool Offset Touch: it sets the height offset in the Z-axis for the selected cutting tool using Smart Tool Write to tool table: this manually writes the offset in the Z-axis to the tool table Z Position: DRO for the Z-axis position Tool Offset: DRO listing the value written to the table for the height offset Tool number: DRO listing tool being programmed Tool in Spindle: this is where you enter the tool number the you wish to record the height offset Zero tool in part: used to establish 0 on part using the Mobile Pad

11 Run Machine Screen 11 The DRO s display the current position of each Axis in the current work offset. You can make changes to the Axis position by typing in a new value. The tool path display generates a view of the programmed tool paths that can be rotated with your mouse. The following buttons are used to interface with the tool path display. Display Mode: this button is currently no activated Regen Toolpath: regenerates the tool path window. Jog Follow: changes the tool path view from cutter to part. Soft Limits: Not used with the Standard CNC Machine. This button allows you to turn the Soft Limits on or off. Soft Limits are preset to ensure the machine does not run beyond the machine boundaries. Current Offset: Displays the current offset number. The shorter display line at the bottom of the tool path window shows the loaded code name and it s location on the hard drive. The longer display line is a message screen and will give you prompts when the program is running, such as press cycle start after tool change Tool Path Display The lower left view window will show the currently loaded G-code program. Cycle Start: starts the program Feed Hold: pauses the program - you can restart the program from the stopping point by clicking Cycle Start. Cycle Stop: stops the program you can not restart from this stopping point but must rewind and restart from the beginning of the program.

12 Run Machine Screen 12 Load Code: load the program code Edit Code: will open a notepad screen to allow code editing Close Code: closes the code Rewind: rewinds the code to the beginning Jog On/Off: turns the manual jog on or off Single Block: allows you to run one line at a time for trouble shooting and testing programs. Simulate: on the computer, runs the program and determines the Simulated Time Run From: allows you to run from any line in the code Line Number: lists the line number of the code you are on. Simulated Time: shows the estimated time to run a program. Elapsed Time: the actual time a program took to run The Feed Rate window: Feed Rate IPM: displays the programmed feed rate IPM inch per minute. Increase: increases the feed rate Decrease: decreases the feed rate Adjusted Feed Rate: shows the adjusted feed rate Spindle On/Off window: Not used with the Standard CNC Machine Spindle RPM: displays the programmed spindle RPM (rotations per minute) Increase: increases the spindle RPM Decrease: decreases the spindle RPM Adjusted RPM: shows the adjusted spindle RPM

13 13 Diagnostics Screen The Diagnostics Screen and has been designed for use by Legacy to help in trouble shooting this machine during initial configuration and out in the field. You will notice that many of the screens and buttons are a duplicate from previous screens. All Axes can also be calibrated using the Axis Calibrations button.

14 The Reference Machine home position establishes a reference location for all Offsets, soft limits and machine movements. Using this location, the machine can automatically stay within it s safe parameters. Referencing Machine 14 When using the Standard CNC system, Set Machine Coordinates on the Machine Setup screen is not used. You will need to use the Reference Machine button found on the Work Offset screen. To set the Reference Machine home position go to the Work Offset screen and move the router to the Home position. You establish the Home position by driving to the following locations using the keyboard jog keys. Y axis 0 home position is centered on the headstock shaft X axis 0 home position X-axis: With a piece of stock in between centers, drive the router so the center of the bit aligns with the end of stock at the headstock end. Mark the rail at the X-axis carriage center pointer. Y-axis: Without moving the X-axis, center the router bit over the part. Mark the Y-axis carriage tray pointer. Z-axis: Without moving the Y or X axes, drive the Z- axis to the top of the screw then lower.25 and mark the Z-axis rail at the top of the Z-axis base plate. Z-axis mark Once you are at this location, hit the Reference Machine button. Your machine home position is now set correctly. The Machine Position DRO displays should read 0. If you crash your machine into the part or physical limits of the machine, you will need to reset the home position by following the above sequence. Y-axis pointer X-axis pointer

15 Setting Up Work Offsets for Flat Stock The Work Offset refers to the XY origin location in reference to the part location. The XY origin is the 0, 0 point for X and Y. The XY origin location is manually set by the machine operator when beginning a new program. The Work Offsets for FLAT STOCK Offset 1 G54 thru Offset 5 G58 are set manually for flat stock work. 15 Flat Stock: The XY origin location on the work offset should match the XY origin location on your program drawing. Illustrated in the diagrams to the right you can see that the operators orientation to the work piece changes. When working on a computer drawing, we sit with the X axis running left and right across the bottom of the screen. When operating the machine, the Y axis is running back and forth to our right. In Conversational CAM all Flat Stock programs are referenced to the operators right front corner of the material. Many CAM programs, including V- carve, Aspire and Art Cam allow you to choose the XY origin during material setup. The most common locations for the XY origin are the center point and the operators right front = drawing left front. Once the XY origin location is determined go to the Work Offsets screen. Manually move the router to the XY origin location on the mounted material blank. Using a pointed router bit as a reference tool, jog to the exact location on the material whether it is a center mark or corner. Touch the router bit to the material for a accurate offset reading. Enable the Offset button you wish to program and reset the X and Y Work Offset Positions to 0. Z may also be set to 0 at this time as a safe Z location. operator H e a d s t o c k Y X Y X Center point Machine Orientation Center point Computer Drawing Orientation operator Y X

16 Setting Up Work Offsets for Turning Between Centers You should select the A Offset 6 G59 found on the Work Offsets screen when turning between centers. The X and Y axis origins are preset at the factory. The Z axis origin can be set manually or with the Smart Tool. The Y 0 is located at the center line of the headstock. X 0 is located at the end of the work piece, closest to the headstock, when using the index drive center and index hub to secure the work piece. 16 Y axis 0 home position is centered on the headstock shaft X axis 0 home position If a different A axis offset position is needed, such as when using a four jaw chuck - it is recommended you set up a second turning offset using one of the other offset locations (G54 G58). Using a pointed router bit, position the router at the new X axis position. In the Work Offsets screen, click a new offset button (Offset 5 G58). Reset the X axis position to 0. Go to A Offset 6 G59 and reference the offset positions for the Y and Z offset locations. Go back to Offset 5 G58 and enter the information from the A Offset 6 positions for Y and Z. X axis 0 home position

17 Tool Touch Off Method - Smart Tool - Smart Tool is an optional accessory for the Standard CNC system - The Smart Tool feature was designed by Legacy Woodworking to aid in finding the length of each cutter to achieve an accurate Z-axis plunge depth. When Smart Tool is on, the OM5 Control Software is prompted to measure each cutter. After a tool change, the cutter length is measure by touching off a senor pad. This measurement is referenced to Z-0 and calculations are automatically made to achieve the programmed cut depth. The Smart Tool feature is a program within the OM5 Control Software. The OM5 Control Software has been programmed to run the Smart Tool sequences when a T1 (tool change) appears in the code if Smart Tool is on. 17 The Smart Tool controls are found on the Tool Setup screen. Smart Tool On: Turns on Smart Tool when working with flat stock. Smart Tool A On: Turns on Smart Tool when working in the A axis for turning. Smart Tool Setup: Is used with Flat Stock to set the Z offset to 0 on the surface of the work piece using the Smart Tool Mobile Pad. Smart Tool Off: Turns off all Smart Tool functions. Smart Tool - Tuning on the A-axis The Z-0 for the A-axis was set during manufacturing prior to shipping. 1 - From the Work Offset screen make sure you are in A Offset 6 G From the Tool Setup screen turn on Smart Tool A On. 3 - Place part between centers in the A-axis. 4 - Load Code on Run Machine Screen. 5 - Begin Code - Cycle Start - Code will move spindle for tool change - After tool change click Cycle Start - Smart Tool program will run and touch off bit to the Stationary Smart Pad and begin the milling program. 6 - If there are more tool changes in the program, Smart Tool will run after each tool change. Smart Tool - with Flat stock The Z-axis 0 Offset for flat stock work must be established prior to running a milling program. This will be done with the Smart Tool Setup button. 1 - From the Work Offset screen, choose a flat stock offset, From the Tool Setup screen turn on Smart Tool On. 3 - Properly mount the part to be milled into the Legacy mill. 4 - Plug the Mobile Smart Pad into the 1/4 jack on the Stationary Smart Pad and place the pad flat on top of your part. 5 - With a router bit in the spindle, move the spindle directly over the Mobile Pad.

18 Tool Touch Off Method - Smart Tool Smart Tool - with Flat Stock cont. 6 - Click the Smart Tool Setup button. A script box will appear asking if the Touch Pad is under the Spindle. Click OK to continue the sequence. The spindle will lower until the router bit comes in contact with the aluminum surface of the Mobile Touch Pad - it will then back off the pad and slowly lower for the calibrating touch. 7 - Once the Spindle has raised off the pad, you will receive a button script prompting you to remove the pad. Remove and unplug the Mobile Touch Pad. 8 - The Spindle will now move to the Stationary Touch Pad. The spindle will repeat the calibrating touch off sequence. The OM5 Control Software has been preprogrammed with the Stationary Touch Pads location. With the added data gathered from the two Touch Pads the Z-axis Offset 0 will now be set From the Run Machine screen, Load Code 10 - Click Cycle Start to begin milling - - Code will move spindle for tool change - After tool change click Cycle Start - Smart Tool program will run and touch off bit to the Stationary Touch Pad and begin the milling program If there are more tool changes in the program, Smart Tool will run after each tool change.

19 Tool Touch Off Method Tool Offset This is an advanced tool library setup program which allows the user to create a customized tool library based on the tools they own. Each tool is individually given a description, a number, and measured to create the height offset. It is vitally important the tool number in the program being run matches the tool number in the library for the desired tool. When choosing Tool Offset as the tool touch off method in Conversational CAM, code is generated to tell the OM5 software to look to the tool library to find the tool height offset. A Reference Tool and Tool Collars are needed to perform the tool library setup. These are available from Legacy. Note: When using Tool Offset as the tool touch off method, it is recommended that you set your work offset Z - 0 using the reference tool. Setting up a tool library without Smart Tool 1 - Click Setup Tool Offsets. 2 - Place the reference tool in the spindle. You will need to manually touch off the reference tool onto a solid surface to establish the Z Position 0. We recommend using a gauge block. 3 - With the reference tool touching the gauge block, click Zero Reference Tool. 4 - Insert the cutter to be referenced. The cutter needs to have a tool collar attached to ensure proper repeatable placement. 5 - Enter Tool Number, we recommend you use tool numbers from 101 up. This will help minimize other programs from referencing the wrong tool number and height offset. 6 - Lower the spindle until the cutter touches the gauge block, click Write to Tool Table. To add another tool, enter a new tool number, place the tool in the spindle, lower the cutter to the gauge block and click Write To Tool Table. Setting up a tool library with Smart Tool 1 - Click Setup Tool Offset found on the Tool Setup screen. This will turn your Smart Tool off. 2 - Click Reference Tool Touch. The spindle will move above the stationary Smart pad. A message screen will ask you to place the reference tool in the spindle. Place the reference tool in the spindle, click OK. The spindle will lower to the Smart Pad and automatically write the Z Position to A message screen will appear to ask you to change the tool number. We recommend you use tool numbers from 101 up. This will help minimize other programs from referencing the wrong tool number and height offset. 4 - Insert the cutter to be referenced. The cutter needs to have a tool collar attached to ensure proper repeatable placement. Click Tool Offset Touch. The spindle will lower to the Smart Pad and write the offset for this cutter to the tool library. Repeat steps 3-4 to continue adding to the tool library. 19

20 Tool Touch Off Method Part Touching off on the part allows the operator to manually bring the cutter to the part surface to set the Z-axis 0 to the surface of the part. Benefits in using the Part touch off method: Allows you to mill exact plunge depths without entering the diameter of the part. Allows you to run the same program on different diameter or thicknesses of parts. When Surface Planing - Part touch off allows you to resurface the same part without having to rewrite the program. The disadvantage is you have to touch off the part every time the program is run. Conversational CAM will write a pause for touching off the part within the generated code when Part is chosen as the tool touch off method. After the tool change, the spindle will move to the part for the touch off sequence. After bringing the cutting to the surface of the part, click cycle start to set the Z-axis to 0 and begin the milling process. Other CAM programs will not write a pause for touching off the part during the program. You will need to touch off the part and set the Z-axis to 0 prior to running the program. Note: Remember to click Smart Tool Off on the Tool Setup screen when setting up a milling process using Part as the tool touch off. You can touch off on both flat stock and turned parts. To increase your touch off accuracy, flat plane or turn round your work stock as the first step in your milling process. To touch off Part Using the manual jog controls, move the cutter to the surface of the part. It is important to use the Step Jog feature to allow small controlled movements. Remember the control key is the Step Jog shortcut key on your keyboard - while pressed, you will move in the set Step Jog mode. Visual accuracy - 1. Bring the cutter down to within.125 of the surface of the part. 2. Using the Jog mode, lower the cutter to the surface of the part. 3. Click Cycle Start if using a Conversational CAM program or 0 your Z-axis if using other design programs. If a closer tolerance is required, we recommend using a piece of paper to achieve tolerances of Bring the cutter down to within.125 of the surface of the part. 2. Place a piece of paper between the cutter tip and wood and continue sliding the paper gently back and forth while slowly lowering the cutter. 3. You will begin to feel the paper drag then catch against the cutter. It is important to use the Jog Controls to lower the spindle. Stop when the paper can no longer move back and forth. 4. Click Cycle Start if using a Conversational CAM program or 0 your Z-axis if using other design programs. Alt Ctrl PgUp PgDn 20

21 Tool Touch Off Method Bull Nose The Bull Nose touch off method was designed for the CNC system that does not have Smart Tool installed and is used to set the Z 0 when turning between centers. The Bull Nose center is a 1.4 diam. x 1.25 Delrin center designed to be placed over the point of the tailstock shaft. When using the Bull Nose in the tool touch off method the Bull Nose is placed on the tailstock shaft and the cutter is brought down to the Bull Nose surface to establish the Z 0 for the A-axis. 21 Using Bull Nose with Conversational CAM programs When using Bull Nose as the touch off method in Conversational CAM, code will automatically generate to run the Bull Nose touch off sequence. 1 - Once the code is loaded into the OM5 Control Software, and Cycle Start is clicked, a prompt will appear in the message screen saying insert and touch off tool 1 (the tool number will reflect the tool you specified while programming this part). 2 - Insert the correct tool and bring the cutter tip to the surface of the Bull Nose. Remember to us the jog control mode to move the spindle. Once the cutter tip is lightly touching the Bull Nose, click Cycle Start. 3 - The Z position will automatically be written to.7, which is the radius of the Bull Nose. The program will continue and finish as programmed. Bull Nose Center Bull Nose with other CAM programs All other CAM programs will not generate code to automatically touch off the Bull Nose when the program is running. The touch off sequence will have to be performed manually during the tool change sequence of the program. 1 - At the tool change prompt, insert the correct tool. 2 - Bring the tool down to the Bull Nose surface using the Jog mode controls. 3 - With the cutter tip lightly touching the Bull Nose, reset the Z-axis Position to Raise the spindle and turn the router on - click Cycle Start. The program will continue and finish as programmed.

22 Standard CNC Fast Start Reference Sheet Single Process Program 1. Turn the power on to the main CNC Tower. 2. Turn the power on to the computer. 3. Open Mach3 Loader from your desktop, Start menu or toolbar at the bottom of your screen. Choose STANDARD from the Session Profile screen. Mach3 will open the OM5 Control Software. 4. The OM5 software will open to the Machine Set screen - hit the flashing red System Reset button. 5. You will need to Set Machine Coordinates by manually jogging all Axes to the 0 home position and Set Machine Coordinates. If Park Spindle was previously performed at end of day, axes will already be at Go to the Work Offsets screen and click the corresponding work offset button for your work type. Offset 1 5 for flat stock or Offset 6 for turning. If turning, also set the Rotational Feed Rate box to the diameter of your work piece. 7. Go to the Tool Set Up screen and turn Smart Tool OFF! 8. Open Conversational CAM V3.1 from the desktop, Start menu or toolbar. 9. Enable Macros 10. From the Main Menu, choose the type of CAM program you wish to create. 11. Answer questions accord to your work piece design. 12. Hit the hard return (Enter button) to generate code and have it appear on the right of the screen. 13. Follow instruction on bottom of screen. 14. Open notebook and paste code to screen by right clicking the mouse and hitting paste OR going to Edit and paste on the notepad menu. 15. Name and save this notepad code to the: Desktop Documents G-code file folder. Your program has now been saved to the hard drive and is ready to accessed by Mach Go to the Run Machine screen and click load code. 17. You will find the code in the: Desktop Documents G-code folder. 18. Choose the correct file and load the code by double clicking the file name or choosing to open the file. 19. Your code is now loaded Hit Cycle Start 20. The program will begin and prompt you to insert and touch of tool insert correct bit and touch off Bull Nose or Part - leave router bit touching the Bull Nose or Part. 21. Hit Cycle Start to continue the program. 22

23 Trouble Shooting Occurrence Possible Cause Corrective Action 23 Smooth Stepper Error code: This code sometime appears when the Esc key is pressed during a running sequence, i.e. touching off the smart tool Clicking noise from motors. One of the motors was driven into the physical limits. Call Legacy for the most recent download plug-in for the Smooth Stepper. Bring the motor back within the proximity switch limits. Run Set Machine Coordinates. When running Set Machine Coordinates the Z axis moves down, away from the proximity switch. If you have burn marks on the wood. System Reset will not reset machine, no movement One of the proximity switches were enabled when Set Machine Coordinates was activated. 1 Bit is dull 2 Router or Spindle RPM is to high 3 Your feedrate is to slow 1 Emergency Stop Button is engaged. 2 No communication with the Smooth Stepper Move all axes off the proximity switches and run Set Machine Coordinates again. You can check if any proximity switches are engaged by checking to see if any of the M1 thru M5 Home DROs are lit on the Diagnostic screen. 1 Sharpen bit 2 Slow Router or Spindle RPMs down 3 Increase your feedrate Release the Emergency Stop Button Power all the way down and restart

24 Glossary Bull Nose: The Bull Nose center is a 1.4 diam. x 1.25 Delrin center designed to be placed over the point of the tailstock shaft. The Legacy Bull Nose is a pointed extension to the tailstock shaft that has been manufactured to an exact thickness to guarantee accurate Z-axis 0 settings when willing between centers. and Bull Nose is a tool touch off method used with the Standard CNC OM5 Control Software specifically designed to accurately set the Z-axis home position for A-axis turning. When choosing Bull Nose as a touch off method, a Bull Nose is placed on the tailstock shaft and the cutter it brought down to the Bull Nose surface to establish Z 0 for the work offset. Conversational CAM: Is a Computer Aided Manufacturing program which uses specific questions to design turnings and flat milling then produces the G-code needed to run the Legacy CNC milling machine. Conversational CAM was designed by Legacy to streamline the design process of commonly milled components without the use of a CAD (computer aided design) software program to draw the parts. Delrin: A self lubricating high grade plastic. Feed rate: Is the speed the cutter moves past the part, measured in IPM inches per minute. When using the A-axis, the feed rate is the speed the part moves past the cutter. Guidelines: larger diameter of cutter = slower feed rate. Deeper the cut = slower feed rate. If the bit chatters, slow down the feed rate speed up the RPMs. Recommended feed rates for the Standard CNC machines are IPM. G-code: are functions in the Numerical control programming language. The G-codes are the codes that position the tool and do the actual work, as opposed to M-codes, that manage the machine; T for tool-related codes, and S and F are tool-speed and tool-feed. The programming language of Numerical Control (NC) is sometimes informally called G-code. But in actuality, G-codes are only a part of the NC-programming language that controls NC and CNC machine tools. OM5 Control Software: The OM5 software has been custom designed by Legacy as an interface to Mach3 and is the control software used to run all Legacy CNC milling machines. The OM5 software was designed as a user friendly screen interface to help utilize the unique milling attributes of the Legacy CNC mills. Part: Refers to the work stock placed in the Legacy Mill. and Is a tool touch off method used in Conversational CAM where the cutter is brought down to the surface of the part to establish the cutter length in reference to the machine Z axis 0 position. RPM Rotations Per Minute: Recommended Maximum Router Bit RPM Bit Diameter RPM , ` 19, , ,000 Smart Tool: Is a tool touch off method designed by Legacy to set the Z-axis height offset in relation to the part surface and router bit length. This eliminates the hassles of setting up tool tables with height offsets. To use Smart Tool, you must have the Smart Tool programming and Stationary Pad installed on your machine as well as the Mobile Pad. When choosing Smart Tool in a Conversational CAM program, code will be generated to run the Smart Tool touch off procedure. Smart Tool must be turned on in the OM5 software program to run Smart Tool successfully. Stepper Motor: Is the type of motor used to drive the axes on Legacy Mills. These are Open Loop impulse motors which measure movement through electrical impulses traveling through a magnetic field. These are a low maintenance, easy to use motor with no internal gear system. If you run into a physical barrier these motors will not be damaged, but you will hear a ratcheting sound. You will need to reference your machine if this happens. Surface Planing: To smooth or level the uneven surface of a work piece by using a flat bottom bit to accurately remove material. Tool Offset: Is a tool touch off method used in the Conversational CAD program. Using a tool library based on the length of each tool in reference to a standard reference tool length. This will allow the operator to assign a number and saved tool data on individual tools. Tool Touch Off Methods: These are the methods available for measuring the router bit length in relationship to the Z 0. The four tool touch off methods used are Smart Tool, Tool Offset, Part and Bull nose. 24

25 G-codes are the codes that position the tool and do the actual work. G0: Rapid positioning G1: Linear interpolation G2: Clockwise circular/helical interpolation G3: Counterclockwise circular/helical interpolation G4: Dwell G10: Coordinate system origin setting G12: Clockwise circular pocket G13: Counterclockwise circular pocket G15/G16: Polar Coordinate moves in G0 and G1 G17: XY plane select G18: XZ plane select G20/G21: Inch/Millimetre unit G28: Return home G30: Return home G31: Straight probe G40: Cancel cutter radius compensation G41/G42: Start cutter radius compensation left/ right G43: Apply tool length offset (plus) G49: Cancel tool length offset G50: Reset all scale factors to 1.0 G51: Set axis data input scale factors G52: Temporary coordinate system offsets G53: Move in absolute machine coordinate G54: Use fixture offset 1 G55: Use fixture offset 2 G56: Use fixture offset 3 G57: Use fixture offset 4 G58: Use fixture offset 5 G59: Use fixture offset 6 G61/G64: Exact stop/constant Velocity mode G68/G69: Rotate program coordinate G70/G71: Inch/Millimetre unit G80: Cancel motion mode G90: Absolute distance mode G91: Incremental distance mode G92: Offset coordinates and set parameters G93: Inverse time feed mode G94: Unite per minute G98: Rapid Height by Z height G99: Rapid Height by R height G-code reference sheet M-codes manage the machine 25 M0: Program stop M1: Optional program stop M2: Program end M3/M4: Rotate spindle clockwise/counterclockwise M5: Stop spindle rotation M6: Tool change M30: Program end and rewind M47: Repeat program from first line M98: Call subroutine M99: Return from subroutine/repeat S codes are related to the tool Speed F codes are related to the tool Feed T codes are tool related and represent the tool number. H codes are tool height related and represent the height offset listed in the tool library for the tool listed. Example: H6 = height offset for Tool 6