Navigation

  • Page 1

    EZ-TROL II CONTROL SYSTEMUSER’S GUIDEVERSION 1.1 2009

  • Page 2

    SmithyCNC EZ-Trol II Control System User’s GuideSmithyCNC (Smithy Co.)170 Aprill Dr., Ann Arbor, MichiganUSA 48103Toll Free Hotline: 1-800-476-4849Fax: 1-800-431-8892International: 734-913-6700International Fax: 734-913-6663www.smithycnc.comCopyright © 2009 SmithyCNC &Smithy Co.All rights ...

  • Page 3

    TABLE OF CONTENTS1 |INTRODUCTION........................................1Development Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Four Steps of Machining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Organization of this Manual. . . . . . ...

  • Page 4

    Initial Machine Homing - one axis at a time . . . . . . . . . . . . . . . . 20Homing Your Machine on All Axes. . . . . . . . . . . . . . . . . . . . . . . . 22Limit Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Basic G-code . . . . . . . . . . . . . ...

  • Page 5

    Manual Data Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37E-Stop . . ....

  • Page 6

    ToAddMore Programming the Machine . . . . . . . . . . . . . . . . . . 6216 | ELECTRICAL PIN OUTS.................................6317 | SCHEMATICS.........................................67SmithyCNC622 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68SmithyCNC 924 Lathe Sc...

  • Page 7

    1INTRODUCTIONThank you for choosing the SmithyCNC EZ-Trol II Control System as the CNC control option foryour SmithyCNC machine. Smithy’s unique EZ-Trol II system not only opens up the world of machining to you but the world ofsmall shop manufacturing. The unique EZ-Trol II user interface prov...

  • Page 8

    control system. Please be sure you are comfortable with the concepts presented beforeproceeding to using the control system. QUESTIONS?Again, thank you for choosing a Smithy product. Contact us if you have any questions not coveredin this manual. We can be reached by phone, Monday through Fri...

  • Page 9

    WARRANTYSmithy WarrantySmithyCNC warrants its machines and control systems for a period of one (1) year to theoriginal purchaser from the date of purchase. If within one (1) year form the date ofpurchase a SmithyCNC machine and/or control system fails due to defect in material orworkmanship, Smi...

  • Page 10

    Telephone Support (Service engineers are available 8 am to 5 pm EST):Service and PartsTel No. 1-800-476-4849Fax No. 1-734-913-6663Email Address: sales@smithy.comInternational: (734) 913-6700Software and Programming Consultancy ServicesIn addition to our customary technical support for the machine...

  • Page 11

    SAFETYOVERVIEWThis section is the most important section of the manual. Remember safety should always bepriority number one and always let common sense be your guide. The safety rules listed below areby no way exhaustive; if any questions arise concerning safe operation, consult with the facto...

  • Page 12

    9Only qualified trained personnel should perform maintenance and testing on electrical circuits and components.10 Do not run the machine or conduct maintenance operations in an environment where flammable or explosive materials are present.11 When testing or adjusting an energized circuit, a ...

  • Page 13

    CONTROL SYSTEM COMPONENTS & FUNCTIONSThe Smithy EZ-Trol II is equipped with 2 control panels located on the operator’s side of the box(opposite the side with the control cables.) These switches are identified below and we suggest thatyou become familiar with these switches before operating ...

  • Page 14

    E-STOP CONTROL PANELFigure 4.2 EZ-Trol IIE-Stop Control Panel1. E-Stop Button – Round red mushroom head push button which when depressed until it latcheswill cause the control system to go into emergency stop mode, or defeat any attempt to exit emer-gency stop mode. This button can be released ...

  • Page 15

    BASIC ELECTRICAL COMPONENTS AND ITS FUNCTIONS1. Motherboard – Chosen specifically to handle the real time requirements of CNC control pro-grams for our machines, it has the connections for the keyboard and mouse, plus a D-subminiaturetype VGA connection for the monitor. The motherboard uses con...

  • Page 16

    a.MESA Electronics 7I47 RS-422 Interface Board (UpperBoard) – Provides 12 RS422 transmitters and 12 RS422 receiversfor differential signaling. b. MESA Electronics 7I37 Isolated I/O Board (LowerBoard) – Provides 16 Inputs and 8 Outputs of optically isolated24 Volt I/O.6. Charge Pump to E-stop ...

  • Page 17

    CONNECTING EZ-TROL IISmithy lathes and mills are equipped with the required cables and connectors for connecting theEZ-Trol system to the machine. Instructions for connecting the conrol to each SmithyCNC machinefollows below:CONNECTING THE EZ-TROL II CONTROL BOX TO THE BED MILLStep 1: Connect th...

  • Page 18

    Be sure to place it in a location that is level and away from potential water exposure. The powersupply box is equipped with handles on the top of the box for easy repositioming. Step 3: Connecting the Power Supply Box to the Control BoxThe EZ-Trol II Control System is shipped with the two (2) 6...

  • Page 19

    Figure 5.4 SmithyCNC EZ-Trol IIPlug Layout for SmithyCNC622Bed MillCONNECTING THE EZ-TROL II TO THE CNC 924 LATHEThe power supply enclosure for the CNC 924 is in the base of the lathe. The CNC 924 Lathe has thesame two cables as the two mill, plus an additional 9-pin cable for signals from to the...

  • Page 20

    LAUNCHING EZ-TROL IIBOOTING EZ-TROL II CONTROL SYSTEMMost of time, you will need to turn on your machine when you launch the EZ-Trol II control systemsoftware. To turn on your machine, please refer to your operator’s manual. Step 1: Once the machine is turned on, push the control box on/off swi...

  • Page 21

    Step 6: A welcome screen will appear that will prompt you to choose what kind of machine you areusing. Click on your machine and the Manual Tab will appear. Figure 6.2 EZ-Trol II Configuration SectorNOTE: You may also create a Desktop Shorcut to easily boot up EZ-Trol II.Now you are ready to use ...

  • Page 22

    NAVIGATING EZ-TROL IITHE EZ-TROL II TABSEZ-Trol II’s interface is broken down into tabs. Each tab is given its own section in this manual thatdescribes the related functions. This chapter will only provide the operator with a brief descriptionof each tab and the conventions used to navigate th...

  • Page 23

    MANUAL TABThe Manual Tab shown above is used to manually jog the machine’s axes. This is also the screenwhere homing the machine and MDI (manual data input) operations are performed. The functionsof this mode will be explained on a later chapter of this manual.Figure 7.2 Manual TabSETTINGS TABT...

  • Page 24

    WIZARDS TABThe newest feature of the new EZ-Trol II Control System is that it has built-in machining Wizardsthat ease your common programming tasks. Simply select the Wizard that best represents the pat-tern you wish to machine. The user interface will then prompt you, in a conversational manne...

  • Page 25

    F11 - used to switch the screen between fullscreen and window mode.•Sliders - Sliders such as those shown on the Auto Screen in figure 5-3 under the “FeedOverride” and “Speed Override are moved by left clicking on the slide and dragging theslider to the desired position. Sliders can also ...

  • Page 26

    HOMING & SETTING OFFSETSOVERVIEWThis chapter will familiarize you with the process of setting home positions for the Smithy CNC bedmill. The control system is capable of setting axes home positions simultaneously, but it would begood practice to set one axis at a time when you first set up t...

  • Page 27

    Figure 8.1 Homing AxesFigure 8.2 Axis Set-up Screen as described on Step 3www.smithycnc.com | 21

  • Page 28

    As each axis moves, watch carefully to become familiar with the speed and direction of movement. If necessary, axes can be interrupted during the homing movement by pressing the E-Stop button. (There are two available to you: one on the control and oneon the software.)Keep an eye on the machine...

  • Page 29

    NOTE: You can tell if the machine is in E-Stop by the red colored E-Stop button on the machine.You will need to click this to start the machine. The machine is on E-Stop when the E-Stop buttonis grayed out. The reason behind this is when the machine is out of E-Stop, you can run a programand jog ...

  • Page 30

    G-Code programming is designed to tell a motor located on the end of each axis screw to act as thehand wheel for that axis. G-Code, much like any human language is made of words. G-Code wordsare bit different than human languages in that the first letter of each word tells a control what thewor...

  • Page 31

    G0 Z0 X0 Y0G1 F10 M3 S1000 Z-0.25Y-1X-1Y0X0G0 Z0M2Not only does this program set the feedrate, it adds a few new elements as well. Notice, the firstblock gives the machine a starting location. By using a block like this we are getting the sequenceto start at an expected location, a known locati...

  • Page 32

    NOTE: You can use the MDI entry point in the manual tab to run this program if you wish.COORDINATE SYSTEMS & OFFSETSA number describes the position of each axis. This number represents the distance between thecurrent position and the machine home position. Since a work piece might be fixture...

  • Page 33

    Figure 8.6 Left: Machine is at Home Position (G54); Right: Part is at Home PositionSmithyCNC 1240 Bed Mill shown.VISEMAIN TABLESTEPPERMOTORVISEMAIN TABLESTEPPERMOTORwww.smithycnc.com | 27

  • Page 34

    NAVIGATING THE AUTO TAB OVERVIEWThis section will introduce the features of the Auto screen and explain how to execute a partprogram from this screen.AUTO TAB PARTSThe auto screen, pictured in figure 9.1, will appear when the Auto Tab is selected. This screen isclicked at the time you are ready ...

  • Page 35

    1POSITION AREAThe position area of the Auto Tab has a digital display of the machine’s positioning of each axis. Ifany of the axis displays are orange, the machine is not homed and the homing operation should beperformed before proceeding. If the numbers are blue, the machien has been homed. 2...

  • Page 36

    2APAN ACROSS DISPLAY AREAThe perspective of the view is changed by clicking and dragging the mouse. 2BZOOM IN OR OUT ON THE VIEWTo change the size display area drawing first hold down the CONTROL key, click and hold themouse button down. Then, moving the mouse pointer up will zoom in. Pulling t...

  • Page 37

    key switch on the front of the control box to the “Safe” mode before proceeding with the toolchange. This will prevent an unfortunate and dangerous accident from occurring should someoneinadvertently make changes at the control while the operator has hands within the machine workarea.Message...

  • Page 38

    10FEED HOLDClicking the FEED HOLD button, denoted by 9 in figure 9.1, will “freeze” the movement of themachine’s axes but it will not turn off the spindle. The button will also change colors, from orange to green. Click the FEED HOLD button again and the machine will start moving again. Y...

  • Page 39

    NAVIGATING THE MANUAL TABOVERVIEWThis section will introduce the features of the Manual screen and describe when the features foundon this screen are used when executing a part program.MANUAL TAB PARTSClicking the manual tab on the top menu and you will be brought to the screen pictured in figure...

  • Page 40

    1POSITION AREAThe position area of the Auto Tab displays the position of each machine axis. If the numberdisplayed is orange, the machine is not in machine home position and must be homed before pro-ceeding. 2JOG AREA & SPEED AREAThe jog area has eight buttons for bi-directional jogging of e...

  • Page 41

    direction of travel is the direction that the cutter will follow as it passes the work piece. Clickingon the X- button will cause the table to move to the right but your work piece will pass under thefixed tool moving to the left This is the negative direction. By clicking on the X+ in the jo...

  • Page 42

    5FEED OVERRIDE EZ-Trol allows the operator to adjust the feed rate up to 120% but it cannot adjust the feed rate at apercentage that would increase the rate beyond the machine’s recommended maximum setting. Forinstance, if the operator wanted to move the X-Axis from one limit to another and a c...

  • Page 43

    12MANUAL DATA INPUTThis field is used for manually entering and executing G-code commands. For instance, it can beused to verify the position of an offset. First home the machine and then enter a known offsetposition such as G55 X0 Y0 Z0 and press enter. This block of code would instruct the m...

  • Page 44

    NAVIGATING THE SETTINGS TABSETTINGS TAB PARTSThe Settings tab allows the user to open, edit and save files. Work piece and tool offsets are alsocreated on this screen. 1EDITORThe editor consists of three sections denoted as 1A, 1B and 1C in figure 11.1. Item 1A is the Saveand Send to Control bu...

  • Page 45

    Pocket - This is used with machines that have ATC (automatic tool changers). EZ-Trol is designed to fit a wide range of machines, some of which may have tool an ATC. Currently your mill does not come with an ATC.FMS - not applicable with Smithy machines.Length - This records the length of the to...

  • Page 46

    The add and subtract radio buttons, denoted by item 3E, tell EZ-Trol to “Add” or “Subtract” the toolradius or length to/from the part zero position.4ZERO ALLClicking on the Zero All button will zero the current values in the X, Y, Z and A axis values for theselected offset. It will not z...

  • Page 47

    NAVIGATING THE WIZARDS TAB OVERVIEWThe EZ-Trol II Control System is designed with built-in machining Wizards that will ease yourcommon G-Code programming tasks. The Wizards library contains a set of geometric patterns thatare commonly encountered in CNC machining jobs. Start your part programmi...

  • Page 48

    1NAVIGATION MENUThe navigation menu lets you do different operations on the Wizards Tab. It includes the follwingoperations:a. NEW - lets you create a new parts program on the Wizards. You can also select the AddNew Operation from the Loaded Wizards Lis, denoted by the number 2 in figure 12:1.b. ...

  • Page 49

    It also lists other important operations that you can use in order to create and save a G-code pro-gram.GENERAL SETTINGSThe first step in using the wizard is to go to “General Settings” and set the preliminary parametersfor the file you will build in the Wizard. Options under General Setting...

  • Page 50

    ADD NEW OPERATIONAs mentioned earlier, the output of several Wizards can be strung together to build a complete CNCpart program. To build up the list of Wizard operations you want to use, click on 'Add NewOperation' and select the desired Wizard to load in the drop down menu. A brief description...

  • Page 51

    To add this wizard to your operation list simply click the ADD button. We will then be presentedwith several input boxes and other options related to the Wizard operation. The initial screen shownis the Advanced Mode, which includes a variety of possible options to choose from in programmingyour...

  • Page 52

    After filing in all the needed information click on ''Send to Control'. This action will generate theG-Code for your program and also switch you over to Auto Tab in EZ-Trol in preparation for yourmachining operation. The generated G-Code is now ready for machining and you will also see a 3Dprev...

  • Page 53

    Operations can also be rearranged by moving it up or down the list. You can also delete anyoperation. To do so simply right click on the operation name on the Operation List and a menu willbe shown for you to pick the desired action. Remember that the gcode generated will be in the sameorder as w...

  • Page 54

    Figure 12.13 Loaded G-Code Program on Auto TabQ SmithyCNCEZ-Trol IIControl System48 | Toll Free 1-800-476-4849

  • Page 55

    UNDERSTANDING G-CODESOVERVIEWThis chapter is designed for the less experienced G-code programmer is written to give the novicea bit more assistance in learning about G-code, why it’s important and how to do it.WHY WRITE YOUR OWN G-CODE?While most machinists today are using CAD/CAM systems for d...

  • Page 56

    BASIC G-CODE THEORYCNC machine tools are controlled by instructions written in a language defined in a document fromthe Electronic Industries Alliance (EIA) entitled "RS-274-D INTERCHANGE VARIABLE BLOCKDATA CONTOURING, FORMAT FOR POSITIONING AND CONTOURING/POSITIONINGNUMERICALLY CONTROLLED M...

  • Page 57

    www.smithycnc.com | 51UNDERSTANDING THE G-CODE PROGRAMThis section of this chapter will look at the blocks of code generated by EZ-Trol, one by one, inorder to illustrate an example of the G-code programming logic that is used by EZ-Trol. It can alsoserve as a helpful guide as you determine how ...

  • Page 58

    N10G04 P5.0Block 10 causes the machine to dwell (G4) for a period of five seconds. This allows the spindle toget up to speed before drilling begins.N11G43Z1.H1Block 11 turns on tool length compensation (G43) and moves the drill to a position 1” above the topsurface pf the part using the tool l...

  • Page 59

    www.smithycnc.com | 53N20G04 P5.0Block 20 paused the machine, G04 for period of five seconds, allowing the spindle to come up tospeed.N21G43Z1.H2Block 21 turns on tool length compensation using the height of tool number 2 in the tool table.N22Z-.25Block 22 positions the cutter at Z-.25.N23G1Z-.35...

  • Page 60

    N41Y.325N42X2.025N43Y1.675N44X.725N45Y1.075N46X.525N47Y.125N48X2.225N49Y1.875N50X.525N51G1G40X.525Y1.075Block 51 moves the machine to X.525 and 1.075. This move causes the tool radius compensation tobe interpolated out of the tool path during this move (G40)N52G0Z1.M09Block 52 moves the tool 1 i...

  • Page 61

    www.smithycnc.com | 55N59G3X1.6Y1.I-.225Block 59 mills another counterclockwise arc starting and ending at X1.6. The center cutter in nowlocated -.225 inches from the center of the circular hole pocket.N60G1X1.8Block 60 moves the end mill in a straight line to X1.8.N61G3X1.8Y1.I-.425Block 61 mil...

  • Page 62

    Q SmithyCNCEZ-Trol IIControl System56 | Toll Free 1-800-476-4849PREPARING YOUR MACHINE BEFORE OPERATIONOVERVIEWBefore a part program can be run, the coordinate system must be shifted, or "offset", so that the X,Y, Z points in the coordinate system match the X, Y, Z points on the work pi...

  • Page 63

    www.smithycnc.com | 573Left click on the “Settings” tab.4The upper right portion of the screen is dedicated to coordinate system offsets. Looking first at the list of coordinate systems (G54, G55, G56, etc.), make sure that theselected coordinate system matches the coordinate system used in t...

  • Page 64

    58 | Toll Free 1-800-476-4849Q SmithyCNCEZ-Trol IIControl SystemWARNING: Do not jog the Z-axis in a negative direction toward the zero surfaces with the block inbetween. Make all Z-axis jogging moves with the block removed, then slide the block on the zeroheight surfaces underneath the reference ...

  • Page 65

    www.smithycnc.com | 59•The "Diameter" field hold the tool diameter.To measure the length of a tool in the spindle, follow the same procedure for setting the Z -axisoffset with the tool to be measured in the spindle. The Z-axis position reading minus the gage blockthickness is the tool...

  • Page 66

    ADDING COMPONENTSOPEN ARCHITECTURE LAYOUT (Easy Upgrade of Computer Components)The open architecture and layout of the control’s electrical components, as well as the designrequirement to use industry standard sized components provides the ability to upgrade componentsas inevitable techinical a...

  • Page 67

    www.smithycnc.com | 61NOTE: You may also add new terminal boards if needed. Please refer to the wiring diagram for theproper witing layout.Step 4: Test and run the program. Make sure that no other programs are affected when you run yournew program.TO ADD MORE PROGRAMMING TO THE MACHINEIf you requ...

  • Page 68

    ELECTRICAL PIN OUTSSECTION 1: 50 pin DDPINAXISFUNCTIONDIR1MachinePECOM2XENA 1 (MF1)+OUT3XENA 1 (MF1)-OUT4XREADY 1 (TM)+IN5XREADY 1 (TM)-IN6YENA 2 (MF2)+OUT7YENA 2 (MF2)-OUT8YREADY 2 (TM2)+IN9YREADY 2 (TM2)-IN10ZENA 3 (MF3)+OUT11ZENA 3 (MF3)-OUT12ZREADY 3 (TM3)+IN13ZREADY 3 (TM)-IN14AENA 4 (MF4)+O...

  • Page 69

    www.smithycnc.com | 63PINAXISFUNCTIONDIR252627282930313233SPINDLEAGNDCOM34SPINDLEDGNDCOM35MACHINE/PROBEOUT36MACHINE/FLOOD-M8OUT37SPINDLE/MIST-M7OUT38SPINDLE/SPINDLEOUT39SPINDLE/VFDOKIN40SPINDLE/ENABLEDIN41MACHINE/ACOKIN42MACHINE/READY (32)IN43MACHINE/INHIBIT_ININ44MACHINE/INHIBIT_OUTOUT45MACHINER...

  • Page 70

    Q SmithyCNCEZ-Trol IIControl SystemPINCNC 622MILLDIRFUNCTIONCNC 924LATHEDIRFUNCTION1PECOMSAFETY GROUNDPECOM SAFETY GROUND2PU1+OUTXSTEP+PU1+OUTXSTEP+3PU1-OUTXSTEP-PU1-OUTXSTEP-4DR+OUTXDIR+DR+OUTXDIR+5DR1-OUTXDIR-DR1-OUTXDIR-6PU2+OUTYSTEP+PU2+OUTZSTEP+7PU2-OUTYSTEP-PU2-OUTZSTEP-8DR2+OUTYDIR+DR2+OUT...

  • Page 71

    PINCNC 622MILLDIRFUNCTIONCNC 924LATHEDIRFUNCTION26AVIOUTSPEEDAVIOUTSPEED27GNDCOMANALOG GROUNDGNDCOM ANALOG GROUND28KA1OUTDIR(REV)N/C29KA2OUTRUN(FWD)N/C30+24VPOWERLOGIC POWER+24V POWER LOGIC POWER310VCOMDIGITAL GROUND0VCOM DIGITAL GROUNDSECTION 3: 9 pin (Lathe Only)PINFUNCTIONDIR1PECOM2+5VIN30VIN4...

  • Page 72

    17SCHEMATICSOVERVIEWThis section shows all the necessary schematics of the control system. All the diagrams areproperly labeled and numbered. Please have this section ready whenever you have questions, inquiries or in need oftechnical help regarding the machine. 66 | Toll Free 1-800-476-4849

  • Page 73

    SCHEMATICS1:SmithyCNC622BedMillPart1CallUsTollFree1-800-476-4849orvisitwww.smithy.com67

  • Page 74

    SCHEMATICS2:SmithyCNC622BedMillPart2CallUsTollFree1-800-476-4849orvisitwww.smithy.com68

  • Page 75

    SCHEMATICS3:SmithyCNC622BedMillPart3CallUsTollFree1-800-476-4849orvisitwww.smithy.com69

  • Page 76

    SCHEMATICS4:SmithyCNC924LathePart1CallUsTollFree1-800-476-4849orvisitwww.smithy.com70

  • Page 77

    SCHEMATICS5:SmithyCNC924LathePart2CallUsTollFree1-800-476-4849orvisitwww.smithy.com71

  • Page 78

    SCHEMATICS6:SmithyCNC924LathePart3CallUsTollFree1-800-476-4849orvisitwww.smithy.com72

  • Page 79

    SCHEMATICS7:SmithyCNC924LathePart4CallUsTollFree1-800-476-4849orvisitwww.smithy.com73

  • Page 80

    SCHEMATICS8:SmithyCNC1240bedMillCallUsTollFree1-800-476-4849orvisitwww.smithy.com74

  • Page 81

    AppendixAPPENDIX ASETTING TOOL LENGTH OFFSETSThis operation is done when you need to measure the tools using the machine to determinethe tool length based on a reference tool. Follow the procedures as described below:1. First set up your reference tool in the Settings Tab of EZ-Trol II. Set Too...

  • Page 82

    APPENDIX BFILE SHARING BETWEEN THE EZ-TROL II CONTROL SYSTEM &WINDOWS PC SYSTEM THAT ARE BOTH ON THE SAME NETWORKThis operation can be achieved in two ways. Option 1: Sharing a folder in your Linux System1. Create a folder you wish to share by navigating to the desired location of the folder....

  • Page 83

    APPENDIX CBASIC INSTRUCTIONS FOR CONNECTING EZ-TROL II TO A WIRELESSNETWORKThe steps described below are the basic procedures on how you can connect EZ-Trol II toa wireless network. Since there would be some differences on the brands andspecifications that you will use, please have your device re...

x