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    1 NCT®201 Controls for Lathes Operator’s Manual Alpha version of SW as of 24/09/2012

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    2 READ THIS MANUAL BEFORE USING THIS PRODUCT. FAILURE TO FOLLOW THE INSTRUCTIONS AND SAFETY PRECAUTIONS IN THIS MANUAL CAN RESULT IN SERIOUS INJURY All operators and service personnel must read this manual before operating the NCT CNC control equipment and all connected machine tools. Keep this...

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    3 CONTENTS 1. Introduction .......................................................................................................................... 6 2. General Operating Information .......................................................................................... 7 Touch screen .......

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    4 5.3.5. The important Variables in one place .................................................................... 34 5.4. Messages ....................................................................................................................... 35 5.4.1. Construction of message numbers .....

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    5 11.2. Restarting the Automatic Operation ............................................................................ 68 11.3. Unconditional Restart the Automatic Operation ......................................................... 69 11.3.1. Interrupting Simple Movements .........................

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    6 1. Introduction Dear User, Thank you for having chosen one of our control systems. We sincerely hope that you will be satisfied in your work with its facilities. Please remember that the skill of operating the machine can only be learned through knowing its part programming fundamentals. S...

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    7 2. General Operating Information Touch screen NCT201 control units have touch screens. You can push the buttons on the screen either with your fingers or by using the stylus provided. You can use a keyboard and mouse set up via any of the four USB ports provided. The operating surface is s...

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    8 2.2 Side Bar Below are all of the side bar buttons and their functions. This allows you to move the side bar from one side to another. This is the WIN-S button, which opens another group of windows and functions. This is the PLC button, which allows you to switch the PLC functions ...

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    9 2.2.1. WIN-S Button The WIN-S button brings up a sub menu which contains the following 24 functions. 1. Mechanical position 2. List of G and M codes 3. Information about main spindle and tools (F, S, T) 4. Single block 5. Directory 1 (for files) 6. Directory 2 (for files) 7. Listing...

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    10 2.2.2. Keypad By pushing the side bar KEYPAD button, an onscreen keyboard will be displayed. It is a general keypad that has numerical buttons, and lower and upper case letters according to the language selected for the control unit. It also has function keys, basic mathematical operators (+-...

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    11 2.2.3. Software Machine Operation Panel The software mechanical panel opens all of the functions necessary to operate the machine. The keys are exactly the same as the machine operating panel. 2.2.3.1. Operating Modes Jog Incremental jog Handwheel Reference point Edit Automatic...

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    12 2.2.3.4. Spindle Speed Override The spindle RPM will be reduced or increased by 10% by pushing on the respective – or + button in the 50-150% range. By pushing the 100% button, the programmed RPM will be set. 2.2.3.5. Program Execution Buttons Single block execution Conditional block...

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    13 Jog Buttons The Jog buttons are used for moving the axis in a selected direction. In case the axis moves towards a reference point, the buttons can select the axis. The arrangement of buttons can vary from one machine type to another. Spindle Start / Stop Buttons M3 causes the spin...

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    14 2.3. User Box A user box is a profile set up for each individual machine operator. Each user box allows for modifications of the control unit as well as allowing additional personal adjustments (ex. the color of the screen, position of windows, etc.). This allows a machine to be used by sever...

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    15 2.3.3. Modifying Your Password SK > Setting > Security Select the user box that you wish to modify and then push the button NEW PASSWORD. You need to provide your old password before inputting a new one. Again, you must confirm the new password twice before it is finalized. 2.3.4. Ca...

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    16  3: Authorization allowing to create and edit an NC program in any memory. The user has the right to set up parameters, to measure a tool, a work piece or to write individual sentences. He has no right to cancel file with “sys” extension, hidden, archive or write protected files. ...

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    17 3. Operation Modes 3.1. Jog Operation Mode Jogging can be completed only while the machine is turned on if there is no EMERGENCY STOP STATUS in the above status field. After starting the operation, JOG will appear in the status field. Choice of Direction You will find +X, -X, +Y, -Y, ...

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    18 3.2. Incremental Jog Operation Mode Incremental jogging can be completed only while the machine is turned on if there is no EMERGENCY STOP STATUS in the above status field. After starting the operation, INCR will appear in the status field. In this operation mode, by pushing any direction ...

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    19 3.3 Handwheel Operation Mode Handwheel Mode can be completed only while the machine is turned on and there is no EMERGENCY STOP STATUS in the above status field. After starting this mode, the status field will show HNDL. Selecting the Step Select the step by using the button on the physi...

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    20 3.3.1. Multiple Hand wheels The control system may also be equipped with a total of 3 hand wheels. These hand wheels each control the movement of the X, Y, Z axes, but they are limited to each axis. If there are more axes, they have to be selected by an axis selection button and only then ca...

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    21 3.5. Automatic Operation Mode A program execution in automatic mode can be completed only while the machine is turned on if there is no EMERGENCY STOP STATUS in the status field. After starting the operation, AUTM will appear in the status field. The automatic mode is an operation mode for...

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    22 For example, if a tool gets damaged, you can start the MDI program, which will do the following: 1. Stop the main spindle rotation. 2. Stop the coolant. 3. Retracts the tool to a position where you can manually intervene. You can also use the MDI mode to easily interrupt a part program if y...

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    23 If you want to restart the control, select Restart from the roll down menu, than select OK. 4. Position Display You can personalize the CRT monitor in such a way that all of the necessary information is always available on screen. You can collect different positions, coor...

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    24 allows you to see the values in mm (inch) in the coordinate system of the work piece, like in the program, instead of the values showing the current position of the machine. Relative Position: After reaching the reference point, the relative position is the same as the absolute position. ...

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    25 4.1. Handling the Position Window The position window will be displayed by pushing the POSITION button in the SOFTKEY / BASIC menu. It can also be displayed through the WINDOWS menu on the sidebar (Win-s). On the header of this window, you will always see the format of the current position. Y...

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    26 5. Status SK > View The View menu brings up a new row of Softkey buttons, which displays the status of all currently running programs. 5.1 Program Blocks during Automatic Execution To display the currently running program, push the Program List button, which will bring up another windo...

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    27 commands within a file (GOTO) because you can see the line containing the jump command and the context of the block where you have to go to. Block Search The Block Search will work only in Auto Mode. It will not work if the following sub menu buttons are shaded: - Cycle start on - Cyc...

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    28 Word Wrap - This will allow you to format long text into a shorter column. Autoscroll Stop When activated, this will display only a portion of the program that is visible in the window. Otherwise, all blocks of the program are visible as the program execution continues. Level up, Level ...

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    29 5.2. Graphic Display of the Tool Path SK > View > Graphic The absolute position can be displayed (independently of the operation mode) in the graphic window. The window will be on the lower right part of the screen. The tool path will be shown as a continuous track. The rapid travers...

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    30 5.2.1.2. Moving You can move the drawing two different ways in the Graphic window: 1) SK > View > Graphic > Move Use the function of the buttons „Left”, „Right“, „Up”, „Down” to move the drawing. The speed of the movement depends on the button turned on (1 px”, „...

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    31 Sketch: You can draw a sketch in the graphic window . Pointing: Instead of straight lines, dotted lines will be used for drawing. Split view: While this button is turned on (indicated by a darkened background), three typical views will be shown at the same time. Three different plane views ...

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    32 5.3. Macro Variables During programming, it is possible to use macros. You can give them a value, read their content or edit them under a table form. By assigning a number, you can give a value directly to that macro variable. In the CNC program you can also give a value to a macro variable i...

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    33 5.3.3. Editing of the Macro Table New Window By pushing the New Window button, the old window will continue to be on display, but a new window will also appear with the same content (although it may hide the old one). The windows can be moved next to each other by grabbing their header, a...

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    34 containing a list of the previous redoes will pop up. Simply select the one you wish to redo by using Up and Down buttons in the SOFTKEY and then press Cancel. An alarm window will pop up with the question: “Do you really want to restore the selected variables?” Press “Yes”. Level...

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    35 5.4. Messages If you need to see all of the control's messages, use the following command chain: SK > Status > All messages The window that pops up is called the Global Errors window. This same window can be called by double-clicking on the message field in the status bar. In t...

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    36 5.4.1. Construction of message numbers 5.4.2. Groups of Messages Messages can be divided into the following main groups: System Alarms: – Alarms due to failure or false setting of servo system – Alarms due to failure of position encoders – HW/SW alarms coming from the NC Other NC er...

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    37 Possible answers for the messages: Cancelling messages by turning the power off and on In case of extremely serious or dangerous alarms, the message cannot be cancelled and the CNC must be restarted. These messages will cut the machine off from the CNC and create an emergency stop stat...

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    38 5.5 Backup Copy To make a backup copy of any general data, use the following command chain: SK > Settings > Prog settings In order to avoid doing this operation one by one, you can make a backup copy from the whole system, containing the following: - macros #500-#999 - every wo...

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    39 5.6 Logbook SK > Status > Log errors The logbook sees and recalls everything that is happening in the control. The error logbook can be saved instantly and forwarded to the NCT service center. The error logbook file helps the repair work get finished faster and cheaper, allowing the dow...

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    40 5.6.1. Filtering the Messages You can filter and relevant messages in the logbook by date or message group. Selecting the Starting Date Double click on the left side date button: Starting Date. A calendar will appear in the middle of the window. Select the starting date. To find the en...

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    41 By pushing the buttons (the header will be darkened), the messages in the selected group will show up. Messages related to the off buttons won’t appear in the logbook window. Order of the message entry The message entries will follow each other in a timely order in the log. As a displa...

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    42 5.8. Status Display The top line of the screen is the status window, You will get a global view of the current state of the control and the machine. This display field location is static, regardless which window you open. In the first line you will find a message field. In this field the fo...

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    43 – JOG: Jog – INCR: Incremental jog – HNDL: Handwheel – REF: Reference point return – SBEX: Block restart 3 Automatic operation and manual data input mode – START: Start – STOP: Stop – NSCH: Block search – GOTO: Go to a block 4 Fourth status field states – INTD: Automa...

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    44 – FLOCK: Function lock – PLC: PLC is not running 5.9. Part and Time Counter SK > Settings > Times/Counters This displays the different time and part counters. Apart from the operating time, the values are free to overwrite. Power on time: Unmodifiable clock that begins when the ...

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    45 6. Program 6.1. Single block SK > Program > Single block With this function you can give an optional F (feed), S (spindle), T (tool), G (G-function), M (M-function) command or even execute a whole block containing one or more commands. 1. Press any of the buttons (JOG), (incremental...

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    46 6.2. CNC Program Creating and editing a CNC program can be done while the machine is still working. The program can be edited while another program is in operation. You can choose between writing a new program or editing a preexisting program. 6.2.1. Creating a new CNC program SK > Pro...

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    47 5. You can also save the file by clicking on the red X on the header of the window. The following message will show up in a window: “The text in the file has changed. Do you want to save the changes?” Push YES. 6. You can now give the file a new name and determine the directory where you ...

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    48 Use "find" field to locate any phrase that you are looking for within the program. The window will jump to the first result and select the line with the phrase. In case of several results, you can navigate among them by using the Last and Next buttons. You can replace any text that ...

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    49 7. Offsets 7.1. 0-points (Work shift) 7.1.1 Work Offset At the NCT201 control, you can use several different zero points. If the dimensions given in a drawing of a work piece cannot be programmed directly related to a basic point, the shifting of the program coordinates may help. You can sav...

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    50 JOG, INCR, HNDL 1. SK > Offset > Measure > Work offset measure 2. Select the work offset (work shift) number. The coordinate system of the part program 0-point will be selected. Double-click the darker field under: Work offs No: Scroll down to the desired work offset number (G54-G...

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    51 Clear all: You can quickly cancel all values by using Clear all, which will cause all of the offset values to change to 0. Clear group: You can quickly cancel all values of a selected work offset by using Clear group, which will cause all of the offset values to change to 0. Save: You can sa...

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    52 7.2.1. Tool offset measuring (on the CNC lathe) The tool offset can be measured in the following operation modes: JOG, INCR, HNDL .1 SK > Offset > Measure > Tooloffset measure 2. Select the work offset (work shift) number. The coordinate system of the 0-point part program will be...

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    53  Click on the Q field on the left side of the table and select the desired number from the drop down menu (0-9)  Type in the radius value of the tool nose (R)

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    54 If you are not going to use the tool nose radius compensation, operation 4 can be skipped. 5. Move the tool tip to a known point in the selected coordinate system. Measuring the tool in X direction You can create a new diameter by turning the stock or you can use a known diameter for tool me...

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    55  Move the tool back in the X direction only until the stock is cleared.  Stop the spindle.  Type in 0 in the Z-axis field of the measuring position and hit ENTER. The geometry offset will be calculated and recorded in the offset table. To make the measured tool offset active, call ...

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    56 wish to redo by using the Up and Down buttons. After the selection is highlighted, press the Redo button and an alarm window will pop up, asking you the question: “Do you really want to restore the selected workoffset/tooloffset values?" Press Yes. *** Attention! Any operations mad...

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    57 7.3. Orientation and Offset of the main spindle With this function you can set the orientation angle of the spindle. This is the angle position to which the spindle will rotate upon the M19 command. If it is a multi-spindle machine, the orientation angle can be adjusted for each of the spind...

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    58 7.3.2. Driving Spindles in Shifted Phase Mode (part transfer between spindles) This function makes it possible to rotate two spindles of a multi-spindle machine in different phases with shifted angles, but with equal revolutions. It can be useful in a sub-spindle machine, where you wish to t...

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    59 will have no effect. It can be stopped only by the M5 command, which will also finish the synchronization of the spindles. Suggestion: You can give the offset in increments as well if you know the resolution of the encoder of the spindle. 8. Program Execution Start and Stop You can start ...

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    60 8.2. Cycle Stop To cancel the START state, press the STOP button during the program execution and the axes will slow down and stop. The execution of M, S, T, and B functions will be continued until the end of block. The STOP state is indicated by the STOP message in the 3rd status field wind...

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    61 8.4. Programmed Stop M00 If the control reads the M00 code during the program execution, the block that contains the M00 command will be executed. The control will then go into the STOP state and the machining will stop. The machining can be continued by pressing the START button. 8.5. O...

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    62 9. PROGRAM EXECUTION INTERVENTION 9.1. Conditional Block Skip You can program a conditional block skip /n at the beginning of a block. The "n" represents the block number. There is a block skip switch button on the operator's panel for activating the /n command. If the switch is ...

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    63 10. DEBUGGING THE PART PROGRAM The following functions help the testing and debugging of the part program:  Single Block Execution  Dry Run  Locking Possibilities  Test Run  Calculation of the Cutting Speed  Description of the G and M Codes These functions are not separate...

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    64 The machine lock and dry run functions can be combined, meaning that both can be switched on at the same time. The POSITION screen and the GRAPHIC POSITION screen show the path already drawn. If the dry run switch is on, then the feed is high. If it is off, then the feed is at the programmed ...

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    65 Note: The TEST RUN button can only be activated in one of the manual operation modes while the axes are stopped. Further details are available from the machine tool builder of each individual machine. 10.7. Calculation of Cutting Speed SK > MIX > Velo calculator This window helps...

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    66 .  Type in the values in the fields you selected and the result will be put in the lower window pane. Feed selection by mm (inch) / minute (G94) and mm (inch) / revolution (G95) G94: mm/minute or inch/minute or degree/minute feed G95: mm/revolution or inch/revolution or degree/revol...

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    67 windows at the same time. All: If this button is switched on (darker background), both groups of codes will appear separately. If it switched off, then the codes will appear together without the group display. Comment: If this button is switched on (darker background), a description of each...

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    68 11. INTERRUPTING AND RESTARTING THE AUTOMATIC OPERATION In many cases the automatic operation needs to be interrupted and restarted at a different time when the machining needs to be continued. There are several scenario cases for this, listed below:  During machining, the program may nee...

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    69 In the second case, it goes to the start position of the interrupted block and it will re-run the whole block. In the third case, it moves back to the interruption position and continues the machining from there. 11.3. Unconditional Restart the Automatic Operation If the automatic operatio...

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    70 axis programmed, the X axis will go back to the original path in the block, whichever contains the X command. You can have the same movement when you switch over to single block mode at the beginning of the block N70 and move the slides away manually then return to the previous point. We can ...

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    71 2nd partial block: Positioning to the point R. This partial block is a positioning block along an axis. In this example, the Z-axis is moving to the position specified by the address R: (G0 R2) 3rd partial block: Hole machining and retraction to the initial position (G98) or to R-point (G99)...

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    72 above the next hole. There are two ways to interrupt the drilling operation: 1. While pulling back the drill, the operator notices that the depth of the hole is not deep enough. He can then press the STOP button, open any of the manual modes and execute the necessary manual operation. After ...

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    73 7th case: Interruption of a linear interpolation not parallel to an axis in a G41 or G42 state. After returning to the automatic mode and pressing the START button, the tool path will be recalculated as we discussed in the 6th case. 8th case: Interruption of a circular interpolation in a ...

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    74 11.4.1. Return to the start position of the block with manual operation In the interrupted state (INTD) of automatic operation, the BLOCK RESTART button can be switched on in any manual operation mode (Jog, Incremental jog, Hand wheel, or handle feed). After it is switched on, the return di...

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    75 11.4.3. Different return moves while the BLOCK RESTART is active. The examples below are meant to show how to return to the start position of an interrupted block that has a movement command. 1st case: The control is in the G40 state and the block is interrupted and restarts a linear interp...

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    76 ... If the drilling cycle is restarted with the BLOCK RESTART condition in effect, then there are three partial blocks in this cycle. 1st partial block: The tool is moving to a position in the selected plane. The start position in this partial block is: X=50, Y=20, Z=10. 2nd partial block: T...

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    77 4th case: The drilling cycle is interrupted and it restarts during the drilling operation. The tool is moved back to the X=100, Y=70, Z=2 starting position of the block when you press the BLOCK RESTART button. If you press the START button, the tool will re-execute the drilling and the retr...

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    78 6th case: Return to the start position of the block after the machining was interrupted in offset mode and the tool was at an inside corner. When the BLOCK RESTART button is pressed, the machining of the inside corner corresponds to the case of the machining of the outside corner. As th...

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    79 11.6.1. Pointing at the Desired Block Pointing to the desired block of the program can be done in the following ways: 1) Select the program for automatic running. Give the access path of the program in the directory, which is accessed after this operation: SK > Program > Directory 1...

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    80 The control will collect all the information in a table below the program list, which will represent all of the commands made since the beginning of the program. The message SEARCH will be displayed in the status field, showing that a block has been searched. Let us examine a fragment of th...

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    81 Tool to be Prepared: T3 The T3 tool is programmed in the N120 block. In this case, the search for the T3 can be done while the T2 is still working. The above example illustrates how the data referring to the tool change is gathered. The tool change is done by means of the M6 command in the ma...

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    82 Other Functions: M50, M51 Other M functions are listed in a separate line. In the sample program, the table has been rotated to the B90 position, which was programmed in the N010 block. For the table rotation, the O9031 macro is called. The following program section can be found in the macro...

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    83 START Without Intervention If the operator presses the START button without any manual operation, the control will reach the necessary conditions in the following order: – First, it executes the selected functions according to their order in the table (i.e. in this case: T2, M6, T3, M12,...

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    84 Manual Operation Intervention Before START If a manual operation mode (jog, incremental jog, or manual handle feed) is selected before pressing the START button, then the distance / distance to go can be moved manually. It is similar to how we've described the BLOCK RESTART and the BLOCK RET...

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    85 Other Intervention Possibilities Before START It is possible to change the order of execution, and cancel the execution of other M -codes before starting the execution of data gathered in automatic mode. Touch one of the functions or coordinates (which should be taken out of the execution af...

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    86 11.6.4. The GOTO Command If you point to the desired block and press the GOTO key, the control will execute the program from the selected block after you press the START button. Contrary to the SEARCH command, it does not gather functions and positions from the beginning of program. It is the...

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    87 12. Settings 12.1. The Sound of KEY CLICKS 12.1.1. KEY CLICK Sounds of the Operating System In the SETTING mode, you can turn the key clicks sounds (generated by the operating system) on and off. If it is turned on, even the keyboard connected to USB connection will give a click sound whe...

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    88 12.2. Program settings In order to modify the program settings, use the following command chain. SK > Settings > Prog. settings The Prog. setting – NCT user window will pop up. Here, you can set the colors, resolutions, language, network, time and other functions of the control pa...

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    89 Save changes: You do not have to press any button for savings, these settings will become valid immediately. 12.2.2. The Sound of Error Messages SK > Settings > Prog.setting > Keyboard You can see three setting fields separated by the frames. In the top Error message sound f...

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    90 12.2.3. The Language of the USB keyboard In the middle USB keyboard field, you can set the language for a keyboard connected to the USB connector. You can enable or disable the beep of the keyboard click by checking the Enable Beep window. 12.2.4. Which keyboard is active? The bottom M...

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    91 You can enable or disable the beep of the keyboard click by checking the Enable Beep window. Save changes: To validate the changes you have made, press the OK button in the right corner of the window.

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    92 12.2.5. Freezing the windows SK > Setting > Prog.setting > Display The Display settings allow you to determine the window size and the location of multiple windows that are visible on the monitor panel. If you want to freeze all of the windows, check the All windows freezing box in ...

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    93 Save changes: To keep the changes you just made, press OK on the Prog.settings – NCTuser window.

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    94 12.2.6. Setting the Help Text Besides the printed version of the operation manual, the help text can be also reached from the control panel through the following command chain: SK > Mix > Operator's help Additional help for the parameter description is possible also: SK > Serv...

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    95 12.2.7. Calibration of the Touch screen 1. SK > Setting > Prog.setting 2. In the window, select the Display tab 3. Press the blue Touch Calibration button. 4. A new menu will then pop up: TUB1: channel. 5. You can now choose calibration on either 4 points or 25 points. 6. Once a ...

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    96 12.2.8. Setting the Resolution of the Screen SK > Setting > Prog.setting > Display . . In the bottom field of the window, you can find the possible screen resolution options. The already selected resolution will be displayed next to Current resolution. If you need to resize the s...

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    97 12.2.9. Setting the time and date SK > Setting > Prog.setting > Display > Date/Time You will find two different setting fields separated by a frame. On the left side, you can set the date and time. In the Current time field, the actual current time is displayed, shown by the h...

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    98 13. CHANNELS One of the most important strengths of the NCT 2xx is the support of the multi-channel control unit. The maximum number of the channel is 8, but it may be different depending on the software version that is being used. The several channels mean several logical CNC controls in on...

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    99 6) You can select different windows to display the content of the different channels by selecting the CH++ button. We can show many more position display windows by adding New window. 7) Other windows are dependant on different channels and can be displayed at the same time. 13.3. The STAR...

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