ROBOFIL 190 - 290P - 310P - 510P: Part 3/3

ROBOFIL 190•290P•310P•510P
NC manual
205 952 110/E/12.1999 ver. F
Part 3/3
204 945 340/E/17.12.1999

Chapter 8
Use of the machine

8.1 Utilization: health and safety
regulations
ROBOFIL 190 8.2 Utilization: adjustment
290P 8.3 Utilization: wire and dielectric
310P
510P
204 931 240/E/17.12.99

Hygiene and safety instructions
Introduction 8.1.3
Guarantee 8.1.3
Modifications 8.1.3
Formation 8.1.3
Safety indications 8.1.4

General 8.1.4
Prohibition signs 8.1.4
Warning signs 8.1.4
Obligation signs 8.1.4
Installation conditions 8.1.5

Premises 8.1.5
Connection to electrical mains 8.1.5
Precautions during use 8.1.5

Protections 8.1.5
Hygiene instructions 8.1.5
Danger of electricity 8.1.5
Storage of diskettes 8.1.5
Actions to be avoided 8.1.6
Safety 8.1.8
Emergency stop circuit 8.1.8
Circuits remaining energized 8.1.8
Control of protective covers and doors 8.1.8
Precautions during maintenance work 8.1.9
Elimination of wastes 8.1.9

General nature of wastes 8.1.9
general recommendations 8.1.9
Hygiene and
Table of
Flow chart for elimination of EDM machine waste 8.1.10 safety
contents
CHARMILLES TECHNOLOGIES 4 923 260/E/12.02.1998 8.1.1

Hygiene and
safety
8.1.2 CHARMILLES TECHNOLOGIES 4 923 260/E/12.02.1998

Introduction
To guarantee afreeable and healthy working

conditions both for persons working on the spark
erosion machines and for persons working in the same
preimses, it is indispensable that some elementary rules
of hygiene and safety related to this machining
process be respeced.
Operators, foremen and also company heads are
called upon to respect the rules listed below.
If these rules are not respected, Charmilles
Technologies cannot be held responsible.
Guarantee Modifications
All machines sold by Charmilles Technologies are Any modification made to the equipment without
guaranteed according to the general conditions of intervention or authorization of Charmilles
sale of Charmilles Technologies, unless otherwise Technologies is the sole responsibility of the customer.
provided for in the sale contract. In such cases, Charmilles Technologies disclaims all
After the guarantee has expired, the customer is free to responsibility.
act as he thinks fit, but it is preferable to call in the
services of Charmilles Technologies.
Training
Technical documents such as drawings, circuit
diagrams, descriptions, illustrations and data
concerning dimensions, weights and other Only persons trained on machines of this type and
characteristics are provided for information purposes their equipment are authorized to work with them.
only and in no circumstances can be considered as Training sessions concerning hygiene and safety
particulars of guarantees. The same holds for any problems must be held annually.
references to standards.
Hygiene and
safety

Safety indications
General
The purpose of the safety indications is to draw attention rapidly and intelligibly to objects and situations likely to
create specific risks.
The safety indications in no circumstances exempt users from taking all required protective measures, and are to
be used only for providing information concerning safety.
The effectiveness of the safety indications depends in particular on complete and constantly renewed information
given to all persons likely to benefit.
Prohibition signs: White background, red surround and diagonal line, black symbol.
Warning signs: Yellow background, black surround, black symbol.
Label placed adjacent to the device

used for cutting off the power supply of
the installation.
lectrical danger
Label placed adjacent to the

components remaining energized while
power is cut off.
Obligation signs: Blue background, white symbol or text.
CHARMILLES TECHNOLOGIES
• Déclencher l'armoire électrique avant toute intervention

de maintenance. Label placed adjacent to the door locks
and on each access panel.
• Switch off main control cabinet before any maintenance
operation.
Hygiene and
• Vor einem Wartungseingriff Steuerschrank Ausschalten.
safety CT 445 294

Installation conditions
Premises Connection to electrical mains
Renewal of the ambient air of the premises must be The 3x 400V AC power supply line to the machine
guaranteed so as to prevent the formation of a must be protected by time-delay fuses of 35A max.
noxious and dangerous atmosphere. For electrical mains with insulated neutral, a
For relevant technical details refer to «Installation differential circuit-breaker must be built in to the
and placing in service» in the maintenance manual. generator connection circuit.
For relevant technical details refer to «Installation
and placing in service» in the maintenance manual.
Precautions during use
Protections Danger of electricity
All protective covers and doors must be kept in During the EDM process the wire is electrically live
place when working with the equipment. throughout its length and constitutes a risk of electrical
The protective devices must not be made discharges by direct contact. Consequently, avoid
inoperative. touching the wire and avoid contact with the machine
framework (risk of short circuits).
After an intervention, all protective devices must be
put back in place before a machining operation.
Charmilles Technologies may disclaim all It is therefore mandatory to:
responsibility in the event of accidents resulting . avoid touching the wire during operation
from no-compliance with the safety regulations. . keep the protective covers and doors in place
Hygiene instructions Storage of diskettes
• To prevent prolonged contact of the skin with the Do not store diskettes close to magnetic field sources
dielectric, gloves must be worn. such as transformers, high power cables, etc..
• Wash the hands after any contact with the
dielectric. Refer to the diskette manufacturer’s instructions
• Protect the eyes against possible splashing of concerning storage
dielectric.
• Do not ingest dielectric.
Hygiene and
safety

Actions to be avoided
Do not use the machine for purposes for which it was not designed
607.*
Do not climb onto the machine
Hygiene and 606.*
safety

Do not hinder free movement of the machine’s axes
608.*
Do not clean the machine with products containing ammonia, since a mixture of the
latter with dielectric causes damage to the wire.
NH3
605.*
Hygiene and
safety

Safety
ROBOFIL machines are built to meet the health and safety requirements of the
European «Machines» directive of 14 June 1989 (89/392/CEE) and its
amendments.
Since 1 January 1996, machines destined for the European market also comply with
the «Electromagnetic compatibility» directive known as EMC directive, of 3 May
1989 (89/336/EEC). These machines are built in accordance with the standards
on electromagnetic interference in an industrial environment (emissions and
immunity).
The machines also comply with the «Low voltage» directive (73/23/EEC) which
came into force on 1 January 1997.
Emergency stop circuit
The emergency stop button works by cutting off power to the machine through a
circuit in wired logic. Machining and movements are immediately stopped without
fail.
Circuits remaining energized
Not all electrical circuits are cut off by the main switch.
The circuits that stay energized after switching off the main switch are indicated by a
yellow label: «Circuit remaining energized» placed adjacent to the component in
question.
Example: three-phase filter on the generator input.
Control of protective covers and doors
Closing of protective covers and doors is controlled by safety switches which cut off
all dangerous electrical power supplies and prevent any movement in the event of
opening.
Hygiene and
safety

Precautions during maintenance Elimination of wastes
work
Wastes resulting from the EDM metal machining

•Respect the safety indications (color pictograms and process must never be thrown into sewers, onto
texts), and prior to any maintenance operation refer garbage tips or other unauthorized places.
to the corresponding chapter.
•Precautions need to be taken when handling and General nature of wastes
packing components of electronic modules so as to
protect them against the destructive effects of
electrostatic discharges. •Used dielectric.
•For all interventions inside the generator cabinet or •Lubricating oil.
the electrical components of the machine, the main •Used filters, loaded with machining metal residues
siwtch must be set at the «OFF» position ( ). and sludge.
This switch can be blocked by means of a padlock. •Various wearing part.
General recommendations
•If the dielectric liquid overflows, it must not be

allowed to soak into the ground or be drained off in
sewers.
•Contact the competent local authorities to acquaint
yourself with the regultory instructions concerning
storage and elimination of waste.
•It should be noted that, in most cases, storage and
elimination of wastes will imply sorting according to
the nature of the pollutants (plastic, metal, etc...)
•Consult the standards in force concerning heavy,
non-recyclables materials.
Hygiene and
safety

Flow chart for elimination of EDM machine wastes (Switzerland)
This chart is of course valid for all other EDM wire cutting installations.
EDM Used
Filtering Drain
Machine dielectric
Wire spool Filter Resins Oil Wearing part
T
Y
P
E
Wire Support Grounding,

contact, wire, Belts Nozzles,
bin for plastic
spool guide braids blokss
N Paper Amberlite •Métallic :

A loaded with type resin tungsten
Thermo-
T Brass, machining • fixed ion : stainl. steel
PVC VACTRA 4 plastic, PVDF,
U Zinc-plated particles SO3/N+
•Others : Polyurethane
R (Lt, Zn, (CH3)3 oil POM
brass diamond polyester
E Fe, Cr, • Counter Ion : saphire
Cu ,Ni) H+ /OH– ceramic
E
L
I
M
I
Special incineration
N Recovery Conventional élimination
A
(High temperature
(Scrap metal dealers, ...) (incineration and other)
T smoke filtering, ...)
I
O
Hygiene and
N
safety 285

Utilization: adjustement
Surface finishes 8.2.3

Specifications on drawing 8.2.4
Validity of the visotactile (Rugotest) method 8.2.4
Work-part and clamping 8.2.5

Introduction 8.2.5
Part clamping system - CT1000 system 8.2.5
Clamping examples 8.2.6
Attachment of earthing braids 8.2.6
ROBOFIL 190 8.2.8
Inspection list 8.2.9

Introduction 8.2.9
Equipment general inspection 8.2.9
«Dielectric» function inspection 8.2.9
«Erode» function inspection 8.2.9
«Wire change» function inspection 8.2.10
Part installation inspection 8.2.10
Parameter adjustments and checks 8.2.10
Program dry run 8.2.11
Starting cutting 8.2.11
Measurement and taking reference 8.2.13

The various machine systems of axes 8.2.13
Definitions 8.2.13
The absolute system of axes 8.2.14
The machine system of axes 8.2.14
The part system of axes 8.2.14
Definition of "AXO" 8.2.15
The electrical touch 8.2.16
Type of electrical touches 8.2.16
Precision electrical touches 8.2.16
Parameters affecting measurements 8.2.16
Parameter MTOL 8.2.16 Table of
Utilization:
Application example 8.2.17
adjustement
contents
Measurement cycles 8.2.19

Generator 8.2.21
General 8.2.21
Isofrequency method 8.2.21
Isopulse method 8.2.21
Machining optimization in roughing 8.2.22
Aj - Servo system mean reference voltage in 1/10 Volts. 8.2.22
B - Time between 2 pulses 8.2.22
WS - Wire feed rate 8.2.23
WB - Wire mechanical tension 8.2.23
INJ - Injection setpoint: Injection is active only in roughing. 8.2.23
Machine optimization in finishing 8.2.23
Aj - Servo control mean reference voltage. 8.2.23
S - Servo control stability, maximum rate 8.2.23
WS affects the wire feed rate 8.2.24
WB - Wire mechanical tension 8.2.24
Other important parameters 8.2.24
Table of
Utilization:
adjustement
contents

Surface finishes
Testing of surface finishes is carried out using apparatus known as roughness meters.
Experience shows that measurement of surface finishes by visotactile comparison
with a standard does not give an error of more than 2 class CH.
The roughness criteria are Ra (Europe) = CLA (UK) = AA (USA).
To obtain a roughness scale, Charmilles Technologies have defined a CH scale
(similar to VDI3400) which is, however, comparable with the standards used.
CH No. = 20 log 10 Ra (µm)
VDI Ra = CLA = AA class VDI Ra = CLA = AA class

3400 3400
CH µm µinch ISO 1302 CH µm µinch ISO 1302
0 0.10 4 N3 23 1.40 56
1 0.11 4.4 24 1.62 63
2 0.12 4.8 25 1.80 72 N7
3 0.14 5.6 26 2.00 80
4 0.16 6.4 27 2.2 88
5 0.18 7.2 N4 28 2.5 100
6 0.20 8 29 2.8 112
7 0.22 8.8 30 3.2 125 N8
8 0.25 10 31 3.5 140
9 0.28 11.2 32 4.0 160
10 0.32 12.8 33 4.5 180
11 0.35 14 N5 34 5.0 200
12 0.40 16 35 5.6 224
13 0.45 18 36 6.3 250 N9
14 0.50 20 37 7 280
15 0.56 22.4 38 8 320
16 0.63 25.2 39 9 360
17 0.70 28 40 10 400
18 0.80 32 N6 41 11.2 448
19 0.90 36 42 12.6 500 N10
20 1.00 40 43 14 560
21 1.12 44.8 44 16 640
22 1.26 50.4 45 18 760
•Definition of roughness criteria

CH No. = 20 log (10 Ra) (µm)
•Significant rules and figures
1µm Ra=CH20 10µm Ra=CH40
if: Ra=Rax2 CH=CH+6 1µm Ra=CH20 2µm Ra=CH26
•The ratio
between 2 successive CH units is 1.12
•The difference
between 2 successive CH units is 12.2%
Utilization:
adjustement

•Rt
is approximately equal to 8 x Ra. Mean Rt = 5 x value of Ra.
•Rz
is the average of 5Rt Max recorded over 5 selected sampling lengths (for
establishment of technology: 0.8 mm).
Notes
- American and English standards state the following relation between values V
(RMS) and V (Ra): V (RMS) = 1.11 V (Ra).
- French standard NF 05051 is comparable to ISO standard 1302 for surface
finish classes.
- The surface finish for a given generator setting will not be the same for different
materials.
Specifications on drawing
Example ➂ ➃
According to requirements: ➁ ➀
(1) Function abbreviations
(2) Symbols and numerical values of the criterion to
(3) or criteria chosen Ra 1.6 ES
(4) Abbreviations of production process
(5) Complementary specifications 1987
Validity of the visotactile (Rugotest) method
For the most current machining modes, samples have been established with a view
to specifying the scheduled quality limit values according to a rate 2 geometrical
series, chosen from those recommended for the «Ra» criterion in French standard
E05 015 and in ISO recommendations 468.
Experience shows that the visotactile comparison process for a given surface with
another type of surface of similar texture is highly accurate.
Its use is greatly appreciated when different firms are drawing up contract
documents, technical specifications, contracts, etc.
These standards are intended to be used for visual and tactile comparison, and not
for calibration of profile meters or other surface finish measurement instruments.
The RUGOTEST, which is a very simple and inexpensive tool, can, due to the
accuracy of the indications it provides and its ease of use, render the greatest
service to all levels of the enterprise, the relations of which will be greatly simplified.
Utilization:
adjustement

Work-part and clamping
Introduction
This paragraph provides the information required to prevent work preparation errors.
Prevention of such errors implies that particularly attention be paid to the following
points:
•Preparation of part
The part must be demagnetized, clean (if necessary descaled), and provided with
reference points for its alignment.
•«Trueness» of the part
•Part clamping system

This must rigidly attach the work part during machining, and must not hinder axis
movements.
Part clamping system - CT1000 system
The work area can be fitted with CT1000 clamping systems

(not available on ROBOFIL 190)
(Refer to description in the "Options" chapter).
Utilization:
adjustement

Clamping examples
134 133
Attachment of earthing braids

Machine performances, both in roughing and finishing are subject to correct
coupling of the part support fitting to earth.
Utilization:
adjustement 218

The variable geometry of this system implies that the following rules be respected:
Ideal cases: closed frame obtained
Other cases Use of 2 braids, obtained with kit CT1000 (N° 942008)
Prohibited case
Utilization:
adjustement 1190

ROBOFIL 190
On the ROBOFIL 190 model, the work table is grounded by means of fixed linking
units. Hence there is no need to be concerned about the position of the grounding
braids.
It is nevertheless important to avoid removing the transverse bar joining the right and
left side units of the work table, as this bar serves as a ground loop.
Utilization:
adjustement

Inspection list
Introduction
Weekly, or prior to undertaking long duration work, the list below makes it possible
to ensure that the equipment is in condition to work under the correct conditions.
This check list is only indicative. Account must be taken of the fact that certain
equipment is not present on all machines (for example temperature control,
grounding cables, device for automatic cutting and threading of the wire, etc.).
This forms a checklist, so as to ensure that nothing is forgotten when starting new
work.
Equipment general inspection
Check the maintenance table (see maintenance manual) and make sure that no
maintenance points will occur during the work.
«Dielectric» function inspection
•Level - if the machine is not equipped with an

automatic compensation system, check the
level and refill manually if necessary
•Filtering - make sure that the message «E706 filter flow
rate too low» does not appear during the
previous cutting operation.
- visually check that the contact cooling is
adequate.
•Deionizing - depends on technology used
•Temperature - 20 °C ± 0.5 °C
«Erode» function inspection
•Cutting contact - wear

- surface
- quality fitting
•Earthing cables and braids - condition of cables Utilization:
- and thightness adjustement

«Wire change» function inspection
•Air pressure for wire cuttion

•Guides - diameter
- cleanliness
- thightness
•Type of wire (diameter, material)
•Spool autonomy
•If a new spool is installed, check:
- quality of spooling
- that there is no oxidation
•Wire recovery tray
•Brake calibration
Part installation inspection
•Clamping system cleanliness

•Part cleanliness - (demagnetization)
•Part clamping
•Part alignment
Parameter adjustments and checks
•Find the absolute references if necessary.

•Run the «guide adjustment» cycle if necessary :
- after movement of the top guide mobile support,
- after replacing the guides.
•Run «nozzle adjustment» cycle if necessary :
- after replacing the nozzles.
•Take the work-piece references, making the necessary electrical touches and
centering operations. Under the following conditions :
- in immersion,
- Z in working position,
- wire speed and tension set to values used for finishing work.
•Set the wire to the programmed starting point if this is not to be done via the
command file.
•Check parameters values in the ADJUST mode.
- make sure that all the parameters affecting execution of the part program have the
desired value.
•Select file .WIR containing the desired wire preparation table.
Utilization:
adjustement

•Select file .TEC containing the desired settings, and perform the modifications if
required.
•Select USER.OFS file, if it is not expected to use the offsets attached to the
technological modes, and enter the desired values.
•ROBOFIL X90,3X0,5X0: verifiy on screen page EXE - LUBRICATION CYCLE that
the job to be executed is not likely to be interrupted by the next greasing deadline.
•Drawing of the program on the screen.
Program dry run
•A program dry run is recommended, even if the program is simple. This ensure :
- that no travel limit will be reached during cutting,
- that there will be no risk of collision, in particular with the clamping system,
- that the program calls the desired modes and offsets,
- that the threading orifices coincide with the programmed positions.
Starting cutting
•Fill the tank (ROBOFIL X020)

•Start the program :
- wait for a few minutes to make sure that cutting is taking place correctly.
Most of the problems related to incorrect settings appear during the first few
millimeters of cutting (Offset, path direction, scale, rotation, etc.).
Utilization:
adjustement

Utilization:
adjustement

Measurement and taking reference
The various machine systems of axes
Definitions
The machine has 5 different axes: the X, Y, U, V and Z axes.
For any movement along these axes, the wire displacement is considered with
respect to the part.
The X and Y axes execute the relative movement between the workpiece and lower
wire guide.
The U and V axes are supporting the top wire guide.

These axes are used to tilt the wire and are parallel to the X and Y axes.
The Z axis manages vertical displacement of the top head.
V
U
Y
X
Utilization:
4260 adjustement

The absolute system of axes
This system is defined by the optical sensors installed on the machine.
This is a fixed system, since the position of the references on the scales do not
change.
By design, the zero points of the various axes are located:

•At negative travel limit for the X, Y and Z axes
•At center of travel for the U an V axes.
There is 1 reference point at each end of the scales.
Briefly, the absolute system of axes is unchangeable and is used by the machine.
The machine system of axes

This system is defined by the operator. Since it is easily modifiable, it is a more
practical system than the absolute system.
The machine system of axes is modifiable and used by the operator.
The part system of axes

The programs used to define a machining path are created according to a system of
axes proper to the part and, in most cases, comparable to the system of axes used
for dimensioning workshop drawings.
To sum up, the part system of axes is defined by the machining program and used
by the programmer.
Utilization:
adjustement

Definition of "AXO"
The term AXO defines the difference between the absolute coordinates and the
machine coordinates
AXO = absolute coordinates - machine coordinate
This is valid for all axes.
+ Ya + Ym
AXOX
+Yp
+Xp
+ Xm
Y
O
AX
+ Xa
0
48
AXO, X and Y can be modified directly by the operator:

•in "REFERENCE" page
•via command «INSERT X machine»
«INSERT Y machine»
In this case, the AXO’s are computed by the machine.
It is possible to lose the data in the memory accidentally (therefore loss of information
concerning positioning). Therefore it is recommended to note the values of AXO
X, Ys.
After taking the reference again at X and Y travel limits, the values of AXO are
entered manually in the parameter page. The machine is then capable of locating
the origin of the machine system of axes.
It is possible to enter the AXO X, Y values with the SMA command.
Utilization:
adjustement

The electrical touch
The machine performs its measurement cycles on the principle of electrical touches.
The electrical touch is used to detect the presence of an obstacle and to measure the
position of the part by application of a machining voltage to the wire and detecting
short-circuits.
Type of electrical touches

Touch type 1
- This is a positive high voltage touch.
- This is a low energy, low wear touch (100 touches on a pin of diameter 10 mm
causes wear of 5 µm).
- This is used for precision measurements.
Type 1 is the machine standard mode.
Type 2 touch
- This is a negative high voltage touch.
- This has high energy and is used to measure rough-cast or oxidized parts.
The electric touch type change is made in the EXE mode (execution parameter).
Precision electrical touches

•The wire must be aligned, and the feed and speed and tension set to the
technological values.
•The part must be degreased, degaussed, free of burrs and carefully aligned.
•The touches must be executed in immersion, in correctly deionized water, after
thermal stabilization.
If the measurement cannot be performed in the water, insofar as possible, use a
hard metal pin of known diameter (10 to 12 mm), maintained at part mid-height.
•Select touch type 1.
•Prior to measurement, the wire must be located at more than 0.5 mm from the part.
Parameters affecting measurements

Parameters affecting performance of measurements are as follows:
•MTOL maximum dispersion of electrical touches within the same cycle
•COE effect of repetition by a cycle by an out-of-tolerance measurement.
Parameter MTOL
Principle of elementary measurement cycle using electrical touch.
In a measurement cycle, an approach touch has just been made; the wire protrudes
from the part to be measured on initial contact, followed by three precision touches.
The distance A between the edge of the part and the wire position after the
electrical touch is not the same for all three touches (relative to the surface finish).
The average of these three values gives the wire position after the measurement
cycle.
Utilization:
adjustement

Definition
MTOL is the maximum dispersion value of the three electrical touches within the
same measurement cycle.
- After the measurement cycle, if one of the 3 touches has a deviation B greater than
the value of MTOL with respect to the average, the error message «measurement
out of tolerance» will be displayed.
- The value of MTOL, displayed by default, is non-significant, so that the use can
adapt it to his requirements.
- Effect of parameter COE when:
COE = 0 the cycle stops from the first out of tolerance measurement
COE = 1 the cycle restarts until measurement within the MTOL tolerance is
obtained.
Conclusion
To obtain adequate precision of electrical touches, the instructions given in the first
part of this recommendation must be respected.
A1
A2
A3
-B +B
Average 60
Application example
Straightening of a part having two ground surfaces
- Make sure that the part is prepared correctly.

- Align the part coarsely; the surfaces A and B are the ground surfaces.
- Straighten surface «A» using a dial gauge. If so desired, it is possible to measure
the angle existing between surface A and the X axis, using the «edge alignment»
function, and to take this into account when running the program. This renders
straightening of the part superfluous. The measurements are always made with the
tank filled and the water perfectly deionized.
- Tighten clamps 1 and 2.
- Check that surface A has not changed and that surface B is correctly aligned.
- Check that the part surface is parallel with the XY plane.
- If not, it is better to clean the part and part mountings and check that both surfaces
of the part are perpendicular. Utilization:
- Make an electrical touch on surface A and enter the desired value on the Y
display. Use the edge function Measurement mode and the remote control.
adjustement

- Make an electrical touch on surface B and enter desired value on the X display.
B 2
X
0
50
Example of calculation of electric contact gap
Precision-ground rectangular work-piece Precision pluq gauge

Flat and perpendicular faces
X1 X2 X1 X2
L ø Pige
gauge
1122
- Carry out an «Edge’s contact on each side of the work-piece and note the value of
X1 and X2 (machine coordinates)
X2 - X1 = (plug gauge ø or L») + wire ø + 2 x stand-off + 2 x electric

contact gap
from which:
Utilization:
adjustement Gap TE = X2 - X1 - ø wire - 2 x stand-off - plug gauge ø (or to «L»)
2
Example of use: searching corner A
Xp
Ym
Pal , D50, R90 Alignment of work-piece

face and taking Rot = 90°
into account 50
Yp
MPR , X-20 Positioning the wire close A 20
to work-piece corner A Xm
1123
Xp
Ym
CRN, DX20, DY20, G0.005,

X0,Y0
Dx
Yp A Automatic calculation of work-
Dy
piece corner A and resetting of
corner A co-ordinates.
Xm
1124
Measurement cycles
Execution procedures of measurement cycles are described in chapter 4.3,

EXE Mode.
Utilization:
adjustement

Utilization:
adjustement

Generator
General
Pulse generation is made according to 2 methods:
Isofrequency method
A current source supplying the electrode and the work part is controlled by a switch
closed at regular intervals. However, a discharge can occur only under certain
conditions which vary constantly. The waiting period for these conditions determines
the striking time td, which varies from one pulse to another; because of this, the
discharge time varies and may become null. Since the discharge energy is not
constant, the surface finish and the sparking time vary.
uG
td 1 td 2 td 3 td 4 td 5
t
X Y X Y
iG
1 2 3 4
Isopulse method
For this method, control of the switch is made taking delays td into account
quantitatively. Consequently, all the discharges are controlled and their energy is
constant. For a given surface finish d, the efficiency and material removal are
maximum.
The surface finish and the spark time are regular.
uG
td 1 td 2 td 3 td 4
t
A B A B
iG
1 2 3 4
Utilization:
t
adjustement

Machining optimization in roughing
A series of technologies corresponds to each wire-part pair, enabling the generator

parameters to be configured in an optimum manner while retaining a safety margin.
This limits risks of unwanted breakage of the wire. A machining setting consists of
the following parameters: B, S, Aj, INJ, M, V, A, TAC, WS, WB, OFF, IAL.
All these parameters are defined in chapter 4 in the setting mode.
Only user files U xyooz.TEC can be modified. During machining, it is advised to

limit modifications to parameters AJ, B, S, WS, WB and INJ. Modification of other
parameters can entail changes in the hidden protection parameters.
To optimize roughing, 2 parameters, B and S, must be considered. As a general
rule, Aj must remain fixed.
Aj - Servo system mean reference voltage in 1/10 Volts.

The value of Aj proposed in the technological tables has been chosen so as to
ensure optimum feed quality.
If Aj is increased: the feed speed decreases and the gap increases.
If Aj is decreased: the feed becomes unstable.
B - Time between 2 pulses

theoretical F approx ~ 1/A + B.
Frequency in kHz
For a given height, the technological value of B may be modified, knowing that:
- B does not affect the surface condition
- B does not affect the gap (if B is located in the linear part of the curve).
When B tends towards its maximum limit, there is a risk of decreasing the gap.
- B affects machining rate (see curve)
- B, if too low, causes wire breakage.
Breakage
Technological B
V (mm/mn)
Utilization:
adjustement

Comment
Technological B is located at a point of the curve from which a decrease in B
produces only a slight increase in speed. During machining without
supervision, B may, if necessary, be increased by approximately 10% to
prevent wire breakage, if the machining conditions were to deteriorate.
WS - Wire feed rate

WS affects cutting rate
WS affects part parallelism
Since wire is higher in roughing (due to setting), the rate will be faster than in
finishing.
WB - Wire mechanical tension

WB affects shape geometry
If WB , precision
INJ - Injection setpoint: Injection is active only in roughing.

Evacuation of metal particles during machining. As a general rule, it is
recommended to decrease the injection pressure for evolutive surface parts so as to
prevent creation of turbulence.
Note
On the ROBOFIL 190, injection pressure is set manually by means of the two
adjustment faucets located to the right of the door. The parameter INJ is
inoperative.
Machine optimization in finishing
To optimize finishing machining, two parameters Aj and S must be considered. As

a general rule, B must remain fixed.
Aj - Servo control mean reference voltage.

•Finishing
If Aj , material removal , rate , part tends to become concave
If Aj , material removal , rate , part tends to become convex.
This effect increases with the height of the part.

It is also accentuated by an excessively low wire tension.
Variation of depth of cut for 1 point of Aj: from 1 to 12 µm, depending on the
setting and the part height.
•Surface finishing
Machining is made at the limit rate. In general, Aj should remain fixed.
Utilization:
adjustement

S - Servo control stability, maximum rate
This parameter sets the variation range for the feed rate.
This is not a «servo» type feed instruction. In no-load machining (approach to part,
for example), it behaves as a travel limit, by setting the maximum rate or the no-load
rate.
•Relationship between S and no-load rate
S = no-load rate/7.32
If S is such that the no-load rate is less than the technological machining rate,
machining is at the «rate limit». Machining is irregular and striations may appear.
•Finishing
S determines a no-load speed equivalent to about 3 times the average machining
rate so as to allow the feed to adapt itself to suit variations in the amount of
material to be removed.
•Surface finishing
Modification of S results in the following tendencies:
If S , rate , material removal , poorer surface finish.
If S , rate , material removal
WS affects the wire feed rate

WS affects cutting speed
WS affects part parallelism
In roughing, since wire wear is greater (because of the setting), the feed rate will be
higher than in finishing.
WB - Wire mechanical tension

WB affects the shape geometry
If WB , precision
Other important parameters

•Water conductivity
Affects the gap. Make sure that the two indicator lights are lit and that the
measured conductivity corresponds to the setpoint value.
•Dielectric temperature
Temperature differences cause expansion of the support and affect the gap.
If T , gap .
Utilization:
adjustement

Utilization: wire and dielectric
The wire 8.3.3

Installing the wire 8.3.3
Automatic threading (ROBOFIL 310 and 510) 8.3.8
Rethreading after breakage during machining
(ROBOFIL 310 and 510) 8.3.10
Further information related to the wire 8.3.11
ROBOFIL 190 8.3.12
The dielectric 8.3.13

Generalities 8.3.13
Regulation of conductivity 8.3.13
Adjustment of minimum injection 8.3.13
Checking of levels and monitoring of cabin door 8.3.14
Switching on/switching off pumps 8.3.14
Working life of filters 8.3.15 Utilization: wire
Monitoring of the dielectric temperature 8.3.16
Table of
and dielectric
contents
ROBOFIL 190 8.3.16

Utilization: wire
and dielectric

The wire
Installing the wire
Comments
The diameter of the wire used varies between 0.1 and 0.3 mm.
The tension on the wire is programmable up to 3 Kg.
Take care to check the condition of the spools before loading:
- quality of winding
- no traces of abnormal oxidation.
Installation of spools on panel (ROBOFIL 290 - 300)

•Extract the spool-shaft assembly from the mountings
•Unscrew one of the nuts
•Fit the new spool on the shaft, taking care to check it.
•Tighten the nut
•Install the spool-shaft assembly on the mountings, respecting the direction of
rotation of the spool.
Spool - holder
Wire spool
Nut
Nut
Shaft
Utilization: wire
804 and dielectric

Installation of wire on front panel (ROBOFIL 290 - 300)
•Place the wire in position along the path numbered from (1) to (9)
•Pull the wire so as to bring the balancing arm horizontal. The spool drive motor
starts. Keep the motor running for a few moments so that the wire places itself
correctly on the belts.
(2)
ROBOFIL 300
Spool drive (3) Encoder "wire presence"
+ brake
ROBOFIL 310
Encoder "wire presence"
+ brake
+ threading motor
ROBOFIL 310
(8) (6) Annealing pulley
(1) (7) (4)
Double pulley:
Double pulley: wire fits in rear groove between
Wire fits in front (9) (5) and (6)
groove between (5)
(7) and (8)
Mobile rocker pulley

controlling the spooldrive
motor
1484
Installation of spools
(ROBOFIL 310 - 500 - 510)
•Extract the spool-shaft assembly from
the mounting
End shields •Loosen one of the end shieds using a
socket head wrench
•Fit the new spool on the shaft, taking
Wire spool
care to check:
- for abnormal traces of oxidation
- winding quality
•Install the spool-shaft assembly on
Shaft
the mountings, respecting the
Socket head wrench direction of rotation of the spool.
Spool - holder Note

When loading large spools, remove
and reverse the end shields.
Utilization: wire
and dielectric 1486

Installation of wire (ROBOFIL 310 - 500 - 510)
Place the wire in position along the path numbered from (1) and (16)
Enclosed wire equipment plate

Left side of the machine Fix the wire between 2
spires of the wire threader
Push the threader through the

eye fixed on the inner wall
8 To the front of
9 the machine
Wire threader
Mobile rocker pulley controlling the

4 spooldrive motor
Wire fits in rear 3
groove between (2) Spool drive

and (3) 2
Wire fits in front

groove between (4)
and (5)
1
Variable position double pulley to
compensate for variation in wire
length
Wire equipment plate.

Front of the machine
Unhook the wire from

10
the wire threader
Wire equipment plate
Pull a sufficient wire
length
11
12
13
14 15
16
Utilization: wire
1487 and dielectric

Manual preparation of wire
ROBOFIL 290 - 300 ROBOFIL 310 - 500 - 510
Deflector Deflector
Contacts Contacts
This device is used to straighten and cut the wire without burrs, facilitating
introduction the top and bottom guides
•Stretch the wire and apply it against both contacts
•Wait a few seconds: the wire lengthens slightly, and is cut where the deflector
is situated
•The wire is now straight and can be threaded in the guides.
Utilization: wire
and dielectric

Manual passage through wire guides
•Run the wire into the threading tube,

making sure not to deform the
ROBOFIL 290/300/500 ROBOFIL 310/510
straightened part (ROBOFIL 310-510)
•Select «manual»
•Withdraw the top contact and start
the wire feed
•Run the straightened wire through the
top guide tube, then through the
bottom guide tube until it is gripped Distributor
by the drive rollers. Blade block
Rethreading block
Machining contact block
Drive rollers
Curling rollers
3936
Wire recovery
The used wire is curled at the outlet from

the drive rollers, then stored in the
machining area.
Worn wire
Recovery area
Utilization: wire
and dielectric734a

Automatic threading (ROBOFIL 310 and 510)
Automatic threading is used when the wire is cut between the two guides.
•Select «Manual»
•Activate wire cutting by means of the key on the front panel (cut block).
•Activate threading by means of the key on the front panel. The wire is guided
by the jet through the lower guide as far as the drive pulleys.
The automatic threading cycle automatically carries out several operations.
- storage of the wire feed speed
- adjustment of the wire feed speed to within 3/8 ths of the rated speed
- contact retraction
- engagement of the threading jet
At the end of the operation, the jet can be stopped by the «tripped jet» key or by
exiting from the manual mode. In both cases the machine performs the following
operations:
- restoration of the set speed
- stopping of the threading jet
Definition of wire table parameters

Preparation of the wire is defined according to a certain number of phases
(according to the type of wire) and includes the fallowing parameters = WS, WB
R, OP, TE, TW, VE, IALR.
- Phase N°
- OP Current operation code
0 = in USER table, indicates possibility of adding a phase
1 = drawing out phase towards the lower port
2 = feeding phase (fine wire)
3 = annealing phase
4 = no servo controlled annealing phase (fine wire)
5 = drawing out phase towards the upper part
- WS Wire feed speed

Expressed in m/min from 0 to15
- WS max Maximum speed support by wire
- WB Wire mechanical tension

Expressed in decanewtons from 0 to 3
- WB max Maximum mechanical tension to be applied to wire
- TE Phase execution time

Expressed in seconds from 0 to 65
- TW Rest time at end of phase

Expressed in seconds from 0 to 65
- IALR Annealing current

Utilization: wire Same value as for setting.
and dielectric

- R Wire resistance
Expressed as hundredths of an Ohm, from I to 250
- VE Wire annealing rms voltage

Expressed in tenths of a Volt from 1 to 250
- WA max Maximum acceleration supported by wire
- WD Wire diameter
Wire preparation sequence for threading

The sequence described in the wire table should enable the wire to be reduced by
20 µm (+ 5 µm/- 2 µm) so that threading can take place correctly. To do this, the
wire is elongated by approroximately 8 cm due to a series of annealing and
drawing operations.
Example
Interpretation of wire tables -XS25WIR (Wire SW25X)
Without annealing maximum drawing is 1%, 4 phases are used to elongate the
wire by approximately 8 cm
Toble XS25.W R
N OP WS WB TE TW IALR R VE
1 3 0.6 0.00 3.000 8.000 16 0.98 6.6
2 5 0.6 0.00 4.200 1.000 3 0.10 2.5
3 3 0.6 0.00 3.000 8.000 16 0.98 6.5
4 5 0.6 0.00 4.200 1.000 3 0.10 2.5
1st phase (N1)

Annealing for 3 seconds at very low speed (WS 0 6 m /min), then wait for 8
seconds.
2nd phase (N2)

Drawing for 4.2 seconds at a rate of 0.6 m/min with the brake applied, then
release for 1 second.
3rd phase (N3)

Annealing for 3 seconds at a speed of 0.6 m/min then wait for 8 seconds.
4th phase (N4)

Drawing for 4.2 seconds at a rate of 0.6 m/min with brake applied, then release
for I second.
Utilization: wire
and dielectric

Rethreading after breakage during machining
(ROBOFIL 310 and 510)
ROBOFIL 310 and 510 offers the possibility of commanding automatic rethreading
in the event of breakage of wire during machining.
Comment Work method

With command RTH, it Rethreading depends on parameter ATH:
is possible to demand
rethreading outside of - Modifiable on «User parameters» page of EXE mode or by command.
the part program. - It is equal to:
The rethreading point 0 Stop on breakage (no rethreading) (by default value)
will be the same as the
point before starting of 1 Rethreading at last marking point or at the beginning of the part
the command. program for "n" (number of rethreadings set by operator) attempts during the
same part program, then stopping. On each restart, the frequency can be
reduced.
2 Rethreading for "n" attempts, then if further breakage, abandon of part
program. But advance up to end of program and continuation of the
command field if present by rethreading at first marking point of the part
program, starts with frequency limiting.
Breakage points
The breakage points are memorized in the INfO mode and displayed, together
with:
- Name of the part program file or command program file (first 8 characters)
- Name of block in which breakage took place
- Breakage position X, Y, U, V
- Number of breaks in same part program
PREP EXE ;; INFO GRAPH

POINTS DE RUPTURE
Programme Bloc X Y U V
N
Comment Marking points

All marking points are The marking points are:
possible threading
points ,i.e. a hole of - The start of the part program (G92)
sufficient diameter to - The threading function (M6)
enable threading. - An auxiliary marking function (M16) to be placed in the part program at the user’s
choice. During a normal run, this function does not cause threading, but
rethreading in the event of wire breakage
! G92 must be placed correctly. This must correspond to a hole
Utilization: wire
and dielectric

Reduction of frequency after rethreading
(See chapter Machining operation automated systeme)
After a rethreading, the machine automaticaly reduces the machining frequency in
order to limit the risks of wire breakage.
This function leads to problems if a wire breakage occurs during finishing, because
a frequency reduction during finishing activated causes a variation in the machining
Gap and hence incorrect dimensions on the part. The reduction of frequency after
threading is activated only if the current setting uses ST = 1 ou ST = 3.
ST = 0 Machining without strategy
ST = I Roughing with strategy - favors speed
ST = 3 Roughing with strategy - favors occuracy
ST = 2 Finishing with strategy - Used with E7 et E17
Treatment of stops during rethreading

After a rethreading during the course of a part-program, the machine executes the
program in dry run mode up to the point of breakage, and then goes into machining
mode.
The stops encountered during the dry run while returning to the point of breakage or
when passing on to the following program, are all ignored.
Further information related to the wire
Wire guides and machining contacts

refer to Maintenance Manual
WIRE CHANGE function
Brake calibration
refer to Maintenance Manual
Checking the brake calibration forms part of the weekly maintenance
operations. For a detailed description of the operations, see the
Maintenance Manual.
List of current wires and their applications

refer to Technologies Manual
Wire breakage
refer to Technologies Manual
chapter «Recommandations for machining»
Utilization: wire
and dielectric

ROBOFIL 190
Fitting of the reels

- Loosen the knurled blocking knob
- Place the reel in position (max. weight: 5 kg) on the horizontal axle, respecting the
direction of unspooling as shown on the wire positioning diagram displayed on the
bottom of the equipment panel
- Block firmly by means of the knurled nut
Centering is done automatically by the conical parts of the stop and the nut.
Placing the wire in position

Place the wire in position by following the path from (1) to (8).
(3)
(4)
(6)
(7)
(2)
(1) (5)
(8)
4744
Passing the wire manually through the guides

- Prepare the wire by means of tension and cutting between the two contacts
- switch on wire unspooling
- Pass the wire through the top head
- Guide the wire into the bottom head until it is gripped by the drive rollers.
Utilization: wire
and dielectric

The dielectric
Generalities
Refer to the maintenance manual for localisation of elements, as well as for filters
adjustment and replacement.
The dielectric function enables several functions to be carried out:

- evacuation of eroded microparticles
- renewal of a clean insulating liquid at 20°.
This function is divided into sub-functions

- filtration
- high pressure injection
- auxiliary circulation (cleaning, contact wetting, threading, low pressure injection)
- thermostabilization
- regulation of dielectric conductivity
- checking.
Regulation of conductivity
- The water conductivity value is adjustable in EXE mode. (page «User Parameters»).
- The actual value measured is displayed in Info mode (page «Survey»).
Note
If conductivity is higher than the value set + 20%, there is defect of conductivity.
The error message «E705: conductivity defect» will appear the next time the
machining generator is switched on. This error does not stop the machine.
It is possible to postpone the execution of a machining operation, if there is defect
of conductivity, by using the M32 function (monitoring of conductivity). M32 is a
modal function (disabled after execution).
Adjustment of minimum injection
Minimum injection provides a minimum flushing when high pressure injection is not
active (INJ=0), for instance for finishing operations or execution of measurements
cycles. The top and bottom flow rates can be adjusted separately according to the
application using the two cocks located at the right side of the front door.
ROBOFIL 290P, 310P and 510P machines are fitted with a flow meter with visual flow
display to facilitate adjustment (the measurement is shown by the middle of the float).
The following settings can be recommended:
Lower injection (flow in liter/min) upper injection

Open finishing 1 5
Utilization: wire
Finishing in the slot 0.5 to 1 2 to 8
and dielectric
for a part height of 50 to 150 mm

Checking of levels and monitoring of cabin door
The machine several statuses, including:
- The dielectric level in the clean reservoir:

- when the machine is switched on, it is forbidden to start the circulation and high
pressure pumps for as long as the level of dielectric in the clean reservoir is not
high enough. As soon as the correct level is attained, the circulation pump starts
up automatically. The high pressure pump can then be switched on.
- during use, an inadequate level is indicated by a message and causes the
pumps to stop working (circulation pump and also high pressure pump if the latter
is switched on). In this case, machining is suspended.
- Level of dielectric in the contaminated reservoir:
the level is monitoredby a probe. An information message is displayed on the
screen if the reservoir needs to be filled. Topping up is done with reference to the
visual indicator located at the front right hand side of the main frame. On certain
models, in the event of a requirement, the additional contribution is provided by
an automatic compensation device.
- Cabin door:
monitoring of the contact indicating the status of the door (open or closed):
- when the door is opened, the high pressure and low pressure injections, the
contact wetting and the threading jet (310/510) are all stopped. In such a
situation, machining is suspended.
- with the door open, it is impossible to switch on the high pressure injection or the
generator, or to execute operations in automatic mode (measuring, movements).
Note
Execution of commands with the door open by means of the remote control.
With the door open, it is possible to execute movement commands, for example
for purposes of simulation, by holding down one of the safety keys of the remote
control (speed variation keys) when starting and during execution of the command.
Switching on/switching off pumps
ISO codes: M50 stopping of pumps (injection, circulation, filtration)

M51 switching on of pumps
Entering the command AUX,50 via the keyboard thus makes it possible for the
operator to stop operation of the pumps without switching off the numerical control.
When there is a long interruption in machining (during the preparation stages of the
machine, or programming phases), stopping pumps in this way has 3 advantages:
- reduced noise level
- energy saving.
Utilization: wire
and dielectric The pumps need to switched on again with the command AUX,51 before resuming
machining. If this is not done, the error message ”E641: Dielectric low” will be
displayed.
Working life of filters
Several factors can affect the working life of filters:

- the metal machined
- the type of wire used
- the dominant machining setting (roughing generates more particles than finishing or
surface finishing)
- the times the machine is temporarily switched off
- the number of filters being used
The table below shows the indicative average values of filter working life according
to their number and the material being machined:
Number of filters Steel Aluminium, brass

4 45 h 15 h
5 60 h 20 h
8 120 h 40 h
10 150 h 50 h
Note
On machines with 4 filters, the number of filters can be increased to 8 thanks to a
kit of 4 additional filters available as an option.
On machines with 5 filters, the number of filters can be increased to 10 thanks to a
kit of 5 additional filters available as an option.
Utilization: wire
and dielectric

Monitoring of the dielectric temperature
The purpose of this monitoring is to detect and indicate any excessive difference
between the dielectric temperature and a set value. It is performed by an external
regulating device located at the rear of the machine. This device makes it possible to
set the value by means of a potentiometer (graduated in degrees), and to set a
ceiling. The set value is fixed at the factory at 20° and the ceiling is fixed by default
at 5° above the set value.
Two timeouts D1 and D2 are used in the NC to adjust the monitoring (timeouts
given in seconds, and modifiable in the screen page Service - Execution Parameters,
Nos. 11 and 12).
Principle of operation:
• If the temperature exceeds the tolerated ceiling for a period longer than timeout
D1 (by default: 1 second), a warning message is displayed for as long as the
problem continues. This temporary status (alert status) makes it possible for the
operator to look into the problem and overcome it.
• If the alert status continues beyond timeout D2 (by default: 4 hours), machining is
stopped, the machine goes into suspension mode, and an alarm message is
displayed
The operator can restart the pumps immediately by means of the command AUX, 51.
When machining is restarted, and if the temperature is still higher than the limit
tolerated, the NC immediately goes into alert status with display of the warning
message. As above, machining is then possible for the duration of D2, even if the
temperature does not fall back within the normal range.
ROBOFIL 190
The ROBOFIL 190 is only provided with temperature adjustment, without any
monitoring by the NC software.
In all circumstances, the injection pressure is set manually by means of the two
adjustment faucets located to the right of the door. The parameter INJ is inoperative.
As a general rule, set the pressure as follows:
- for roughing, select maximum pressure (setting 4)
- for finishing, surface finishing or for performing measurement cycles, reduce the
pressure to the values of the orange graduation zone.
(Examples of adjustment: finishing -> 0.4 finishing in the slit -> 0.7).
!
Opening of the cabin door interrupts injection and circulation of dielectric. For
this reason you are advised – except when interventions are required inside the
cabin – to keep the door closed and the pump switched on, so as to maintain
stable temperature and deionization.
Utilization: wire
and dielectric

Chapter 9
Options
1. Autotransformer
ROBOFIL 190 2. Autorestart
290P 3.
4.
Language diskette
Auxiliary M functions
310P 5. DNC3
510P 6. System CT 1000

7. EJECT 300-500
8. Termogamma cooler
Options described in the

technologies manual:
- Taper Expert
- Machining with 0.1 mm wire
- Cutter machining
204 931 240/E/17.12.99

Autotransformer
Introduction 3
Characteristics 5 Auto-of
Table
transformer
contents
Connection 5
CHARMILLES TECHNOLOGIES 4 927 310/E/04.02.1997 1

Auto-
transformer
2 CHARMILLES TECHNOLOGIES 4 927 310/E/04.02.1997

Introduction
Charmilles Technologies machines are wired to operate from 380V or 400V three-
phase mains. Auto-
If the mains voltage is different, it is possible to supply the machine through an transformer
autotransformer.

Characteristics
Dimensions 655 x 460 x 465

Input voltage 204V, 220V, 240V, 400V, 420V, 440V, 480V, 575V
Output voltage 380V
Power 10kVA or 12 kVA (depending on model)
Connection
The autotransformer is connected to the machine supply line.
Mains voltage Machine

other than 380V power supply
Autotransformer
Auto-
transformer

Option AUTORESTART
Table of
AUTORESTART
Description of the fonction 3 contents

AUTORESTART

Description of the fonction*
When there is a power failure, the whole installation is cut off, and only the 3.6 V
batteries ensure saving of the data in RAM.
When power is restored, the Autorestart option provides automatic reconnection of

power supplies about 3 seconds after mains power is restored, on condition that the
interruption has lasted less than 3 minutes. An audio/visual signal (lasting 2 to 3
seconds) informs the operator that power has been restored.
- Removal of a jumper link on the UA-SAL board allows reconnection to be enabled
whatever the duration of the interruption (operation carried out by Charmilles AUTORESTART
Technologies After Sales Service).
- A key contact allows the automatic reconnection function to be completely enabled
or disabled.
Depending on the value of the ART user parameter, the option will in addition
execute an automatic restart of the current program:
- ART = 0 No automatic restart
The current program remains in suspended mode. Data are saved.
The operator can check the status of machining then restart program
execution with the START button.
ART = 1 Automatic restart occurs only if the interruption has lasted less than 3
minutes. The operator is also informed of this event by the audio/visual
signal.
If the interruption has lasted more than 3 minutes, the program is put into
suspended mode as above.
ART = 2 Automatic restart of the current program occurs however long the
interruption has lasted.
Caution: This mode of operating will only be enabled if the jumper link
mentioned above has been removed.
Furthermore, a restart after an interruption longer than 3 minutes does
not allow quality machining to be guaranteed, in particular because of
a possible temperature discontinuity (part, dielectric, machine).
Note:
There will be no automatic restarting if the machine was stopped normally by
the operator using either the "Power off" key or the "Emergency stop" button.
* This function is supplied as standard on certain models.
AUTORESTART

AUTORESTART

Language diskette option
Language
Table of
Loading 3 option
contents

Language
option

Loading
This procedure is used to change the language of the text appearing on the screens.
•Insert the "Language" diskette into drive B:.

•In the EXE mode, select the "Program execution" function. The machine is in
suspension mode.
•Using the "Change Unit" function, display the drive B: directory.
•Select the file corresponding to the desired language (•CMB extension).
•Select the "Cut" function. Language
•Press the "START" key on the front panel. option

Language
option

Auxiliary M functions
Introduction 1
Encoding of auxiliary function 1
•Format of user M functions 1
•Description of functions 2
•Recalling 2
Definition of functions 3
Input and output connectors 4
•Connector locations 4
•Connector diagrams 4
•Connector wiring 5
•Input connector X4 5
Table
M of
•Output connector X3 6 Functions
contents

M
Functions

Introduction
These functions are used to synchronize an external item of equipment with the
machine. It is possible to control one or several simple accessories using signals
generated by the part program (sending and reception of signals).
These signals are managed so as to avail of 4 functions:

•Set/reset of an output with status storage
•Programmable duration pulse
•Output with wait for acknowledgement
•Await input.
Depending on the communications mode desired, the inputs and outputs can be
used with the above-mentioned functions.
The 8 outputs and inputs (numbered 1 to 8) are accessible on IFMAC26, on
connectors X3 and X4 of the machine box respectively.
Encoding of auxiliary functions
User M function format
Mms
M : auxiliary function
m : signal code
s : input or output number
The inputs and outputs are concerned by the following functions:
Functions Codes Inputs Outputs

Set 100 X
Reset 110 X
Pulse 120 X
Acknowledge 130 X X
Await 140 X
Example M
- Pulse function code: 120 Functions
- If output 3 is considered, the corresponding M function is M123.

Description of functions
Each connector has 8 inputs or outputs which can be used according to the
functions described above.
Output connector: X3
Output No. Available functions

Set Reset Pulse Acknowledge
1 M101 M111 M121 M131
2 M102 M112 M122 M132
3 M103 M113 M123 M133
4 M104 M114 M124 M134
5 M105 M115 M125 M135
6 M106 M116 M126 M136
7 M107 M117 M127 M137
8 M108 M118 M128 M138
Input connector: X4
Commands EAI, ESR and ESP relative to the external signals occupy inputs 6, 7
and 8. Input 5 concerns the operator key, which offers the capability of blocking
access to certain menus. Consequently, if these commands are used, the corres-
ponding M functions cannot be used.
Recalling
EAI,1 : error signal reception unlocking

ESP,1 : unlocking of reception of external signal simulating the “execution
suspension” key.
ESR,1 : unlocking of external reception signal simulating the “execute” key.
Input no. Available functions

Acknowledge Await
1 M131 M141
2 M132 M142
3 M133 M143
4 M134 M144
5 M135 M145
6 M136 M146 or external STOP ESP
7 M137 M147 or external Start ESR
8 M138 M148 or external Error EAI
M
Functions

Definition of functions
M101 to M108
Set Function: Set to 1 and storage of selected output.
M111 to M118
Reset Function: Reset and storage of selected output.
M121 to M128
Pulse Function: The output takes on the state for a programmable duration of
1/100 to 1 second by means of parameter 16 (step by step adjustment of 1/100 s).
When parameter 16 is negative, the input is in inverted logic.
M131 to M138
Acknowledge Function: A 1 status is sent to the selected output and maintained until
arrival of an external signal (acknowledgement) on the same input number.
The output is then reset. If the function is interrupted during the acknowledgement
waiting cycle, the program will run the next block after the interruption.
Pay attention to reserved inputs (see function description)
Reset
Output
Input
Acknowledge
Waiting period Program continuation
M141 to M148
Await Function: This function is used to wait for detection of a signal on the selected
input so as to continue running the program. If a machine suspension occurs, the
waiting time is continued on continuation of the program.
Pay attention to reserved inputs (see function description)
Expected signal
Input
Waiting period Program continuation
M
Functions

Input and output connectors
Location of connectors
The input and output connectors X4 and X3 respectively are accessible on a board
IFMAC inside the machine box.
Please consult the maintenance manual to determine the position of this board and
connectors X3 and X4.
X1
X7
X8
X2 X9
User M functions X3 X10

output connector X3
User M functions
X4 X11
output connector X4
X5 X12
X6 X13
631a
Connector diagram
Terminals 1 and 3:
Machine terminals
Terminals 2 and 4:
External power supply terminals
1: machine 0
2: input 0 external
3: machine -24V
4: External «—» input
114
M
Functions

Connector wiring
Depending on the power and number of external items of equipment used, the
power supply can be made in two ways:
•The power supply provided by the machine is sufficient: strap terminals 1 and 2
and terminals 3 and 4;
•If not, the power supply may be external (from 24 to 28 V): This is to be connected
across terminals 2 and 4 of the connector.
Input connector X4
User Machine
1 0 Machine
2k
2k
2 kk
2
3 -24V Machine
117a
Minimum closed circuit current: 10 mA with 24 V minimum

Minimum pulse time at input: 10 ms.
+ 2 External power supply : 24V to 28V

to be connected across 2 and 4
0 Machine 1
17
input 8 or error signal reception
9 external with EAI = 1
21 M138, M148 prohibited
13 input 7 or reception of external
starting signal with ESR = 1
18
M137, M147 prohibited
10 input 6 or reception of external
22 suspension signal with ESP = 1
14 M136, M146 prohibited
19 input 5 (operator key)
11
input 4
23
15 input 3
20
12 input 2
24
input 1
16
4 0 If external power supply
--24V Machine 3 DO NOT STOP TERMINALS 1/2, 3/4 M
116a
Functions

Example of input control
• Direct IN
-24V
IN
• Via transistors
-24V
118a
Output connector X3
Machine User
0 Machine
1
OUT
-24V Machine 3
1145
M Level 1 : VOH: 22 to 30 V
Functions Level 0 : VOL: 1.5 V max
IOL : 2 A max per output.

Caution
Imax supported by fuse (for all outputs): 3A
Pulse minimum time at output: 200 ms
+ 2
0 Machine
+ Machine 1 External power supply:
24 24V to 28V to be connected across 2 and 4
-
+ 16
output 1
- 20
+ 12
output 2
- 23
+ 15 output 3
- 19
+ 11 output 4
- 22
+ 14 output 5
- 18
+ 10 output 6
- 21
+ output 7
13
- 17
+ output 8
9
- 4
0 If external power supply,
--24V Machine
0 Machine 3 DO NOT STOP TERMINALS 1/2, 3/4.
115
Examples of output controls
• Via relay COM
Relay
OUT
• Opto-coupled COM
1 1k kΩ
22kk Ω
OUT
120
M
Functions

M
Functions

Communication DNC 3
Introduction 3
Configuration of the machine 4

Installation of the option 4
Configuration parameter 4
Configuration of the front panel 4
•Location of switches 4
Configuration of the peripheral board 5
Communication page 7
Description of communication Protocol 8

General considerations 8
•Connection between the Host and the machine 9
•Down-line loading of files (Host to machine) 10
•Up-line loading of files (machine to Host) 10
•Getting a directory 10
•Executing machine cycles by the Host 10
Communication Messages 11
•*CON,Host Identification - Connect the host with the machine 11
•*DIS - Disconnect the machine from the Host 11
•*STO,dev:filena.ext - Store file from Host to machine 12
•*Itext - Information line message 13
•*CLO - Close (make permanent) stored file 13
•*GET,dev:filena.ext - Retrieve file from machine 14
•*R - Information line request 15
•*DIR,dev: - Get a directory from Machine 15
•*DLF,dev:filena.ext - Delete file from machine 16
•*RNM,dev:filena.ext1,newfilena.ext.2 - Rename a file 17
•*SPG,dev:filena.ext - Select part program for execution 18
•*CCF,dev:filena.ext - Select command file for execution 18
•*STR - Start cycle 19
•*STP - Stop cycle 19
•*ABO - Abort cycle 20
•*RMS - Machine status request 20
•*RET - Request for extented status message 21
•*RME - Machine error request 23
•*Q - Command status request 23
•*RPT - Repeat last message 23
•*ROM - Operator request 24
•*ESC - Resetting of protocol 24
•*MSG, text - Free Message 24
•*PAR - Machine parameter 25
Communication Diagrams 27
•Connection and disconnection between the Host and the machine 27
•Down-line loading of files (Host to machine) 28
•Operator request 29
•Erase a file 30
•Rename a file 31
•Up-line loading of files (machine to Host) 32
•Directory 33
•Executing and stopping machine cycles by the Host 34 Table of
•Survey of the cycle 35 DNC3
•Repeat last message 35
contents

DNC3

Introduction
Note
See documentation of the TRANS3 software
The DNC3.2 option allows:

- Transfer and management of files (ASCII and binary) between the machine and the
PC equipped with the TRANS 3 software.
- Monitoring of the machine from the PC with the possibility of appeal (alarm) and
remote consultation by telephone line if the PC is equipped with a MODEM.
- Remote control of machining.
The configuration of the computers can vary considerably depending on the options
selected (standard PC linked to a machine, use of a MODEM, use of a DPC8
board, use of a QUINX network); this description will be limited to the case of a
standard PC with 2 serial ports, 1 mouse, 1 machine connected by RS 232 link.
! The DNC3 option can only be used if the machine is installed in an

enclosed cabin or in a controlled access workshop.
DNC Socket
DNC3
637a

Configuration of the machine
Installation of the option
The menu on screen must be the initialization menu.

- Insert the DNC3.2 option diskette into the driver.
- Select «LOAD»
- check the installation of the option in the INFO mode: the declared options are
displayed in black (grey display otherwise).
Configuration parameter
- In the EXE mode, select «SERVICE» then «COMMUNICATION».

- Configure the DNC parameters:
(see user’s manual, EXE mode -> SERVICE -> DNC3)
Canal: Must be at 1 in order to use the socket under the keyboard

Baud rate: Can vary between 0 and 19,200 bauds but must be the same as for
the PC; in general 9,600 for a long link or for tests.
Protocol: Should be at 12 for the DNC3
Time limit 1:Should be at 2,000
Time limit 2:Should be at 5,9999
Configuration of the front panel

(see documentation of the TRANS 3 software).
Location of switches
SW1 SW2 SW3

RS232 cabling, Normal
SW1 SW2 SW3
RS232 cabling, Reverse
DNC3
SW1 SW2 SW3 1244

Configuration of the peripheral board
This board is placed at level 11 of the electrical cabinet on the ROBOFIL 1020 and
2020/4020/6020 and on the level 12 on the ROBOFIL 300/310/500/510.
The link between the RS232 and the peripheral board is provided by optical fibers
Switch SJ1
Switch SJ2
Selector on 110V Switch SJ3

2025
Switch SJ1:
Determines the type of cables used. (Tx and Rx wires crossed or not crossed in the
cable).
OFF Switches ON
Rx = Rx Rx = Tx
from 1 to 8
Tx = Tx Tx = Rx
Switch SJ2:
Determines the type of link. (RS232, RS423 or RS432).
OFF Switches ON
RS232
from 1 to 8 RS422
RS423
DNC3

Switch SJ3:
Determines the transmission speed.
Speed (bauds) Switches Position ON
RS232 8
RS423 19200 Bd 6
RS423 9600 5
RS423 4800 4
RS423 2400 3
RS423 1200 2
RS423 50-600 1
DNC3

Communication page
The DNC3 page, in the INFO mode, makes it possible to follow the progress of
operations between the machine and the computer.

DNC3
CONNECTED
Host File
Previous command
Current command
State Error
Message
DNC FS
SURVEY MACHINE RUNNING MESSAGES DNC3 MODAL BLANK

PROGRAMS STATE
F1 F2 F3 F4 F5 F6 F7
DNC3

Note Description of Communication Protocol
It isn't necessary to
know the description of
the communication
protocol to use General Considerations
TRANS3.
The protocol is a half-duplex asyn-chronous point to point protocol with the Host as
master of the line.
The Host has commands to connect the machine, to download and upload program
text files to and from the machine, to select machine cycles and part pargrams, to
start, restart, stop or abort the selected cycle and to request the status of the
machine.
Communication is by means of messages. Each Host message will be

acknowledged. The maximum acknowledgement latency is 500 milliseconds. The
machine sends no unsolicited messages to the Host.
All messages are of binary type.
•Start of message <DLE> <STX>

•End of message <DLE> <ETX>
If the control code <DLE> is included in the message, it is sent twice.
A CRC (CRC-16) follows the end of the message and replaces the checksum of the
protocol currently in use.
The calculation of CRC starts after STX and finishes after ETX.
The <DLE> codes inserted by the protocol to obtain transparency are not taken into
account in the CRC calculation. That is to say <DLE> before <ETX> and repeated
DNC3 <DLE>.

Format of the messages
Information type message

Start ofde
Début message
message End
Fin of
demessage
message
<DLE><STX>*I . . . . . . . . . . . . . . . . <DLE><DLE> . . . . . . . . . . . . . . . . <DLE><ETX><CRC><CRC>
Transparency
Codes codes
de transparence
Characters inclus
Caractères included in CRC
dans CRC
<DLE>>STX> Start of message 10h/02h
<DLE><ETX> End of message 10h/03h
<DLE><DLE> binary code 10h in the orinigal message 10h/10h
<CRC><CRC> CRC in two characters CRC-16=X^16+X^15+X^2+1

1253
The lenght of the user messages is limited to 128 bytes. This lenght must include all
the data bytes without taking the protocol into account. That is to say that the
characters listed below are not counted in the lenght of the message header *1
<DLE><STX>,<DLE><ETX>,<DLE> for transparency,

<CRC><CRC>, and message header *1
The machine replies to all the commands as follows:
*BSY if the command is accpted but not yet executed,

*OK if the command is accepted and terminated,
*INV if the command is invalid .
*CHK if the checksum is wrong.
*ERRtyp in case of command error.
Connection between the Host and the Machine
It is necessary, except for the *RMS command, to connect the Host and the machine
with the *CON command. If the connect command is accepted, the machine
replies with *OK.
After the session, the Host must send a disconnect command: *DIS the ma-chine is
then free to accept another connect command.
DNC3

Down-line Loading of Program
(Host to Machine)
The Host is able to store files on the machine by using a sequence of commands
with informative replies by the machine. The *STO command is given first to declare
where to store the file on the machine. It is followed by *I information messages
which transfer one record each from the Host to the Machine.
The sequence is terminated by the *CLO command which means the end of the
information from the Host.
Up-line Loading of Program

(Machine to Host)
The Host is able to retrieve files on the machine by using a sequence of commands
with informative replies by the machine. The *GET command is given first to identify
the desired file on the machine. It is followed by *R information record requests to
transfer one record each from the machine to the Host by *I information record
messages.
The sequence is terminated when the machine sends an *EOF end of file message
after all the *I information messages have been sent.
Getting a Directory
The Host is able to get directories from the machine environment by using a
sequence of commands with informative replies by the machine. The *DIR command
is given first to identify the desired directory on the machine. It is followed by *R
information record requests to transfer one directory record from the machine to the
Host by *I information record messages.
The sequence is terminated when the machine sends an *EOF end of file message
after all the *I information messages have been sent.
Executing Machine Cycles by the Host
The Host is able to select either an individual part program or a command file which
belongs to the machine environment (it may have been previously down-loaded as
described above).
An individual part program is selected with the *SPG command. A command file,
which specifies machine parameters, operations and/or part programs, is selected
by the *CCF command.
The machine cycle is actually started in both cases by the *STR command. This
command is also used to continue a cycle after a stop.
A machine cycle commanded by the Host can be stopped asynchronously by the

Host with the *STP command.
DNC3

The Host can also abort either an interrupted cycle, or a cycle that was not started,
with the *ABO command.
The Host can request machine status conditions at any time with the *RMS
command. It will get information about the state of the communication, the state of
the machine, etc...
If errors have occurred, the Host may get the error numbers with the *RME
command.
With the *Q command, the Host will get the status of the last command when
required.
Communication messages
Host Commands with possible Machine Replies
*CON,Host Identification Connect the Host with the Machine
A communication session between the Host and the machine starts upon receipt of
the *CON command. The machine will refuse any other command between
sessions, except the status commands (machine status, machine error, command
status). The Host Identification text is given only for information purpose.
Possible responses are:
*OK Connection accepted

*CHK Checksum error in com-mand
*INV Command invalid: still connected in another session
*ERROCC Connection request igno-red: machine is busy
*DIS Disconnect the machine from the Host
At the end of a session, the Host must send the *DIS command to terminate
gracefully the connection. The *DIS command can also be used to cancel a session
with another Host.
The *DIS command will stop any Host commanded cycle and abort any up-load or
down-load in progress. Current Host commanded cycle, if any, will remain
suspended: an operator may then restart it if necessary.
*OK Command accepted and terminated

*BSY Command accepted but still busy
*INV Command invalid (the previous connection is already terminated)
*ERRtyp An error occurted when stopping the operation previously running:
• down-line load:error in removing the temporary file

• up-line load:errors from *STO or *R command
DNC3

“typ” indicates the type of error:
DEV Device read/write error
LCK Device is write-protected
NFD File not found
NOM No media (cartridge) present
*STO,dev:filena.ext Store file from Host to machine
Open a file for output: once this command is accepted, the Host sends data with *I
information line commands.
The file name must be supplied in its full format: there is no default device or
extension. Device names are 2 or 3 characters long and are followed by
a “:” character.
Possible device names are:
A: or B: –> cartridge tape unit

MEM: –> memory device
If the machine is not able to accept the command (for example because it is busy on
a previously commanded cycle, or because no session is currently opened), it will
send back the reply *INV invalid command.
For a store operation to the cartridge, the command replies with *BSY (Command
busy) during the directory lookup of the cartridge which can take up to 45 seconds.
The transfer of the file information cannot take place until after this lookup is complete
and the *Q (Command Status Request) command replies *OK.
If the Host sends a line of information before the end of the lookup the machine will
reply *INV to that information line message.

*INV Command invalid: previous operation is not terminated
*ERRtyp Error condition on lookup, where
DEV Device write error
NFD Syntax error
NOM No media (cartridge) present or syntax error (device name not sup-plied)
ROO No more room on the device (either in directory or file storage area).
DNC3

*Itext Information Line Message
With this message the Host sends a record to be stored in the file opened by a
previous *STO command.
For a store operation to the cartridge the command replies *BSY (Command busy)
during the writing to the cartridge which occurs every 512 characters and can take
up to 30 seconds.
The next transfer of the file information cannot take place until after this writing is
complete and the *Q (Command Status Request) replies *OK.
If the Host sends a line of information before the end of the writing of the previous
line, the machine will reply *INV to that new information line message.
*OK Command immediately accepted and executed, next *Itext may begiven
*INV Command invalid: no file open for storing or previous command still
busy
ERRtyp I/O error condition, where
ROO No more room on the device (file storage area).
In case of a *INV invalid reply, data has not been recorded by the machine and
should be sent back after correct processing of the error.
*CLO Close (make permanent) Stored File
Make permanent the transfer of information from the Host. The directory device is
updated.
If the device is a tape cartridge, the machine replies with *BSY (Command busy)
during the directory update of the cartridge which can take up to 45 seconds.
The next operation cannot take place until after this update is complete and the *Q
(Command Status Request) command replies *OK.
If the Host requests another operation before the end of the update the machine will
reply *INV invalid command to the new command.

DNC3

*INV Command invalid: no file open for storing or previous command not
terminated
ERRtyp I/O error condition, where
ROO No more room on the device (file storage area).
*GET,dev:filena.ext Retrieve File from Machine
Open a file for input: when this command is accepted, the data will be sent to the
Host with *I information line messages upon receipt of *R (Information request)
commands.
extension. Device names are 2 or 3 characters long and are followed by a “:”
character.

For a retrieve operation from the cartridge, the command replies with *BSY
(Commande busy) during the directory lookup of the cartridge which can take up to
45 seconds.
The transfer of the file information cannot take place until after this lookup is complete
and the *Q (Command Status Request) command replies *OK.
If the Host requests a line of information before the end of the lookup the machine
will reply *INV to that information request.
*OK Command accepted and terminated, waiting for *R Information Request

*INV Command invalid: previous operation is not ended
*ERRtyp I/O error condition, where
“typ” Indicates the type of error:
DNC3

DEV Device read error
NFD File not found or syntax error
NOM No media (cartridge) present or syntax error (device name not supplied
*R Information Line Request
With this message, the Host asks the machine to send the next record (*Itext) from
the file opened by the *GET command, or the next directory line from the directory
requested by the *DIR command.
If no file is currently being opened for input, or no directory currently being

requested, the machine will reply with an *INV invalid command message.
For a retrieve operation from the cartridge, the machine replies *BSY
(Commande busy) during the seek on the cartridge which occurs every 512
characters.
The seek can take up to 30 seconds. If the Host requests a line of information before
the end of the seek the machine will reply *INV (Invalid command) to that new
information request.

*CHK Checksum error in command
*EOF End of file, terminate successfully the transfer of the file or the directory
*Itext Next recording of file or directory.)
*INV Command invalid: no file open for retrieval or directory requested, or
previous command not terminated
*ERRtyp I/O error condition, where “typ” indicates the type of error:
NFD Requested file not found
NOM No media (cartridge) present.
*DIR,dev: Get a Directory from Machine
Get a complete directory from the machine environment: when this command is
accepted, the data will be sent to the Host with *I information line messages upon
receipt of *R (Information request) commands.
.
The directory name must be supplied in its full format: there is no default device.
Device names are 2 or 3 characters long and are folowed by a ":" caracter.
Possible device names are :

DNC3

If the machine is not able to accept the command (for exemple because it is busy on
For a retrieve operation from the cartridge, the machine replies *BSY (Commande
busy) during the directory lookup of the cartridge which can take up to 45 seconds.
The transfer of the directory information cannot take place until after this lookup is
complete and the *Q (Command Status Request) command replies *Itext.
If the Host requests a line of information before the end of the lookup the machine
will reply *INV to that information request

*EOF End of file, terminate successfully the transfer of the directory
*Itext First line of directory, where “text” is one line of information from the
directory (without carriage return or line feed before the checksum).
Waiting for *R Information Request.
*ERRtyp I/O error condition, where “typ” indicates the type of error:
NFD Syntax error
NOM No media (cartridge) present or syntax error (device name not supplied)
*DLF,dev:filena.ext Delete File from Machine
This command deletes the requested file in the machine environment.
character.

On slow devices (tape cartridge), the machine will reply with a *BSY message
(Busy). The Host must then check successful completion of the operation by reques-
ting commandstatus with *Q (Command Status Request) commands.
DNC3


*INV Command invalid:
previous operation is not ended –> file is not deleted
NFD Requested file not found or syntax error
NOM No media (cartridge) pre-sent or syntax error (device name not supplied)
*RNM, dev: filename.extension Rename a file

1 new name extension 2
dev: name of device (drive)

filename name of file ( max. 6 characters)
extension 1 extension of file name (max. 3 characters)
new name new name of file
extension 2 extension of new file name
This command enables the name of a file to be changed.
character.

(Busy). The Host must then check successful completion of the operation by
requesting command status with *Q (Command Status Request) commands.
The possible responses are:
*OK No errors
*BSY Command accepted, machine busy
*CHK Parity error
*INV Invalid command
*ERRtyp Generic error
DNC3

“typ” Indicated the type of error
DEV access to the device
LCK device is write-protected
NFD source file not found
NOM no medium present in device
DUP destination file already exists
*SPG,dev:filena.ext Select Part Program for Execution
Select a part program file for execution: when this command is accepted the
program can be started with a *STR command or cancelled with an *ABO
command.
character.

(Busy).
The Host must then check successful completion of the operation by requesting
command status with *Q (Command Status Request) commands.
*OK Command accepted and ready, waiting for *STR (Start Cycle)
*CCF,dev:filena.ext Select Com-mand File for Execution
Select a command file for execution: when this command is accepted the cycle can
be started with a *STR command or cancelled with an *ABO command.
DNC3

character.

(Busy). The Host must then check successful completion of the operation by
requesting command status with *Q (Command Status Request) commands.
*OK Command accepted and ready, waiting for *STR (Start Cycle)
*INV Command invalid –> previous operation is not ended
*STR Start Cycle
If there is an active Host selected part program or command file cycle this command
will cause the machine to start or continue the selected cycle.
*OK Command accepted and executed - state of the cycle must be checked
with the *RMS/*RME commands
*INV Command invalid: no part program or command file selected or
previous com-mand not terminated.
*STP Stop Cycle
If there is a Host commanded cycle which is not stopped, it will be stopped

(suspended). It may be restarted with the *STR command.
DNC3

This command has the same effect as pressing the STOP key on the front panel. If
the cycle is already stopped, it has no effect.
*OK Command accepted and executed

*INV Command invalid (no Host commanded cycle or other invalid
condition).
*ABO Abort cycle
If there is a host commanded cycle which is stopped (suspended), it will be aborted.
This command has the same effect as pressing the RESET key on the front panel. If
the cycle is already terminated or not yet suspended, it has no effect.
*OK Command accepted and executed

*CHK Checksum error com-mand
*INV Command invalid (no host commanded cycle or other invalid
condition).
*RMS Machine Status Request
Requests the machine for its status conditions.
*MST,LsHsCsSsMsFsRsTttttNnnnnnDuuu
Status indicator reply. The small “s” represents a one or a zero.
The codes and their meanings are:
L0 Machine connected (i.e. not in local mode)

L1 Machine not connected
H0 Host control inhibited (connec-tion prohibited because of local activity)
H1 Host control permitted (connec-tion possible or done)
C0 Machine not in Host commanded cycle
C1 Machine in Host commanded cycle
S0 Machine active (cycle on)
S1 Machine stopped (cycle off)
M0 Machine not at programmed stop
M1 Machine at programmed stop (M00 or M01 instruction or STP
command)
DNC3

F0 No machine fault since last status scan
F1 Machine fault has occurred since last status scan.
R0 No operator request waiting
R1 Operator request waiting. The host system must send the *ROM
command.
Tttttt Value in seconds of max-imum time for connection. 59999 indicates
infinite time.
Nnnnnn Serial number of the machine
Duuu uuu - Name of the default device of the machine.
*RET request for extended status message
This command asks the machine what are its possibilities of transferring and
checking at a given time. The host can, as for the standard status message, ask and
receive, without being connected, the extended status message.
Reply by the machine:

*MET, L1I0J0R0W0X0Y0Z0E000
L Local (Status of the connection)

This parameter is identical to the present parameter of the *MST command
L = 0: The machine is connected
L = 1: The machine is not connected
I Status of machining
This parameter corresponds to the status of the STOP led (red)
I = 0: The RED lamp is OFF
I = 1: The RED lamp is ON
J Status of machining
This parameter corresponds to the status of the START led (green)
J = 0: The GREEN lamp is OFF
J = 1: The GREEN lamp is ON
The parameters I and J replace the parameters M and S of the *MST command.
I J
0 0 Machine free
1 1 Machine in suspension
0 1 Machine is currently machining
1 0 -Impossible-
R Operator request
Indicates the request by the machine’s operator for an intervention agreed by
the host. See the command HSR. The value of R is set back to zero after
execution of the ROP command by the host.
W Permission to transfer files

This parameter indicates at a given moment whether the host is permitted to
use the file manager.
W = 0: The transfer is not permitted: file manager occupied.
W = 1: The transfer is permitted: the host can use in writing the file manager
of the NC. DNC3

X Status of file transfer
This parameter indicates the status of occupation of the file manager by the
host.
X = 0: The host is not using the file manager.
X = 1: The file manager is reserved by the host.
This flag is in the status essentially for DEBUG reasons. It shows the status of
the machine: the machine cannot prohibit the file transfer during a transfer.
X = 0 and W = 0
File transfer prohibited from the host
Reading commands are nevertheless allowed.
Commands in writing answer *INV.
X = 0 and W = 1
File transfer allowed from the host.
X = 1 and W = 0
File transfer from the host in progress.
X = 1 and W = 1
Impossible
Y Machining allowed from the host

Y = 0: Machining commands are prohibited from the host.
The NC answers with *INV to a machining command.
Y = 1: Machining commands are allowed from the host.
Z Machining in progress from the host

Z = 0: No machining in progress
Z = 1: Machining in progress from the host
Z = 0 and Y = 0
Machining prohibited from the host:
Machining commands answer with *INV.
Z = 0 and Y = 1
Machining allowed from the host.
Z = 1 and Y = 1
Machining in progress from the host.
Z = 1 and Y = 0
Impossible
When machining is in progress from the host, intervention on the NC is

impossible.
E Last machine error

E0000: no error
EAxxx: warning
EExxx: machine error: the machine is in suspension
EFxxx: fatal error: the machine is stopped
DNC3

*RME Machine Error Request
Requests the machine for its next error code.
*OK Command accepted, no more errors to report

*MER,Eeee Next machine error code
*MER,Aeee *MER,Feee where eee
Error code (3 decimal digits).
*Q Command Status Request
With this message, the Host asks the machine to send the command status (*BSY,
*OK or error) of the last operation. This request must be used each time a *BSY
(Busy) message is sent back to the Host to check for completion of the operation.
*OK Last command accepted and terminated

*BSY Last command accepted but still busy
*EOF End of file, terminates successfully the transfer of the file. Last command
was *R
*Itext Next line of file text, where “text” is one line of infor-mation from the file
(without carriage return or line feed before the checksum). Last com-
mand was *R
*INV Command invalid –> previous operation is not ended
*ERRtyp I/O error condition on previous lookup or transfer, where
DEV Device read/write error
NFD Requested file not found
ROO No more room on the device (either in directory or file storage area).
*RPT Repeat Last Message
The Host can send this command to receive an exact copy of the last machine reply
message in case of a transmission failure.
If the *RPT command replies with *CHK or *INV, this response is ambiguous
because it can be a retransmitted message or an indication of invalid *RPT. In such
a case, the machine must be resynchronized with the Host.
DNC3

*INV Command invalid (machi-ne not connected)
other Repetition of the previous reply.
*ROM operator request
The operator will have the possibility of indicating a particular state to the host under
the following conditions:
•If the machine is not connected, the HSR command entered at the keyboard will
prepare the message to be returned to the host. The code eee will have to be
defined for each state expected. Entry of this command together with a valid state
code will update the field R (R1) of the machine state message.
•If the machine is connected, a dedicated key of the keyboard will allow entry of a
single request whose code is 000.The machin state message (R1) is updated.
The request code acquired in this way can be known by the host by means of the
*R0M message
The possible responses are:

*CHK Checksum error
*INV No request being processed (R0)
*MOR, Meee
eee state code
The affirmative response by the machine to the *ROM message will update the field
R (R0) of the state message.
*ESC (Escape link) Resetting of protocol.
The current command is aborted, the connection is broken.
Possible answers are:

*INV Command invalid
*MSG,Text Free Message
The host can at any time send a Free Message to the machine. The message will be
displayed fully in the DNC3 page in the «Message» heading and on the message
line (black text on yellow background). The text can have a maximum of 80 ASCII
characters and must not contain the characters CR or LF.
Possible answers are:
DNC3 *OK
*CHK Checksum error in command.

*PAR, number of parameter Machine parameters
Several important parameters or values concerning the machine environment are

accessible through this function. The host designates the value to be obtained by the
command:
Posible answers are :

*INV Command invalid
*Ivalue The answer is of the form: *Ivalue of the parameter in ASCII.
The accessible values of parameters are:
*PAR,n Die sinking Wire cutting
1 COM version COM version

2 EXE version EXE version
3 PIL version PIL version
4 CRTC version CRTC version
5 Master EXEC version Micro-seq version
6 Machine number Machine number
7 Machine switch Machine switch
8 Options installed Options installed
9 Machine positions X,Y,Z,C,A,B Machine positions X,Y,Z,U,V
10 Part positions X,Y,Z,C,A,B Part positions X,Y,Z,U,V
11 Number of current setting Number of current setting
12 Technol. file name Technol. file name
13 Programmable parameter Programmable parameter
14 Synchronization of reading Synchronization of reading
15 Programmable parameter and resetting to Programmable parameter and resetting to
zero zero
16 Part program Part program
17 Part program Part program
18 Command program Command program
19 Command program Command program
20 Name of the part program Name of the part program
21 Name of the command program Name of the command program
22 Name of the command sub-program Name of the command sub-program
23 Total time Total time
24 Machining time Machining time
25 - Upper pressure
26 - Lower pressure
27 - Speed in mm/min
28 - Speed in mm2/min
29 Current unit Current unit
30 Part number -
31 - Part height
32 Offset number Offset number
33 Offset value Offset value
34 Number of the tool -
35 - Machining (USAI...)
36 - Protection
37 - Tool radius
38 Machining timeremaining -
39 Master PIL version -
40 Current message line Current message line
41 Message line -1 Message line -1
47 Message line -7 Message line -7 DNC3

Programmable parameters (Reading)
Parameter 13 is programmable. It has no predetermined format. The command

*PAR specifies the address of the data item to be received and the format to be
used. DNC3 returns a character string representing the data item read and
formatted.
*PAR,13,c,seg:off,t,l,d
Length of this message: 26 characters.
c: Number of the NC processor

0 = COM
1 = EXE
seg:off Actual address of the variable to be read. seg and off are numbers
expressed Hexadecimally over 4 digits.
t: Type of data item (length and sign)

0 = Bytes (0 to 255)
1 = Signed byte (0 to +- 127)
2 = Word (0 to 65536)
3 = Signed word (0 to +- 32767)
4 = Length (0 to MAXLONG)
5 = Signed length
1: Length of the character string returned. This field always consists of two
digits (example 1 and code 01).
d: Number of digits after the decimal point.

0 = Whole variable. No decimal point
n (1 to 9) = Number of digits to the right of the point
Synchronization parameter
Parameter 14 is used to test and set to zero the synchronization signal (semaphore)
GLOBAL.PARIS established by the auxiliary function 15 (AUX/15).
The host system can thus obtain the status of the semaphore; reading it sets it back to
zero.
DNC3

Communication Diagrams
Connection and disconnection between the Host and the Machine
HOST MACHINE
Connect
*CON, Host Ident
Retry No response *CHK *ERROCC *INV *OK
Retry Checksum error
Retry
Error message Still connected
Next command
1254
HOST MACHINE
Disconnect
*DIS
Retry No response *CHK *INV *BSY *OK

Error message
Not connected
*Q
Retry No response *CHK *BSY *INV *OK
Retry
Error message
Next connection
DNC3 1255

Down-line Loading of Files (Host to Machine)
HOST MACHINE
*STO, File
Retry No response *CHK *INV *ERRtyp *BSY *OK
Error message
Error message
*Q
Retry No response *CHK *BSY *INV *ERRtyp *OK
Retry Busy
Error message
Error message
Send data
*Itexte
Error message
Error message
*Q
Retry Busy
Error message
Error message
Last text line?
Next line no
DNC3
1256

yes
End of file
*CLO
Error message
Error message
*Q
Retry Busy
Error message
Error message
Next command
1257
Operator request
HOST MACHINE
*ROM
Retry No response *CHK *INV *MOR,Meee
Error message
Use the information
DNC3
1258

Erase a file
HOST MACHINE
*DLF, file
Retry No response
*CHK *INV *ERRtyp *BSY *OK
Error message
Error message
*Q
Retry Busy
Error message
Error message
Next command
DNC3
1259

Rename a file
HOST MACHINE
*RNM, file
Erroe message
Erroe message
*Q
Retry Busy
Erroe message
Erroe message
Next command
DNC3
1260

Up-line Loading of files (Machine to Host)
HOST MACHINE
*GET, file
Error message
Error message
*Q
Retry Busy
Error message
Error message
Receive data
*R
Retry No response *CHK *INV *BSY *Itexte *EOF

*ERRtyp
Error message
*Q
Retry No response *CHK *BSY *INV *Itexte *EOF

*ERRtyp
Retry Busy
Error message
Enregistrer la line
Store the ligne
Next line
Close the file
Next command
DNC3
1261

Directory
HOST MACHINE
*DIR, directory
Retry No response *CHK *INV *ERRtyp *BSY *Itexte
Error message
Error message
*Q
Retry No response *CHK *BSY *INV *ERRtyp *Itexte
Retry Busy
Error message
Error message
Use the information
Send data
*R
Retry No response *CHK *INV *BSY *Itexte *EOF

*ERRtyp
Error message
*Q
Retry No response *CHK *BSY *INV *Itexte *EOF

*ERRtyp
Retry Busy
Error message
Next lime
Next command
DNC3
1262

Executing and Stopping Machine Cycle by the Host
HOST MACHINE
*SPG, fichier
*CCF,
Retry No response *ERRtyp *BSY *OK
*CHK *INV
Error message
Error message
*Q
Retry Busy
Error message
Error message
Start cycle
*STR
Retry No response *CHK *INV *OK
Error message
Survey of the cycle
*STP
Error message
oui
Restart program?
non
Abart cycle
*ABO
Error message
DNC3 Command 1263

Survey of the Cycle
HOST MACHINE
*RMS
Retry No response *CHK *INV *MST,LsHsCsSsMsFsRs
Error message
non/no/nein Is there an error?
yes
Recquest mahine error
*RME
Retry No response *CHK *INV *MER,Eeee *OK
Error message
Machine error message
Prochaine commande
1264
Reapeat Last Message
HOST MACHINE
- If checksum error received
*RPT
*CHK *INV
*Send previous message
Resynchronize Checksum error
Resynchronize
Use message
DNC3
1265

HOST
HOTE MACHINE
*RET
Retry
Nouvel essai Pasresponse
No de réponse *CHK *INV *MET, L1I0J0R0W0X0Y0Z0E000
Retry
Nouvel essai Checksum error
Erreur total contrôle
Error message
Message d'erreur
Next command
Prochaine commande
1264
DNC3

SYSTEM CT 1000 Applications
Concept of System CT 1000 3
Technical features 3
Maintenance 3
Placing the rails in position 4

Rigidification set 5
Adaptation of CT 1000 system onto CT 300 table 6
Use of H30-H60-H100 vices 7

Use of two pairs of vices 9
Use of two several vices 10
Use of clamping blocks 11

Use of 30 clamping blocks 13
Use of 45 clamping blocks 14
Use of 75/120 clamping blocks 15
Use of clampint blocks with 2 supports 16
Use of clamping blocks + vices 17
Use of special 45 clamping blocks 18
Use of thin workpiece clamping blocks 19
Use of ultra-thin workpiece clamping blocs 20

Use of thin workpiece clamping blocks (example) 21
Use of the clamping set on CT pillars 22

Use of clamping set on CT-pillars (example) 23
Use of the parallel rail 24

Use of the parallel rail (example) 25
Use of clamping set for vertical cylindrical workpieces 26
Use of clamping set for horizontal cylindrical workpieces 29
Use of the CT/Erowa interface 30
Use of the CT/Hirschmann interface 31
Use of the CT/Mecatool interface 32
Use of the CT/3R interface 33

Table of
System
Use of blocks for horizontal clamping 34
Use of blocks for horizontal clamping (example) 35 contents
CT 1000

System
CT 1000

SYSTEM CT 1000 Applications
Concept of System CT 1000

•Optimal comfort for the user.
•Lateral tightening of workpiece so as to make the upper and lower workpiece

faces totally accessible for machining (nozzles touching workpiece).
•Rapid setting up.
•High repositioning accuracy.
•Full use of the notion of SMED (Single Minute Exchange Die).
•Tightening by conventional clamping retained.
•Easy Z referencing.
•Thanks to a specific interface, it is possible to use 3R, Hirschmann, Mecatool

and Erowa clamping units.
Technical features
Materials
•The rails are in stainless steel
•All the other units of the System CT 1000 are made with a steel derived from
stainless steel, and are produced by precision micro- casting. They are made
extremely hard by means of a thermal treatment, and finally they are given an
anti corrosion treatment by nickel plating.
Accuracy of the system

The parallelism of the reference planes and the repositioning of the various
supports is < 5 µm.
Maintenance
Bearing in mind that the units of the clamping system are of high precision, it is
important to give them appropriate maintenance.
Regular cleaning guarantees constant accuracy and longer life for the system.
For this purpose, use rectified benzine with a clean cloth, or if necessary a brass-
wire brush, taking special care in the ground parts.
System
After use, put away the units in their cases until they are needed again.
CT 1000

Placing the rails in position
A B1
D B
B2
C1
C
D1
D
C1
424
Procedure
•The transverse rail A is positioned and fixed at the back of the tank. Normally this
rail will be kept in this position wherever possible, since it is already referenced
Note according to the X axis.The second transverse rail C is free.
If the parallel rail B is
not used, the possibility •Put in the rail B and move it to the desired position. Tighten the screw B1.
is available of making
use of the 2 blocks D as •Tighten the screws B2.
a clamping block (see
page 8) by •Finally tighten the screws C1 of the rail C.
disconnecting them from
the rail by means of the In this way a semi-closed clamping frame with highly accurate squareness is
screws D1. obtained. To obtain a closed frame, i.e.2 transverse rails + 2 mobile rails, the same
method as above is used. The rail C is always tightened last.
System For dismantling, use the same procedure in reverse.

CT 1000

Rigidification set
A1
B
B1
Article : WA0320
1164
This set is an option for the Robofil 4020 machines; for Robofil 6020 machines, it is
included in the CT 1000 System WA 6000 clamping set.
Procedure
•Place the bar A on the rear rail and tighten the screws A1 supplied.
•Place the bar B against the front rail and tighten by means of the trapezoidal nuts
B1 supplied.
In this way, flexion with heavy loads is improved by a factor of at least 2.
System
CT 1000

Adaptation of CT 1000 system onto CT 300 table
A1
A B
B1
1216
Procedure
•Remove the rear rail of the CT 300 table
•Place the transverse rail A in the desired position by means of the screws and
washers A1 supplied.
•Position the parallel rail B and fix it with the screws and washers B1 supplied.
All the units of the CT 1000 System can be used with the rails above.
System
CT 1000

Use of the H30-H60-H100 vices
Situation N° 1
C
B2
B
A1
B1
Article H30 : WA0010

H60 : WA0020
H100 : WA0030
Butée Z : WA0040 441
Procedure
•Place a pair of vices A and B in the rail so that there is one fixed jaw and one
mobile jaw facing each other.
Warning
•Tighten the vice A, whose fixed jaw will be used, in the desired position by means Machining in the area
of the screws A1. of the corners (hole of
large dimension or slot
•Position the workpiece on the mobile Z-stop(s) C placed between the 2 vices. opening on to the
outside) can lead to a
•Bring the vice B up against the workpiece, having previously loosened the screw slackening of clamping
B2 tension and hence
cause the workpiece to
•Tighten the screws B1 fall off.
•Carry out the lateral tightening of the workpiece by means of the mobile jaw
(screw B2)
•Remove the mobile Z-stop(s). The workpiece is now properly clamped.
H30 vices H60 vices H100 vices
Admisble workpiece H. H< 60 60<H<100 H>100 System

CT 1000

Use of H30-H60-H100 vices
Situation N° 2
Article H30 : WA 0010

Article H60 : WA 0020
Article H100 : WA 0030 E
Z stop : WA 0040
In cases where the workpiece is of large dimensions, the H30, H60 and H100
vices are also suitable for providing additional clamping in another direction.
Procedure
•Position the workpiece according to the preceding procedure (p.5) without

removing the movable Z stops(s) C.
•Depending on workpiece size, place in position and fix a certain number of

extension units D.
•Ensure final fastening by means of the screws and clamps E supplied.
•Remove if necessary the movable z stops (s) C.
System
CT 1000

Use of 2 pairs of vices
C1
C C2
A
C
D
C2
C1
B
D
435
The use of 2 pairs of vices is recommended when the workpiece is of large

dimensions and the machining areas are near the edges.
Procedure
•With the rail A blocked and the rail B free, position the workpiece on 3 mobile Z-
stops.
Warning
Machining in the area
•Adjust the vices C against the workpiece and fix them in the rail A using the screws
of the corners (hole of
C1.
large dimension or slot
opening on to the
•Adjust and fix the vices D in the rail B.
outside) can lead to a
slackening of clamping
•Maintain the rail B against the workpiece and fix it.The workpiece is now perfectly
tension and hence cause
held in position according to the X and Y directions and there should be no play
the workpiece to fall off.
remaining between the workpiece and the vices.
•Carry out the lateral tightening by means of the 2 mobile jaws (screws C2)
•If necessary remove the mobile Z-stops.
In this way this fixing method guarantees there will be no collision of nozzles with
the workpiece, thanks to the total freeing of the upper and lower faces. System
CT 1000

Use of several of vices
Examples
436
System
CT 1000 443

Use of clamping blocks
Article Bloc 30 : WA0260

Bloc 45 : WA0270
Bloc 75 : WA0220
Bloc 120 : WA0050
Bloc with 2 supports : WA 0300 437
Procedure
With the use of the clamping blocks, we come back to the conventional
arrangement of a clamping frame with lips, with the additional advantage of rapid
mobility of the supporting lips.
•Depending on workpiece size, position and fix a certain number of clamping

blocks.
•The method of installing the clamp is determined by the workpiece height (see
fig.2)
•When extensions are used (fig.3) each extension is fixed individually by means of
the special screw supplied, by inserting a screwdriver or an offset wrench (s = 3) in
the upper hole.
System
CT 1000

0 - 29 mm
95 max.
65 max.
65 min.
59 max.
35 min.
28 min.
Fig. 2
416 415 414 413
Tournevis à boule
s=3
Clef coudée
s=3
Fig. 3
417
Maximum clamping height
ROBOFIL 2000 ROBOFIL 4000/6000

X
X 270 360
System
CT 1000 423

Use of 30 clamping blocks
Exemples
System
CT 1000

Use of 45 clamping blocks
Exemples
606
System
CT 1000 601

Use of 75/120 clamping blocks
Exemples
446
System
CT 1000 439

Use of clamping blocks with 2 supports
Examples
1159
System
CT 1000

Use of clamping blocks + vices
Exemples
438
System
CT 1000 431

Use of special 45 clamping blocks
Fig. 1
Article : WA0280
605
The special 45 clamping blocks are particularly suitable for fixing workpieces with
chamfer of high values.
Maximum dimension of chamfer: 5 x 45°
Procedure
•Depending on workpiece size, position and fix a certain number of clamping

blocks.
•The method of installing the clamp is determined by the workpiece height (see fig.
2)
•When extensions are used, each one is to be fixed individually by means of the
special screw supplied, by passing an S = 3 screwdriver or angled wrench
through the upper hole. (see page 7, fig.3)
;;
;; H
H
H
0 < H < 30 mm 30< H < 65mm 60< H < 95mm
System
Fig. 2
603 CT 1000 604 602

Use of thin workpiece clamping blocks
Fig. 1
Article : WA 0070 308
Procedure
•The use of these clamping blocks designed for thin workpieces is suitable for
workpieces up to a max. height of 25 mm.
•The specific shape of this accessory is particularly adapted for machining as close
as possible to the edge of the workpiece (fig.1).
•The method of installing the clamp is determined by the workpiece height
8 < h < 25 0<h<8 0<h<4

Brass
thickness 5mm
Sytem 1000
h. max. = 25
h. min. = 8
h. max. = 8
50
h. min. = 0
X min.
h. max. = 4
h. min. = 0
50 20 min 50 X min.
X min. X. min
h. min. 0 42 h. min. 0 40
h. max. 8 38 h. max. 4 38
System
Fig. 2
432 434 CT 1000 433

Use of clamping blocks for ultra-thin workpiece
Fig. 1
Article : WA0330
1161
The use of clamping blocks for ultra-thin workpieces is adapted for workpieces up to
a maximum height of 20mm. This article is particularly useful in conjunction with the
Micro-Cut 1000 option.
Procedure
•The particular shape of this accessory is specially adapted to machining as close

as possible to the workpiece edge (fig. 1).
•The manner in which the clamp is installed depends on the workpiece height
(fig. 2)
2 < h < 20 0 < h < 6,5 0 < h < 1,5
Brass
thickness 5mm
;;; ;;;;;;
;;;; ;;; ;;;
;;;
;;; ;;;
h. max. = 20
60 20 min 60 X min. 60 X min.

h. min. = 2
h. max. = 6,5
h. min. = 0
h. max. = 1,5
h. min. = 0
X min. X. min
h. min. 0 42 h. min. 0 40
h. max. 6,5 38 h. max. 1,5 38
System Fig. 2
1156a CT 1000 1157a 1158

Use of thin workpiece clamping blocks
Exemples
445
System
CT 1000 444

Use of the clamping set on CT pillars
C
X
Article : WA0250 426
Procedure
•Position the workpiece on the pillar(s)
•Fix the small plate A according to X or Y, by means of the hexagonal brace B and
the T-nut C
•Make the necessary stack of braces B and supporting jacks D according to

workpiece height.
•Fix and tighten the clamp E
•When the workpiece is not connected to the same electrical potential as the
clamping frame, proceed as follows:
- disconnect the earthing cables attached to the rails
- screw these cables onto the small plates A.
System
CT 1000

Use of clamping set on CT pillars
Exemples
427
Distance beyond machine travel

X
Robofil 2000 4000 6000
X 60 65 65
System
CT 1000 425

Use of the parallel rail
A
E
C
B
Article : WA 0240 428
Procedure
•Disconnect the earthing cables A, unscrew and remove the rail B .

Note
The parallel rail does •Place the T-nuts C (supplied with the parallel rail) in the groove of the diabase
not include the pillar.
clamping block 75
(WA0220) which is •Position the parallel rail and fix it with the screws and washers D supplied.
frequently used in these
cases. •Place the earth cables in the positions E provided for them if the workpiece is not
electrically energized
System
CT 1000

Use of the parallel rail
Exemples
429
System
CT 1000 430

Use of the clamping set for vertical cylindrical
workpieces
Fig. 1
Procedure
•According to the diameter of the workpiece (see fig.2 and 3) carry out tightening
of the workpiece on a plane surface (for example marble surface plate)
•Adjust the flatness of the ensemble by using the adjusting screws with the help of a
pillar-mounted comparator (Fig. 3).
•Tighten the adjusting screws (Fig. 4).
•Mount the resulting ensemble on two clamping blocks (Fig.5). Secure with 3
clamps and 3 spacer blocks positioned along the axis of the adjusting screws.
System
CT 1000

workpieces
Screwdriver or
X
wrench S = 3
Wrench S = 4
d1 max. = 100 mm
d1 min. = 20 mm
d1
A X = ------------- + 10
1,732
d1 0,05 A
;;
Wrench S = 4
d2
;;
Z
d2
Y = ------------- +40
Z 1,532
d2 Z =25 ± 0,05
d1 max. = 32 mm
d1 min. = 9 mm
Fig. 2
422
Adjustment Fig. 4
420
screw
S = 2,5
Adjustment
screw
S = 2,5
Adjustment
screw
S = 2,5
;;;;;
Comparator
418
;;;;;
CHARMILLES TECHNOLOGIES 4 927 400/E/06.02.1997
plane Surface
Fig. 3
System
CT 1000
27
workpieces
120 Clamping block
75 or 120 Clamping block
; ; ; ; ; ;
3 chocks
;;; ;;;
;;;;;;
;;;
;;;
;;; ;;;
;;;
;;;
Fig. 5
421
System
CT 1000

Use of clamping set for horizontal cylindrical
workpieces
C
X Y
diam. min 20 9
diam. max. 50 30
Procédure
•Place the workpiece up against the ground reference faces of the clamping block
120 C.
•Adjust the L-iron with its adjusting screws A above the workpiece.
•Carry out tightening by means of the screws B.
System
CT 1000

Use of the CT / Erowa interface
B
C
Procedure
•Place the T-nut A in the groove of the CT pillar.
•Position the support block ITS 6451.00 B on the pillar.
•Tighten the block by means of the screws C and the small plates D supplied.
•Screw down the earthing cables in the positions E provided.
System
CT 1000

Use of the CT / Hirschmann interface
Procedure
•Place the T-nut A in the groove of the CT pillar
•Position the interface B on the pillar, parallel to the Y axis, and tighten it by means
of the screws C.
System
•Screw down the earthing cables in the positions D provided. CT 1000

Use of the CT / Mecatool interface
A
B
Procedure
of the screws C.
System
CT 1000 •Screw down the earthing cables in the positions D provided.

Use of the CT / 3R
D
B
A
Procedure
of the screws C.
System
•Screw down the earthing cables in the positions D provided CT 1000

Use of blocks for horizontal clamping
B A
B
Fig. 1
This set allows clamping of workpieces held by stops against the transverse rail. In
this way the inner and outer faces of the workpiece are completely unobstructed. It is
possible to combine the use of these blocks with the H30, H60 and H100 vices.
Procedure
•Position the workpiece on 3 mobile Z-stops A.
•Adjust and fix a B pair of blocks in the rail.
•According to the size of the workpiece, position and fix a certain number of
extensions C. (fig. 2)
•Carry out the final tightening with the clamps D supplied.
;; ; ; ;
•If necessary free the mobile Z-stops.
System
Fig. 2
CT 1000
;;;;; B C
609

Use of blocks for horizontal clamping
Example
System
CT 1000 611

System
CT 1000

Eject 300-500
Introduction 3
Description of automatic ejection 4

Elementary conditions 4
Description of function AUX, 13 5
Ejection system 5
Figure N° 1 6
Figure N° 2 7
Error messages 8
Dimensions and physical characteristics of cut part 9
Height of attachment 4 mm (0,15748 inch) 10
Height of attachment 4.5 mm (0,17716 inch) 11
Height of attachment 5 mm (0,19685 inch) 12
Example of use of graphs for height 5 mm 13
Special case - Triangular attachment on curved surface 14
Production of programs with triangular attachment 15

Preliminary study 15
Programming an attachment with the aid of PROFIL+ 15
4 elementary application cases 16
Example of programming using variables 19
Cylindrical bore 19
Tapered bore 19
Table of
Eject 300-500
Enabling of the Eject option by a .CMD control program 21 contents

Eject 300-500

Introduction
The aim of using a triangular attachment is to avoid a slug falling on the arms or
becoming jammed between arm and part. It comprises two successive phases:
- Formation of the attachment with the aid of ISO functions G48 and G49. A
description of these functions is contained in Chapter 7, “ISO programming”.
- evacuation of a slug, which can be done in two ways :
- breaking off the attachment and manual removal
- automatic evacuation, with the aid of the EJECT 300-500 option, through the
AUX, 13 command.
The EJECT 300-500 option has the advantage of allowing sequencing of roughing
and finishing without intervention by the operator.
Dimensional parameters (height, attachment angle used by G48 and G49) are
accessible on the EXE - SERVICE - CYCLES screen page.

CYCLES
Measures THREADING
Axo U: 0.000 Number of trials: 3

Axo V: 0.000 Threading position
Axo Z: 0.000 U: 0.000
V: 0.000
ZB: 30.000 Axo Z: 300.000
Default HCA 30.000 Pulley Height: 860.000
Z Max: 495.000
Z Travel: 105.000 # rethreads per Part-progr: 2
Frequency reduction: 10
PART PROGRAM Slug evacuation
TOL: 000.003 Height 6.000
RTOL: 000.003 Angle 1.000
Frequency reduction: 30
Initial Block:
G61G63M03M07M08M20M28M31
Axo U:
DNC FS
DATE CYCLES COMMUNIC. LANGUAGE SECURITY
HOUR
Axo U Axo V Axo Z ZB HCA Z Max Travel Z

Eject 300-500
F1 F2 F3 F4 F5 F6 F7

Description of automatic ejection
Elementary conditions
•Clamping of parts: the parts must bear on a support to withstand the force exerted
along direction - Z during ejection.
•If a vice is used for clamping, the workpiece should be sustained by the Z-stop.
;;;;
;;
-Z
;;;;;; Stop Z
194
•The striking point must be located at least 100 mm (0,3937 inch) from the Y+
travel limit.
•Flat surface for triangular attachment.
•Threading pilot hole smaller than ejector diameter, or displacement by MVR prior
to ejection.
•The center of gravity of the surface must be located within the surface of the cut
part.
•Choose the triangular attachment as near as possible to the center of gravity.
•Choose the striking point at approximately 0.85 times the attachment - center of
gravity distance starting from the suspension point (depending on the moment of
the cut part and the ejector speed).
;;;;;;
Striking point
;;;;;;Attachment point Centre of gravity
195
•If it is foreseeable that the cutoff part (chip) will be difficult to extract, several partial
chips can be cut.
Eject 300-500 After removing the chips, the parts can be finish machined by the contour program.

Description of function AUX, 13
•All the partial steps required to evacuate the cut part are combined in function
AUX, 13.
•The contour and its attachment are cut using functions G48 and G49.
•The machine then returns to the program starting point, to await further instructions.
(see Figure N° 1)
•AUX, 13 enables retraction of the Y axis prior to striking and positioning of the
ejector:
- Movement along Z axis + 10 mm (+ 0,03937 inch)
- Movement along V axis + 54 mm (- 1,9685 inch)
- Movement along Y axis + 100 mm (+ 3,937 inch)
•The cut part is ejected and evacuated outside the work area. (see Figure N° 2)
Ejection system
•The ejector is a pneumatically controlled piston.

•The «extended» position indicates whether the ejection has been successful or not.
•After actuating the ejector, if the extended position is not reached, a second and
third stroke are struck before stopping the machine with error display «Chip not
ejected».
! For safety reasons, when working with AUX, 13, parameter ATH must be
«0» or «1».
•ATH Rethreading condition
•«0» Stop on breakage
•«1» Rethreading over n attempts
Therefore, it is guaranteed that, after n attempts, the machine stops and the
part is not finishing machined without tests.
Eject 300-500

Figure N° 1
Cutting of part contour with triangular attachment, wire cutting and return to program
starting point.
Legend
(1) Machined part
(2) Cut part (chip)
(3) Ejection piston assembly
(5) Triangular attachment
(7) Top head
3808
Eject 300-500

Figure N° 2
Positioning of ejector and retraction of arm by moving the Y and V axes.
Ejection of cut part (chip).
Legend
(1) Machined part
(2) Cut part (chip)
(3) Ejection piston assembly
(5) Triangular attachment
(7) Top head
3809
Eject 300-500

Error messages
•«E710: Piston not stay down»

The machine has not detected the return of the piston to the upper position.
Start the operation again.
If the proldem persists, checks that the piston has gone up; if not , check the
compressed air supply and the switch S51.
•«E711: Slug not evacuated»
The machine has not detected the low position of the piston.
Check that the slug has in fact been evacuated.
Check the part-programm, the compressed air supply and the switch S52.
•«E608: Limit Y»
End of negative mechanical Y travel has been reached.
More the axe in the + Y direction.
Eject 300-500

Dimensions and physical characteristics of cut part
Tests have shown that most of the cut parts can be suspended by a 5 mm high
attachment with an angle of 1° (see table, with height 5 mm).
However, if bigger and more complex parts are cut, a shear force, a bending force
and accessorily a torsion force can appear, depending on the position of the
triangle. It is for this reason that it is not possible to indicate a maximum weight for
the parts to be cut.
The tables below highlight the relationships between weight, attachment-center of
gravity distance and tensile strength.
These can be used to determine the parameters required for adequate ejection
conditions.
The tensile strength curves divide the graph into 2 :
•the + area (adequate conditions) and
•the - area (inadequate conditions).
•+ area
All the forces can be absorbed in the triangle and the part is held correctly.
•- area
The part is badly held. Reconsider the attachment point. If the part is cylindrical,
the risk of later tilting is practically excluded. However, automatic ejection remains
possible.
Comment
To simplify matters, the torsion force is not taken into consideration in these
tables.
Note
- For light weight parts, but with a high moment on the suspension surface
(weight < 600 g (1,3227 lb) and moment > 100 Nmm (2540 Ninch)), the
height should be increased to 6 mm (0,2362 inch).
- For materials of low tensile strength, such as aluminium, the height can also be
increased.
- For hardened parts, and since the strength of the material has been increased,
the height must be reduced.
However, this must not be less than 4 mm (0,15748 inch) for cylindrical parts
and 4 (0,15748 inch) to 5 mm (0,19685 inch) for tapered parts.
Eject 300-500

Height of attachment 4 mm (0,15748 inch)
Angle of attachment 1.5°
Weight of cut part

(g)
1000
900
800
700
600
500
400
+
300
Tensile strength
200
-- 2
1400 (N/mm
1300
)
1200
1100
100 1000
0
(mm)
0 10 20 30 40 50 60
Security 1.2 distance from attachment
Eject 300-500 to centre of gravity
200

Height of attachment 4.5 mm (0,17716 inch)
Weight of cut part

(g)
1000
900
800
700
600
500
400 +
300
Tensile strength
2
1200 (N/mm )
200 1100
-- 1000
900
800
100
0
(mm)
0 10 20 30 40 50 60
Eject 300-500
to centre of gravity
201

Height of attachment 5 mm (0,19685 inch)
Weight of cut part
(g)
1000
900
800
700
600
500
+
400
300
200
-- Tensile strength
900 (N/mm2 )
800
700
600
100 500
0
(mm)
0 10 20 30 40 50 60
Eject 300-500 to centre of gravity
199

Example of use of graphs for height 5 mm
Exemple N° 1
•Data
Weight 400 g (0.8818 lb)
Distance 30 mm (1,1811 inch)
Tensile strength 600 N/mm2 (15240 N/inch2)
•Result
The function curve 600 N/mm2 shares the graph.
The cut part, located in the positive area, is correctly maintained by the suspension
triangle.
Exemple N° 2
•Data
Weight 250 g (0,5511 lb)
Distance 45 mm (1,77 inch)
Tensile strength 900 N/mm2 (22860 n/inch 2)
•Result
The 900 N/mm2 function curve shares the graph.
The cut part, located in the negative area, will tilt.
The attachment location should be changed.
Eject 300-500

Special case - Triangular attachment on curved surface
The triangular attachment must always be machined on a flat surface.

For bores or the surfaces of curves, it is necessary to machine a flat to support the
attachment.
The finishing program describes the contour of the finished part.
The location of this flat depends on the diameter of the bore and part height (see
bore programming examples).
Test sheet for bores

Testing of width «s» of the attachments
S (mm)
0,15
S
0,14
0,13
0,12
0,11
0,10 H
80
H
0,09 75
H
70
0,08 H
65
H
0,07 60
H
55
0,06 H
50
H
0,05 45
H
40
0,04 H
35
H
0,03 30
H
25
0,02
0,01
(mm)
Ø5 Ø10 Ø15 Ø20 Ø25 Ø30 Ø35 Ø40
Reading example
•Data diameter 20 mm (0,7874 inch)
height 55 mm (2,16535 inch)
Eject 300-500
•Result s =0.05 mm (0,001968 inch) 193

Production of programs with triangular attachment
Preliminary study
- Part contour
Make sure that the geometry of the cut parts (slugs) makes it possible to remove
them.
Possibly envisage breaking up the slugs to facilitate removal.
- Center of gravity
Determine approximately the position of the center of gravity of the slug.
- Positioning of the attachment
The attachment must be located as close as possible to the center of gravity.
- Positioning of the impact point
The impact point is located on the segment delimited by the attachment and the
center of gravity, but closer to the latter.
Recommendation: impact point = 0.85 x distance between the point of attachment
and the center of gravity.
Programming an attachment with the aid of PROFIL+
The contour of the part is programmed normally in PROFIL+, without entry radius.
- the OFFSET and TAPER functions, with or without taper, must be set directly before
the first descriptive line of the contour.
- exit from the contour has no exit radius
- the last line of the contour does not contain the minor word FINISH.
The PROFIL program is translated into ISO by the converter, then modified as follows
by the text editor:
- A0 is attached to G28 (constant angle taper) —> G28A0
The progressive change of the taper angle occurs in the next straight line segment
encountered on the path after the appearance of G28.
- D0 is attached to G42 (offset to the right) —> G42D0
- G0 1 is replaced by G48 (forming of first side of the attachment)
- the two penultimate lines are replaced by G49 (forming of second side of the
attachment by inclination of the wire in the opposite direction to G48)
Eject 300-500

Important remark :
•In the case of machining dies, it is possible to use the same program for
roughing and finishing. Instructions concerning the triangular attachment are
controlled by the BLD parameter:
Roughing: BLD=0 —> rejection of inactive optional blocks: the attachment is
executed
Finishing: BLD=1 —> rejection of active optional blocks: the attachment is
ignored.
Because of this, the burr left over after ejection is eliminated.
•On the other hand, machining a punch with a triangular attachment requires 2
distinct programs.
•Simulation mode (TSIM=1) allows execution of axis movements and threading
operations while ignoring making the attachment.
;;;;
•G48 and G49 cannot be used with Geomax or with Twist.
;;;;
4 elementary application cases
Matrix covered in reverse direction
;;;;
pn/1 (.PRF)
010:begin/origine
020:taper/0
030:offset/0,right
040:line/a,90
050:line/a,0,d,5,direct
060:line/a,-90,d,5,direct
100:line/a,-90,x,0,y,0 Schéma 4
110:end
%1 (.ISO)
N010G92X0Y0
N020G28
N030G42
N040G01X0Y5000A0D0
N050X5000Y5000
N060X5000Y-5000
N070X-5000Y-5000
N080X-5000Y5000
N090X0Y5000
N100X0Y0
N110M02
%1 (modified .ISO)
N010G92X0Y0
N020G28A0
N030G42D0
N040G48X0Y5000
N050X5000Y5000
N060X5000Y-5000
N070X-5000Y-5000
N080X-5000Y5000
N090G49
Eject 300-500 N110M02

Matrix run in forward direction
;;;;
;;;;
;;;;
pn/2 (.PRF)
010:begin/origine
020:taper/0
030:offset/0,left
040:line/a,90
050:line/a,180,d,5,revers
;;;;
060:line/a,-90,d,5,revers
100:line/a,-90,x,0,y,0
110:end
Schéma 5
%2 (.ISO)
N010G92X0Y0
N020G28
N030G41
N040G01X0Y5000A0D0
N050X-5000Y5000
N060X-5000Y-5000
N070X5000Y-5000
N080X5000Y5000
N090X0Y5000
N100X0Y0
N110M02
%2 (modified .ISO)
N010G92X0Y0
N020G28A0
N030G41D0
N040G48X0Y5000
N050X-5000Y5000
N060X-5000Y-5000
N070X5000Y-5000
N080X5000Y5000
N090G49
N110M02
;;
In both the following cases, the
machined part is a punch.
Finishing is therefore impossible.
Punch run in forward direction
;;
pn/3 (.PRF)
010:begin/x,0,y,10
020:taper/0
;;
030:offset/0,left
040:line/a,-90
060:line/a,-90,d,5,direct
100:line/a,90,x,0,y,10
110:end
Schéma 6
Eject 300-500

%3 (.ISO)
N010G92X0Y10000
N020G28
N030G41
N040G01X0Y5000A0D0
N050X5000Y5000
N060X5000Y-5000
N070X-5000Y-5000
N080X-5000Y5000
N090X0Y5000
N100X0Y10000
N110M02
%3 (modified .ISO)
N010G92X0Y10000
N020G28A0
N030G41D0
N040G48X0Y5000
N050X5000Y5000
N060X5000Y-5000
N070X-5000Y-5000
N080X-5000Y5000
N090G49
N110M02
;;
Punch run in opposite direction
pn/4 (.PRF)
;;
010:begin/x,0,y,10
020:taper/0
030:offset/0,right
040:line/a,-90
060:line/a,-90,d,5,revers
100:line/a,90,x,0,y,10
110:end
Schéma 7
%4 (.ISO)
N010G92X0Y10000
N020G28
N030G42
N040G01X0Y5000A0D0
N050X-5000Y5000
N060X-5000Y-5000
N070X5000Y-5000
N080X5000Y5000
N090X0Y5000
N100X0Y10000
N110M02
%4 (modified .ISO)
N010G92X0Y10000
N020G28A0
030G42D0
N040G48X0Y5000
N050X-5000Y5000
N060X-5000Y-5000
N070X5000Y-5000
N080X5000Y5000
N090G49
Eject 300-500 N110M02

Example of programming using variables
The variables are used to adapt a basic program to a very slightly different part
shape:
•Variation in height of part
•Variation of angles
•Variation in reference height
•Variation in attachment position, etc.
Two variable programs are proposed as an example concerning cylindrical and
tapered bores with triangular attachment.
Usable in rough machining, these programs avoid the use of fastidious calculations
by using variables.
! These programs are valid for an attachment of 6 mm (0,2362 inch)

maximum with an angle of 1°.
Variable h 1 must always be equal to or greater than 25 mm (0,98425 inch).
Cylindrical bore
Variables
h1 part height. Modify height only if h is greater than 25 mm (0,98425 inch)
d1 bore diameter
I1 distance of attachment support with respect to axis.
PROFIL+ program
010:h1=25
020:d1=5
030:l1= sqr [[d1*d1/4-[0.4+(h1-25)*0.02]^2]]
040:begin/x,0,y,0
050:taper/0
060:offset/0,right
070:line/a,0
080:line/a,-90,d,l1,direct,y,small
090:arc/r,d1/2,xc,0,yc,0,direct,y,large
100:line/a,-90,d,l1,direct
110:line/a,180,x,0,y,0
120:end
ISO program ISO modified program

% %
N040G92X0Y0 N040G92X0Y0
N050G28 N050G28A0
N060G42 N060G42D0
N070G01X2468Y0A0d0 N070G48X2468Y0
N080X2468Y-400 N080X2468Y-400
N090G02X2468Y400I0J0 N090G02X2468Y400I0J0
N100G01X2468Y0 N100G49
N110X0Y0 N120M02
N120M02
Tapered bore
Variables
h1 part height. Modify height only if h is greater than 25
d1 bore diameter
w1 taper angle
r1 reference height Eject 300-500
I1 distance from attachment support to axis.

PROFIL+ program
010:h1=25
020:d1=5
030:w1=2
040:r1=25
050:l1= sqr [[d1*d1/4-[0.4+(h1-25)*0.02]^2]]
060:référence/r1
070:begin/x,0,y,0
080:taper/w1,sharp
090:offset/0,right
100:line/a,0
110:line/a,-90,d,l1,direct,y,small
120:arc/r,d1/2,xc,0,yc,0,direct,y,large
130:line/a,-90,d,l1,direct
140:line/a,180,x,0,y,0
150:end
ISO program ISO modified program

% %
N070G92X0Y0W25000 N070G92X0Y0W25000
N080G29 N080G29A2000
N090G42 N090G42D0
N100G01X2468Y0A2000D0 N100G48X2468Y0
N110X2468Y-400 N110X2468Y-400
N120G02X2468Y400I0J0 N120G02X2468Y400I0J0
N130G01X2468Y0 N130G49
N140X0Y0 N150M02
N150M02
Rework of top part
Reference plane S :Triangular

attachement width
Triangular attachment
202
! For taper bores, part geometry may differ according to the position of the
reference plane with respect to the surfaces of the part.
Comment
•In the taper mode, the program is described in the reference plane and gives the
wire inclination.
•If the reference plane is located between 2 surfaces of the part, only the geometry
of the bottom part is to be respected. If the top part is remachined, the error
engendered cancels out.
Note
Eject 300-500 In the finishing mode, a normal ISO program for the contour considered can
again be used, both in tapered and cylindrical machining.

Enabling of the Eject option by a .CMD control program
Intentionally, automatic evacuation control by EJECT is not done in the .ISO part
program, but in a .CMD program. Because of this, ramming can be abandoned at
any instant, or an impact point correction can be made without modifying the .ISO
program.
Instance where the impact point does not coincide with the starting point
At the end of a program with triangular attachment, the axes are at the starting point
and the AUX, 13 command is enabled to make the impact at this point.
If the impact point chosen is different from the starting point, it is necessary to carry
out the appropriate relative movement MVR in the command program to position the
ejector at the chosen spot before executing the evacuation function AUX, 13.
Example of a command program:

The example below shows the command program PN1.CMD for cutting two circular
bores and a die:
Roughing : 2 bores : program D12TRI.ISO (special contour with a flat part; see
Special case - Triangular attachment on a curved surface)
die : single program H.ISO with BLD=0
Finishing : 2 bores : program D12.ISO (normal contour)

die : single program H.ISO with BLD=1 (attachment ignored)
80
65
PN: H
41,2
3
40
PN: D12TRI
PN: D12
15
0
0
20
50
80
100
203
Eject 300-500

Command program
;pn 1.CMD
CCF, INIPAR
GOH, H40
MOV,.U0,.V0
REX, E2,.H40
CLE, 0.05
MOV, X 20, Y65
THD
BLD,0 Acceptance of traingular attachment
SPG, D12TRI.ISO Call for 1st subroutine
MVR, X1.5
AUX, 13
MOV, 80, Y15
THD
SPG, D12TRI.ISO Recall for 1st subroutine
MVR, X1.5
AUX, 13
MOV, X50, Y41,2
THD
SPG, H.ISO Call for 2nd subroutine
AUX, 13
;FINITION Copy, if necessary, of 1st part,

BLD,1 ignoring triangular attachment
REX, E7
CLE, 0
MOV, X20, Y65, U0, V0
THD
SPG, D12 Finishing of 1st subroutine without attachment
WCT MVR and AUX 13 are replaced by WCT
MOV, X 80, Y15
THD
SPG, D12 Finishing of 1st subroutine without attachment
WCT
MOV, X50, Y41.2
THD
SPG, H Finishing of 2nd subroutine without attachment
WCT
CCF, INIPAR
;END
Eject 300-500

Contact
Charmilles Technologies SA
rue du Pré-de-la-Fontaine 8-10
1217 Meyrin 1, Geneva/Switzerland
Tel. +41 (0)22 783 31 11
Fax +41 (0)22 783 35 29
www.charmilles.com
Agie Charmilles Group

ROBOFIL 190 - 290P - 310P - 510P: Part 3/3

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What safety precautions are mentioned?

What safety precautions are mentioned?

What are the different types of signs mentioned for safety?

What are the different types of signs mentioned for safety?

ROBOFIL 190•290P•310P•510P

205 952 110/E/12.1999 ver. F

204 945 340/E/17.12.1999

Use of the machine

290P 8.3 Utilization: wire and dielectric

204 931 240/E/17.12.99

Safety indications 8.1.4

Installation conditions 8.1.5

Precautions during use 8.1.5

Actions to be avoided 8.1.6

Precautions during maintenance work 8.1.9

Elimination of wastes 8.1.9

CHARMILLES TECHNOLOGIES 4 923 260/E/12.02.1998 8.1.1

8.1.2 CHARMILLES TECHNOLOGIES 4 923 260/E/12.02.1998

To guarantee afreeable and healthy working

CHARMILLES TECHNOLOGIES 4 923 260/E/12.02.1998 8.1.3

Warning signs: Yellow background, black surround, black symbol.

Label placed adjacent to the device

Label placed adjacent to the

Obligation signs: Blue background, white symbol or text.

• Déclencher l'armoire électrique avant toute intervention

8.1.4 CHARMILLES TECHNOLOGIES 4 923 260/E/12.02.1998

Premises Connection to electrical mains

Precautions during use

Protections Danger of electricity

Hygiene instructions Storage of diskettes

CHARMILLES TECHNOLOGIES 4 923 260/E/12.02.1998 8.1.5

Do not climb onto the machine

Hygiene and 606.*

8.1.6 CHARMILLES TECHNOLOGIES 4 923 260/E/12.02.1998

CHARMILLES TECHNOLOGIES 4 923 260/E/12.02.1998 8.1.7

Emergency stop circuit

Circuits remaining energized

Control of protective covers and doors

8.1.8 CHARMILLES TECHNOLOGIES 4 923 260/E/12.02.1998

Wastes resulting from the EDM metal machining

•If the dielectric liquid overflows, it must not be

CHARMILLES TECHNOLOGIES 4 923 260/E/12.02.1998 8.1.9

Wire spool Filter Resins Oil Wearing part

Wire Support Grounding,

N Paper Amberlite •Métallic :

8.1.10 CHARMILLES TECHNOLOGIES 4 923 260/E/12.02.1998

Surface finishes 8.2.3

Work-part and clamping 8.2.5

Inspection list 8.2.9

Measurement and taking reference 8.2.13

CHARMILLES TECHNOLOGIES 5 949 180/E/16.06.1996 8.2.1

8.2.2 CHARMILLES TECHNOLOGIES 5 949 180/E/16.06.1998

CH No. = 20 log 10 Ra (µm)

VDI Ra = CLA = AA class VDI Ra = CLA = AA class

CH µm µinch ISO 1302 CH µm µinch ISO 1302

•Definition of roughness criteria

CHARMILLES TECHNOLOGIES 5 949 180/E/16.06.1996 8.2.3

Validity of the visotactile (Rugotest) method

8.2.4 CHARMILLES TECHNOLOGIES 5 949 180/E/16.06.1998