XYZ Machine Tools ProtoTRAK KMX CNC User manual

XYZ Machine Tools Ltd.
Woodlands Business Park
Burlescombe, Tiverton, Devon EX16 7LL
T: 01823 674200 F: 01823 674201
www.xyzmachinetools.com
Copyright 2019, XYZ Machine Tools Ltd. All rights are reserved. No part of this publication may be reproduced,
stored in a retrieval system, or transmitted, in any form or by any means, mechanical, photocopying, recording or
otherwise, without the prior written permission of XYZ Machine Tools Ltd.
While every effort has been made to include all the information required for the purposes of this guide, XYZ Machine
Tools Ltd. assumes no responsibility for inaccuracies or omission and accepts no liability for damages resulting from
the use of the information contained in this guide.
All brand names and products are trademarks or registered trademarks of their respective holders.
XYZ Machine Tools
ProtoTRAK®KMX CNC
Safety and Quick Start Guide
Part Number: 17640
Version: 180619
Covers all XYZ KMX Turret Mills

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XYZ Machine Tools
ProtoTRAK KMX CNC control, Safety and Quick Start Guide
Introduction
This guide provides important safety Information and a very brief description of the operation of the
CNC control.
Full safety and operating information is provided in the ProtoTRAK KMX Safety, Programming,
Operating, and Care Manual. Please take time to read and understand this manual before using the
machine. This manual can be downloaded from the support pages of our website
https://www.xyzmachinetools.com/customer-support/downloads-manuals/
Safety
This machine is designed for the machining of cold metal within the stated capacity of the machine
with axes movement occurring by manual use of handwheels or CNC control.
This machine must not be used for machining flammable materials (e.g. magnesium) without
undertaking a risk assessment and incorporating any additional safety measures identified.
It is designed to be used in a standard workshop environment only.
It is the responsibility of the employer, machine owner or controller to ensure that this machine is
installed, operated and maintained in accordance with the Provision and Use of Work Equipment
Regulations (1998) or equivalent local regulations.
In particular, the responsible person must:
1. Undertake a Risk Assessment on the use of this machine, paying particular attention to the
unique characteristics of the Prototrak control system (for example, operating mode selection
and access to the work zone)
2. Generate and apply Safe Operating Procedures for the use of the Prototrak machine
3. Provide any additional training, safeguarding and PPE identified by the risk assessment.
This machine must only be operated by trained and experienced operators.
The following Safety Features must be checked on a regular basis (e.g. at the start of every shift):
1. E-stop
a. In DRO mode, press the E-stop button and ensure that the control flags up critical error
0055 (machine disabled) and that the axes and spindle cannot be started.
2. Table Guard Interlock
a. Start the spindle and then open each door guard in turn. Check that the spindle stops
quickly (less than 3 seconds) and that the spindle brake is on.Check that the spindle
(and powered knee on SLV) cannot be started.
b. With the table guard open, check that the feedrate is limited to 2m/min (78 ipm). The
DRO display will not change and will still show 2540mm/min, so check that the feedrate
drops/increases as you jog the axes and open/close the guard (X axis is the best).
c. Go into DRO mode, open the table guards and then turn off or remove the air supply.
Close the table guards and check the Door open message stays on the screen and that
the spindle cannot be started.
3. Safety Speed Monitoring –If you have manual handwheels, move the table in any mode
other than DRO, RUN or TOOL TABLE. Check for a fault 232 or 233, depending on which
axes was jogging (unintended motion).
4. Guards: Inspect the guards for signs of damage (especially the transparent panels). Replace
if any part of the guard is damaged. Replace the transparent panels in accordance with the
stated schedule, regardless of their apparent condition (see the FAQ on our website for why
this is important).
Notes on the E-stop and Table Guard critical safety functions:
•E-stop:
•This is provided by a safety rated, hard-wired E-stop system controlled by the E-stop

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ProtoTRAK KMX CNC control, Safety and Quick Start Guide
button on the pendant. When the machine is E-stopped (button pressed in), the axes,
spindle and other potentially hazardous machine functions are disabled by removal of
power.
•Air pressure (for the spindle brake and optional air powered drawbar) is NOT released in
E-stop. To remove air pressure; disconnect the air supply at the quick release coupling.
•To reset the E-stop, twist to release the E-stop button and then press the blue POWER
ON button (for about 1 second). When the button is released, the machine will come
out of E-stop.
•Releasing the E-stop button and pressing the POWER ON button, will always take the
machine out of the hardware E-stop condition (unless there is a fault with the safety
circuits). However, the machine may still be disabled because of the current machine
mode, or on the results of software safety checks undertaken by the control (e.g. fault
232). This an “NC Not ready” state; and should not be confused with the hardware E-
stop condition.
•The hardware E-stop also disables the auto lube pump, so always leave the machine in
this condition if not being used for a while, to avoid emptying the oil tank unnecessarily.
•Table Guards:
•With either (or both) of the table guards open, it is not possible to run the spindle or
operate the powered knee (SLV model).
•If the air pressure to the machine is less than about 50psi, it will not be possible to start
the spindle, even with the table guards closed.. This interlock has been provided to
ensure there is sufficient air pressure to stop the spindle quickly when the table guards
are opened.
•If pressure is lost whilst the table guards are closed. It will be possible to continue to
run the spindle until the guards are opened. Once opened, you will not be able to re-
start the spindle again, even if the guards are closed.
When operating this machine, always observe the following safety precautions
•Do not operate this machine without knowing the function of every control key, button, knob,
or handle.
•Always wear the appropriate personal protective equipment, including safety glasses and
safety shoes.
•Do not wear loose fitting gloves whilst operating this machine as they could easily get caught
in moving parts.
•Never wear rings, watches, long sleeves, neckties, jewelry, or other loose items when
operating the machine.
•Keep your hair away from moving parts. Wear adequate safety head gear.
•Never operate any machine tool after consuming alcoholic beverages, or taking strong
medications, or while using non-prescription drugs.
•Carry out a COSHH risk assessment and use the correct protection equipment, e.g. barrier
cream/latex gloves, to prevent harm from items such as cutting fluid, lubrication oil and other
substances used on the machine.
•Do not use compressed air to remove swarf or clean the machine. This can damage the
slideway seals and create coolant mist which can be harmful. XYZ recommend the use of
BioConcept cutting fluids which do not present a risk to the respiratory tract.
•Always ensure the appropriate guarding is in place for the machinery operation being
undertaken. Never reach around a guard to gain access to the part, tool, or fixture.
•Observe and understand the warning and safety information labels affixed to this machine.
•Do not attempt to tamper with or override any guarding/safety device fitted to the machine.
•Stop the machine spindle, open the table guards and take the CNC control out of an active
mode (DRO, RUN, TOOL TABLE):
oBefore changing tools.
oBefore changing parts.
oBefore you clear away the Swarf, oil or coolant. Always use a chip scraper or brush.
oBefore you make an adjustment to the part, vice, coolant nozzle or take measurements.

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ProtoTRAK KMX CNC control, Safety and Quick Start Guide
•If you need to rotate the spindle by hand: open the table guard (to ensure the spindle is
safely disabled) and temporarily remove the air pressure to release the spindle brake.
•Keep the working area clear and remove all tools (spanners, chuck keys etc.) from the
machine before you start the machine running. Loose items can become dangerous flying
projectiles.
•Keep work area well lit. Ask for additional light if needed.
•Be aware that the machine can move unexpectedly so do not lean on the machine while it is
running.
•To prevent slippage and personal injury, keep the working area around the machine dry and
clean. Ensure there is no swarf, oil, coolant and obstacles of any kind around the machine.
•Avoid getting pinched in places where the spindle, table or guards create "pinch points" whilst
the machine is in motion.
•Securely clamp and properly locate the workpiece in the vice or fixture. Use proper tool
holding equipment.
•Do not raise the cutting tool above the table guards without additional guarding measures
such as a cutter guard.
•If your machine is fitted with manual handwheels: keep the handle folded inside the hand
wheel at all times except when required to hand crank the table, to prevent injury during
powered axes movement.
•Use the correct tooling for the process being undertaken. Never use damaged or worn tools
and ensure the correct cutting parameters (speed, feed, and depth of cut) are used in order
to prevent tool breakage.
•Prevent damage to the workpiece or the cutting tool. Never start the machine (including the
rotation of the spindle) if the tool is in contact with the part.
•Avoid large overhangs on cutting tools when not necessary.
•To prevent fires, keep flammable materials and fluids away from the machine, hot swarf and
workpieces.
•Never change gears when the spindle is rotating
•Stop and disconnect the power to the machine before undertaking any cleaning or
maintenance
Operating Controls
Front of Pendant

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ProtoTRAK KMX CNC control, Safety and Quick Start Guide
Keyboard Hard Keys
GO: initiates motion in Run
STOP: halts motion during Run
LOOK: part graphics in Program and Program I/O modes
INC/ABS: switches all or one axis between incremental and absolute
INC SET: loads incremental dimensions and general data
ABS SET: loads absolute dimensions and general data
X, Y, Z: selects axis for subsequent commands
0-9, +/-, . : inputs numeric data with floating point format. Data is automatically + unless +/- key is
pressed. All input data is automatically rounded to the system's resolution.
MODE: to change from one mode of operation to another
RESTORE: clears an entry
IN/MM: causes inch to metric or metric to inch conversion of displayed data
ACC: turns coolant on and off
F/C: selects between fine and coarse resolution on Electronic Handwheels (if fitted)
Arrow Keys
Between the LCD Screen and the hard keys is a column of arrow keys.
Up key, down key: these are located at the top and bottom of the column, respectively. They
have several uses:
•feedrate override in RUN and DRO modes
•page forward, page back to move through events in a program
•data forward, data back to move through the data in an event
Select Keys (7 off):These keys are called soft keys. A description of the current function or
use of each of these keys will be shown on the LCD screen next to each key. If there is no
description beside a key, that key has no function in the current mode.
Emergency Stop Switch
See safety section for more information on the E-stop button.
The Liquid Crystal Display (LCD)
The information displayed on the LCD screen is usually divided into 4 sections.
The top, status line, shows the system's current status. This includes the mode, inch or mm
measurement and part numbers.
Beneath this, and filling most of the screen, is the information area. Position data, program data and
graphics are shown here. In addition, message windows will be displayed here.
Beneath the information area is a single "conversation" line. When numeric data is required, the
conversation line will appear for you to see the values you enter, before they are set into the system.
On the right side of the LCD are boxes describing the current function of the adjacent soft key.
There is an LCD screensaver built into the control. If the system is inactive (e.g. no user input or
axes movement) for 20, continuous minutes, the LCD will turn itself off (black screen). Press any key
to bring the screen back to its previous display. The key you press will be ignored, except to turn the
screen on.

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XYZ Machine Tools
ProtoTRAK KMX CNC control, Safety and Quick Start Guide
Switch Box Controls
POWER ON: Press and hold in for about 1 second to reset the
machine from a hardware E-stop (including at first power on). The
switch will light up blue to indicate the machine is out of hardware E-
stop.
SPINDLE: Use to turn the spindle on and off (in the forward or
reverse direction, depending on the gear selected). The spindle can
only be run if the table guards are closed. For KMX 2000 and SLV, the
control must be in a spindle enabled mode (DRO, RUN etc.) and the
spindle will turn off automatically, at the end of a programme run.
KNEE: Use to raise or lower the knee using the power knee feed (SLV
only). The table guards must be closed to operate the power knee
DRAWBAR: Use to clamp and unclamp tools using the optional, air
powered drawbar.
Rear of Pendant
On/Off switch: This switch turns the pendant on and off. It does not affect the electrical cabinet
except that it controls the 24VDC power used by the E-stop and table guard safety modules.
USB1/USB2: These are USB ports used for external keyboards or memory sticks for programme I/O
(and software updates). DO NOT plug anything else into these ports (e.g moble ‘phones).
Test Port: DO NOT plug anything into this connector.
AC SPDL EN: This connector is only used on some KMX, PT3 upgrades. It is internally connected to
110VAC in certain modes. DO NOT plug anything else into this connector.

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XYZ Machine Tools
ProtoTRAK KMX CNC control, Safety and Quick Start Guide
CBB PWR: This connector is not used on Euro KMX models. It is internally connected to 110VAC.
DO NOT plug anything (else) into this connector.
UPGRADE-AUX: This connector is only used on some KMX, PT3 upgrades. DO NOT plug anything
else into this connector.
SPDL SW BOX: This connector is not used on Euro KMX models. It is internally connected to
110VAC. DO NOT plug anything into this connector.
UPGRADE SW BOX: This connector is not used on Euro KMX models. It is internally connected to
110VAC. DO NOT plug anything into this connector.
Warning: never plug/unplug any cables with the power on
(other than USB) as this may damage the pendant!
Powering Up the System
To turn on the machine, rotate the power switch on the Electrical Cabinet to the On position. Then
turn on the pendant using the On/Off switch on the back.
The control will go through its boot up sequence. When it is finished, the following screen will
appear.
Press the CHECK SYSTEM select key.
The machine will always power up in an Estop condition, Press the POWER ON button when you are
ready to start moving the machine. Many control functions, like programming can be done with the
machine in the E-stop condition (which saves you lube oil).
Please refer to the Operating Manual for full operating instructions.
Turning off the System
Press Mode, Restore, Shut Down and finally answer Yes.
Turn the power off at the back of the pendant. Turn the power off at the machine electrical cabinet.
The ProtoTRAK control should be shut off, at a minimum, every week. Failure to reboot may cause
the control to run slowly.
Maintenance
Please refer to the schedule on the machine and in the service manual for important maintenance
activity.

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XYZ Machine Tools
ProtoTRAK KMX CNC control, Safety and Quick Start Guide
XYZ Machine Tools Ltd.
ProtoTRAK UK Warranty Policy
ProtoTRAK products are warranted to the original purchaser to be free from defects in workmanship
and materials for the following periods:
Product
Warranty Period
New ProtoTRAK Controlled Machine
12 Months
Any Exchange Unit or Spare Part
6 Months
The warranty period starts on the date of the invoice to the original purchaser from XYZ Machine
Tools Ltd (XYZ) or their authorised distributor. If a unit under warranty fails, it will be repaired or
exchanged at our option for a properly functioning unit in similar or better condition. Such repairs or
exchanges will be made carriage paid within the UK mainland.
Disclaimers of Warranties This warranty is expressly in lieu of any other warranties, express or
implied, including any implied warranty of merchantability or fitness for a particular purpose, and of
any other obligations or liability on the part of XYZ (or any producing entity, if different). Warranty
repairs/exchanges do not cover incidental costs such as installation, labour, etc.
•XYZ is not responsible for consequential damages from use or misuse of any of its products.
•ProtoTRAK products are precision mechanical/electromechanical measurement systems and
must be given the reasonable care that these types of instruments require.
•Replacement of slideway wipers and covers is the responsibility of the customer.
Consequently, the warranty does not apply if swarf or coolant have been allowed to enter the
mechanism.
•This machine is designed to cut common, metallic engineering materials (such as steel and
aluminium). DO NOT use to cut special materials (such as composites or abrasives) without
agreement from XYZ Machine Tools. Any damage caused to the machine by processing such
materials will not be covered by the warranty.
•Accidental damage, beyond the control of XYZ, is not covered by the warranty. Thus, the
warranty does not apply if an instrument has been abused, dropped, hit, disassembled or
opened.
•Improper installation by or at the direction of the customer in such a way that the product
consequently fails, is considered to be beyond the control of the manufacturer and outside
the scope of the warranty.