ZAPbp BP93p User manual

© Zakład Automatyki Przemysłowej B. P. 1
CNC ELECTRIC DISCHARGE MACHINE
BP93p
zapbp.com.pl
Zakład Automatyki Przemysłowej B.P.
99-300 Kutno,
Kuczków 13,
fax.: [phone],
Tel.: [phone].
26-200 Końskie,
ul. Młyńska 16,
fax.: [phone],
Tel.: [phone].

© Zakład Automatyki Przemysłowej B. P. 2
1. GUIDELINES REGARDING USER SAFETY
a) The precondition for the safe and efficient operation of the machine is to read this
operation manual carefully and strictly follow all safety instructions contained therein.
b) Prior to the first use of the machine, undergo appropriate training.
c) The BP93p Electric Discharge Machine must be used, according to its purposes,
exclusively.
d) Before commencing work, make sure you are well familiar with operating the machine
and its correct use.
e) Before each maintenance and adjustment of the BP93p machine, disconnect it from
power supply.
f) Always disconnect power supply, before filling or changing water in the tank.
g) Should water from the tank be spilled, clean it with the machine disconnected from
power supply.
h) Apply integrated spot lighting, in order to make sure your workpiece is well lit.
i) Remove all freely moving elements from the machine, in order to make sure that it
can be transported safely.
j) Do not use the machine, if its guard is damaged.
2. INTENDED USE
The BP93p cavity type electrical discharge machine is intended to perform electron
discharge machining of all types of steel, cast iron, alloys, aluminium, and other electro-
conductive materials. It is used primarily to produce injection moulds, blanking dies, and
when machining tools after thermal and/or chemical treatment.
The PP15 control system applied in the machine enables the following:
a) Creating executive programs based on G- and M-codes;
oCarrying out a drilling process: along any straight line in the machining
space; along any straight line, including a rotating movement of the
electrode (A-axis); along any arc, within the XY-plane; spirally, along the
Z-axis;
oProgramming activation/deactivation of additional functions, when drilling,
such as: vibrating motion of the electrode; orbiting around a circle; and
orbiting around a square (applicable to the Z-axis only);
oProgramming selection of one of the ten available systems of working
coordinates;
oDeclaring execution of ncavities in the pre-defined direction;
b) Communicating with a PC, via RS232, Bluetooth, or an SD card;
c) Storing up to 20 executive programs on an SD card.
3. THE UNIT INCLUDES:
Standard version:
A mechanical frame with a co-ordinate table and a tank;
An oscillator with programming and controlling systems;
A petroleum tank with a set of pumps and filters;
A petroleum level sensor.

© Zakład Automatyki Przemysłowej B. P. 3
Accessories:
TE-1 EDM lathe,
GO-3 rotary head,
MD-1 Micro EDM machine,
UR-1 and UR-2 adjustment handles,
WS-1 and WS-2 spinning heads,
PDT-1 and PDT-4 rotary tables.
4. TECHNICAL PARAMETERS
BP93p for diamond discs
MACHINE
The area occupied by the machine
0.9m2
Dimensions
750x700x1900mm
Standard tank
610x400x200mm
Working table
235x335mm
Travel along the XYZ-axis
250x180x180mm
Distance between the table and spindle
(min/max)
70/250mm
Height of workpiece (max)
140 mm
Weight of workpiece (max)
50 kg
Weight of electrode (max)
4 kg
Accuracy of positioning
0.02 mm
Electric drive in axis
X, Y, Z
Drive
Stepper motors 1.8
Electrode material
Cu, graphite
Total weight (without petroleum)
330kg
TANK
Volume
160 litres
Dielectric fluid
Petroleum, paraffin oil
Filtering medium
Paper
OSCILLATOR
Drilling current
30A
Electrode working voltage
250V
Supply voltage
3x380V
Power input
1.5kW
Petroleum level sensor
Volumetric
5. DESIGN
The welded structure of the table supports a flagstone and the mechanical frame of
the machine. Next to it, there is an oscillator cabinet with a reader. Under the table, there is
a tank with a pump and filter.
5.1. MECHANICAL SECTION
This section includes:
a) a table,
b) a tank with pump, filter, and supply and discharge conduits for dielectric fluid,
c) a mechanical frame comprised of the following components:
ofoundation (a cast-iron truss),
oadjustable legs screwed to the foundation,
oa trolley,
olinear ball bearings in the X-axis that connect the foundation to the trolley,
olinear ball bearings in the Y-axis that connect the foundation to the table,
oa measuring power screw in the Y-axis,

© Zakład Automatyki Przemysłowej B. P. 4
oa handle with a nut for the Y-screw, screwed to the trolley,
oa measuring power screw in the X-axis,
oa handle with a nut for the X-screw, screwed to the trolley,
oa stepper motor Y,
oa stepper motor X,
oa play elimination unit in the X- and Y-axis, with a weight suspended on a
tensioning cord,
oa brake in the Y-axis,
oa brake in the X-axis,
oa table with T-shaped grooves, threaded holes, and a rubber seal to connect
to the tank,
oa tank with a distributor,
odistributor valves with hoses,
ooverflow and discharge hole with gates,
oL-shaped frame with electric equipment and guards,
oa head comprised of the following elements:
a linear ball bearing in the Z-axis with a strip with an electrode holder
being its integral part,
a bed connected to the L-shaped frame that holds a linear ball bearing,
a handle that holds a nut for the Z-screw, screwed to the strip,
a measuring power screw in the Z-axis,
a stepper motor Z,
a head guard,
oa strip with an electrode holder.
5.2. DIELECTRIC FLUID CIRCULATION
Under the table, there is a tank unit with a pump and filter. The entire unit can be
pulled out to the front of the machine. The unit is connected to the machining tank by two
hoses. The dielectric fluid contained in the tank is supplied through a filter paper, and then
flows into the distributor located on the tank side. The distributor had three valves connected
in parallel, one of which is dedicated to filling the tank, and the other two to washing out
erosion product, during machining. There is an overflow and discharge hole, located on the
discharge side – it enables complete discharging of the dielectric fluid, provided that an
appropriate gate has been installed in the tank to keep the fluid at a desired level.
5.3. ELECTRICAL SECTION
This section includes:
a) an oscillator cabinet with a microprocessor controller;
b) a petroleum level and temperature sensor;
c) electronic systems installed in the frame.
Attention!!!
Detailed schematic and assembly diagrams are available at the manufacturer's after
expiration of the warranty period, if requested.
Description of operation
The synchronizer generates a rectangular travel of adjustable pulse time Tand idle
time t. It energises the inverter amplifier. The magnitude of current pulse in the 1-30A
inverter depends on the set-point defined for the R142 potentiometer (CURRENT
AMPLITUDE). The voltage level set for the potentiometer is compared to the voltage drop
detected in the R191 resistor. The difference in the signal energises the T42 and T40
amplifiers, and the T44 terminal of power transistors.

© Zakład Automatyki Przemysłowej B. P. 5
Should there be a short circuit or irregular voltage drops between electrodes, the
power supplied to energise the terminal is reduced. It is controlled by the following systems:
T27, PO1, T29, T30, and US23. One of the electrodes is connected to the M potential
(system earth). The other electrode is connected to the D110 current oscillator output and
the so-called ignition spark oscillator, i.e. 250V keyed voltage, using the T192 transistor,
synchronous with de-energising of the mentioned oscillator. Its operation is signalled by the
lighting up of the IGNITION lamp.
The signal coming from the active electrode is supplied to the system that identifies
and forms control runs of the motor, i.e.
T27, P01, R90, C36, US15
“SHORT CIRCUIT”
Retract electrode
T28, P02, R90, C37, US14
“OPERATION”
Stop electrode
T28, P02, R106, C38, US13
“SLOW DOWN”
Retract, if work efficiency
has exceeded 90%
including the following signals:
US11
Periodic retracting
C+
Positive rotation pulse
C-
Negative rotation pulse
all of which are transferred to the reader and microprocessor controller system.
The reader is responsible for controlling displays, keypad, and meters assigned to each of
the axes, as well as for energising stepper motors, according to the set program.
The signalling system collects information from a sensor that detects petroleum level and
temperature at limiting switches, and from a thermistor installed on the inverter radiator. It
signals erroneous statuses, by the flashing of an appropriate signal lamp. In the case of
automatic working mode, the system shuts down the oscillator (T20, ST1) and generates an
additional acoustic signal.
If the RC oscillator is activated, the inverter of the oscillator (US23) is shut down, while the
T26 and D60 systems are also activated to generate the “OPERATION” - Stop motor signal,
as well as the PK2 relay of the C100 capacitor powered by a 250V ignition resistor is also
activated. In this mode, the synchroniser works for a shorter period of time, the T192 and
T193 systems are activated, and the afore-mentioned inverter is deactivated. The signals
that control the motor are generated in the same manner as the ones controlling the
oscillator-based operation.
6. INSTALLING AND CONNECTING THE MACHINE
One must exercise extra attention and thoughtfulness, when drilling with the BP93p machine.
Pay particular attention to the fire protection of both the machine and the room in which it
operates, as sparks are produced that may come into direct contact with the dielectric fluid.
The EDM machine must be installed in a separate room that meets the following conditions:
Good lighting;
Low level of noise;
Good ventilation (it is recommended to extract the gases accumulating above the
machine);
Good fire protection (have a carbon-dioxide extinguisher available);
Air temperature in the 15-25o C range;
Medical protection (first aid kit);
Fire protection: fire-fighting equipment should be placed in easily accessible places
that are not exposed to hazards (as much as possible).
The machine must be positioned in such a way that there is convenient access to the main
switch and all the components subject to periodic inspections. The machine must be subject

© Zakład Automatyki Przemysłowej B. P. 6
to period examination performed by a Sanitary and Epidemiological Station, in order to
measure the level of electromagnetic field emission and define “hazard areas” in a given
room.
Attention!!!
The warning signs compliant with PN-74/T-06260 must be located next to the entrance to the
room where the machine operates. In addition, there must also be a site plan showing all
locations where electromagnetic field intensity was measured.
After finishing work:
travel by a specific value, to remove the electrode from the material (Manual Mode [R]
-> Travel -> By the value),
deactivate the main switch,
drain petroleum,
make sure there is no leak from the dielectric fluid tank,
disconnect the plug from the mains,
before leaving the room, make sure that fire extinguishers are in their proper places.
7. DESCRIPTION OF ADJUSTMENT RANGES PRESENTED ON FRONT
PANELS

© Zakład Automatyki Przemysłowej B. P. 7
1) CURRENT AMPLITUDE [A] potentiometer: Variable adjustment of the discharge
current amplitude, I=<1, 30>,
2) EFFECTIVNESS [%] potentiometer: Drilling efficiency adjustment, P=<0,100>,
3) SHORTING[%] potentiometer: Adjustment of electrode retracting delay, resulting from
short circuits or incorrect operation, z=<0,100>,
The knobs 2 and 3 are used to set the machine working conditions, in the automatic mode.
The motor will continue lowering the electrode, until the required discharge factor has been
exceeded. The motor is re-started, if the frequency of discharges is lower that the required
factor, following material consumption and increasing the working gap. If the frequency of
occurring short circuits is higher that the required short circuit threshold, the electrode is
retracted, until short circuit is eliminated. Then, the electrode travels to the material again.
4) PERIOD switch: on/off period retracting of electrode (during of drilling). Function
parameters (time of withdrawal and time of travel) are adjusted by means of
potentiometers: WITHDRAWAL, RETURN WORK,
5) IMPULS [μs] potentiometer: Variable adjustment of pulse time, within the range of
Ti=<5,1100>,
6) BREAK [μs] potentiometer: Variable adjustment of idle time, within the range of
tp=<5,100>,
7) AUT. REG. BREAK switch: Automatic adjustment of idle time. Pressing the key set
the value of idle time, according to the configuration of the “BREAK” potentiometer.
Idle time is extended to 100μs, if incorrect operation is detected. This function is
applied, if drilling is carried out in difficult conditions. It results in an increased
electrode consumption,
8) VALVEswitch: on/off pulse spraying of the dielectric fluid. Fuction:
ois activated only if period retracting of electrode is on.
oprovides pulse spraying from the nozzle connected to the periodically
switching solenoid valve (for activated periodic withdrawal, the valve is
switched on at the end of the electrode departure from the material),
9) PUMP switches:
oPUMP1 (bistable key): on/off pump 1 (the pump won’t be activated if the
current oscillator is turned off),
oPUMP2 (bistable key): on/off pump 2 (not installed in the standard),
oPUMP1! (monostable key): on/off pump 1,
10)RC GENER switch: on/off the RC relaxation oscillator. It is used when the gap is
silted up, or if there is an electrode gap generated, when working with a transistor
oscillator. The RC generator must be used sporadically, as it considerably increases
electrode consumption,
11)SMOOTHING switch: on/off a low-current oscillator I=(1, 3, 5) [A]. It is used to
smooth drilled surfaces (roughness Ra<2 μm),
12)GENERATOR ON switch: activates the current oscillator (the current oscillator won’t
be activated in the event of an emergency signal [see subsection 16], an open
bathtub or raised working space cover),
13)GENERATOR OFF switch: deactivates the current oscillator,
14)STOP ENERGY: emergency switch,
15)Ignition switch with a key that activates the control,
16) Signal lamps
oIgnition: Signals operation of the ignition system. It is lit permanently, if there
are no discharges. If there are, it is dimmed, and goes out, if electrodes are
shorted.
oWork: Signals the occurring of the set / more than the set number of
discharges in the gap, and also stopping of the drive (electrode) in the
automatic mode.

© Zakład Automatyki Przemysłowej B. P. 8
oShorting: Signals the occurring of a short circuit and retracting of the electrode,
in the automatic mode.
oDielectric level: Signals low level of dielectric.
oDielectric temperature: Signals the excessive temperature of dielectric.
oFire extinguisher: Signals activates the fire extinguisher GG-1,
oHeatsink temperature: Signals the excessive temperature of current oscillator,
oFire extinguisher supply:Signals the operation of a power supply unit for the
fire extinguisher GG-1,
oPower network: Signals the presence of 230V mains voltage,
oNo phase: Signals lack of phase.
17)The PP15 controller
8. REMARKS CONCERNIG OPERATION
a) Prior to commencing work, level the foundation with the cast-iron table.
b) All non-varnished metal components must be protected against corrosion (lubricated
with oil).
c) The stepper motors used as drives work in the open feedback loop circuit. If motors
working in that circuit are overloaded, it may result in measuring errors.
d) Make sure that screws are clean and lubricated, and that drives corresponding to
each of the axes work properly in full scale, prior to each operation, and particularly
after downtime. If any irregularities are found, lubricate screws with molybdenum
grease and repeat the action described above.
e) Results displayed in readers must be treated as rough data. If it is necessary to
obtain highly accurate data, use precise measuring equipment, e.g. measurement
strips.
f) Drilling results displayed on a reader are erroneous, which results from gap
enlargement (parameter Sb) and electrode wear (function f(Ze)). Therefore, when
setting the depth of drilling, start with the following calculation, based on
characteristics:
DIMENSION entered = DIMENSION required - Sb+ f(Ze)
g) Prevent petroleum from soiling and make sure that the filter is not contaminated
excessively. To that end, carry out period cleaning of the tank:
opump out the maximum possible quantity of petroleum to a separate container,
odry the tank, remove the lid, and disconnect the discharge line,
opour out the remaining old petroleum, remove silt, and clean the tank,
ore-install and push the tank to its original location,
owhen pouring clean or settled petroleum into the tank, make sure that the
drain hole is unplugged.
Attention!!!
It is not allowed to start and operate the machine, if its guards are open, or limiting switches
locked.
9. GENERAL SAFETY PRECAUTIONS
a) Only people that underwent appropriate training in the operation of the EDM machine
are allowed to work with it.
b) The operator should wear loose clothes, without any elements that could be trapped
mechanically in the machine.
c) The workpiece must be fastened to the table – it is not allowed to machine the piece,
if it is held in hand.
d) It is absolutely required to:
okeep the place clean and tidy!

© Zakład Automatyki Przemysłowej B. P. 9
okeep third parties away from the machine, when it is in operation.
e) Recommendations:
oworkstation should be equipped with individual medical kits for treating
injuries.
oworkstation should be located in a well-lit, quiet, and clean room, which
ensures that the operator can focus on their work and do it with precision.
omake sure that third parties do not have free access to the machine.
oworkstation can be secured with a lathing mesh (for example) to protect it
against radio noise. Similarly, the mesh can be use to cover windows (thus
creating the Faraday cage).
oif the operator is exposed to electric shock, which results in their paralysis*,
immediately disconnect power supply (press the STOP ENERGY button on
the front panel of the oscillator, or use the CIRCUIT BREAKER switch located
on the right lateral wall of the oscillator; then, provide first aid required for
people exposed to electric shock.
10.FIRE INSTRUCTIONS
Fire hazard can result from the presence of the following products:
a) Dielectric fluid – petroleum;
b) Petroleum vapours and gaseous by-products that are derivatives of the anaerobic
decomposition of the dielectric fluid. The biggest fire hazard is posed by gaseous by-
products generated above the working area, as they can reach concentrations that
ignite or explode easily; the same applies to the dielectric fluid, if its ignition
temperature is exceeded.
c) If the EDM machine is operated incorrectly, e.g. because the workpiece and electrode
are not adequately cooled, or especially when there is air present in the working area
of a drilling electrode – if it protrudes above the surface of the dielectric fluid, or it is
not submerged enough.
It is absolutely forbidden to:
a) Smoke tobacco in the vicinity of the machine;
b) Use open fire, in the vicinity of the machine;
c) Store rags or other materials that could work as wicks, when near the machine;
d) Have any third parties present near the machine, if they were not trained in fire safety,
regarding EDM workstations;
e) Use the machine, if the ignition temperature of the dielectric fluid is exceeded, or if the
machine works for a long time under heavy load;
f) Use the machine, if the level and temperature sensor has not been configured
properly and activated;
g) Use the machine, if the working area is not adequately submerged (at least 3cm
below the surface of the dielectric fluid);
h) Carry out repair work or other work that may lead to damaging the tank or igniting the
dielectric fluid;
i) Modify electric or hydraulic systems, without prior consulting with ZAPbp.
Recommendations:
a) Use a separate, well-ventilated room.
b) Use the machine in a location that ensures safe exiting and disconnecting power
supply in the room, as well as access to fire-fighting equipment, in the event of fire.
c) It is recommended to prevent fluid from spilling over a large area, if there is a failure
of the dielectric supply system. Provide a directed run-off of the fluid outside the
building, or into a special tray, e.g. via a special hole.
d) It is recommended to use an additional, automatic fire suppression system.
e) It is also recommended to use a central fire suppression system in the room.

© Zakład Automatyki Przemysłowej B. P. 10
f) Use a blowing system that eliminates vapours from above the tank, or a spot extractor
– vapours must be directed outside the working room. The extracting system must
be efficient, in order to eliminate any condensation of the dielectric fluid in conduits, or
possible isolated water pools, as that can pose a fire hazard.
g) It is absolutely forbidden to operate the machine without supervision.
Protection measures:
a) At least two carbon-dioxide extinguishers or halide fire extinguishers within easy
reach, if there is fire.
b) A fire blanket.
Fire extinguishing procedure:
a) Disconnect supply voltage (press the STOP ENERGY button).
b) Eliminate flames.
c) Use a fire extinguisher (Attention!!! Do not aim the stream of gas directly at the
petroleum surface, as it can result in splashing of the dielectric fluid).
d) Call external services and act adequately to the course of events.
14.INSPECTIONS AND MAINTENANCE OF THE MACHINE
The machine must undergo period inspections, carried out at an authorised service
workshop of the manufacturer – every 2 years.
Responsibilities of the user:
a) Keep the machine clean;
b) Change filters after every 200 hours of operation;
c) Change seals in the lids of both filter housings, as necessary;
d) Refill petroleum systematically, up to the level marked on the tank;
e) Clean the tank every 12 months;
f) Prevent petroleum from spilling outside the machine and form pools; similarly, make
sure there is not post-erosion silt deposited in the tank;
g) All systems and guards must be checked, before each operation;
h) The power network supplying the machine must be efficient (check the technical
condition of connections and neutral points – PE);
i) Report all noticed malfunctions or unexpected events to the authorised service
workshop of the manufacturer.

© Zakład Automatyki Przemysłowej B. P. 11
15.TECHNOLOGICAL CHARAKTERISTICS
Electrode: copper M1E
Workpiece: steel
Dielectric fluid: paraffin oil
Other parameters: tp=50μs, P=10%, z=50%

© Zakład Automatyki Przemysłowej B. P. 12
Electrode: copper M1E
Workpiece: steel
Dielectric fluid: paraffin oil
Other parameters: tp=50μs, P=10%, z=50%

© Zakład Automatyki Przemysłowej B. P. 13
Electrode: copper M1E
Workpiece: steel
Dielectric fluid: paraffin oil
Other parameters: tp=50μs, P=10%, z=50%

© Zakład Automatyki Przemysłowej B. P. 14
16.ADDRESSES OF DEALERS
a) FILTERS
oWE-325
Przedsiębiorstwo Produkcyjno Handlowe Motoryzacji EXMOT (A manufacturer and supplier
of filters), 19-300 Ełk, ul. Przemysłowa 6B, Tel.: [phone], Fax: (87)
621-31-59, Email: [email protected], exmot.pl
oL-325 or L-520
Spółdzielnie Inwalidów Two-Met (Disabled workers co-operative), 95-100 Zgierz, ul.
Dąbrowskiego 13, Tel./Fax: [phone], Tel.: [phone], Email: marketing@two-
met.pl, [e-mail], www.two-met.pl
b) GLEITMO 100 MOLYBDENUM GREASE
FUCHS OIL CORPORATION (PL) Sp. z o.o., 44-101 Gliwice, ul. Kujawska 102,
Tel.: [phone], Fax: [phone], Email: gliw[email protected], fuchs-oil.pl
c) COPPER AND OTHER NON-FERROUS METALS
HUTMEN S.A., 53-234 Wrocław, ul. Grabiszyńska 241, (Headquarters) Tel.: [phone],
Fax: [phone], Email: biuro.spol[email protected], www.hutmen.pl
HUTMET sp.j.- Retail Outlet, 53-234 Wrocław, ul. Grabiszyńska 241C, Tel.: [phone],
(71) 339-03-00, Fax: [phone], Email: [e-mail], www.hutmet.metale.pl
d) WORKING DIELECTRIC FLUID
oEDR 3
ORLEN OIL Sp. z o.o., 31-323 Kraków, ul. Opolska 100, Tel.: [phone],
(24) 201-03-70, fax: [phone], Email: [e-mail],
www.orlenoil.pl
oPARAFFIN
SOLON, 81-002 Gdynia, ul. Morska 316A, Tel./Fax: [phone], Email:
solonsobcz[email protected], www.solongdynia.za.pl

1
Programmable controller for electro-erosion removal machines
manufactured by ZAPbp.
Operator's manual.
zapbp.com.pl
Zakład Automatyki Przemysłowej B.P.
99-300 Kutno,
Kuczków 13,
Fax: [phone],
Tel.: [phone].
26-200 Końskie,
ul. Młyńska 16,
Fax: [phone],
Tel.: [phone].

2
Table of Contents
2 Control Panel...............................................................................................................4
2.1 Keyboard Layout...................................................................................................................... 4
2.2 Menu Layout............................................................................................................................ 5
3 Manual Working Mode ...............................................................................................6
3.1 Travel....................................................................................................................................... 6
3.1.1 Manual Travel.................................................................................................................. 6
3.1.2 Travel by a specific value................................................................................................. 6
3.1.3 Travel by a specific step................................................................................................... 7
3.1.4 Travel toward specific coordinates ................................................................................. 7
3.1.5 Travel Home .................................................................................................................... 8
3.1.6 Travel to characteristic points ......................................................................................... 9
3.1.7 Travel to the beginning of program ................................................................................ 9
3.1.8 General error messages regarding travels ...................................................................... 9
3.1.9 Limiting switches ........................................................................................................... 10
3.2 Configuration of coordinates ................................................................................................ 10
3.2.1 Operator’s coordinates.................................................................................................. 10
3.2.2 A list of base coordinates .............................................................................................. 11
3.2.3 Physical coordinates...................................................................................................... 11
3.3 Alignment .............................................................................................................................. 12
3.3.1 Within a hole ................................................................................................................. 12
3.3.2 On the mandrel ............................................................................................................. 13
3.3.3 Error messages regarding alignment............................................................................. 14
3.4 Statistics................................................................................................................................. 14
3.5 Settings.................................................................................................................................. 15
3.5.1 Date/Time...................................................................................................................... 15
3.5.2 Type of rotating instrument .......................................................................................... 15
3.5.3 Language........................................................................................................................ 16
3.5.4 Additional functionalities .............................................................................................. 16
4 Programming Mode ..................................................................................................17
4.1 List of programmes................................................................................................................ 17
4.2 Transfer of program .............................................................................................................. 18
4.3 New program......................................................................................................................... 19
4.4 Error messages ...................................................................................................................... 20
4.5 The principles of writing a program, using G- and M-codes ................................................. 20

3
4.5.1 G-codes (preparatory functions) ................................................................................... 21
4.5.2 G-codes (standard cycles).............................................................................................. 22
4.5.3 M-Codes ........................................................................................................................ 23
5 Automatic Working Mode.........................................................................................24
6 A pattern of preparatory procedures, before commencing a drilling process .........25

4
1Control Panel
1.1 Keyboard Layout
Fig. 1
The keyboard attached to the operator panel is comprised of the following elements:
[1] A block of directional keys (they control the direction of movement and the turning movement of the
working bit of the machine machine);
[2] The Ignore Short Circuit button [IZR] (it is used during travelling, if it is necessary to ignore the contact
between the working bit and the table; if this function is active, the following messages appears on
the screen: IZR);
[3] A numeric keypad;
[4] A block of navigational keys (it is used to navigate through the controller menu);
[5] A block of [P], [R], and [A] keys that are used to select one of the following working modes:
Programming, Manual Mode, or Automatic Mode.
[6] The [STOP] button (it is used to stop any current operation);
[7] The [DEL] button (it is used to delete individual programmes);
[8] A block of [F1], [F2], and [F3] functional keys (their current function is displayed on a LCD display,
directly above each of the buttons).

5
1.2 Menu Layout
The menu layout has been presented on the diagram below:
Working mode
Main Menu
Sub-Menu
Manual Mode
Travel
By value
By step
To coordinates
Home
To characteristic points
To the beginning of program
Configuration of
coordinates
Operator’s coordinates
A list of base coordinates
Physical coordinates
Alignment
Within a hole
A hole in the XY-plane
A hole in the XZ-plane
A hole in the YZ-plane
A gap along the X-axis
A gap along the Y-axis
A gap along the Z-axis
On the mandrel
Rotation around the X-axis
Rotation around the Y-axis
Rotation around the Z-axis
Statistics
Settings
Date/Time
Type of rotating instrument
Additional functionalities
Language
Programming
List of programmes
Transfer of program
Bluetooth
RS232
New program
Automatic Working Mode
By pressing one of the three keys that define the working mode (see
Fig. 2), the User will be directed to the Main Menu dedicated to a
particular working mode. The afore-mentioned operation will not be
possible, if we have started declaring parameters that are necessary for a
selected function, or when the controller is carrying out a selected
operation (e.g. travel by a certain value).
Fig. 2
To navigate through the menu structure, use the block of navigational
keys (see Fig. 3). See below to learn about the operations assigned to
each of the keys:
[1] [↑] The cursor moves up to another item on a menu list;
[2] [↑] The cursor moves down to another item on a menu list;
[4] [ENT] It enables entering a sub-menu;
[5] [ESC] It enables exiting a sub-menu.
Fig. 3

6
2Manual Working Mode
Initial notes:
The machine will only work within the positive quadrant of the global co-ordinate system that is also
referred to as a physical co-ordinate system.
If the user attempts to travel toward negative physical coordinates, the system will generate an
appropriate error message.
The coordinates displayed on the LCD display are operator's coordinates corresponding to the datum
point of a local co-ordinate system.
The datum point of a local co-ordinate system can be adjusted, in relation to the global co-ordinate
system.
The following working ranges apply:
oLinear coordinates:
Physical coordinates = <0 to 999.995>;
Operator's coordinates = <-999.995 to 999.995>;
oAngular coordinates:
Physical coordinates = <-999˚59’ to 999˚59’>;
Operator's coordinates = <-999˚59’ to 999˚59’>.
2.1 Travel
2.1.1 Manual Travel
Intended use: This function is responsible for travelling the working bit of the machine in a specific direction,
and according to a specific turning movement, by pressing and holding one of the keys included in the
directional keypad (see Fig. 1). This function will not be available, once the user has entered a window
dedicated to a selected operation (e.g. travel by a specific value).
2.1.2 Travel by a specific value
Intended use: This function is responsible for travelling the working bit of the machine by a specific value,
along a single axis or many axes simultaneously.
Access path: Manual Mode [R] -> Travel -> By the value of
Screen:
Course of action:
1) Select a specific direction and turn during travel, by pressing an appropriate key included in the
directional keypad (see Fig. 1).
oThe entry window dedicated to the selected axis of travel will be displayed.
2) Enter the required value of travel, using the numeric keypad ([DEL] – Deletes the entered character;
[ESC] – Cancels the option of entering a value).
3) Accept the entered value, by pressing [ENT].
4) Declaration of movement for another axis – go back to item 1.