1539 Operation Manual Do

Rotary Index Shot Peening System
for Dana Corporation
Description of Operation
Project 1539
December 2003
Rotary Index Shot Peen System - Project 1539 Machine Operation
Table Of Contents
I. Introduction - System Overview -1-
Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -2-
II. Machine Controls Layout and Description -3-
Main Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -4-

Main Control Station Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -5-
Miscellaneous Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -6-
Blast Media Flow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -7-
Blast Air Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -8-
Jog Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -9-

Manual Jog Pendant Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -10-
Touchscreen Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -12-

Entering and Editing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -12-
Selecting Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -12-
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -12-
Resetting Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -12-
Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -14-
Security Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -14-
Adding Employee Pictures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -16-
Operator Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -17-

Introduction Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -17-
Identification Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -18-
Monitor Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -20-
Manual Mode Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -22-
Alarm Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -25-
Machine I/O 1 Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -26-
Machine I/O 2 Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -27-
Pop-Up Menus and Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -28-

Help Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -28-
Setpoint and Limits Pop-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -28-
Recipe Store Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -29-
Recipe Recall Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -29-
Part Selection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -30-
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Recalling Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -30-

Adding Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -30-
Modifying Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -30-
Deleting Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -31-
Exiting Part Select Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -31-
Search of Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -31-
Part Information Entry Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -32-
Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -32-
Part Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -32-
Part Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -32-
Part Picture Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -32-
Process Document Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -33-
Surface Number Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -33-
Storing Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -33-
CNC UTILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -34-

0. Main CNC Utility Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -34-
Drive List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -34-
Directory List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -34-
PC File List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -35-
NEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -35-
Edit Part Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -35-
Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -35-
Move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -35-
Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -35-
1. Editing Part Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -36-
Save File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -36-
Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -37-
Exit Edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -37-
Renumber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -37-
Renumber Base & Increment Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -37-
Text Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -38-
Programming Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -38-
Editing Programming Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -39-
2. Search and Replace Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -41-
Cancel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -41-
Replace All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -41-
Find Again . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -42-
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -42-
Find . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -42-
Whole Word Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -42-
Case Sensitive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -42-
Find String . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -42-
Replace With . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -42-
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III. Machine Operation -43-
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -43-
Machine Power Up and Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -44-

Machine Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -44-
Machine Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -45-
Machine Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -45-
E-Stop Controls and Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -46-
Overtravels and Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -47-
Operation in Manual Mode ( Jogging and Homing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -48-

To Activate the Jog Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -48-
Homing Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -48-
Jogging Axes in Continuous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -49-
Jogging Axes in Incremental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -49-
Operation in Auto Mode (Running a Cycle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -50-
Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -51-
Running the Table Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -51-
Jogging the Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -51-
Fixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -52-
Rotating the Fixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -52-
Miscellaneous Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -53-

Dust House . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -53-
Sweco Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -53-
Media Adder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -53-
Pressure Pots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -54-
Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -54-
Blast Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -54-
Machine Faults and Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -55-

Fault Shutdowns & Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -56-
Information Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -57-
IV. Programming -59-
Program Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -60-
Motion Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -61-
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Position Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -61-

Absolute/Incremental Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -61-
Feedrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -61-
Example Motion Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -61-
M-Codes (Miscellaneous Functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -62-
Dwells and Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -63-

Dwell Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -63-
Loop Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -63-
Recipe Recall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -64-
Surface Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -65-

Description of Surface Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -65-
Operation of Surface Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -65-
Special Considerations for Surface Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -65-
Programming Using Teach Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -66-

Teaching to Program Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -66-
Program Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -67-
Running a Test Mode Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -68-
Running a Single Block Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -69-
Sample Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -70-

Example Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -70-
Appendix A: PC Backup and Restore -71-
Making a backup image of the PC’s harddrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -71-
Restoring a backup image of the PC’s harddrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -71-
Booting from a CD/DVD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -71-
Appendix B: PRIMS Directory Structure -72-
Appendix C: SETTING.INI -73-
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I. Introduction - System Overview
The PROGRESSIVE TECHNOLOGIES INC. Rotary Index Shot Peening System consists of a single
3-axis gantry style robot, a rotary index cabinet with two blast zones and rotating part fixtures, a two-
stage pressure pot media delivery system, and a media reclaim system. This machine is intended to
process a ring and pinion gears.
The intention of this manual is to describe how PROGRESSIVE TECHNOLOGIES INC. implements
industrial standard controls and devices for the peening application. This manual does not and is not
intended to give full operating instructions for vendor supplied equipment. Please refer to the
supplied vendor manuals.
The Robotic Peening System is an integration of three major sub-systems or assemblies:
1. Blast Cabinet Assembly

2. Reclaim/Blast Assembly
3. Controls Assembly
Each assembly is composed of smaller sub-systems, modules, and each module is composed of still
smaller sub-systems called products. Refer to the Table of Contents in the Service Documents
section for a breakdown by sub-assembly.
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Machine Specifications
ROBOT
X-Axis Z-Axis A-Axis
Home Position 0 in. 0 in. 0 deg.

+ Travel Limit 12.1 in. 24.1 in. 78 deg.
- Travel Limit -0.1 in. -0.1 in. -8 deg.
Max Speed 500 in./min 500 in./min 1800
deg./min
Low Speed 5 in./min 5 in./min 18 deg./min
Medium Speed 50 in./min 50 in./min 36 deg./min
High Speed 100 in./min 100 in./min 90 deg./min
Small Increment 1 in. 1 in. 1 deg.
Med Increment 0.1 in. 0.1 in. 0.1 deg.
Large Increment 0.01 in. 0.01 in. 0.01 deg.
BLAST SYSTEM
Shot Flow Control 10 - 100 lbs/min.
Air Pressure Control 10 - 100 PSIG

II. Machine Controls Layout and Description
This section describes the location and function of the various controls located around the
machine.
The intention of this section is to describe how PROGRESSIVE TECHNOLOGIES INC. implements
industrial standard controls and devices for the peening application. This manual does not and is not

Main Control Station
The Main Control Station is located on the side of the main electrical enclosure.

Main Control Station Buttons

POWER Pressing this push button light will turn on the control power.
ON This push button light will illuminate when the control power is
on.
POWER Pressing this push button will turn off the control power.
OFF
CYCLE Pressing this button once will put the machine in a Cycle Hold
STOP condition. The cycle can be resumed by pressing the Cycle Start
palm button. Pressing the CYCLE STOP button while in the Cycle
Hold condition will terminate the current cycle.
EMERGENCY This red push button resets the emergency stop state of the system.
STOP RESET A reset will not occur unless ALL emergency stop devices are
reset or returned to their untripped state before pressing this
button.
This push button light illuminates when the system is in E-STOP.
OVERTRAVEL This push button is used to override a robot over-travel condition
OVERRIDE so that the servo drive can be re-enabled and the robot can be
jogged off the over-travel switch. Refer to the Overtravels &
Recovery Procedure for additional information
EMERGENCY Pressing this push button will force the system into
STOP EMERGENCY STOP. Pull to allow E-stop Reset.
JOG PENDANT This selector switch is used to turn the Jog Pendant On and Off.
ENABLE

Miscellaneous Controls
BLAST This hour meter indicates the number of hours the machine blast
HOURS guns have operated.
CYCLE This light indicates that the cycle is armed and ready to index and
STATUS begin the next cycle once the current cycle has finished. This light
is located on the front of the cabinet.
CYCLE This button is used to initiate a Process Cycle or a Test Cycle or to
START restart a Process Cycle or a Test Cycle from a Cycle Hold
Condition. After clearing the light curtain, the palm button may be
pressed briefly to start a Process Cycle or a Test Cycle. If the Cycle
Start button is pressed while a Process Cycle is in progress (and not
in Cycle Hold) then the next cycle will start when the current cycle
is done (the next cycle is armed).

Blast Media Flow Control
The Blast Media Flow Control is located on the pressure pot junction box.
SHOT FLOW CONTROLLERS #1-4 (1-4MC1 FC)
The shot flow controllers measure and regulates the flow rate of steel shot to the blast
nozzle from the pressure pots. Shot flow controller 1MC1 FC (Media flow #1) and
2MC1 FC (Media flow#2) monitor and control the magnavalves for zone #1. Shot
flow controller 3MC1 FC (Media flow #3) and 4MC1 FC (Media flow#4) monitor
and control the magnavalves for zone #2.
The controllers operate in REMOTE mode and receive set point signals from the
PLC. The controllers are calibrated for 10-100 pounds/minute of steel shot.
Refer to the Electronics Incorporated Installation Manual for a description on the

setup and use of the shot flow controller.

Blast Air Pressure Control
The Blast Air Pressure Control is located on the pressure pot junction box.
AIR PRESSURE CONTROLLER (PR1PC)
The air pressure controller regulates the pressure of the air in the pressure pot and the
air delivered to the blast nozzle.
The controller operates in REMOTE mode and receives a set point signal from the
PLC. The controller is calibrated for 10-100 psig.
Refer to the Honeywell Installation Manual for a description on the setup and use of
the pressure controller.

Jog Pendant
The jog pendant allows the operator to jog & home the axes, store axes positions, and test part
programs while watching the axes move. To activate the jog pendant, place the Machine Mode
selector switch to the MAN position and then place the JOG PENDANT selector switch to the ON
position .

Manual Jog Pendant Controls
Continuous Jog The normal mode of the Jog Pendant is Continuous Jog Mode,
Mode which is indicated when the BLOCK, INCR JOG, and HOME
lights are all off.
Store Key This key is active only after preparing a program for editing on the
program edit screen. Pressing it stores the current position of the
axes. It has no function in any other mode. The HOME JOG light
will flash if a position is successfully stored.
Cycle Run Key If Jog Pendant block mode is active, pressing and holding this key
will force a Jog Pendant Single Block Cycle Start. If this button is
released a Single Block Cycle will go into Cycle Hold. This button
must be released and pressed again after a program line to execute
the next program line.
Block Mode & The Block Mode indicator illuminates to indicate that the system is
Indicator in Single Block mode. To place the machine in Block Mode, turn
Test Mode on and then press the Block Mode button. Press the
Block Mode button again to turn Single Block Mode Off. The
Block Mode Indicator will be illuminated when the machine is in
Single Block Mode.
Jog Speed Key This key allows the operator to toggle between low, medium, and
& Indicator high jog speeds in JOG mode and small, medium, and large
increment in INCR JOG mode. If either JOG or INCR. JOG mode
is selected, pressing and releasing this key will index the jog speed
/ increment to the next level. The Speed indicator displays the
currently active speed / increment as follows:
Off = Low Speed / Small Increment
Flashing = Medium Speed / Increment
Solid = High Low Speed / Large Increment

Incremental Jog Pressing this key will activate INCR. JOG mode. The indicator
& Indicator illuminates to indicate that the control is in INCR. JOG mode. If
the key is pressed again or either of the MODE SELECT or HOME
key is pressed, INCR MODE will be terminated and the indicator
will be turned off.
Home Jog Mode If any robot axes need to be referenced, pressing this key will
& Indicator activate HOME JOG mode. The HOME indicator illuminates to
indicate that the system is in Homing mode. If the key is pressed
again or the INCR. JOG key is pressed, HOME JOG mode will be
terminated and the indicator will be turned off. HOME JOG mode
is also terminated when all axes have been homed.
Jog Keys If the JOG PENDANT is currently active in CONT. JOG or INCR.
JOG, pressing any of these keys will move the selected axis in the
direction indicated. If the JOG PENDANT is in HOME mode,
pressing the minus key for the X, Z, or A axis will place that axis
into a homing sequence (pressing the positive key for the X, Z, or
A axis while it is homing will stop the homing sequence for that
axis).
E-stop Push Puts the control into E-Stop mode. All axis motion is disabled. It
Button must be pulled out, and the E-Stop must be reset by pressing the
Emergency Stop Reset pushbutton before axis motion is
re-enabled.
Motion Enable Located on the side of the jog pendant, this button must remain
Push Button pressed when any access door is open, to enable robot motion. The
proper operation of the motion enable button must be checked at
regular intervals.
Index This key is used to manually index the table. If this key is held
Table down, the table will index to the next position and stop. The key
can be briefly pressed to jog the table short distances. The table
can only be jogged if the work doors are fully open.
Jog This key is used to jog the fixture drive. If this key is held down,
Fixture the fixture drive will jog.

Touchscreen Operating Instructions
Entering and Editing
Some screens require user input. Because this is an industrial process, care must be taken to
enter the data correctly.
To enter a value, press the data entry button or field to be entered. If the field requires a
numeric entry, a numeric keypad will be displayed. Otherwise an alpha-numeric keypad will
be displayed. Enter the new value using the keypad and press the ENTER key to register the
data into the screen field.
If the new value is not accepted, a message box will appear indicating that the data was
rejected with the reason for the invalid data. After acknowledging this message, the entry
will revert back to its original value and editing can continue. This situation will occur most
often while entering data such as setpoints and alarm limits. Acceptable ranges for certain
variables have been defined within the program database to prevent erroneous and
undesirable entries which may cause harm to the machine or to the personnel running the
equipment.
Selecting Screens
Located in the upper portion of every screen is a toolbar of icons which represent every
screen within the operator interface. Clicking the desired icon will load the associated
screen. This feature provides easy access to any screen at any time.
Error Messages
During normal operation, extensive error checking takes place. When an error is detected a
corresponding message will be displayed on the screen. This message describes the error and
often recommends some corrective action. To remove an error message and resume normal
operation, press the ENTER key. If the error message persists, record the error and contact
PROGRESSIVE TECHNOLOGIES.
Resetting Alarms
When an alarm is active, the following message will be displayed at the bottom of the
screen: SYSTEM FAULT ACTIVE. To clear the alarm(s), switch to the Alarm screen by
clicking on its icon from the toolbar. Click the CLEAR ALARMS button at the far right of
the screen to reset all active alarms. Alarms may also be reset by clicking on the BELL icon
located in the status bar at the bottom of any screen.
To view additional information about an alarm, click on the HELP MESSAGE button and
then click on the alarm message. A help message will be displayed giving information on

possible causes for the alarm and items to check in order to correct the fault.

Security
The operator interface uses a security system to assure unauthorized personal do not change
process parameters. If an attempt is made to change a parameter without proper security
clearance, a warning message is displayed on the screen. Press on the message to clear to
warning.
Security Levels
Level 1: This level is less than the default level and should not be used.
Level 2: Manual control functions can be operated in manual mode. Parts can
be selected. Alarms can be reset.
Level 3: Same as level 2 privileges, plus part parameters can be modified, saved
and deleted. This level also includes the ability to change setpoints
and limits on the monitor screen.
Level 4: Level 3 privileges plus the ability to exit out of the system.
Logging Into System
To log into the system press the SECURITY LOCK icon, , located on the status bar at the
bottom of every screen or on the identification screen. The Security Menu will appear on the
screen as follows:

Select the appropriate user from the list and the corresponding picture will appear if it exists.
A password must then be entered followed by pressing the LOGIN button. If the name and
password are correct, a successful login message will appear. Press the OK button to clear
the message. NOTE: Passwords are case sensitive.
If the information is not correct, the user will be prompted with a message indicating that an
improper password was entered. Press the OK button to clear the message. Logging out of
the system is done by opening the Security Menu, and pressing the LOGOUT button. This
will remove the operator name and clock number and set the security levels to the default
level 2.

MODIFY, ADD, and DELETE buttons are only available if a user has successfully
performed a login and has the appropriate security level. These buttons allow additional
users to be added to the system as well as modifying and deleting current user information.
The following screen will appear if the MODIFY or ADD button is pressed. If a user was
selected before pressing the MODIFY button, the fields will contain the information stored
with the user. If the ADD button is pressed the fields will be empty in preparation for
creating a new user.
Adding Employee Pictures
Copy all employee picture files (name.bmp, where name is the employee’s name) to the
directory ‘C:\prims\xxxx\pictures’ (where xxxx is the machine project number). When
adding or modifying a user, enter the path name for the employee picture
‘C:\prims\xxxx\pictures\name.bmp’ or press the button to the left of the Employee Picture
text box. A browse window will appear. Select the directory in which the employee picture
is located, click the filename of the picture, and click ‘open’.

Operator Screens
Introduction Screen
Function: Provides a means of monitoring the loading of the application. As each component of
the program loads, a status message is displayed in the lower portion of the screen. If
an error occurs a message is displayed which may help correct the problem.

Identification Screen
The Identification Screen provides a means to select and display operator and part information. Part
specific information such as serial numbers and operator comments are entered on this screen. Most
of the information on this screen must be completed before the system can begin a cycle.
Operator information is recalled by logging on to the system through the Security button(the padlock
icon). Part Selection is made by clicking on the PART SELECTION icon. The part number,
descriptions, robot program, surface selections, and BMP filenames stored with each part number
will be recalled. The fields can be modified or edited by the user.

Security - Login / Logout

Clicking on this icon will display the Security Menu for the PRIMS system.
Part Selection Icon

To access part numbers, a PART SELECTION icon is placed on the Identification screen.
Clicking on the PART SELECTION icon calls the Part Selection Screen pop-up, where the
user can select, modify, and add part numbers. Selecting a part fills in the part number and
description fields with the information stored with the part.
Process Document
Many companies describe a process for each part by generating a process document. This
document will contain mounting instructions, process instructions, fixturing information,
masking information, pictures, sketches, schematics, process numbers, powder numbers, and
any other process requirements which the operator should consider when processing the
selected part. The VIEW PROCESS DOCUMENT button will display a viewer with the
process document for the selected part displayed. To exit the viewer, the operator will click
on the EXIT button at the top of the viewer.
The process document filename and path are defined on the Part Modify screen. The file to
be displayed must be stored in "Rich Text Format" which is available from Word Perfect,
Word, and most other word processors.
Surface Number Selection
The surface selection bits are sent to the PLC so the part program knows which surfaces to
process during a cycle. The operator can change the default ON/OFF setting by clicking the
check box. Surface descriptions are stored with each part number along with a bit signaling
whether the surface is on or off.
Previous Picture / Next Picture / Zoom Buttons
Any given part may have up to six associated pictures. The PREVIOUS PICTURE and
NEXT PICTURE buttons will fill the part picture area with the next or previous picture (if
available) for the current part. If no part picture is associated with the current part, a message
will be displayed. Part pictures are correlated with part numbers using the MODIFY button
on the Part Select form. Pressing the ZOOM button or clicking on the picture will show an
enlarged view of the image. To return to normal size, press the UNZOOM button or click on
the picture.

Monitor Screen
The Monitor Screen provides a means of monitoring the operation of the system parameters during
the machine process. This screen displays the status of the key machine parameters at the top of the
screen. The indicator "lights" will change color and text when the status changes. The actual values
are the instantaneous values measured by the system.
The setpoints, alarm limits (high and low), and the shutdown limits(high and low) are entered and
stored as recipe parameters. These values can be edited by clicking on them or through the Setpoint
and Limits Pop-up. To access the Setpoint and Limits Pop click/press on the setpoint field for the
value you wish to change.
The calculated variables (minimum, maximum, and average) are computed from the actual values.
The calculated variables are only updated when the machine has reached stable operating conditions.
Note: System may be different than screen shown above.

A recipe requires the entry of any or all of the following information:
Blast Parameters
1) Air Pressure Setpoint

2) Air Pressure Limits
The yellow limits are the high and low warning range
The red limits are the high and low shutdown range
3) Shot Flow Setpoint(s)
4) Shot Flow Limits
The yellow limits are the high and low warning range
The red limits are the high and low shutdown range
Blowoff Parameters
1) Blowoff Time in seconds.
Cycle Information:
Active Program
The currently selected program is displayed in the active program window. During a
cycle, the current line of the program will be highlighted.
Axis Data
The current axis data is displayed in this windows including axis positions, feedrate,
and the current surface selected.
System Information
Information for the current cycle is displayed in this window. This includes the In-
Cycle time in seconds, the Cycle Start time, and the Cycle Stop time.

Manual Mode Screen
The Manual Mode screen is used to perform manual functions.
MACHINE MODE AUTO/MAN
This selector switch is used to place the machine in either AUTO (Automatic) mode
or MAN (Manual) mode. Press the selector switch to change the mode. This selector
switch will turn yellow when the machine is in Automatic Mode. Note: It is possible
to place the machine in Auto mode Even though this selector switch still indicates
Manual. This is if Single Block Mode is Turned on with the Jog Pendant.
TEST MODE OFF/ON
When this selector switch is in the ON position Test Mode is selected and Test Cycles
not Process Cycles may be run. .

RECLAIM AUTO/ON
When this selector switch is in the AUTO position, the reclaim blower motor will
turn on when a machine cycle is started and will run for a set amount of time after the
machine cycle has ended. The reclaim blower motor will start when this selector
switch is placed in the ON position.
BLOWOFF AUTO/ON
When this selector switch is in the ON position, the part blowoffs will turn on.
Selecting the AUTO position will allow the blowoffs to be controlled by the machine
cycle.
BLAST ZONE 1 OFF/AUTO
When this selector switch is in the AUTO position, zone 1 blasting will be allowed
during a machine cycle. Placing this selector switch in the OFF position will disable
zone 1 blasting during a machine cycle.
BLAST ZONE 2 OFF/AUTO
When this selector switch is in the AUTO position, zone 2 blasting will be allowed
during a machine cycle. Placing this selector switch in the OFF position will disable
zone 2 blasting during a machine cycle.
TABLE DRIVE AUTO/RUN
When this selector switch is on the RUN position, the table drive motor will start.
This will not cause motion of the table, as the clutch is not yet engaged. In the AUTO
position, the table drive motor will turn on at the beginning of a cycle and off after a
period of inactivity after a cycle completes.
INDEX TABLE DRIVE
This push button is used to jog and index the table. If this button is held down, the
table will index to the next position and stop. The button can be briefly pressed to jog
the table short distances. The table can only be jogged if the work doors are fully
open.
JOG FIXTURE DRIVE
Press this push button to jog the fixture drives. The fixtures only rotate at the blast
and blowoff stations.

FIXTURE DRIVE JOG SPEED
Select the desire speed for jogging the fixtures by clicking on the LOW, MEDIUM, or
HIGH button.
RAISE WORK DOORS
Press and hold this push button to raise the work doors. Releasing the push button
will stop the doors from raising.
LOWER WORK DOORS
Press and hold this push button to lower the work doors. Releasing the push button
will stop the doors from lowering.
HOME AXIS
Press and release this push button to home all machine axis. If the axis are already
homed they will move to the home position.

Alarm Screen
The Alarm screen will display the active alarms in chronological order.
The Alarm System keeps a stack of up to 15 current alarms. Whenever an alarm is detected
in the system, it is time stamped and put into the Alarm Stack. During operation one failure
can cause several alarms. The time stamp will allow the user to determine the first noted
problem along with any additional alarms that happened after the initial problem.
To view additional information about an alarm, press the HELP MESSAGE button or the
QUESTION icon at the bottom of the screen and then press the alarm message. A help
message will be displayed giving information on possible causes for the alarm and items to
check to correct the fault. Press the message to close it.
To clear all active alarms, press the CLEAR ALARMS button on this screen or the BELL
icon at the bottom of every screen.

Machine I/O 1 Screen
The Machine I/O 1 screen provides a means of viewing the status of the PLC digital inputs.

Machine I/O 2 Screen
The Machine I/O 2 screen provides a means of viewing the status of the PLC digital outputs.

Pop-Up Menus and Screens
Help Message
If a value is entered which is not within the proper range, an error message will be shown.
Press on the message to return to the parameter window.
Setpoint and Limits Pop-up
This window directly correlates to the data shown on the Monitor Screen and will update
upon clicking the ACCEPT button. The user can enter data for each field as long as it lies
within the limits shown next to the corresponding field. If the Alarm Percent and/or
Shutdown Percent fields are enabled, the Alarm and/or Shutdown Limit fields will be
calculated automatically based upon the ‘Setpoint’ value.

Recipe Store Form
After the desired changes, to the parameter data, have been made, edit the recipe name and
number if needed. Otherwise, the new data will over-write the data stored under the current
recipe name and number. Clicking on the button on the STORE icon will bring up the recipe
store window.
Hit the ENTER key or click on the ‘OK’ to save the recipe under the name and number
shown in the window.
Recipe Recall Form
To recall an existing recipe click on the RECALL Button. The Recipe Recall window will be
displayed.
All of the recipe names and their corresponding numbers will appear in the list box. High-light the
desired recipe and click on the SELECT button to recall the stored recipe.

Part Selection and Maintenance

Clicking on the PART SELECTION icon, located on the Identification screen calls the Part
Selection Screen pop-up, where the user can select, modify, add, and delete part numbers.
Recalling Part Numbers
Part numbers are displayed by the list on the left side of the screen. If the part number list
becomes larger than the display area, a scroll bar will appear on the right side of the list if
more part numbers are available. By clicking on the desired part, the accompanying picture
will be displayed to aid in the selection process. With the part number high-lighted, clicking
on the SELECT icon will load all of the associated data for the desired part.
Adding Part Numbers
Clicking on the ADD icon will display the Part Information Entry Form, and prepare it for
new part entry.
Modifying Part Numbers
Highlight the part number you wish to modify and click on the MODIFY icon. The Part
Information Entry Form will be displayed with the current part number information.

Deleting Part Numbers
Highlight the part number you wish to delete and click on the DELETE icon. The part
number will be delete from the part number database. A security level of 4 is required to
delete part numbers.
Exiting Part Select Screen
Click on the EXIT icon to leave the Part Selection Screen without selecting a part number.
Search of Part Number
Use these functions to locate part numbers.

Part Information Entry Form
Use this form to enter new or edit existing part number information. Complete the form as
needed then click the UPDATE icon to save and exit. To exit without saving click the
CANCEL icon.
Part Number
The Part Number is a unique alpha-numeric name of up to 40 characters which describes the
part and is used as the key field to store and recall the Part Number Information.
Part Program
The Part Program is a unique program that is stored on the computer.
Part Description
This is a description of the part being processed. The description is divided into two
separate lines to allow for a longer entry. Each of the lines consist of 44 alphanumeric
characters. If this information is filled in when the part number is stored, it will be recalled
whenever the stored part number is recalled.
Part Picture Selection
Stored with each part number are up to six(6) picture filenames. These filenames indicate the
BMP format file which contains the pictures of the part. The part picture in slot one will be
displayed on the Identification and Part Selection screens. The remaining pictures can be
displayed by using the NEXT PICTURE and PREVIOUS PICTURE buttons on the

Identification screen. Enter the path and file name for the picture you want displayed or use
the browse button to locate the file.
Process Document Selection
Many companies describe a process for each part by generating a process document. This
document will contain mounting instructions, process instructions, fixturing information,
masking information, pictures, sketches, schematics, process numbers, and any other process
requirements which the operator should consider when processing the selected part. This
document can be any Rich Text Format document. Enter the path and file name for the
process document you want displayed or use the browse button to locate the file.
Surface Number Selection
Surface descriptions are also stored with each part number along with a bit signaling whether
the surface is on or off. The surface selection bits are sent to the PLC so the PLC knows
which surfaces to process during a cycle.
Storing Part Numbers
Once the fields are filled in, clicking the UPDATE button will refresh the database with the
new information and allow further editing. If the storage of the part number is not successful,
an error message is displayed. Press on the message and proceed to correct the problem.

CNC UTILITY
The CNC utility allows the user to work with part programs on the PC. The utility also allows part
program editing, search and replace, deletion and copying of part programs. The main screen is shown
below.
0. Main CNC Utility Components
Drive List
The drive list allows the user to select the part program location from local drives, removable
drives, or network drives. The selected drive and directory will be used for part program
upload and download.
Directory List
The directory list box shows the current directory on the PC for which part program files will be
displayed in the PC file list box. Change the directory list box to the desired location on the PC
hard drive for Part Programs.

PC File List
The PC File List displays the Part Programs located in the current directory for the selected drive.
To select a file for download, select the file with the left mouse button. To select multiple files,
select the first file; then press the SHIFT key and select a second file. All files between the two
selected files will be selected. If the operator presses the CONTROL key individual files can be
selected.
Once the files to be downloaded are selected, the user can download them by pressing the
DOWNLOAD button or by pressing the right mouse button and moving the file container to the
CNC picture or the CNC file list box.
NEW
The NEW button will open the part program editor and create a blank part program file.
Edit Part Program
The part program editor allows a user with an appropriate security level to edit part programs
stored on the PC hard drive. To edit a file, select the file to be edited with the left mouse button,
then click on the EDIT button with the left mouse button. The part program editor will activate
allowing the user to modify the part program. Be sure to save any changes before exiting the
editor.
Delete Part Program
The DELETE command button will delete the part programs currently selected in the PC File
List. Confirmation of each deletion is required. Files can only be deleted from the PC hard
drive. They cannot be deleted from the CNC program list.
Move to Floppy
This command button will copy all part programs selected in the PC File List to the A: Floppy
Disk drive.
Exit
Stop the CNC utility program and return to the calling program.

1. Editing Part Programs
The part program editor allows a user with an appropriate security level to edit part programs
stored on the PC hard drive. To edit a file, select the file to be edited with the left mouse button,
then click on the EDIT button with the left mouse button. The part program editor will activate
allowing the user to modify the part program. Be sure to save any changes before exiting the
editor. The part program editor will colorize the program as well as assist the user in modifying
the part program. The program editing window appears as follows:
New File
This button will create a blank part program for editing.
Open File
This button will query the user for a new part program file to open and edit.
Save File
This button will save the edited part program on the PC hard drive. To rename the part program
or to make a different version of the program, select the SAVE FILE AS button.

Save File As
This button will query the user for a new part program file name to save the edited part program
as on the PC hard drive. The user can utilize this method for making multiple copies of the
program.
Search
This button will display a search and replace dialog box which will allow the user to find text
strings and replace them. Multiple searches, multiple replaces and other options are available
on the dialog box. See the Search And Replace Components section later in this manual.
Exit Edit
Pressing this button will exit the part program editor and return the user to the CNC Utility form.
Renumber
The user can renumber the part program line numbers by pressing the RENUMBER button with
the left mouse button. It will utilize the selected Renumber Base Value and Renumber Increment
Value from the two pull down boxes hidden beneath the text box. To reveal these two boxes,
press the RENUMBER button with the right mouse button. The two combo lists will be
displayed. To make them disappear, repress the RENUMBER button with the right mouse
button.
To Renumber the program, click the Renumber icon with the left mouse button.
The Renumber command will change all of the part program line numbers. It will find any
GOTO statements and reassign them to the same line as it pointed to before the renumbering was
started.
Renumber Base & Increment Values
The default base value for line numbers is 1000 and the default increment value is 10. If the user
desires to change the base value or increment, they can reveal the two combo lists by pressing

the RENUMBER button with the right mouse button. The Edit Box is resized to show the base
and increment combo lists. Press the BASE VALUE COMBO button to show a list of possible
base values. The user can select from the list or type in a different base value. Press the
RENUMBER button with the right mouse button to resize the text box to it's default size. If the
RENUMBER button is pressed with the left mouse button, the new base and increment values
will be used to renumber the program.
Text Box
This control displays the selected part program. It has many built in features for assisting the
user in editing the displayed text.
The user can add text, delete text, and copy text using normal key strokes. Data can be written
to the clipboard using the Control-C or the right mouse button. Data can be pasted from the
keyboard using Control-V or the right mouse button.
The text box is color coordinated:
All M-Codes are displayed in red.
All Comments are displayed in green.
All line number are displayed in blue.
If the program is longer than one page, a vertical scroll bar will be displayed for scrolling
through the program. The normal Page-Up, Page-Down keys can also be used. Control-
Page-Up will move to the start of the program. Control-Page-Down will move to the end
of the program. Lines can be inserted by pressing the ENTER key.
Programming Aids
These buttons on the right aid in programming commonly used statements in a part program.
Clicking one of these buttons will place the corresponding m-code, motion, process parameters,
program command, or miscellaneous function at the prompt in the text box.
The special buttons are used for teach programming. To teach a part, select the desired teach
mode and/or option(s). Then start out with the part mounted on the spindle as it would be during
the desired process cycle. The gun manipulator is then jogged into the first position, and the
position is stored using the digitizing function on the jog pendant. The manipulator is then
jogged to the second position, and so on. As a result the gun can be positioned anywhere without
worrying about axis coordinates. After the positions are stored, the program editor is used to
insert things like G-Codes, M-Codes, Feedrates and comments.
Additional special buttons are included for using constant surface velocity and programming
using tool point coordinates which are described after the Search and Replace Components.

Editing Programming Aids
Part programming aid buttons may be added/modifed/removed by the user by clcking on the
EDIT BUTTONS button. Note that the buttons in the special category can not be modified. The
EDIT BUTTONS button will turn yellow to indicate that the system is in edit mode. Clicking
the button again will return the system to normal mode.
Adding A Button
During edit mode, click on an existing button in the desired group for the new button. The
screen below will appear.
Click on the NEW BUTTON button and the form will be cleared for entering information on a
new button. See Editing A Button for details on how to fill out this form.
Deleting A Button
During edit mode, click on the button to be deleted, then click on the DELETE BUTTON button.
Editing A Button
Enter the desired text for the Button Label and Tool Tip text. Select the Variable Set for the
button. See the Button Variables topic later in this manual for learning how to use variables.
Select the Group that the button should appear in on the Part Program Editor screen. Enter any
code that should be inserted into the part program when the button is pressed into the Code text
area. If a keyboard is not available, click on the EDIT CODE button to display a graphical
keyboard for entering the code. See the Entering Insert Code section later in this manual. When
finished, click ACCEPT to save the new button or click CANCEL to return to the Part Program
Editor without saving any changes.

Button Variables
Entering Button Variables for a button causes a screen to appear when a part programing aide
button is clicked for entering values to be inserted into the part program.
After clicking the ACCEPT button the following code will be inserted into the part program.
G90G01X10Z10A10B10F50(MOVE ABSOLUTE)
Editing Button Variables
While in edit mode click on the button to be edited and then click on the EDIT VARIABLES
button. The following screen will appear.
Button variable sets may be used for multiple buttons. For example, the screen abov e shows

the Move_Robot set of variables. It is used for the buttons Move Absolute and Move
Incremental. Use the NEW VARIABLE button to create a new set of button variables. Click
the DELETE SET button to delete the current variable set. Be certain that the variable set is
not used by any buttons. Use the NEW VARIABLE and DELETE VARIABLE buttons to
add or remove variables to the set. The Variable Label field is the text that will be displayed
to the user when clicking on a button (see the Part Program Dialog screen shot above). The
Number field is used to identify the variable when entering the Insert Code for the part
program.
Editing Insert Code
The Code text box contains the insert code that will be inserted into the part program when
the user clicks on the button. The insert code can be static text such as:
G00X30Z54.375A0B0C0 (MOVE HOME)
The insert code may also include variables that are entered by the user such as:
G90G01X10Z10A10B10F50(MOVE ABSOLUTE)
Once a variable set is selected for a button, such as the one shown above in the Editing
Button Variables section, they can be used in the insert code as follows:
G90G01X%1%Z%2%A%3%B%4%F%5%(MOVE ABSOLUTE)
The label X Axis: referring to button variable 1 is represented in the Insert Code as %1%, Y
Axis: variable 2 is represented as %2%, and so on for all of the entered variables. When
values are entered by the user, the %n% code will be replaced with the appropriate value.
2. Search and Replace Components
Cancel
This button will exit the Search and Replace Dialog box and return the user to the Edit form.
Replace All
This button will search the complete part program and replace all instances of the Find String

with the Replace String. No prompts will be displayed. There is no UNDO for this
command.
Find Again
This button will repeat the previous find command. It will find each instance of the Find
String until it reaches the end of the part program. Then a "Search String Not Found"
message will be displayed.
Replace
This button will replace the currently found string with the replacement string. It will not
repeat the process. There is no UNDO for this command.
Find
The FIND button will locate the Find String within the part program from the current cursor
position to the end of the part program. If the string is not found, a "String Not Found"
message will be displayed.
Whole Word Only
This rarely used option is supposed to only find whole words in the part program which
match the Find String. Thus if you were searching for the word "Jack" in the part program it
would find it in the line "Jack is a boy" but would not find it in "A jackrabbit start".
Case Sensitive
If the user checks this box, the find and replace functions will only match the find strings if
they are exact copies of the Find String with regard to case. The default is for the CASE
SENSITIVITY button to be turned off.
Find String
This string is the pattern which is searched for using the find and replace command buttons.
Replace With
If the user selects the REPLACE button, the program will replace the highlighted string with
the text in the replacement with box. If the user selects replace-all, all occurrences of the
find string in the part program from the cursor position to the end of the program will be
replaced with the replacement string.

III. Machine Operation
The intention of this manual is to describe how PROGRESSIVE TECHNOLOGIES INC. implements
industry standard controls and devices for the peening application. This manual does not and is not
Safety
Operating any automatic equipment can be hazardous. The best way to reduced hazards is to
know the equipment and develop safe operating habits.
As a minimum the operator should:
C Read and understand all operator manuals.

C Check that all personnel are clear of the robot and peripheral equipment before
releasing the machine E-Stops.
C Check that all personnel are clear of the robot and peripheral equipment before
moving the robot in manual mode or starting an auto cycle of any kind.
C Never place himself between the robot and an immovable object.
C Never remove or disable a safety device or operate a machine with a safety
device removed or disabled.
C Never operate a machine in need of repair.

Machine Power Up and Shut Down
Machine Start Up
1. Switch the main electrical enclosure disconnect to the "ON" position.
2. Open the main air supply valve.
3. Turn on the PRIMS PC
4. Push the CONTROL POWER ON push button on the Main Control Station.
5. Verify that all personnel are clear of robot travel and that all E-stop controls have
been reset.
6. Push the EMERGENCY STOP RESET push button on the operator station to
perform the E-Stop reset.
7. Verify the light on the EMERGENCY STOP RESET push button has turned off and
the E-STOP message is no longer displayed at the bottom of the screen.
8. Press the Clear Alarms Button or the ‘?’ icon at the bottom of every screen to clear
any alarms.
9. Home gun mover axes.

Machine Shut Down
1. Press one of the Emergency Stop push buttons to disable power to the robot servo
drives. This should be done whenever the machine is not in use.
2. Press the CONTROL POWER OFF push button on the Main Control Station.
3. Exit PRIMS and shut down the computer.
4. Switch the main electrical enclosure disconnect to the "OFF" position.
5. Close the main air supply valve to relieve the air from the system.
Machine Lockout
Follow all Local Lock Out Tag Out procedures. The following is a list of items to be turned off and
locked out prior to service.
1. Shut off the main air supply shutoff valve and then lock-out and tag-out.
2. Turn off the main electrical enclosure disconnect and then lock-out and tag-out.

E-Stop Controls and Recovery
An E-Stop condition can be generated in one of three ways.
The first way is by actuating one of the manual E-Stop controls. If at any time the machine does
unpredictable action or operation that is hazardous to the machine or operator, use these controls to
immediately stop all machine operations.
The hand actuated E-Stop controls are located in the following locations:
C Control Station located on the side of the main electrical enclosure.

C Jog Pendant
C Control Station 1CS located on the rear of the blast cabinet.
An E-Stop condition can be generated by pressing any one of these E-Stop push buttons. The E-Stop
condition is reset by pulling the E-Stop push button out and then pushing the EMERGENCY STOP
RESET push button.
The second way by which an E-Stop can occur is by the robot moving into an overtravel limit switch.
Typically, this E-Stop condition will only occur if the robot has not been homed, and as a result the
software overtravels limits are not active. Refer to the next section, Overtravels and Recovery, for
resetting out of this type of E-Stop condition.
The third way a system E-Stop can occur is by the machine logic inducing the condition. The E-Stop
condition such as this is usually caused by encoder following error exceeding the limit entered into
the control by the OEM. Probable causes for excessive following error include: faulty servo drive,
excessive friction in the mechanical drive system, bad motor or encoder.

Overtravels and Recovery
If during the course of operation, the physical limits of the robot's travel are exceeded, an axis
overtravel switch will be tripped. This will cause an E-Stop condition, thus halting all machine
motion. To assist the operator in identifying the problem, a message will appear on the screen
indicating the axis and direction of the overtravel.
To recover from an overtravel condition:
1. Prepare the robot for jogging with the jog pendant.
2. While pressing and holding the OVERTRAVEL OVERRIDE push button, press the
EMERGENCY STOP RESET push button to perform an E-Stop reset.
3. While continuing to hold the OVERTRAVEL OVERRIDE push button, jog the
overtraveled axis in the opposite direction of the overtravel.
4. Release the override push button.
5. Press the Clear Alarms button or the question mark icon to clear the Overtravel
alarm(s).
6. If the overtravel was caused by any other reason than the robot not being homed yet,
investigate the cause of the overtravel before continuing to operate the machine.

Operation in Manual Mode ( Jogging and Homing)
This section explains how to manually move the machine axes for such purposes as homing,
process/part set up, programming, fault recovery, maintenance and several other reasons. Manual
operation can be controlled from the Jog Pendant.
To Activate the Jog Pendant
1. Place the Machine Mode selector switch in the MAN position.
2. Place the Jog Pendant Enable selector switch in the ON position..
Homing Axes
Follow this procedure to home the axes with the pendant:
1. Verify that all personnel are clear of the robot.
2. Select home jog by pushing the HOME button on the pendant. Verify this by
checking that the light above HOME is illuminated.
3. If any access door is open, press and hold the motion enable push button or
close the access doors.
10. Press the axis -jog button, and verify that the axis is moving in the negative
direction. The axis will automatically home to the point that defines the
absolute machine zero for the axis.
Note: Press the axis positive jog button to abort homing for the axis.
5. Repeat step 4 for each of the remaining axes.

Jogging Axes in Continuous
Follow this procedure to jog the axes with the pendant:
1. Select the jog speed desired (refer to jog pendant description for jog speeds).
2. Verify that all personnel are clear of the axes.
4. To jog the axis, press the + or the - key to move the axis in the direction
desired. Be sure to watch the robot while jogging, to avoid hitting anything.
Jogging Axes in Incremental
Follow this procedure to jog the axes with the pendant:
1. Select incremental mode and the jog increment desired (refer to jog pendant
description for jog increments).
2. Verify that all personnel are clear of the axes.
4. To jog the axis, press the + or the - key to move the axis in the direction
desired. Be sure to watch the robot while jogging, to avoid hitting anything.

Operation in Auto Mode (Running a Cycle)
With the start-up procedure complete and all axes homed once, the operator can run an AUTO cycle.
The following procedure is used:
1. Make certain the following conditions have been met.
C Machine is out of E-STOP.

C The service doors are closed.
C The work doors are closed.
C Test Mode is selected off.
C All desired blast zones are enabled.
C The robot axes have been homed.
C The Machine is in AUTO mode.
C Reset all fault conditions.
2. Verify the following items on the PRIMS system:
C Verify all operator information is complete and accurate.

C Verify the correct part and recipe has been chosen.
C Verify all surfaces to be processed have been chosen.
C Verify the READY FOR CYCLE message is being displayed at the
bottom of the screen.
4. Load part on fixture.
5. To start the cycle, the operator must press the CYCLE START palm button.
When the cycle is started, the reclaim will start, the work doors will open and the table will index to
the next position. The work doors will then close. The PC/PLC will then run the selected part
program.
A cycle that is in progress will be placed in a Cycle Hold condition if a cycle hold fault condition
occurs during a cycle. During a Cycle Hold Condition, the robot will stop and the blast guns will
turn off. It is also possible to enter the Cycle Hold condition by simply pressing the CYCLE STOP
push button while a cycle is in progress. A cycle will be terminated if the CYCLE STOP push
button is pressed while the machine is in a Cycle Hold condition. To put the machine back in cycle
from the Cycle Hold condition, clear any faults and then press the CYCLE START push button.

Table
The table is designed to rotate parts into each of the three stations. The parts are first placed in the
loading and unloading station. Next the table rotates them into the blasting station. At the start of
the next cycle, the parts are rotated into the blowoff station. The cycle following that will rotate the
parts back to the loading and unloading station to be removed.
Running the Table Drive Motor
Place the TABLE DRIVE selector in the ON position, located on the Manual Mode screen, to
run the table drive motor. If the TABLE DRIVE selector switch is in the AUTO position
then the table drive motor will start during a cycle and turn off after the cycle (after a preset
time interval has expired).
Jogging the Table
The table will index automatically during a cycle.
The table can also be jogged manually either from the operator screen or from the jog
pendant. To Jog the table from the screen press the INDEX TABLE push button located on
the Manual Mode screen. To Jog the table from the Jog Pendant enable the Jog Pendant and
press the INDEX TABLE DRIVE button. If the push button is held down, the table will
index to the next position. The button can be briefly pressed to jog the table short distances.
The following conditions must be met before the table can be manually jogged.
• The control power must be on.

• The machine must not be in Emergency Stop.
• The machine must be in manual mode.
• The work doors are both in the fully raised position.
• The light curtain must be clear.
• The table drive motor must be running.
• The service doors must be closed or the Motion Enable push button on the side
of the Jog Pendant must be pressed.

Fixtures
The fixtures are designed to rotate parts about their vertical centerline during the blasting and
blowoff process.
Rotating the Fixtures
The fixtures will rotate automatically during a cycle. They will start automatically when the
table indexes to start a cycle and will remain running. They will automatically turn off if
there is an extended period during which there are no cycles.
The fixtures can also be jogged manually either from the operator screen or from the jog
pendant. To Jog the fixtures from the screen press the JOG FIXTURE DRIVE push button,
located on the Manual Mode screen. To Jog the fixtures from the Jog Pendant enable the Jog
Pendant and press the JOG FIXTURE button.
The following conditions must be met before the fixtures can be manually jogged.
• The control power must be on.

• The machine must not be in Emergency Stop.
• The machine must be in manual mode.
• The work doors are both closed or the light curtain is clear.
• The service doors must be closed or the Motion Enable push button on the side
of the Jog Pendant must be pressed.

Miscellaneous Operations
Dust House
The dust house consists of a blower, filter bank, and solenoids used to clean the filters. The dust
house blower generates the high velocity air flow to draw the dusty air and shot through the reclaim
system. Dust is then separated from the air by the bank of filters. The filters are cleaned
automatically by a sequential air purge, causing the dust to drop into hopper located below the filters.
A slidegate at the bottom of the hopper can be manually opened to drop the dust into a trash bucket.
Sweco Unit
The Sweco media classifying unit is located below the cyclone. Media classifying units act to
further sort the media and large debris which the cyclone has passed. It does this by using vibrating
filter screens. The Sweco unit consist of a set of screens and a motor which shakes the screens. The
screen with the largest opening is installed highest; this removes large debris. The second screen is
sized to allow small debris such as dust and broken shot to pass through while carrying the proper
size shot back to the pressure pot.
Media Adder
The media adder system is used to store and add shot to the reclaim system as needed. This is
accomplished by a solenoid actuated diaphragm valve located on the lower point of the adder which
allows shot to fall into the reclaim tube when the solenoid is energized. The media adder solenoid
will be turned on for a predefined time period if the upper media probe in the lower pressure pot is
not covered after a media transfer from the upper to the lower pot has taken place.

Pressure Pots
This machine has a two stage pressure pot system. The pressure pots are designed to allow a
continuous flow of media into a pressurized blast system. Two pots are required, the lower one to
which the blast hoses are connected is maintained at the blast pressure selected by the operator, while
the upper pot alternates between depressurized during media loading and pressurized during media
transfer to the lower pot.
The Pressure pot can cycle whenever the reclaim is running (unless a blown fuse fault has occurred).
The cycle begins when the lower media probe in that pressure pot becomes uncovered. The
sequence of operation is:
1. Seal upper pot

2. Pressurize upper pot
3. Open media valve between pots
4. Wait a preset time period for media transfer
5. Close media valve between pots
6. Ventilate upper pot to dust house
7. Open upper media valve
After the media transfer time (step 4), the media probes are checked.
If the lower probe in the pressure pot is uncovered, a PRESSURE POT LOW MEDIA FAULT
occurs which prevents the next auto cycle.
Pressure Control
The pressure control system consists of an automatic PID pressure controller and a controlled
pressure regulator. An analog signal sent from the PLC commands the pressure level.
Blast Control
The Blast control system consists of an air pilot valve for controlling blast air, a pinch valve for
controlling shot, and a magnetic control valve (Magnavalves) which through an automatic PID
controller allows precision control of shot flow at the desired pound/minute rate. Each gun is
controlled by this system of components. An analog signal sent from the PLC commands the flow
level for all four guns while the blast control is configured to control a set of two guns which each
corresponds to one of the two blast stations.

Machine Faults and Messages
PLC generated and PRIMS generated faults are put into three categories:
Level 1: E-Stop Fault is the most severe fault. All motion is stopped and drives disabled on
E-Stop. A Machine Cycle cannot be resumed from an E-Stop condition.
Level 2: Cycle Abort Fault stops and terminates the current Machine Cycle.
Level 3: Cycle Hold Fault stops the current Machine Cycle although in some cases the cycle
may be resumed after the problem is corrected.
Level 4: Inhibit Cycle Fault does not affect the current Machine Cycle but prevents any
subsequent cycles from being started.
Messages are put into two categories:
Level 1: Warning Messages alert the operator of conditions that are abnormal but do not
affect the Machine Cycle.
Level 2: Information Messages inform the operator of normal conditions which may be
helpful to know.

Fault Shutdowns & Recovery
The cycle may be halted before completion if one of the following occurs:
1. A fault is detected.
2. The cycle stop push button is pressed.
3. An emergency stop condition occurs.
A cycle can not be continued if an Emergency Stop or if a Cycle Abort Fault occurs during a cycle.
Some faults that cause a Cycle Hold to occur also make it impossible to continue the current cycle.
In these cases, the operator should make note of where the cycle stopped in the part program for
future use in finishing that particular part. For other faults where it is okay to reset the fault and
continue the cycle after a cycle hold, the reason for the fault occurring must be corrected before
continuing the cycle.
If the cycle had stopped due to a fault, the machine fault message will be displayed at the bottom of
every screen, however only four messages can be displayed at a time. Up to twelve fault messages
can be displayed on the Alarm Screen. Help messages are available for all faults.
Once the fault has been corrected, press the question mark icon or the Clear Alarms button. The
fault message should then disappear from the screen. If the operators security level is not high
enough, the operator must inform their supervisor, and the supervisor will be responsible for clearing
the fault.
Once the fault has been cleared and reset, the cycle can sometimes be resumed by pressing the
CYCLE START palm button.

Information Messages
BLAST ZONE NOT SELECTED

This message will appear if Test Mode is not selected and the Blast Zone 1 Off/Auto
and the Blast Zone 2 Off/Auto selector switches are both in the Off position.
BLOWOFF SELECTOR SWITCH NOT IN AUTO MODE

This message will appear if the machine is in Auto mode and the Blowoff Auto/On
selector switch is in the On Position.
CONTROL POWER OFF

This message indicates that the Control Power is off.
CYCLE HOLD
This message will appear when a Process Cycle is in Cycle Hold.
CYCLE HOLD (SINGLE BLOCK)

This message will appear when a Single Block Cycle is in Cycle Hold.
CYCLE HOLD (TEST CYCLE)

This message will appear when a Test Cycle is in Cycle Hold.
HOME ALL AXES

This message will appear when one or more of the axes need to be homed.
IN CYCLE
This message will appear when the machine is in a process cycle and is not in cycle
hold.
JOG PENDANT ENABLED

This indicates that the jog pendant has been enabled.
NOT IN AUTO MODE

This indicates that the machine is not in Auto Mode. The machine must be in Auto
Mode before Process Cycles can be run.
OPERATOR INFORMATION NOT COMPLETE

A part must be selected prior to starting a machine cycle.
READY FOR CYCLE

This message will appear when the conditions required to run a Process
Cycle have been met.

READY FOR SINGLE BLOCK CYCLE

This message will appear when the conditions required to run a Single Block
READY FOR TEST CYCLE

This message will appear when the conditions required to run a Test
SERVICE DOOR(S) NOT CLOSED

This message indicates that one or more of the service doors are not closed.
SINGLE BLOCK CYCLE IN PROGRESS

This message will appear when the machine is in a single block cycle and is not in
cycle hold.
SYSTEM FAULT ACTIVE

This message will appear when the machine is in a single block cycle and is not in
cycle hold.
SYSTEM IN EMERGENCY STOP

This message will be displayed when the machine is in Emergency Stop.
TABLE NOT INDEXED

This message indicates that the table is not rotated to the indexed position limit
switch.
TEST CYCLE IN PROGRESS

This message will appear when the machine is in a Test Cycle and is not in cycle
hold.
WARNING PROCESS LIMIT EXCEEDED

This message will appear when the system detected a process parameter outside the
alarm limits but not outside the shutdown limits.
WORK DOORS NOT CLOSED

This message will appear if a cycle is not in progress and the work doors are open.

IV. Programming
The machine performs process operations by executing a series of commands that make up a part
program. These commands are interpreted by the controller to move the machine axes and activate
peripheral equipment.
Part programs are very valuable. Develop a good program management system. Keep back-up files
and have hard copy listings of your programs stored in a safe place.

Program Structure
Program Names
Programs are stored in the memory of the controller and are named by numbers that can range from 1
to 999999. A more meaningful part name can be entered as a comment line at the top of the
program.
Sequence Numbers
Each line in a part program can be assigned a sequence number to distinguish one line from another.
Sequence numbers begin with an N followed by a one to five digit numeric value.
Sequence numbers can be assigned at random to specific lines or to all lines if desired. The control
has a feature that will assign and/or renumber all the program lines.
Comment Lines
Comments are be very useful to operators and to the developer of the program. Comments can be
used to describe the details of a program.

Motion Commands
Position Command
A position command is made up of an axis name followed by the desired axis positional data for
either an absolute or incremental move. The axis name is a letter such as X, Y, or Z, for linear axes
and A, B, or C for rotary axes.
Absolute/Incremental Mode
Axis moves in a part program may be specified in absolute mode or in incremental mode. A G90 on
a line by itself or placed before a motion commend will place the machine in absolute mode. All
axis moves after this code in the program will move to the position specified. A G91 specifies
incremental mode. After a G91 occurs all moves specified will be incremental moves with respect to
the current position. At the start of a part program, the machine is in absolute mode by default.
Feedrate
The feedrate command accompanies position commands to specify the speed at which the axes
should move. The command consists of an F followed by the numeric value of the desired speed.
The numeric value defines the vector speed of the programmed axes, which means the speed along
the path of the tool.
Example Motion Commands
The following program lines are some examples of motion commands:
.
.
G90 (Absolute Mode)
X10Z20F100 (Move from current position to position X10,Z20)
X20Z30F100 (Move from position X10,Z20 to position X20,Z30)
G91 (Incremental Mode)
X2Z3F100 (Move from position X20,Z30 to position X22,Z33)
X-4Z-6F100 (Move from position X22,Z33 to position X18,Z27)
.
.

M-Codes (Miscellaneous Functions)
Miscellaneous function codes (M-Codes) initiate machine functions and establish operating
conditions. There are several standard M-Codes that are well established for general use.
PROGRESSIVE TECHNOLOGIES also has established codes that are used to enable process
specific commands and actions. Some M-Codes are modal, that is once programmed, they stay in
effect until canceled by another M-Code in their modal groups. Not all M-Codes may apply for this
specific application.
Note: Only (1) ONE machine specific M-code can be placed on a program line.
CODE FUNCTION
M02 End of Program Stop
M03 Spindle Clockwise

M04 Spindle Counter-Clockwise
M05 Spindle Stop
M45 Write Process Record
M50 All Blast Media On

M51 Zone #1 Blast Media On
M52 Zone #2 Blast Media On
M60 All Blast Media Off

M61 Zone #1 Blast Media Off
M62 Zone #2 Blast Media Off
Notes: To allow sufficient time for media to begin flowing, it is recommended that media M-
codes be followed with a three-second delay (G04X3). This will ensure that a stable
stream of media is flowing from the nozzle before the robot begins moving.

Dwells and Loops
Dwell Command
The Dwell command is used in a program to delay execution of subsequent program lines. The most
common reason for welling is to allow peripheral equipment time to start or stop after being called to
do so.
The Dwell command is comprised of the standard “G04" plus the “X” argument which denote the
time in seconds of the dwell. For example, a programmed block like G04X5 would cause program
execution to dwell for 5 seconds.
Loop Command
The Loop command allows repeat execution of one or more lines in a program. The Loop command
is actually made up of two program lines. The LOOPxx command precedes the program lines that
are to be repeated, where xx equal the number of time the lines are to be repeated. The ENDLOOP
command is placed after the last program line to be repeated.
Example:
In this example the four lines between the LOOP and ENDLOOP commands will be
executed five times.
.
.
LOOP5 (Execute the following line 5 times)
X10Z20F100 (Move to upper process position)
X20Z30F100 (Move to mid process position)
G04X5 (Delay for 5 seconds)
X25Z35F100 (Move to lower process position)
ENDLOOP
.
.

Recipe Recall
The process setpoints, alarm limits, and shutdown limits are stored in the memory of the controller
under a recipes named by numbers that can range from 1 to 32000. The Recipe command is used in
the part program to select the desired recipe. The Recipe command is the word RECIPE followed by
the number of the desired recipe.
Example:
In this example recipe 5 will be requested.
.
.
RECIPE5 (Select Recipe 5)
.
.

Surface Selection
Description of Surface Select
Surface Selection is a method used to create a flexible part program. The most common
implementation of surface select is to write a part program that divides a large part into small
sections which can be processed when necessary and skipped when desired. Program sections are
normally designed to cover a detail or feature of the part such as a groove, a land, or a segment. In
practice, if a single detail of a large part needs to be reprocessed, that section of program can be
turned on and the rest of the program skipped saving process time.
Operation of Surface Select
Surfaces are selected on the Identification screen, from check boxes. These check boxes correspond
to surfaces 0 to 11. If a surface is turned off then that portion of the program will not be executed.
The rough outline of a part program would look like this:

(EXAMPLE SURFACE SELECT PROGRAM FOR PART X)
Z1F50
(PROCESS SURFACE #0)
SURFACE0
>> ENTER SURFACE PROGRAM LINES HERE <<
M45 (SAVE RECORD)
ENDSURFACE
Z1F50
(COMMENT)
(PROCESS SURFACE #1)
SURFACE1
>> ENTER SURFACE PROGRAM LINES HERE <<
M45 (SAVE RECORD)
ENDSURFACE
(COMMENT)
Z1F50
X0Z0A0F50
M02
Special Considerations for Surface Select
Compare the blocks between the surfaces. These blocks reference the same position for the Z Axis.
This must be done to ensure that if Surface 0 is skipped the gun will be in the proper place to move
to Surface 1. This scenario is repeated between every surface.
IMPORTANT: If the part geometry is severe and the above practice is not followed, collisions
between the gun and part will occur when surfaces are skipped.

Programming Using Teach Mode
The part program tells the robot what axis to move, when to turn on the blast air, media, and etc.
You can create and edit these part programs in either of two ways, off-line programming or Teach
programming.
Teach programming is a powerful tool that can save hours of programming time. To teach a part, you
start out with the part mounted as it would be during the desired process cycle. The machine axes
are then jogged into the first process position, and the position is stored using the teach function.
The axes is then jogged to the second process position, and so on. As a result you can position the
gun where you want without worrying about axis coordinates. After the positions are stored, the
program editor is used to insert G-Codes, M-Codes, Feedrates and comments as necessary.
Teaching to Program Editor
1. Prepare for Jogging from the jog pendant.
2. Prepare PRIMS to select a program for editing.
3. Select or create a program to receive new information.
4. Position cursor at the point where input is needed. Click the Teach Absolute or the
Teach Incremental button on the Program Editor screen.
5. Position the machine axes at the point to be recorded.
6. Press the store key on the Jog Pendant. The current axis positions are recorded to the
part program.
7. Repeat steps 4 - 6 as required.
8. When finished teaching points, be sure to save the program.

Program Testing
Programs can be tested with the use of two different methods. These method are:
1. Test Mode
2. Single Block
Test Mode: Activate Test Mode by placing the Test Mode selector switch on the Manual Mode
screen in the ON position. During Test Mode Program execution, the blast media
will not turn on when commanded to do so. Test Mode is used to verify a program
without the blast on. A Test Cycle can be run with the service doors open if the
Motion Enable pushbutton on the side of the Jog Pendant is pressed and held.
WARNING: EXTREME CAUTION MUST BE USED WHEN USING TEST
MODE. THE ROBOT CAN OPERATE AT FULL SPEED WITH
THE DOORS OPEN.
Single Block: When this mode is activated, the control will execute a single program block each
time the Cycle Start button on the Jog Pendant is pressed. If the Cycle Start button on
the Jog Pendant is released during a Single Block Cycle the machine will go into
Cycle Hold. After a program line is done executing the machine will go into Cycle
Hold. The Cycle Start button on the Jog Pendant must be released and pressed again
in order for the next line of the program to begin executing. Test Mode must be ON in
order for Single Block to be used. A Single Block can be run with the service doors
open if the Motion Enable pushbutton on the side of the Jog Pendant is pressed and
held.
WARNING: EXTREME CAUTION MUST BE USED WHEN USING SINGLE
BLOCK MODE. THE ROBOT CAN OPERATE AT FULL SPEED
WITH THE DOORS OPEN.

Running a Test Mode Cycle
WARNING: EXTREME CAUTION MUST BE USED WHEN USING TEST MODE. THE
ROBOT CAN OPERATE AT FULL SPEED WITH THE DOORS OPEN.
Running a Test Cycle is similar to a Process Cycle except the blast media and blast air for the blast
guns can not be turned on. However, remote setpoints continue to operate for testing purposes. The
service doors can also be open during a TEST cycle (*). Test mode is provided for verifying task
programs and for maintenance. With the MACHINE POWER UP procedure complete and the
ROBOT is HOMED, a TEST cycle can be run. The following procedure is used.
Test mode is provided for demonstrating and verifying task programs.
C Auto Mode is selected.

C Test Mode is selected.
C The Jog Pendant is not enabled.
C A part program is selected and the required fields are filled in on the
operator screen.
C The work door is closed.
C The service doors are closed or the Motion Enable pushbutton on the
side of the Jog Pendant is held in.
C All fault conditions are RESET.
2. The display should now display the "READY FOR TEST CYCLE" message.
3. To start the cycle the operator must press the CYCLE START palm button.
4. To place the test cycle in cycle hold press the CYCLE STOP push button.
* To run a test cycle with the work door open the MOTION ENABLE push button located on
the side of the jog pendant must be pressed during the entire time the cycle is in progress.

Running a Single Block Cycle
WARNING: EXTREME CAUTION MUST BE USED WHEN RUNNING A SINGLE BLOCK

CYCLE. THE ROBOT CAN OPERATE AT FULL SPEED WITH THE DOORS
OPEN.
When this mode is activated, the control will execute a single program block each time the Cycle
Start button on the Jog Pendant is pressed. If the Cycle Start button on the Jog Pendant is released
during a Single Block Cycle the machine will go into Cycle Hold. After a program line is done
executing the machine will go into Cycle Hold. The Cycle Start button on the Jog Pendant must be
released and pressed again in order for the next line of the program to begin executing. Test Mode
must be ON in order for Single Block to be used. A Single Block can be run with the service doors
open if the Motion Enable pushbutton on the side of the Jog Pendant is pressed and held. Remote
setpoints continue to operate for testing purposes. Single Block mode is provided for verifying task
programs and for maintenance. With the MACHINE POWER UP procedure complete and the
ROBOT is HOMED, a Single Block cycle can be run. The following procedure is used.
C Auto Mode is selected.

C Test Mode is selected.
C The Jog Pendant is enabled.
C A part program is selected and the required fields are filled in on the
operator screen.
C The work door is closed.
C The service doors are closed or the Motion Enable pushbutton on the
side of the Jog Pendant is held in.
C All fault conditions are RESET.
C Press the Block Mode button on the Jog Pendant so that the Block
Mode light is illuminated on the Jog Pendant.
2. The display should now display the "READY FOR SINGLE BLOCK CYCLE"
message.
3. To start the cycle the operator must press the Cycle Run button on the Jog Pendant.
palm button.
4. To place the Single Block Cycle in Cycle Hold release the Cycle Run button on the
Jog Pendant.

Sample Programs
Below is a simple task program showing the suggested use of the programming commands. For
clarity the sequence numbers have been omitted.
Example Program
(PROGRAM 2888)
(CUSTOMER PART NUMBER 123456789)
(USE FIXTURE #3)
RECIPE2 (SELECT RECIPE 2)
LOOP2 (PERFORM PROCESS TWICE)
M51 (TURN BLAST ZONE 1 ON)
G04X3 (DWELL)
G90X5Z6A23F100 (MOVE ABSOLUTE)
M61 (TURN BLAST ZONE 1 OFF)
G04X3 (DWELL)
M52 (TURN BLAST ZONE 2 ON)
G04X3 (DWELL)
G90X8Z10A45F100 (MOVE ABSOLUTE)
M62 (TURN BLAST ZONE 2 OFF)
G04X3 (DWELL)
ENDLOOP
X0Z0A0F100 (MOVE HOME)
M02

Appendix A: PC Backup and Restore
Making a backup image of the PC’s harddrive

(Requires multiple CD-R discs)
1. Place a blank CD-R in the CD-RW Drive.

2. Start Norton Ghost. Select Backup under the Basic activities, then click next.
3. Verify that the entire PC hard drive is selected as the source (the left side of the screen is
highlighted). For the destination, select Recordable CD or DVD, then click next.
4. Click Advanced Settings, click on the CD Drivers tab, then place a check in the Assign Drive
Letters box and click OK.
5. Click next, next, continue, then Run Now.
6. Click OK for the computer to reboot and start the backup process.
7. Change to the next CD when prompted and label the CDs appropriately.
8. When the backup is complete the computer will automatically re-boot into windows.
9. After windows is up, run Ghost. Check the log. An item should show the time and date of
the backup and whether it was a success or failure.
10. It is recommended to test the validity of the ghost image made. Place the first CD-R of the
backup in the CD-RW drive and shutdown the PC.
11. Turn on the PC. A message should be displayed “Press any key to boot from CD/DVD.”
Press a key and the PC will boot off the CD and start the Ghost application.
12. Select Local, then Check-image file. Select @CD-R1 as the source which should show the
ghost image. Selecting open will initiate the verification process.
13. Swap discs as prompted.
14. When the verification is done, a message indicating that the image file passed will be
displayed.
15. The log file in Ghost will also be updated with the status of the verification.
16. Remove the CD-R from the drive and reboot the computer.
Restoring a backup image of the PC’s harddrive

1. Insert Ghost 2003 backup disc into the DVD/CD drive.
2. Turn on the PC. As it boots up a message should be displayed “Press any key to boot from
CD/DVD.” – Press any key.
3. Once Ghost is running at the initial prompt type Enter for Ok.
4. Select Local, Disk, From Image.
5. From the pull down menu select @CD-R1 which should be the internal CDRW/DVD
6. Select OK to start the restore process.
7. When restoration is complete, Remove the CD/DVD and reboot the computer.
Booting from a CD/DVD

If the PC doesn’t prompt for the Boot from DVD/CD message, try the following.
1. If there are two CD/DVD drives in the PC, try placing the CD/DVD in the other drive.
2. Reboot the PC, and press F2 to enter setup when prompted. Verify that the boot sequence is 1.
Floppy, 2. CD/DVD, 3. C:

Appendix B: PRIMS Directory Structure
Many of the PRIMS directories are definable in the Settings.ini file and may have been changed from
the defaults shown below. See Appendix D for more information.
Application Directory
C:\PRIMS\XXXX\
Data Logger Directory (files for the strip chart)

C:\PRIMS\XXXX\DATA
Help Directory
C:\PRIMS\XXXX\HELP
Part Program Directory

C:\PRIMS\XXXX\Part Programs
Picture Directory
C:\PRIMS\XXXX\Pictures
Process Document Directory

C:\PRIMS\XXXX\Process Documents
Report Directory
C:\PRIMS\XXXX\Reports
NOTE: XXXX in any path name refers to the Progressive project number of the machine.

Appendix C: SETTING.INI
The PRIMS/CITS system requires several parameters. They are defined in the settings.ini text file
which is located in the c:\PRIMS\xxxx directory, where xxxx is the project number. This file defines
the following:
[DataBases]
Setup DB Location of the main database containing all of the table
information controlling the application.
Example: Setup DB=c:\PRIMS\xxxx\PRIMS.MDB
Data DB Location of the database containing data logger files, alarm

logs, preventive maintenance, and flight recorders sent todisk.
Example: Data DB=c:\PRIMS\xxxx\PRIMDATA.MDB
Operation DB Location of the database containing tables that may change

frequently during normal operation, such as recipes and part
identification.
Example: Operation DB=c:\PRIMS\xxxx\Operation.MDB
PartProg DB Location of the database which defines the buttons for the Part
Program Editor.
Example: PartProg DB=c:\PRIMS\xxxx\Partprog.MDB
Data Location DB Location of the database files representing each machine cycle.
Example: Data Location DB=c:\PRIMS\xxxx\DATA\
AutoLog Setting this to true will automatically log the current cycle for
reporting. Use this feature when there is no part program
(CNC or ROBOT) which turns on the record data bit to
PRIMS/CITS. This option will generally be false.
Example: AutoLog=False
[Reports]
Reports Location Location of the directory containing the general PRIMS/CITS
reports (Start, Stop, ...).
Example: Reports Locationl=c:\PRIMS\xxxx\reports\
PM History All Location of the Preventive Maintenance report which details all
items which have a PM history.
Example: PM History All=c:\PRIMS\xxxx\pm_hista.rpt

PM History Location of the Preventive Maintenance report which details a

single item's PM history.
Example: PM History=c:\PRIMS\xxxx\pm_hist.rpt
[Help]
Help Location Location of the main help files for the PRIMS system.
Example: Help Location=c:\PRIMS\xxxx\help\
PM Help Location Location of the PM help files for the PRIMS system.
Example: PM Help Location=c:\PRIMS\xxxx\help\pm\
[Part Program]
Part Program Location Location of the part programs for uploading and downloading.
This field is only a possible example. Check the PartIdent_Def
table for any file location fields.
Example:
Part Program Location=c:\PRIMS\xxxx\Part Programs
Process Doc Location Location of the process document folder. This field is only a
possible example. Check the PartIdent_Def table for any file
location fields.
Example: Process Doc Location=c:\PRIMS\xxxx\procdoc\
Picture Location Location of the part and employee pictures.

Example: Picture Location=c:\PRIMS\xxxx\pictures
Number of Pictures Set to the number of part pictures that can be entered for each
part. This may require adding more Part_Picture_X
mnemonics to the data dictionary.
Example: Number of Pictures = 6
Number of Surfaces Set to the number of surfaces/options that can be used for part
programming. This may require adding more
Surface_X_Dsript and Surface_15_Bit mnemonics to the data
dictionary.
Example: Number of Surfaces = 16
Modify Surfaces Set to the number of surfaces to be shown on the part

modification screen. If this field is set to -999 or if it does not
exist, then the part modification screen will shown all surfaces
set by the Number of Surfaces field.

[Communications]
WinOLPC Path This option appears if there is a Fanuc Robot entered in the
Comm_Def table. Set to the path of the WinOLPC application
for PRIMS/CITS to launch from the identification screen.
Example: WinOLPC Path= c:\WinOLPC.exe
ROBOT USER ID This option appears if there is a Fanuc robot entered in the
Comm_Def table. Set this to the user ID entered on the Fanuc
Robot.
Example: ROBOT USER ID=PTI
ROBOT PASSWORD This option appears if there is a Fanuc robot entered in the
Comm_Def table. Set this to the user password entered on the
Fanuc Robot.
Example: ROBOT PASSWORD=PTI
ControlEngine This option appears if there is a SIEMENS plc entered in the

Comm_Def table. See SIEMENS documentation for details. This
setting should always be like the example.
Example: ControlEngine=wcS7 = 2
UpdateRate This option appears if there is a SIEMENS plc entered in the

Comm_Def table. Set this option to the timer value, in
milliseconds, for PRIMS/CITS to read from the PLC.
Do not change this unless there are problems. Less than 500
may cause PRIMS/CITS to loose performance.
Example: UpdateRate = 500
Dual Process Set this option to true for a dual process CNC application.
Example: Dual Process = True
AbsingleUART Set this option to true for an AB CNC that only has the
capability to communicate with one port at a time.
[Feeder]
Number of Feeders Set this options to the number of feeders used on CITS.
Example: Number of Feeders = 2
Feeder Type Set this to the type of feeders used. The choices are: Miller,
Example: Feeder Type = Miller

[Consumables]
Num of Current Part Usage Vars
Sets the number of usage variables to be displayed in the
current section of the consumables screen.
Example: Num of Current Part Usage Vars=12
Num of Since Last Reset Usage Vars

Sets the number of usage variables to be displayed on the right
side of the consumables screen which displays the total values
since the reset button was last pressed.
Example: Num of Since Last Reset Usage Vars=30
[Misc.]
Title Sets the title for the project. Typically this will be PRIMS or
CITS. This option is available for customers with another
requirement or a customized project such as the Saturation
Curve Solver.
Example: Title = PRIMS
Log Interval Sets the strip chart data logging interval in seconds. This is set
to 1 second in almost all cases, but can be increased if a job is
recording lots of data or running very long cycles and they want
to cut back on the amount of data recorded.
Example: Log Interval=1
Debug Used for development purposes only. Make sure this is turned
off.
Example: Debug=False

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Rotary Index Shot Peening System

for Dana Corporation

I. Introduction - System Overview -1-

Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -2-

II. Machine Controls Layout and Description -3-

Main Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -4-

Blast Media Flow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -7-

Blast Air Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -8-

Jog Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -9-

Touchscreen Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -12-

Operator Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -17-

Pop-Up Menus and Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -28-

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Recalling Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -30-

CNC UTILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -34-

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III. Machine Operation -43-

Machine Power Up and Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -44-

E-Stop Controls and Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -46-

Overtravels and Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -47-

Operation in Manual Mode ( Jogging and Homing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -48-

Operation in Auto Mode (Running a Cycle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -50-

Miscellaneous Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -53-

Machine Faults and Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -55-

IV. Programming -59-

Program Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -60-

Motion Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -61-

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Position Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -61-

M-Codes (Miscellaneous Functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -62-

Dwells and Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -63-

Recipe Recall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -64-

Surface Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -65-

Programming Using Teach Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -66-

Program Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -67-

Running a Test Mode Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -68-

Running a Single Block Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -69-

Sample Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -70-

Appendix A: PC Backup and Restore -71-

Making a backup image of the PC’s harddrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -71-

Restoring a backup image of the PC’s harddrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -71-

Booting from a CD/DVD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -71-

Appendix B: PRIMS Directory Structure -72-

Appendix C: SETTING.INI -73-

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I. Introduction - System Overview

The Robotic Peening System is an integration of three major sub-systems or assemblies:

1. Blast Cabinet Assembly

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Home Position 0 in. 0 in. 0 deg.

Shot Flow Control 10 - 100 lbs/min.

Air Pressure Control 10 - 100 PSIG

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II. Machine Controls Layout and Description

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Main Control Station

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Main Control Station Buttons

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Blast Media Flow Control

SHOT FLOW CONTROLLERS #1-4 (1-4MC1 FC)