Get Started With Ultimax4

704-0111-101
Ultimax
Getting Started with Ultimax Manual
August, 2002 Revision A
Getting Started with

Ultimax Manual
Ultimax 4 Dual Screen and Max
Consoles
for
Hurco Machining Centers
Hurco Manufacturing Company reserves the right to incorporate any

modifications or improvements in machines and machine specifications
which it considers necessary, and does not assume any obligation to make
any said changes in machines or equipment previously sold.
Hurco products and services are subject to Hurcos then current prices,
terms, and conditions, which are subject to change without notice.
The information in this document is subject to change without notice and does not
represent a commitment on the part of Hurco Companies, Inc. (Hurco). No part of this
document may be reproduced or transmitted in any form or for any purpose without the
express written permission of Hurco. However, Hurco does authorize the creation of two
electronic and two paper photocopies by the original Hurco machine tool purchaser, or
his authorized designee.
2001-2002 Hurco Companies, Inc. All rights reserved.
Patents: U.S. Patents B14,477,754; 5,453,933; Canadian Patent 1,102,434;

Japanese Patents 1,649,006 and 1,375,124; other Patents pending.
Hurco and Ultimax are Registered Trademarks of Hurco Companies, Inc.
UltiPocket and AutoSave are trademarks of Hurco Companies, Inc.
AutoCAD, Autodesk, and DXF are registered trademarks of Autodesk, Inc.
Fanuc is a registered trademark of Fanuc LTD.
IBM and PC/AT are registered trademarks of International Business Machines
Corporation.
MS-DOS and Microsoft are registered trademarks of Microsoft Corporation.
Many of the designations used by manufacturers and sellers to distinguish their products
are claimed as trademarks. Hurco has listed here all trademarks of which it is aware.
For more information about Hurco products and services, contact:
Hurco Companies, Inc.
One Technology Way
P.O. Box 68180
Indianapolis, IN 46268-0180
Tel
(317) 293-5309 (products)
(317) 298-2635 (service)
Fax
(317) 328-2812 (service)
For Hurco subsidiary contact information, go to Hurcos website:
www.hurco.com
Ultimax System
August, 2002
ii
Revision A
Using This Manual

Standard Text Icons
This manual may contain the following icons:
Caution
The machine may be damaged, or a part ruined, if the described
procedure is not followed.
Hints and Tricks

Useful suggestions that show creative uses of the Ultimax features.
Important
Ensures proper operation of the machine and control.
HURCO
Troubleshooting
Steps that can be taken to solve potential problems.
Warning
The operator may be injured and the machining center
severely damaged if the described procedure is not
followed.
Where can we go from here?

Lists several possible options the operator can take.
Ultimax System
August, 2002
iii
Sample Screens
Some sample screens in this manual were captured on a stand-alone
Ultimax system. The screens on your system may vary slightly. The Input
screen below illustrates softkeys and includes the software version (circled
below).
Figure 1.
Input Screen
Ultimax screens have three areas of primary interest:
iv
Softkeys on the right side of the touch screen. Available

softkeys may change even when the text and data entry area
does not.
Fields to the left of the softkeys. A field is an area that

display or receives information entered by the operator.
Prompt and error message area at the bottom of the screen.

In the sample screen above, the message area reads, Select
softkey or press <Enter> to change part program name.
Revision A
Table of Contents
Machine and Console Basics
Machine Components .......................................................................................... 1-1
Consoles............................................................................................................... 1-2
Control Panel Function Groups ............................................................... 1-3
Emergency Stop Buttons.......................................................................... 1-4
Programming Keyboard........................................................................... 1-5
Text Screen Data Entry................................................................ 1-5
Programming Mode ......................................................... 1-5
Text Screen Cursor Control Keys .................................... 1-6
Softkeys ....................................................................................... 1-7
Numeric Keypad .......................................................................... 1-7
Pop-up Text Entry Window ......................................................... 1-8
Optional Computer Keyboard.......................................... 1-8
Graphics Screen Data Entry......................................................... 1-9
Axis, Spindle, and Machine Control...................................................... 1-11
Override Knobs.......................................................................... 1-11
Jog Unit ..................................................................................... 1-12
Setting Jog Unit Parameters....................................................... 1-14
Machine Control ........................................................................ 1-15
Machine Operations ............................................................................... 1-16
Machine Mode ........................................................................... 1-16
Auto Cycle Mode Softkeys............................................ 1-17
Single Cycle Mode ........................................................ 1-17
Test Run Mode............................................................... 1-24
Manual Mode ................................................................. 1-26
Spindle ..................................................................................... 1-28
Tool Changer ............................................................................. 1-28
Coolant ..................................................................................... 1-28
Communications Panel ...................................................................................... 1-29
Power Up ........................................................................................................... 1-30
Routine Daily Checks ............................................................................ 1-30
Machine Power ...................................................................................... 1-30
Establishing Servo Power ...................................................................... 1-32
Calibrate the Machine ............................................................................ 1-33
Axes Calibration .................................................................................... 1-34
Warm Up the Machine........................................................................... 1-34
Ultimax System
August, 2002

Automatic Tool Changers .................................................................................. 1-35
Loading a Tool into the Spindle............................................................. 1-35
Unloading a Tool from the Spindle ....................................................... 1-36
Loading Tools into the ATC Magazine ................................................. 1-37
Removing Tools from the ATC Magazine ............................................ 1-38
Large Tools in the ATC Magazine ........................................................ 1-39
The ATC Map ........................................................................................ 1-40
Resetting the ATC Map ............................................................. 1-41
Shut Down ......................................................................................................... 1-42
Emergency Stop Shut Down.................................................................. 1-42
Park the Machine ................................................................................... 1-43
Control Power Off Time ........................................................................ 1-43
vi
Revision A
Table of Contents
File Management and System Configuration

File Management ................................................................................................ 2-2
Storage Functions................................................................................................. 2-3
Read Program From Disk ........................................................................ 2-4
Abort a Read Program from Disk ................................................ 2-4
Write Program to Disk ............................................................................. 2-5
Part Program, Directory and Subdirectory Names ...................... 2-6
Disk Operations List Directory................................................................ 2-7
Change to Directory..................................................................... 2-7
Rename Program.......................................................................... 2-7
Delete Program ............................................................................ 2-8
Copy Program .............................................................................. 2-8
Program Mask.............................................................................. 2-8
Select Current Storage Drive ....................................................... 2-9
Create Directory......................................................................... 2-10
Delete Directory......................................................................... 2-10
Tag All Programs....................................................................... 2-11
Untag All Programs ................................................................... 2-11
Toggle Program Tag .................................................................. 2-11
Copy All Tagged Programs ....................................................... 2-12
Delete All Tagged Programs...................................................... 2-12
Format Diskette...................................................................................... 2-13
Select Current Storage Drive ................................................................. 2-13
Export Program as Text File .................................................................. 2-13
Change NC Dialect ............................................................................................ 2-14
Download/Upload .............................................................................................. 2-14
Serial Port Status Messages ....................................................... 2-16
Upload Receive...................................................................................... 2-17
Aborting an Upload.................................................................... 2-17
Upload an NC Part Program to a Disk Drive............................. 2-17
Upload a Part Program to Memory............................................ 2-18
Download Send...................................................................................... 2-19
Aborting an Download............................................................... 2-19
Download a Part Program from Memory .................................. 2-19
Download an NC Part Program from the Current Drive ........... 2-20
Select Port .............................................................................................. 2-21
Abort Operation ..................................................................................... 2-21
Reset Port Parameters ............................................................................ 2-21
Default Communication Settings............................................... 2-21
Ultimax System
August, 2002
vii

Serial Port Setup .................................................................................... 2-22
Protocol ..................................................................................... 2-22
Baud Rates ................................................................................. 2-22
Setting Serial Port ...................................................................... 2-22
System Configuration ........................................................................................ 2-23
Current System Date .............................................................................. 2-24
Current System Time ............................................................................. 2-24
Control Power Off Time ........................................................................ 2-24
AutoSave Time ...................................................................................... 2-25
Screen Blank Time................................................................................. 2-25
DRO Display Units ................................................................................ 2-26
Setting the DRO Display Units.................................................. 2-26
Changing DRO Character Size .................................................. 2-26
Text Entry Window................................................................................ 2-27
Turning On the Text Entry Window.......................................... 2-27
Turning Off the Text Entry Window ......................................... 2-27
File Display Method .............................................................................. 2-27
Video Hardware Type............................................................................ 2-27
Set Network Parameters......................................................................... 2-28
Set Color Parameters.............................................................................. 2-28
Text Color Parameters ............................................................... 2-28
Graphics Color Parameters ........................................................ 2-29
Storage Functions Color Parameters.......................................... 2-30
Display Machine Specifications ............................................................ 2-30
Display Software Configuration ............................................................ 2-31
Display Ladder Configuration ................................................... 2-32
Backup Config and Machine Files......................................................... 2-33
Restore Config Machine Files ............................................................... 2-33
Read DXF File ................................................................................................... 2-34
Change Editor .................................................................................................... 2-34
CRT Degauss ..................................................................................................... 2-34
Change Language............................................................................................... 2-34
Upgrade System Files ........................................................................................ 2-35
Display Error Messages ..................................................................................... 2-36
Reset Master...................................................................................................... 2-37
viii
Revision A
Table of Contents
Programming Basics
Part Programming Setup ...................................................................................... 3-1
Part Fixturing and Tool Loading.............................................................. 3-2
Part Program Names ................................................................................ 3-2
Part Setup ................................................................................................. 3-3
Entering Part Setup Information .................................................. 3-4
Part Setup Fields .............................................................. 3-6
Part Setup Softkeys .......................................................... 3-7
Safety Work Region..................................................................... 3-8
NC Work Offsets ......................................................................... 3-9
NC Probing Part Setup............................................................... 3-10
Tool Setup.............................................................................................. 3-11
Entering Tool Setup Information ............................................... 3-12
Tool Setup Fields ........................................................... 3-16
Tool Setup Softkeys....................................................... 3-18
Automatic Feed and Speed Calculations ................................... 3-20
Entering Zero for Speed (RPM) Value .......................... 3-20
Entering Actual Speed (RPM) Value............................. 3-21
Formulas for Automatic Calculations............................ 3-21
Program Parameters ............................................................................... 3-22
General Parameters .................................................................... 3-23
Holes Parameters ....................................................................... 3-28
Milling Parameters..................................................................... 3-31
Cutter Comp Parameter.............................................................. 3-34
NC Parameters ........................................................................... 3-37
NC Configuration Parameters........................................ 3-38
M and G Code Program Numbers ................................. 3-40
NC Variables.................................................................. 3-41
Erase Functions.................................................................................................. 3-42
Erase Current Program........................................................................... 3-42
Erase Running Program ......................................................................... 3-45
Restore Functions............................................................................................... 3-46
Graphics ............................................................................................................. 3-51
Views ..................................................................................................... 3-52
Zoom ...................................................................................................... 3-54
Graphics Parameters .............................................................................. 3-54
Data Block Search.................................................................................. 3-56
Graphics Error Checking ....................................................................... 3-58
Running Part Programs ...................................................................................... 3-59
Ultimax System
August, 2002
ix

European Manual Safety Override Mode .............................................. 3-60
Entering the Access Code .......................................................... 3-62
Entering a New Access Code..................................................... 3-63
Changing an Existing Access Code ........................................... 3-63
Error Conditions..................................................................................... 3-64
Stop Motion ........................................................................................... 3-65
Re-Run Entire Program.................................................. 3-66
Concurrent Programming................................................................................... 3-67
Software Options ............................................................................................... 3-70
Ultimax Programming Training............................................................. 3-70
Appendix
Index
Revision A
Figure List
Figure 1-1.
Figure 1-2.
Figure 1-3.
Figure 1-4.
Figure 1-5.
Figure 1-6.
Figure 1-7.
Figure 1-8.
Figure 1-9.
Figure 1-10.
Figure 1-11.
Figure 1-12.
Figure 1-13.
Figure 1-14.
Figure 1-15.
Figure 1-16.
Figure 1-17.
Hurco Machine with the Ultimax 4 Console....................................... 1-1

Ultimax 4 Console and Max Console ................................................. 1-2
Ultimax 4 Console Panel Groups........................................................ 1-3
Max Console Panel Groups................................................................. 1-4
Pop-up Text Entry Window ................................................................ 1-8
Graphics Screen .................................................................................. 1-9
Remote Jog Unit................................................................................ 1-12
Auto Screen (Conversational Programming ) ................................... 1-17
Run Program Screen ......................................................................... 1-19
Single Cycle Screen (Conversational Programming) ....................... 1-21
Single Cycle w/ Program Information (Conversational) .................. 1-22
Test Run Screen (Conversational Programming) ............................. 1-24
Manual Screen................................................................................... 1-26
Communications Panel ..................................................................... 1-29
Input Screen ...................................................................................... 1-31
Manual Screen Showing Uncalibrated Axes..................................... 1-33
ATC Map Screen .............................................................................. 1-40
Figure 2-1.
Figure 2-2.
Figure 2-3.
Figure 2-4.
Figure 2-5.
Figure 2-6.
Figure 2-7.
Directory Structure.............................................................................. 2-2

Current Program Screen...................................................................... 2-3
Conversational Download/Upload screen......................................... 2-15
NC Download/Upload screen ........................................................... 2-16
System Configuration screen ............................................................ 2-23
CNC Configuration Screen ............................................................... 2-31
Ladder Configuration Screen ............................................................ 2-32
Figure 3-1.
Figure 3-2.
Figure 3-3.
Figure 3-4.
Figure 3-5.
Figure 3-6.
Figure 3-7.
Figure 3-8.
Figure 3-9.
Figure 3-10.
Figure 3-11.
Figure 3-12.
Figure 3-13.
Figure 3-14.
Part Zero Relative to Machine Zero Viewed Looking Down at Table3-3

Axis Motion ........................................................................................ 3-3
Part Setup Screen ................................................................................ 3-4
Safety Work Region Fields on the Part Setup Screen......................... 3-8
Work Offsets for NC Programs .......................................................... 3-9
Tool Setup Screen ............................................................................. 3-12
Cutter Compensation......................................................................... 3-14
Input Screen ...................................................................................... 3-22
General Parameters Screen ............................................................... 3-23
Positive First Peck Offset.................................................................. 3-26
Negative First Peck Offset ................................................................ 3-26
Chord Error ....................................................................................... 3-28
Holes Parameters Screen................................................................... 3-29
Milling Parameters Screen ................................................................ 3-31
Ultimax System
August, 2002
xi

Figure 3-15.
Figure 3-16.
Figure 3-17.
Figure 3-18.
Figure 3-19.
Figure 3-20.
Figure 3-21.
Figure 3-22.
Figure 3-23.
Figure 3-24.
Figure 3-25.
Figure 3-26.
Figure 3-27.
Figure 3-28.
Figure 3-29.
Figure 3-30.
Figure 3-31.
Figure 3-32.
Figure 3-33.
Figure 3-34.
Figure 3-35.
Figure 3-36.
Figure 3-37.
Figure 3-38.
Figure 3-39.
Figure 3-40.
Figure 3-41.
Figure 3-42.
xii
Milling Parameters Screen with Insert Arc and Insert Line Softkeys3-34
Cutter Compensation Using the Insert Arc Parameter...................... 3-35
Cutter Compensation Using the Insert Line Parameter..................... 3-36
NC Parameters Screen....................................................................... 3-37
NC ParametersConfiguration Parameters Screen ......................... 3-38
NC ParametersM and G Code Program Numbers Screen ............ 3-40
Input Screen with Erase Functions Softkey ...................................... 3-42
Erase Functions ................................................................................. 3-43
Input Screen with Do you really want to Erase? Message ............ 3-44
Input Screen with Erase Running Program Softkey ......................... 3-45
Input Screen with Restore Functions Softkey................................... 3-46
Input Screen with Restore Functions ................................................ 3-47
Input Screen with Do you really want to Erase? Message ............ 3-49
Current Directory Screen After Selecting a Restore Function.......... 3-50
New Block Screen with Miscellaneous Functions............................ 3-51
Graphics Screen with Isometric View............................................... 3-52
Graphics Screen Showing All Planes................................................ 3-53
Graphics Parameters Screen.............................................................. 3-54
Identifying a Portion for the Search .................................................. 3-56
Data Block Displayed After the Search ............................................ 3-57
Graphics Screen Error Message ........................................................ 3-58
Access Code Message on Manual Screen......................................... 3-60
CE Status & Diagnostics Screen ....................................................... 3-61
Incorrect Code Message on CE Status & Diagnostics Screen .......... 3-62
Enabled Field on CE Status & Diagnostics Screen........................... 3-62
Error Message on the Auto Screen ................................................... 3-64
Input Screen with Concurrent Running Program.............................. 3-67
Input Screen with Exchange Edit/Run Programs Softkey ................ 3-68
Revision A
Table List
Table 2-1.
Table2-2.
Table2-3.
Table2-4.
Table2-5.
Transfer Types for Conversational and NC Programs...................... 2-15

Default Communication Settings ...................................................... 2-21
Text Color Parameter Defaults.......................................................... 2-28
Graphics Color Parameter Defaults Defaults.................................... 2-29
Storage Function Color Parameter DefaultsDefaults....................... 2-30
Table 3-1.
General Parameter Ranges and Default Values ................................ 3-27
Ultimax System
August, 2002
xiii
Ultimax System
August, 2002
xiv
Chapter 1

This chapter explains basic machine and console operations.
Machine Components
Before using the machine, you should become familiar with its
components. Because of European Committee (CE) requirements, Hurco
machines sold in Europe differ somewhat from those sold elsewhere. The
figure below identifies some of the easily recognized components of a
machine. The console is in front of the machine, facing the operators
area.
Figure 1-1.
Hurco Machine with the Ultimax 4 Console
Hurco machines are available with several hardware and software options.
Information about these options is available from Hurco or your Hurco
Distributor.
Ultimax System
August, 2002
1-1
Consoles
The Ultimax 4 console and the Max single screen (Max) console use
Ultimax software:
Figure 1-2.
Ultimax 4 Console and Max Console
The console, and the electrical components required to operate it, are
called the control or the CNC (Computer Numeric Control). Some of
the electrical components are built into a separate enclosure kept in the
machines electrical cabinet.
Some of the controls internal components, such as disk drives and
memory, are like those in a PC. Disk operations, such as copying, deleting
and storing files, are also similar.
The floppy drive is located on the consoles right side panel. To protect
the drive from debris, the protective floppy drive cover should be closed,
except when inserting or removing a diskette. The floppy drive is standard
on the Ultimax 4 console, and optional on the Max console.
Hurco offers the optional Delight package for the Ultimax 4 console. The
Delight package includes a keyboard tray, document holder and print
holder. An optional keyboard tray is also available for the Max console.
A miniature PS/2 keyboard and tray package is available for the Max
console.
The Max Classic optional package for the Max console is also available
from Hurco. The Max Classic package includes touchscreen graphics,
floppy drive, memory upgrade to 64 MB RAM, hard drive upgrade to 2
GB.
Information about options is available from Hurco or your Hurco
distributor.
1-2
Revision A
Control Panel Function Groups

The buttons, keys, and knobs on the Ultimax 4 and Max consoles are
grouped by their functions
Here are the control panel groups on an Ultimax 4 console:
Figure 1-3.
Ultimax 4 Console Panel Groups
The Ultimax 4 console also has a power on button, emergency stop button,
and brightness control thumbwheels for the Text screen and Graphics
screen. Some consoles are also equipped with contrast control
thumbwheels.
Ultimax System
August, 2002
1-3

Here are the control panel groups on a Max console:
Figure 1-4. Max Console Panel Groups
Emergency Stop Buttons

There is an Emergency Stop button located on each console and one on
the Remote Jog Unit. Press the Emergency Stop button to stop all spindle
and table motion. This button locks down when pressed. To release it,
twist the button in the direction indicated by the arrows.
Note
Learn the location of all Emergency Stop buttons on the machining
center before operating.
Caution
If the Emergency Stop button is pressed during execution of a part
program, the tool must be jogged clear of the part before resuming
operation.
1-4
Revision A
Programming Keyboard
Program a job at the machine while reading from a blueprint or program
worksheet. The prompts on the Text screen lead you through each element
of a part program. Enter machine operations, part dimensions, and other
parameters by selecting the appropriate screen softkeys and console
buttons.
Set up and run part programs, and manage part program files using the
following data entry keys:
Text Screen Data Entry
Softkeys
Numeric Keypad
Pop-up Text Entry Window
Graphics Screen Data Entry
Text Screen Data Entry

Text screen data entry keys are used for entering programming
information into the Text screens fields. These keys are located in the
center of the consoles Programming Keypad.
Programming Mode
Programming Mode console keys are named for the screens they activate:
Ultimax System
Input displays the main programming screen used to create and

edit part programs. From this screen, access Part Setup, Tool
Setup, Part Programming, Program Parameters, Copy and Change
Blocks, and Restore and Erase menus.
Auxiliary accesses program storage management, system

configuration settings, DXF files, reset master, and the upgrade
system files menus.
Review for Conversational programs, provides an outline view

of the blocks currently programmed, including type of block and
tool used. Jump to a desired block by typing the block number and
pressing Enter. For Numerical Control (NC) programs, the Review
key displays or re-displays the NC part program.
Help displays help text. Place the cursor on a field in question

and press the Help key. If help text is available, it will appear in a
pop-up window. Help is not available for all screens.
August, 2002
1-5

These keys function as they would on a standard PC keyboard:
Insert - type over and replace current text.
Delete - delete the character to the right of the cursor.
Home - position the cursor before a line of text.
End - position the cursor at the end of a line of text.
Page Up - position the cursor at the beginning of the previous

page.
Page Down - position the cursor at the beginning of the next page.
Text Screen Cursor Control Keys

These keys control cursor movement and perform programming
operations:
1-6
Arrow keys - move the cursor from one field to the next, or
advance a part program to the next data block.
Enter key () - accept the information typed in a text field, or

move to the next field.
Special Function keys
C console key - Use the C console and Clear keys to delete

the value at the current cursor position.
Delete console key - Use the F console and Delete keys

together to delete the character to the left of the cursor.
Arrow console key - Use the F console key in combination

with the arrow keys to quickly move the graphics cursor on
the graphics screen.
Revision A
Softkeys
Softkeys have a three-dimensional look on the touch screen of the console.
Each softkey is labeled with an operation. Touching the softkey selects its
operation.
If a softkey appears grayed out, the operation is not available because
the cursor is not in a specific field, or the machine does not support the
option.
Note
Another way to activate a softkey is to press and hold the F console
key while you simultaneously press the number key that corresponds
to the softkey number (F1, F2, . . . F8).
Numeric Keypad
The numeric keypad allows you to enter numbers and calculate values in
the Text screen. Perform the following operations with this keypad:
Ultimax System
Enter numeric data into fields on the screen.
Perform calculations using the mathematical symbols (, ,

, +) on the keypad.
August, 2002
1-7

Enter part program names using the Pop-up Text Entry Window (if the
console does not have an optional computer keyboard). The Pop-up Text
Entry Window automatically appears when text is required, such as
naming a part program. The sample screen below contains this window:
Figure 1-5.
To select characters from the Pop-up Text Entry Window:

1. Simultaneously hold down the F console key while using the
appropriate Arrow key to move the cursor to a character.
2. Simultaneously pressing the F console key and the Select
console key. The selected letter appears in the Input screens
text field.
3. Press the Enter key after characters are selected in the text
field (e.g., after a program name is created).
Optional Computer Keyboard
If the console is equipped with an optional computer keyboard, use it to
enter data into a field. Press the Enter key to update a field and advance
the cursor.
1-8
Revision A
Graphics Screen Data Entry

Note
You must have the Graphics option installed on the Max console to
access the Graphics screen.
Graphics screen buttons appear across the bottom of the screen:
Figure 1-6. Graphics Screen
Use the console trackball on the Ultimax 4 console, Select console key,
and Draw console key with the Graphics screen. Use a stylus or touch the
Max console screen in place of the console trackball.
Roll the trackball on the Ultimax 4 console with your fingers to operate it.
The trackball can be used to perform the following tasks:
Ultimax System
Move the crosshair cursor to select a Graphics screen

button. Graphics screen buttons may change, depending
upon the part program and previous button selections. For
the Max console, use a stylus or touch the Graphics screen
button.
Draw a rectangle around an area on the Graphics screen.

Enlarge the view in the rectangle with the Zoom Box screen
button.
August, 2002
1-9

The Draw console key is used to display or re-draw the graphics screen.
Unless the Graphics option is installed on the Max console, the graphics
screen will not appear when the Draw console key is pressed.
The Select console key is used with the trackball to select specific
elements on the Graphics screen.
The following functions are performed by the Graphics screen buttons:
View - selects a different perspective from which to display

the part. The screen buttons change when View is selected.
Full Scale - redraws the part currently displayed in full size,

after exiting the Zoom function.
Zoom Box - isolates a portion of the drawing and increases

the size of that section to show more detail.
Parameters - provides access to a Graphics Parameters

screen for changing the default settings for the graphics
functions.
DB Search - (data block search) select a portion of the

graphic and the data block for that portion displays on the
text screen. DB Search is helpful for tracking down the area
of a program that is incorrect.
For information on using graphics with part programs, see the Graphics
section in the Programming Basics chapter.
1-10
Revision A
Axis, Spindle, and Machine Control

The following keys and knobs are used to control machine movement and
adjust the spindle and axes.
Override Knobs
Three knobs on the upper console allow you to override the programmed
axis feedrate, rapid, and spindle speed.
The Override knobs function as follows:
Ultimax System
Axis Feed Rate - controls the programmed axis feedrate during an

auto run program. Turning the dial to counterclockwise slows the
feedrate; turning the dial to clockwise speeds the feedrate.
Selecting Min slows the spindle to 10% of the nominal value.
Selecting Max increases the feedrate to 150% of the nominal value.
Spindle Speed - controls the spindle speed. Turning the dial

counterclockwise slows the spindle; turning the dial clockwise
increases spindle speed. Selecting Min slows spindle speed to 640
RPM slower than the nominal value. Selecting Max increases
spindle speed to 640 RPM faster than the nominal value.
Rapid Override - overrides the programmed rapid traverse; the

speed at which the table moves from one point to another.
Selecting Min slows the table speed to 10% of the nominal value.
Selecting Max increases the table speed to 150% of the nominal
value.
August, 2002
1-11
Jog Unit
Use the Jog Unit to manually jog the axes. The Console Jog Unit is on the
Max console. The hand-held Remote Jog Unit can be removed from the
console and carried closer to the work piece. The Remote Jog Unit is
standard on the Ultimax console and an option on the Max console. Both
Jog Units function the same:
1.
Select an axis with the Axis Select Switch.
2.
Use the Jog Feed Keys:

a.
Select either the + or Jog Feed Keys.
b.
Adjust Jog Feed Override to override the

programmed axis feedrate.
Or
3.
Use the Hand Wheel Multiplier:

a.
Select a hand wheel resolution with one of the

Hand Wheel Multiplier Keys.
b.
Rotate the Jog Hand Wheel.
Important
Other than the Emergency Stop button, the Jog Unit does not affect
running programs.
Figure 1-7.
1-12
Remote Jog Unit
Revision A

The dials on a Jog Unit are defined as follows:
Axis Select Switch select the axis to jog (0, X, Y, Z, A, B).
Jog Feed Override control the jog speed (10% to 150%) of the
nominal value. Use this dial to touch off the tool and move the X
and Y axes to touch off the part for Tool and Part Setup.
Jog Feed Keys - select minus (-) or plus (+) jog direction.
Jog Hand Wheel - select minus (-) or plus (+) jog direction.
Hand Wheel Multiplier Keys - define the hand wheel resolution.
x1 defines a one-to-one ratio (each click equals .0001 inch,

or .00254 mm).
x10 defines a 10-to-one ratio (each click equals .001 inch, or

.0254 mm).
x100 defines a 100-to-one ratio (each click equals 0.01 inch,

or .254 mm. One full turn equals 1 inch, or 25.4 mm).
Store Position Key - record the axis current position in the part
programs setup screens.
Note
See the Setting Jog Unit Parameters section for instructions on
setting the Jog Unit parameters.
Use a Jog Unit to manually jog the axes:

1.
Select an axis with the Axis Select Switch.
2.
Use the Jog Feed Keys:

a.
Jog axis direction by select either + or .
b.
Use the Jog Feed Override to override the

programmed axis feedrate.
Or
Use the Hand Wheel Multiplier:
Ultimax System
a.
Select a hand wheel resolution with one of the

Hand Wheel Multiplier Keys
b.
Rotate the Jog Hand Wheel to jog axis direction.
August, 2002
1-13
Setting Jog Unit Parameters

To access the parameters :
1-14
1.
Press the Manual Mode console key to display the Manual

screen.
2.
Press the Manual Function (F2) softkey. The Jog Unit

parameters are displayed:
Manual Jog Feed - enter the desired manual jog

axis feedrate. The range is from 0.0 to the
machines maximum feedrate.
An axis may have a maximum jog feedrate slower
than other axes. This slower axis can only move at
its maximum jog feedrate (and not the higher
feedrate of other axes).
For example, the X and Y axes on a machine each
have a maximum jog feedrate of 787 inches per
minute (ipm). The Z axis has a maximum jog
feedrate of 100 ipm. Without using the jog feedrate
override, the X and Y axes can jog at 787 ipm , but
the Z axis is limited at 100 ipm.
Manual Spindle Speed - enter the spindle speed

when the Spindle On console key is pressed. This
value can not be greater than the machines
maximum spindle speed. Entering a negative value
(e.g., -500) causes the spindle to reverse (turn
counterclockwise) at that speed.
Revision A
Machine Control
Machine Control buttons start and stop machine operation. The buttons
function as follows:
Power On - enables the relay control system. This button must be

illuminated to operate the machine, but may be switched off while
creating or editing a part program.
Start Cycle - activates machine operation. When the machine is in

an active mode, the Start Cycle flashes to indicate the machine is
ready. When this button is pressed again, the light switches off.
To turn Control Power On:

1.
Press the Power On console button.
2.
Press the Manual Mode console key.
3.
Press the Start Cycle console button.
Important
Never press the Start Cycle button without knowing exactly what the
machine will do.
Stop Cycle - stops axes movement, then stops the spindle.
Feed Hold (Motion Hold on Max console) - stops all axes

movement, except a tap operation, when the tool is in the
programmed feedrate region. Pressing the button a second time
allows machine positioning to resume.
To Stop an Automatic Machine Operation:

Press the Stop Cycle button to stop the axis, then the spindle.
Or.
Ultimax System
1.
Press the Feed Hold (or Motion Hold) console button to stop
axis motion.
2.
Press the Spindle Off console key to stop the spindle.
3.
Press the Feed Hold (or Motion Hold) console button again.
August, 2002
1-15
Machine Operations
The Machine Operations console keys are needed to run part programs
and control the machine during cutting. These keys are labeled under the
Machine Mode, Spindle, Tool Changer, and Coolant groupings.
Machine Mode
The Machine Mode console keys have these functions:
1-16
Auto - allows you to run a part program automatically.
Interrupt - halts machine operation during automatic execution of

a program to allow manual functions, such as cleaning the work
piece.
Single - provides access to the Single Cycle screen. In this mode,

the machine stops the axes after each automatic operation. Pressing
the flashing Start Cycle button causes the automatic machining
operation to resume.
Test - provides access to test run facilities such as Dry Run and
Feed and Speed Optimization.
Manual - provides access to manual machine operations that allow

axis positioning with the jog unit.
Revision A

Auto Cycle Mode Softkeys
Pressing the Machine Mode Auto console key displays the Auto screen.
The part program to be executed appears in the Running Part Program
field.
Figure 1-8.
Auto Screen (Conversational Programming )
For Conversational part programs, the Start Block and End Block fields
display the programs first and last data blocks. If you want to execute
only a certain portion of the program, these fields may be changed.
Identify the start and end data blocks of an NC Program by touching the
appropriate softkey.
Ultimax System
August, 2002
1-17

The following softkeys are available on the Auto, Single Cycle and Test
screens:
Check for Errors checks the program from the Start

Block through the End Block and displays the error status.
The number of the data block containing the error is
included in the error message.
The time required for error checking depends on the
programs length and complexity. Touch the Abort
Operation softkey to stop error checking at any time.
Compute Estimated Run Time a pop-up window

displays an estimate of time it takes to run the program.
Pressing any console key will remove the pop-up window.
Touch the Abort Operation softkey to stop computing
estimated run time.
Error checking automatically occurs during Compute
Estimated Run Time.
Recovery Restart restart a Conversational part program;

typically the point at which the program was interrupted. If
necessary, Start and End Blocks can be changed from the
default. See the Program Execution section of the NC Part
Programming Manual for Recovery Restart and NC
Programs.
For a Conversational Mill Contour data block, Recovery
Restart can only occur at segment 0 of a Mill Contour data
block, not at a segment within a data block.
If a Conversational Pattern data block is selected as the Start
Block, the number of the starting location must be entered.
The End Block for a Pattern Start Block must either be at or
after the Pattern End, or the end of the program.
Hints and Tricks

Use the Graphics display (press the Draw console key) to help determine
the correct Start Block.
1-18
Revision A
Figure 1 - 9.
Run Program initiate program execution and display

monitoring information. If the machine is not calibrated, the
Manual screen immediately displays.
Run Program Screen
The current positions of all axes, the Tool in Spindle,

Spindle RPM, and the axes federates are shown in the upper
portion of the screen.
The lower area of the screen displays the Spindle Load

Monitor (the percentage of full load on each axis), the data
block executed, the type of operation, and the part count.
The bottom portion of the screen is reserved for program

status and error messages.
Note
On the NC Auto monitoring screen, NC data blocks being executed
appear above the Program Running message. The next block to be
executed appears above the prompt.
Ultimax System
August, 2002
1-19

These are the monitoring softkeys that may be available for Auto Cycle
mode:
1-20
Reset Part Count the number of times a program was

executed. To return this value to zero when a new program
starts, touch the Reset Part Count softkey.
Select DRO change the size of the digital read out (DRO)
on the screen. From the Select DRO screen you can see
machine information displayed in either Full Status or Full
DRO. Full Status displays the current location of machine
and part axes, as well as other machine information. Full
DRO displays the current location of machine and part axes,
Distance to Go and other machine information (with
abbreviated categories).
Chip Removal Forward On/Off turn the chip auger in

the forward (clockwise) direction on or off. This softkey is
only available if your machining center uses a chip auger.
Chip Removal Reverse On/Off turn the chip auger in the

reverse (counterclockwise) direction on or off. This softkey
is only available if your machining center uses a chip auger.
Coolant Washdown On turn the coolant washdown on to

wash chips from the enclosure.
Coolant Washdown Off turn off the coolant washdown.
Worklight On/Off turn off the enclosure worklight. This

softkey is only available if your machining center is
equipped with an enclosure worklight
Toggle Rapid Override Enable enable or disable the

ability to override the programmed rapid traverse using the
Rapid Override console knob.
Revision A

Single Cycle Mode
Press the Machine Mode Single console key and the Single Cycle screen
appears. In Conversational Programming the machine halts (with the
spindle running) after each hole operation, contour segment, or milling
subroutine. For NC Programming, the machine halts with the spindle
running after each data block is executed.
Figure 1-10.
Single Cycle Screen (Conversational Programming)
Note
For information on the Single Cycle screen softkeys, see the Auto
Cycle Mode Softkeys section.
Ultimax System
August, 2002
1-21

Touch the Run Program softkey and this screen appears:
Figure 1-11. Single Cycle with Program Information (Conversational

Programming)
Note
After touching the Run Program softkey, machining resumes when
the flashing Start Cycle button is pressed.
During execution of the part program, you can switch between Auto and
Single Cycle operations by pressing the corresponding console key.
Caution
Standard moves are not made before executing a Single Cycle.
Examine the part program to determine the precise tool movement to
avoid interference with fixturing before executing a Single Cycle
operation.
1-22
Revision A

These are the monitoring softkeys for Single Cycle mode:
Ultimax System
Reset Part Count the number of times a program

was executed. To return this value to zero when a new
program starts, touch the Reset Part Count softkey
Chip Removal Forward On/Off turn the chip auger in

the forward (clockwise) direction on or off. This softkey is
only available if your machining center uses a chip auger.
Chip Removal Reverse On/Off turn the chip auger in the

reverse (counterclockwise) direction on or off. This softkey
is only available if your machining center uses a chip auger.
Select DRO change the size of the digital read out (DRO)
on the screen. From the Select DRO screen you can see
machine information displayed in either Full Status or Full
DRO. Full Status displays the current location of machine
and part axes, as well as other machine information. Full
DRO displays the current location of machine and part axes,
Distance to Go and other machine information (with
abbreviated categories).
Coolant Washdown On turn the coolant washdown on to

wash chips from the enclosure.
Coolant Washdown Off turn off the coolant washdown.
Toggle Rapid Override Enable enable or disable the

ability to override the programmed rapid traverse using the
Rapid Override console knob.
Worklight On/Off turn off the enclosure worklight. This

softkey is only available if your machining center is
equipped with an enclosure worklight.
August, 2002
1-23

Test Run Mode
Test Run mode is used to verify the part program and check for program
errors. For Conversational programs, you can adjust the programmed
feedrates and spindle speeds while cutting the part. The an NC Digitizing
feature for NC programs is accessed through the Test Run screen.
Press the Machine Mode Test console key to display the Test Run screen:
Figure 1-12.
Test Run Screen (Conversational Programming)
These are the softkeys for Test Run mode:
Dry Run perform a program test run to identify potential

problems before cutting the part. Specify all or a portion of
the part program that will be tested in the Start and End
blocks.
Trace the tool over the part at the programmed minimum Z
level with the Spindle Off. Peck cycles and roughing passes
are skipped.
Caution
If the Z-Start value is set below the stock surface, the minimum Z
value must be programmed so the tool does not plunge into the part.
1-24
Revision A
Feed & Speed Optimization fine tune execution of the

Conversational part program. Use the Axis Feed Rate and
Spindle Speed dials to adjust the following values within the
Start and End Blocks:
Set Speed modify the spindle speed rate for a

mill subroutine or all speed rates for a mill contour.
Set Plunge Or Segment Feed modify the initial
plunge feedrate of the displayed data block or
current segment of a mill contour.
Set Feed modify the feedrate for a mill
subroutine or all feedrates in a mill contour. Set
Feed does not affect the Rapid Traverse feedrate.
Note
Feedrates for Drilling and Boring operations can be adjusted using
either the Set Plunge Or Segment Feed or the Set Feed softkeys.
Using Set Plunge Or Segment Feed and Set Feed overwrites the
original values with adjusted values. When the test run is completed,
the original values are automatically erased and replaced with the
new values. The new values become effective with the next
execution of the program
Ultimax System
Check for Errors See the Auto Cycle Mode Softkeys

section.
Compute Estimated Run Time See the Auto Cycle

Mode Softkeys section.
August, 2002
1-25

Manual Mode
Manual Mode provides access to machine operations that enable axis
positioning, machine calibration, and other operations.
Pressing the Machine Mode Manual console key displays the screen
shown below. The information at the top of the screen includes the current
position of each axis relative to machine absolute and part zero. Refer to
the Part Setup section of this manual for more information about these
functions.
Figure 1-13.
1-26
Manual Screen
Revision A

These are the softkeys for Manual mode:
Tool In Spindle - indicates which tool is currently in the spindle.

If there is no tool in the spindle, enter a zero (0).
Manual Function Setup access the CE Status & Diagnostics

screen. See the European Manual Safety Override Mode section
of this manual for more information about this softkey.
Park Machine - center the table and leave the spindle at the home
position. See the Park the Machine section of this manual for
more information.
Warm Up Machine warm up an idle machine. See the Warm

Up the Machine section of this manual for more information.
Orient Spindle - ensures that the Z axis is at the correct height for
a tool to be inserted in the spindle.
Important
The Orient Spindle softkey will not function unless the enclosure
doors are completely closed.
Ultimax System
Reset Servos and Spindle - activates only to enable recovery from

certain types of electronic hardware faults such as overloads.
Calibrate Machine establish absolute zero for each axis on the

machining center. See the Calibrate the Machine section of this
manual for more information.
August, 2002
1-27
Spindle
On - activates the spindle if the machine is in manual mode. The

Start Cycle button must also be pushed to start spindle rotation.
Off - stops spindle rotation during manual operation if the Spindle

On button was previously pressed.
Tool Changer
Auto - activates the automatic tool changing function. When

selected, all operator-initiated tool changes will be automatic.
Manual - activates the manual tool changing function. When

selected, all tools must be manually inserted into or removed from
the spindle; bypassing the automatic tool changer.
Coolant
1-28
Auto - activates the selected coolant to spray whenever the tool is

below the Retract Clearance plane. The coolant turns off when the
tool moves above the Retract Clearance plane, or during a tool
change. This key can not be activated in Manual mode. Pressing
this key a second time turns off the coolant operation.
Primary - functions only on machines equipped with a primary

(i.e., flood) coolant system. Activates the primary coolant system
when the machine is in Auto or Manual mode, and overrides an
Coolant Auto operation. Pressing the Primary key a second time
turns off this operation.
Secondary - functions only on machines equipped with a

secondary coolant system (e.g., Coolant Through Spindle, CTS).
Activates the secondary coolant system when the machine is in
Auto or Manual mode and overrides Coolant Auto operation.
Pressing the Secondary key a second time turns off this operation.
Revision A
Communications Panel
Each Hurco machine may be connected to peripheral devices through a
communications panel located on the machines electrical cabinet.
Figure 1 - 14.
Communications Panel
The communications panel may contain a servo-use counter to record

machine usage. An optional cabinet light is positioned above the
remaining connectors.
Communication connectors may include two serial ports and two network
connectors. The BNC connector is used for 10Base2, thin coaxial network
cabling. The RJ45 connector is used for 10BaseT, unshielded twisted pair
network cabling. The circular plug in the center of the plate connects to
optional indexer equipment. Refer to the Appendix for more
information.
Ultimax System
August, 2002
1-29
Power Up
The operator must perform routine checks before attempting to power up
the machine.
Routine Daily Checks

Several mechanical elements require visual inspection, regular
maintenance, and lubrication checks to ensure proper machine operation.
For detailed descriptions of these operations, refer to the Maintenance and
Safety Manual.
Machine Power
The machines On/Off switch supplies power to the entire machine,
including the console. The power switch is located behind the machine, on
the electrical cabinet door.
When the machine is turned on, start up and self-test information appears
on the console screen. Power must be switched off before maintenance
may be performed inside of the electrical cabinet.
Warning
High voltages inside of the electrical cabinet can cause
injury or death. Only qualified and trained maintenance
personnel are authorized to open the electrical cabinet
doors.
When the machine powers up, the following information is displayed on
the screen:
1-30
BIOS Configuration information.
Loading executive - please wait.
Initialization messages.
Scanning and loading language files.
The last part program used when the machine shut down.
Revision A

After the machine powers up, the Input screen appears:
Figure 1-15.
Input Screen
Ultimax will power up in either Conversational or NC mode (ISNC or

Basic NC), depending on the programming last used. The Editor Type
field on the Input screen will display the current mode.
If the Input screen does not appear, or contains error messages, refer to the
Diagnostics Manual for assistance.
Note
Before powering off the machine, refer to the Shut Down section.
Ultimax System
August, 2002
1-31
Establishing Servo Power

Perform the following steps to establish servo power:
1-32
1.
If necessary, release all Emergency Stop buttons.
2.
Press the Machine Mode Manual console key.
3.
Press the Power On console button. When the machine is

switched on, this button lights up.
4.
If there is a servo or spindle error, touch the Reset Servos

and Spindle softkey to clear it. The Start Cycle console
button begins to flash.
5.
Press the Start Cycle button to turn on the machine servos.

The Start Cycle button stops flashing.
Revision A
Calibrate the Machine

Machine calibration establishes the machine reference point - absolute
zero - for each axis. Absolute zero is the location on the table where the X
and Y axes intersect, and is typically set at or near a corner on the table.
Once established, absolute zero does not change.
To calibrate the machine:
1.
Press the Input console key. The Input screen appears.
2.
Press the Machine Mode Manual console key to display the

following screen. The Cal Status field indicates the machine
calibration status.
Figure 1-16.
Ultimax System
Manual Screen Showing Uncalibrated Axes
August, 2002
1-33
Axes Calibration
To calibrate all axes, follow these steps:
1.
Touch the Calibrate Machine softkey on the Manual screen.

The Start Cycle button begins to flash.
2.
Press the flashing Start Cycle button. The Axis Limit

Switches field indicates the status of the machines limit
switches as each axis calibrates.
3.
The Machine field for each axis displays the calibrated

position after calibration is completed.
Note
After calibration, the X or Y Machine field values can be 0.0 or the
Maximum Travel Limit for the axis.
Warm Up the Machine

Warming up an idle machine improves its performance. A machine that
has been idle for at least an hour should be warmed up before cutting
parts. The warm up cycle takes approximately 15 minutes to complete.
Control power must be on, and the axes must be calibrated before the
machine can be warmed up.
Follow these steps to warm up the machine:
1.
Touch the Warm Up Machine softkey on the Manual screen.

The Start Cycle button begins to flash.
2.
Press the flashing Start Cycle button. At the conclusion of

the warm up cycle, axis movement stops and the Start
Cycle button is no longer illuminated.
Follow these steps to cancel the warm-up cycle (after pressing the Start
Cycle button):
1.
Press the Feed Hold console (Motion Hold on Max console)

button.
2.
Press the Spindle Off button.
3.
Press the Feed Hold (or, Motion Hold) console button a

second time, or press the Stop Cycle button.
Important
To cancel the warm up cycle before pressing the Start Cycle button, press
any Machine Mode console key.
1-34
Revision A
Automatic Tool Changers

Hurco machining centers use either a Swing-Arm Random Pocket
Automatic Tool Changer (ATC) or a Horizontal Chain Type ATC. Both
types of ATCs function essentially the same.
Each tool is inserted into a tool holder before being loaded into the
spindle. The orientation hole in the tool holder must always line up with
the orientation key in the tool changer. Tool changer stations are
numbered to identify and locate each tool.
Important
Only use tools that are dimensioned for the maximum spindle speed.
Loading a Tool into the Spindle

Use this procedure to manually load a tool into the spindle:
Ultimax System
1.
Press the Machine Mode Manual console key to prevent the

ATC from moving while you insert a tool. The Manual
screen appears.
2.
Touch the Orient Spindle softkey to position the spindle for

tool insertion. If there is a tool in the spindle, refer to the
Removing a Tool from the Spindle section.
3.
Insert the tool holder into the spindle. Make sure the tool
holder slots align with the spindle head guides.
4.
Release the Spindle Unclamp button to secure the tool in the

spindle. Be certain that the tool is firmly seated.
5.
Touch the Tool In Spindle softkey. The Tool In Spindle

field appears.
6.
Make sure the tool number in the Tool In Spindle field

matches the number of the tool in the spindle. If the
numbers do not match, enter the correct tool number.
7.
To load a tool into the ATC magazine, see the Loading

Tools into the ATC Magazine section.
August, 2002
1-35
Unloading a Tool from the Spindle

To manually remove a tool from the spindle, follow these steps:
1-36
1.
Press the Manual Mode console key. The Manual screen

appears.
2.
Hold the tool to prevent it from dropping.
3.
Press the Spindle Unclamp button. The spindle unclamp

button is either on the side of the spindle, or the front of the
spindle. Refer to Parts Listing and Wiring Diagrams
Manual for your machine for a drawing showing the Spindle
Unclamp button location.
4.
The tool disengages. Pull the tool out of the spindle.
5.
Release the Spindle Unclamp button when the tool is free.
Revision A
Loading Tools into the ATC Magazine

The ATC takes a tool from the spindle and automatically loads it into the
magazine, if space allows. The tools location in the magazine is recorded
in the ATC Map (the Horizontal Chain Type ATC does not use an ATC
Map). Before loading a tool into the ATC magazine, the Servo power
must be On, and the machine must be calibrated.
Warning
Do not manually load tools directly into the magazine.
To load the tool currently in the spindle into the ATC magazine:
1.
2.
Touch the Tool In Spindle softkey. The Tool in Spindle,

Next Tool, and ATC Map (Swing-Arm Random Pocket
ATC only) fields appear. For more information about the
ATC Map, see The ATC Map section.
3.
Verify that the Tool In Spindle value matches the tool

currently in the spindle. If the numbers do not match, enter
the correct tool number.
4.
Enter the same tool number into the Next Tool field.
5.
Press the Tool Changer Auto console key.
6.
Enter a new tool number into the Next Tool field. The ATC
Map field must be Auto.
7.
Press the Tool Changer Auto console key. The Start Cycle
light begins flashing.
8.
Clear the tool changer and shut the enclosure door. Press the
Start Cycle button. The Tool In Spindle field will be
updated to the next tool value.
Ultimax System
If the Next Tool is an Auto tool, it was placed into

the magazine when the previous tool was removed
from the spindle.
If the Next Tool is a Manual tool, you will be
prompted to insert it into the spindle.
August, 2002
1-37
Removing Tools from the ATC Magazine

Remove tools from the ATC magazine by following these steps:
1.
2.
Touch the Tool In Spindle softkey to access the Tool In

Spindle screen. If there is no tool in the spindle, set the Tool
In Spindle field to 0 (zero).
Note
The ATC Map field will indicate if the tool selected is in the
magazine, and its location.
1-38
3.
Enter the tool number (of the tool you want to remove in the
magazine) into the Next Tool field.
4.
Press the Tool Changer Auto console key to move the Next
Tool into the spindle.
5.
Clear the tool changer area and shut the enclosure door.
Press the Start Cycle button to initiate the tool change.
6.
Press the Spindle Unclamp button and manually remove the

tool from the spindle.
7.
Repeat steps 2 through 6, as needed, to remove additional

tools from the ATC magazine.
Revision A
Large Tools in the ATC Magazine

A part program may require tools with large diameters. These tools can be
manually loaded by the operator, or automatically loaded.
Note
The ATC magazine capacity is reduced by half for tools larger than
80 mm (125 mm for some machines).
Follow these steps to load large tools into the ATC magazine:
1.
Touch the ATC Map softkey from the Tool In Spindle

screen. The ATC Map appears. See The ATC Map section
for more information.
2.
Touch the Max. Tool Dia. More than XX mm softkey.
3.
An ATC Map will be cleared! Are you sure you want to

change Max. Tool Diameter to more than XX mm?
message appears.
Important
Each time you switch between large and small tools, the entire ATC
Map will be cleared and the magazine must be reloaded.
Ultimax System
4.
Touch the Yes softkey. The ATC Map will clear, then
reappear. Only the odd numbered tool pockets will be
available.
5.
Reload tools into the magazine using the Loading a Tool

into the Spindle section.
6.
Return to the default setting of Maximum Tool Diameter

XX mm or Less by using the previous procedure and
touching the Max. Tool Dia. XX mm or Less softkey.
August, 2002
1-39
The ATC Map

Ultimax optimizes tool change speed by eliminating redundant rotation of
the ATC magazine. Because tool numbers and tool pot numbers on the
magazine may not correspond, the ATC Map keeps track of tool location.
You can view the ATC Map at any time to determine where a tool is
located in the magazine. To view the ATC Map, follow these steps:
1.
Press the Machine Mode Manual console button.
2.
Touch the Tool In Spindle softkey.
3.
Touch the ATC Map softkey. The following screen appears:
Figure 1-17.
ATC Map Screen
Toggle the ATC Map field between Manual and Auto by pressing the
Tool Changer Auto console key.
1-40
A Manual tool is any tool that is not currently in the ATC

Map. A Manual tool must be manually inserted into, and
removed from, the spindle; and is not placed in the tool
magazine. If you want a Manual tool in the tool magazine,
you must convert it to an Auto tool in Tool Setup.
An Auto tool is any tool that is currently listed in the ATC

Map.
Revision A

Note
The default setting for ATC Map field is Manual. A qualified Hurco
Field Service Engineer can change the default setting to Auto.
Resetting the ATC Map

If you are emptying the ATC magazine and loading new tools, you must
first clear the ATC Map:
1.
Press the Machine Mode Manual console button.
2.
Touch the Tool In Spindle softkey to access the Tool In

Spindle screen.
3.
Touch the ATC Map softkey.
4.
Touch the Reset ATC Map softkey. A message will appear

asking if you wish to continue with the procedure. Select
Yes to continue.
After clearing the ATC Map, load the first tool into the spindle as
described in the Loading a Tool into the Spindle section.
Ultimax System
August, 2002
1-41
Shut Down
Use one of the following three shut down methods to shut power off to the
servos and stop lubrication from pumping onto the ways. Always shut
down the machine before turning off machine power.
Important
If the machine will not be used for several days, or the shop has
power surges or blackouts, turn off machine power at the main
power switch.
Emergency Stop Shut Down

To shut down the machine quickly, press the Emergency Stop button. An
Emergency Stop has been depressed message appears on the screen.
Warning
Emergency Stop shut down is not good for the
machines table, especially if the table is long and has
heavy equipment attached to one end. Before pressing
the Emergency Stop button, park the machine or center
the table.
To restart the machine:
1-42
1.
Twist the Emergency Stop button to release it.
2.
3.
Press the Power On button.
4.
Press the Start Cycle button.
Revision A
Park the Machine

Parking the machine centers the table and leaves the spindle at the home
position. Before parking the machine, the Servo Power must be On, the
machine must be calibrated, and the Tool In Spindle must be zero (0).
Follow this procedure to park the machine:
1.
2.
Touch the Park Machine softkey. The Start Cycle button

flashes.
3.
Press the Start Cycle button. The machine moves to the park
position.
To restart a parked machine:

1.
2.
3.
Control Power Off Time

Control Power Off Timer automatically shuts the machine down if it
has been idle for a specified amount of time. The table is not
centered when using Control Power Off Time shut down. To shut
down the machine using the Control Power Off Time:
1.
Select the Auxiliary console key to access the Auxiliary

screen.
2.
Touch the System Configuration softkey. The System

Parameters screen appears.
3.
In the Control Power Off Time field, enter the number of

minutes to wait before automatic power shut off. If this field
is zero (0), the machine will not automatically shut down.
4.
You may still use the control for programming, but power to
the servos is not available.
To restart the machine:
Ultimax System
1.
2.
3.
August, 2002
1-43
1-2
Revision A
Chapter 2
File Management and

System Configuration
This chapter explains how to manage part programs, customize system settings, manage
and upgrade system software. Every operation described can be accessed through the
Auxiliary screen. Press the Auxiliary console key to view the Auxiliary screen.
File Management
Part programs are stored on the Computer Numeric Control (CNC) hard
drive, or on floppy diskettes. Each hard drive contains one main
directorythe root directory. An operator cannot create this directory, but
directories and subdirectories can be stored in it to enhance file
management.
Compare file management to a filing cabinet. The hard drive is the filing
cabinet. A directory is a file cabinet drawer. A subdirectory is a file folder
inside a drawer. Part programs are individual sheets of paper that are
stored loose on the hard drive, or filed in directories and subdirectories.
Hard Drive
(Root directory "C")
Subdirectories
Directories
Part Program Files
Figure 2-1.
Ultimax System
Directory Structure
August, 2002
2-2
Storage Functions
The Current Program screen contains softkeys that access file storage
functions such as reading and writing programs. This section explains how
to access storage functions.
Touch the Storage Functions softkey on the Auxiliary screen . The Current
Program screen appears.
Figure 2-2.
Current Program Screen
The disk drive currently available is listed at the top of the screen. See the
Select Current Storage Drive section for information on selecting a
different drive.
Small icons that symbolize storage devices appear in the bottom left
corner of the screen. An indicator blinks on each icon when the drive it
representsis accessed. If you have installed the UltiNet option and you
have an active network connection, a network drive icon will also display.
Note
The floppy disk drive is located on the right side of the console (you
must have the Floppy Disk option installed to access the floppy disk
drive on a Max console). See the Consoles section in the
Machine and Basics chapter for information.
Ultimax System
August, 2002
2-3
Read Program From Disk

You can load a previously created part program from a hard drive of
floppy diskette into the control. Follow these steps:
1.
On the Current Program screen, touch the Read Program

from Disk softkey.
2.
Display the directory where the program resides.
3.
Highlight the program and press Enter to select it.
4.
A pop-up message appears notifying you Ultimax

is reading the program.
The programname (name the program was saved
under) appears in the upper left-hand corner when
the program is loaded.
Press the Input console key to view the program. For

Conversational programs, do not press the Input console key
until the hard drive icons indicator light stops blinking.
Note
NC programs are much larger than Conversational programs.
Loading large NC programs may require more memory than is
installed. If you frequently use large NC programs, contact an
authorized distributor about adding memory.
Abort a Read Program from Disk

To stop reading a program from disk, touch the Abort Operation
softkey.
2-4
Revision A
Write Program to Disk

To write (save) a part program to the current drive, follow these steps:
1.
Touch the Write Program To Disk softkey on the Current

Program screen. The Current Directory screen appears.
2.
Touch the Select Current Storage Drive softkey. Choose the

drive on which the program will be stored - hard drive,
floppy drive, or network drive (if UltiNet is installed).
3.
If you created directories, use the Arrow keys to highlight

the name of the directory that will receive the program.
Touch the Change to Directory softkey to select the
highlighted directory.
4.
Touch the Begin Operation softkey. The control will prompt

you to enter the part program name. See the Part Program,
Directory and Subdirectory Names section for
information.
5.
Save the program by using one of these methods:
To save the program with the same name, press the

Enter key. If a program with the same name
already exists in the directory, a Program already
exists. Overwrite it? message appears. To copy
the current version of the program over the older
version, touch the Yes softkey. Touch the No
softkey to save the older version.
Type in a new program name and press the Enter
key.
Hints and Tricks

If you modify a part program, you can save both the original and
modified programs. Save the modified program under a different
name, and youll still have the original program, too.
When a part program is saved, a three-character file extension is
appended after a period to the program name . The file extension
defines the programming mode or dialect. Default file extensions
are:
.HD3 (Conversational part program)
.HNC (NC part program, BNC dialect)
.FNC (NC part program, ISNC dialect).
Ultimax System
August, 2002
2-5

Note
.HD5 filenames are not supported and must be converted to .HD3 to
be used with the Ultimax system.
Part Program, Directory and Subdirectory Names

Part program names can be up to 12 characters long, including the
period and three character file extension. Directory and Subdirectory
names can be up to 12 characters long.
The following characters are valid for part program, directory and
subdirectory names:
2-6
Upper and lower case letters (A-Z, a-z)
Numbers (0-9)
&
(single quote)
- (hyphen)
_ (underscore)
Revision A
Disk Operations List Directory

The Disk Operations List Directory helps you manage part programs and
files. The current directory and disk drive displays at the top of the screen.
A list of part programs stored in the current directory appears in the body
of the screen. To access the Disk Operations List Directory menus:
1.
Touch the Disk Operations List Directory softkey on the

Current Program screen. The Current Directory screen
appears.
2.
Access file management operations similar to those used in

personal computers - discussed in the following pages.
Change to Directory
Change the current directory. Use the Arrow keys to highlight the
desired directory and touch the corresponding softkey. The Current
Directory screen updates to display the directory, subdirectory, and
part program names. Part programs have an .HD3 extension.
Hints and Tricks

Another way to change the directory is to highlight the desired
directory and press Enter.
Rename Program
To rename a program, follow these steps:
1.
Select a directory. Use the Arrow keys to highlight the

program to be renamed.
Note
A selected part program will either be highlighted or appear below
the list of all programs available in the current directory.
2.
Touch the Rename Program softkey on the Current

Directory screen.
3.
Type in a new program name using the pop-up Text Entry

Window or optional keyboard. See the Part Program,
Directory and Subdirectory Names section for more
information.
Note
Touch the Abort Operation softkey to stop the renaming process.
Ultimax System
August, 2002
2-7
Delete Program
To delete a part program, follow these steps:
1.
Select a directory and use the Arrow keys to highlight the

program to be deleted.
2.
Touch the Delete Program softkey on the Current Directory

screen.
3.
An Are you sure you want to delete this program?

message appears.
Touch the No softkey to leave the program intact.

Touch the Yes softkey to erase the program.
Copy Program
To reorganize part programs, or to copy programs between the hard and
floppy drives and the network (if the UltiNet option is installed), follow
these steps:
1.
Select a directory and use the arrow key to select the

program you wish to copy.
2.
Touch the Copy Program softkey on the Current Directory

screen.
3.
Select the directory in which the copied program will be

stored.
4.
Touch the Begin Operation softkey. If the program already

exists, you are asked if you want to overwrite it. Touch the
Yes softkey to overwrite the existing program. Touch the
No softkey to abort the overwriting.
Program Mask
A program mask limits the programs displayed on the screen to a specific
group. Program names that do not match the program mask are not
displayed in the program listing. A program mask can contain up to 12
characters (including the period and three characters for the file
extension).
To change the program mask in the current directory:
2-8
1.
Touch the Change Program Mask softkey on the Current

Directory screen. The cursor appears at the current
extension.
2.
Type in the desired mask and press the Enter key. Only
programs matching the mask will be displayed in the
program listing.
Revision A

You can also use wildcards with program mask. A wildcard is a character
that can match any character or sequence of characters. Use the ? as a
wildcard for a single character, and the * as a wildcard for one more
characters.
Here are some ways to use wildcards with program mask:
To see all part programs that begin with the letter

G in the current directory, Type G*.* and press
the Enter key.
To see only the ISNC part programs (*.FNC file
extension) in the current directory, type *.FNC
and press the Enter key.
To see all part programs and files in the current
directory, type *.* and press the Enter key.
Important
Once the NC file mask is changed, the *.FNC or *.HNC default is
lost. To return to the original defaults, delete the NCPARAMS.SET
file.
Select Current Storage Drive

Touch the Select Current Storage Drive softkey on the Current Program
screen to store a program on the hard drive or to a floppy disk. Softkeys
allow you to choose the drive in which to store the program.
Note
If the UltiNet option is installed on your machine, the Network
Drive E softkey will appear on the Select Current Storage Drive
screen. For more information, see the UltiNet Option Manual.
Ultimax System
August, 2002
2-9
Create Directory
To create a directory or subdirectory:
1.
Touch the More softkey on the Current Directory screen.
2.
Touch the Create Directory softkey.
3.
Use either the pop-up Text Entry Window or keyboard to

enter the name of the directory you want to create. See the
Part Program, Directory and Subdirectory Names section
for information.
4.
Press the Enter key to create the directory.
Note
Touch the More softkey to return to the first page of the Disk
Operations List Directory softkeys.
Delete Directory
Remove a directory or subdirectory from the hard drive. Directories and
subdirectories containing part programs cannot be deleted. In addition, the
floppy disk drive and hard disk drive cannot be deleted.
To delete a directory:
1.
2.
Select the desired directory using the Arrow keys.
3.
Touch the Delete Directory softkey.
4.
Touch the Yes softkey. A Deleting Directory message

appears. If you do not want to delete the selected directory,
touch the No softkey.
Note
2-10
Revision A
Tag All Programs

Tag a program for copying or deleting. To tag programs:
1.
2.
Touch the Tag All Programs softkey.
3.
An asterisk (*) appears to the left of every part program in

the Current Directory list.
Note
Untag All Programs

Remove the tag markers from all of the tagged programs in the directory.
To untag all programs, follow these steps:
1.
Touch the More softkey.
2.
Touch the Untag All Programs softkey on the Current

Directory screen.
3.
The asterisk (*) is removed from every program in the

Current Directory list.
Note
Toggle Program Tag

Add or remove a tag marker from one or more part programs. To toggle
the program tag:
1.
2.
Select a part program from the current directory list.
3.
Touch the Toggle Program Tag softkey.
4.
If the part program was tagged with an asterisk (*), the * is

removed. If the part program was not tagged, an * appears
to the left of the part program name in the program list.
Note
Ultimax System
August, 2002
2-11
Copy All Tagged Programs

To copy all of the tagged part programs:
1.
2.
Select the desired part programs.
3.
Touch the Copy All Programs softkey. These softkey are

available:
Begin Operation copy tagged programs into the

Current Directory.
Change to Directory copy the tagged programs
into another directory.
Create Directory create a new directory and
place the copied programs into it.
Select Current Storage Drive select one of the
storage drives to hold the copied programs.
Note
You cannot place a copied program into the same directory as the
original program.
Delete All Tagged Programs

To delete all the tagged part programs:
1.
2.
Touch the Untag All Programs softkey.
3.
Touch the Yes softkey to delete tagged programs. Touching

the No softkey leaves the tagged programs intact.
Note
2-12
Revision A
Format Diskette
Note
You must have the Floppy Disk option installed on the Max console
to use and format a floppy diskette.
Format a diskette that is not pre-formatted. To format diskettes, follow
these steps:
1.
Insert a diskette in the floppy (A) drive.
2.
Touch the Format Diskette softkey on the Current Program

screen. A prompt appears asking if you want to continue the
process. Touch the Yes softkey.
3.
A prompt appears for selecting the format density. Touch

either the 720KB or 1.44 MB softkey.
4.
Type in a Disk Volume (name) Label at the prompt, or press

the Enter key to ignore. The volume label can contain up to
eight characters and is displayed as part of the directory
listing.
5.
Formatting may take a few minutes. A Formatting floppy

disk message appears in a pop-up window. When
formatting is complete, a Floppy disk format complete
message appears in a pop-up window.
Select Current Storage Drive

Touch the Select Current Storage Drive softkey on the Current Program
screen to store a program on the hard drive or to a floppy disk. Screen
softkeys allow you to choose the drive in which to store the program.
Export Program as Text File

Touch the Export Program as Text File softkey on the Current Program
screen to send a Conversational program as a text file to a floppy diskette
or network drive (if the UltiNet option is installed). The Conversational
program must be saved before it can be exported as a text file.
Note
This feature is not available for NC programs.
Ultimax System
August, 2002
2-13
Change NC Dialect
Touch the Change NC Dialect softkey on the Auxiliary screen to switch
between the Basic Numerical Control (BNC) and Industry Standard
Numerical Control (ISNC) dialect when creating NC part programs
Download/Upload
Transfer part programs between the CNC and various peripheral devices
(e.g., PC, external disk drive) with the Download/Upload softkeys on the
Auxiliary screen.
The baud rate determines how fast a single bit of information is
transferred between two serial modems. The baud rate is measured in
characters per second.
Note
Improper cable connections and incompatible communications
settings are the most common problems that prevent communication
between two electronic devices. Refer to the machine Parts Listing
and Wiring Diagrams Manual for cabling requirements.
Hints and Tricks

Always use your fastest computer for transferring programs to the
CNC.
2-14
Conversational programs can be transferred between the

CNCs memory and peripheral devices.
NC programs can be transferred between peripheral devices

and the CNCs memory or current drive.
Revision A

Transfer
Memory to
Peripheral Device
(Download Send)
Current Drive to
Peripheral Device
(Download Send)
Peripheral Device to
Current Drive
(Upload Receive)
Peripheral Device to
Memory
(Upload Receive)
Table 2 - 1.
Conversational
NC
Yes
Yes
No
Yes
No
Yes
Yes
Yes
Transfer Types for Conversational and NC Programs
Note
Upload/Download screens differ between Conversational and NC
programming, but the softkeys function the same.
Figure 2 - 3.
Ultimax System
Conversational Download/Upload screen
August, 2002
2-15

The following screen is the NC Download/Upload screen:
Figure2 - 4.
NC Download/Upload screen
Serial Port Status Messages

The status of the Upload/Download process is displayed on the screen.
Messages appear in a pop-up window for Conversational programs, and in
the Serial Port field for NC programs.
2-16
Conversational
Message
NC
Message
(Not Busy)
Waiting to
Receive
(Busy Reading
Leader)
Receiving Data
(Busy Loading)
Sending Data
(Busy Sending)
Waiting to Send
(Waiting To
Send)
Revision A
Description
The Serial Port was not
requested to transmit any data.
The Serial Port is active and
ready to receive data. Begin
sending data from the peripheral
device.
receiving data from the
peripheral device.
sending data from the CNC.
waiting for the peripheral
device to be ready to receive data.
Upload Receive
Receive a part program from peripheral devices, such as a PC. Follow the
instructions on the screen to complete the part program transfer to the
CNC. While an NC program is being uploaded, an R (reading) or W
(writing) icon appears on the screen.
Aborting an Upload
To abort a Conversational programming upload, touch the Exit softkey.
To abort an NC programming upload, touch the Abort Operation softkey.
Upload an NC Part Program to a Disk Drive

Note
Only NC part programs can be uploaded in the following manner.
Upload an NC part program from a remote device to a disk drive:
Ultimax System
1.
Set up the port parameters. Refer to the Serial Port Setup

section.
2.
Make sure the Source/Dest parameter is set to Disk File to

store the part program to the current drive.
3.
Touch the Upload Receive softkey.
4.
Select the port to receive the program.
5.
If needed, select the disk drive to receive the program.

a.
Touch the Select Current Storage Drive softkey on

the Upload/Download screen.
b.
Select the appropriate device.
6.
If needed, select the directory to receive the program.
7.
Name the part program and press the Enter key. The
Auxiliary screen redisplays.
8.
The screen message changes from Not Busy to Busy

Reading Leader.
9.
Upload the program from the remote device. The program is

sent to the disk drive. The screen message changes to Busy
Loading and then to Not Busy upon completion.
August, 2002
2-17
Upload a Part Program to Memory

Note
Both Conversational and NC part programs can be uploaded in the
following manner.
Follow these steps to upload a part program from a remote device into the
CNCs memory:
1.
Set up the port parameters for the appropriate port.
2.
Set the Source/Dest parameter to Memory to save the part

program into the CNCs memory.
3.
Start the program loading operation by touching the Upload

Receive softkey on the Upload/Download screen.
4.
Touch the appropriate softkey to select the correct port to

receive the program. If there is currently a program in
memory, a Should the current file in memory be deleted?
5.
a.
Touch the Yes softkey to delete the current

program from memory and continue uploading.
b.
Touch the No softkey if you want to save the

current program in memory to a disk drive.
The Status Message appears. Initiate data transfer from the

remote device. The Status Message changes when the
upload is complete.
Note
An NC part program loaded into the CNC memory buffer may be
machined while it is loading
2-18
Revision A
Download Send
Download a part program from the CNC to peripheral device. During
downloading, a status message displays. When the download is complete,
a confirmation message appears.
While an NC program is being downloaded, an R (reading) or W
(writing) icon appears on the screen.
Aborting an Download
To abort a Conversational programming download, touch the Exit softkey.
To abort an NC programming download, touch the Abort Operation
softkey.
Download a Part Program from Memory

Note
Both Conversational and NC part programs can be downloaded in
the following manner.
Follow these steps to send a copy of a Conversational or NC program in
memory to a remote device via a serial port:
Ultimax System
1.
Prepare the remote equipment to receive the program sent

by the control.
2.
Make sure the desired program is currently in memory.
3.
Press the console Auxiliary key.
4.
Touch the Download/Upload softkey.
5.
Set up the port parameters.
6.
For NC, set the Source/Dest parameter to Memory to

retrieve the part program from the CNCs memory.
7.
Touch the Download/Send softkey to start the part program

transfer.
8.
Press the appropriate softkey for the sending port.

Downloading begins and the Status Message appears.
9.
Upon completion, the system displays the Part Program

Written and the Status Message changes.
August, 2002
2-19
Download an NC Part Program from the Current Drive

Note
Only NC part programs can be downloaded in the following manner.
To send an NC program from the current drive to a remote device, follow
these steps:
1.
Prepare the remote device to receive the program.
2.
Select the Download/Upload softkey on the Auxiliary

screen.
3.
Setup the port parameters. Refer to the Setting Serial Port

section.
4.
Set the Source/Dest parameter to Disk File to access the part

program from the current drive.
5.
Select the Download/Send (F3) softkey.
6.
Select the port to which to send the program.
7.
Select a disk drive, if the current drive does not contain the
program to be sent.
a.
Touch the Select Current Storage Drive softkey.
b.
Select the storage drive.
8.
Select a directory, if the current directory does not contain

the program to be sent.
9.
Select the program to be sent by highlighting it with the

Arrow keys and pressing the Enter key. The program
automatically downloads.
10. The message next to the sending port number changes to

Busy Sending. The message changes to Not Busy when
the download completes.
2-20
Revision A
Select Port
Touch the Select Port softkey on the Upload/Download screen to switch
between serial ports. The screen changes to display the other port and its
settings.
Note
The Select Port softkey is only available for Conversational
programs.
Abort Operation
Touch the Abort Operation softkey to stop the current NC programming
upload/download operation.
Reset Port Parameters

Reset the displayed serial port to its default values by touching the Reset
Port Parameters softkey on the Upload/Download screen.
Default Communication Settings

The communication settings to the following default values:
Communication Setting
(Field)
Protocol
Baud Rate
Character Length
Stop Bits
Parity
Source/Dest
Table2 - 2.
Conversational
XON/XOFF
9600
8
1
None
NA
NC
XON/XOFF
9600
NA
NA
NA
Memory
Default Communication Settings
Important
Before attempting to transmit a part program, the CNCs serial port and
peripheral port must be identically configured.
Ultimax System
August, 2002
2-21
Serial Port Setup

Protocol
Protocol or handshaking refers to the method that data is transferred
between two devices. The Ultimax control uses hardware and software
protocols.
Refer to the Appendix for descriptions of these protocols and the reasons
to select each. An operator who wants to write communications utilities
will find this information useful. Here are the Protocol Option softkeys:
RS491 Level 1 CTS/RTS softkey
RS491 Level 2 XON/XOFF softkey
RS491 Level 3 Full Handshake softkey
Baud Rates
Choose between seven baud rates. Select the proper baud rate for the
connected equipment using the Baud Rate fields softkey menu.
Important
The 9600 baud is the default setting for the control. This speed is
adequate for most applications.
The baud rates for the remote device and the control must match.
Setting Serial Port

Follow these steps to change Serial Port settings for each port:
2-22
1.
Move the cursor to the Protocol field on the

Upload/Download screen and touch the appropriate
communication protocol softkey.
2.
Move the cursor to the Baud Rate field and touch the baud
rate softkey for the port.
3.
For Conversational programming Upload/Download, select

the Character Length, Stop Bits, and Parity by entering the
appropriate value in each field.
Revision A
System Configuration
Access the System Configuration screen to customize console settings:
1.
Press the Auxiliary console key to access the Auxiliary

screen.
2.
Touch the System Configuration softkey to access the

console settings.
Figure 2 - 5.
Ultimax System
System Configuration screen
August, 2002
2-23
Current System Date

System date and time are maintained even when the console is off. These fields should be
checked and values entered only if the battery runs down.
To enter todays date into the system, move the cursor to the Month field
on the System Configuration screen, and follow these steps:
1.
Type the number of the month. Press the Enter key to move
to the next portion of the field.
2.
Type the number of the day. Press the Enter key.
3.
Type the last two digits of the year. Press the Enter key.
Note
After 2000, the year will display as one digit, even if two digits
are entered. For example, if you enter 02 for the year 2002,
it will display as 2.
4.
Touch the Set Current System Time softkey.
Current System Time

This field uses a 24-hour clock. For example, 1:30 p.m. is entered as
13:30. To enter the current time into the system, follow these steps:
1.
Enter an hour. Press the Enter key to move to the next

portion of the field.
2.
Enter the minutes. Press the Enter key.
3.
Enter the seconds, if desired. Press the Enter key.
4.
Touch the Set Current System Time softkey to store this

date when saving a program.
Control Power Off Time

Specify the maximum time the axes can be idle before automatically
shutting down the machine. See the Control Power Off Time section in
the Machine and Console and Basics chapter for more information.
2-24
Revision A
AutoSave Time
Use the AutoSave feature to periodically save a copy of the Conversational
part program to the hard drive in a file named saveprog.hd3. While the
part program is being saved, the system displays Autosaving Part
Program message.
Set the AutoSave Time field on the System Configuration screen to
specify how often programs should be automatically saved to the hard
drive. Enter zero (0) in the AutoSave Time field to disable this feature.
Programming changes made after the last AutoSave are lost if the CNC is
rebooted or loses power. When the control is restored, the last AutoSave
version of the program automatically appears on the screen.
Note
The AutoSave feature is not available for NC programs.
Important
AutoSave does not save a program to its original programname or drive.
Refer to Write Program to Disk for instructions on saving a program.
Screen Blank Time

Determine how long the console can remain idle before it goes blank with
the Screen Blank Time feature. Screen Blank Time is similar to a PCs
screen saver.
Enter a time in minutes in the Screen Blank Time field on the System
Configuration screen. The screen will go blank after the entered time:
Ultimax System
For Ulitmax dual screen console - If the console keys or

buttons are not touched, and the machine is not moving for
the specified time, the Text screen will go blank. In
addition, if the Draw console key, Select console key, or
trackball are not touched for the specified time, the Graphics
screen will also go blank.
For Max console If console keys or buttons are not

touched, or the machine is not moving for the specified
time, the screen will go blank.
August, 2002
2-25
Important
To redisplay blank screens, move the trackball or press any console
key. The first keystroke is used to re-activate the blank screen. The
second keystroke begins programming input.
DRO Display Units

The Digital Read Out (DRO) shows the current position of the axes and
their feed rate. The DRO may be set to display this information in
millimeters or inches, independent of the unit of measurement used in the
part program.
The DRO is viewed in the Manual or the Auto Mode screens. A status line
at the bottom of the screen indicates program units (mm or in).
Setting the DRO Display Units

To set the DRO display units (metric or inches):
1.
Move the cursor to the DRO Display Units field on the

System Configuration screen.
2.
Touch the Inch softkey to set the DRO display to inches.

Touch the Metric softkey to set the DRO display to metric.
Changing DRO Character Size

You can change the DRO character size only for the Auto screen. Touch
the Toggle Display softkey to change from the standard display to the
Quad Size display. Touch the Toggle Display softkey again to change the
DRO display size back to standard.
2-26
Revision A
Text Entry Window

If an optional keyboard is not installed, enable the pop-up Text Entry
Window to enter alphabetic characters and numbers. For instructions on
how to use the pop-up window, refer to the Text Entry Window section
of the Machine and Console Basics chapter.
Turning On the Text Entry Window

To enable the pop-up Text Entry Window
1.
Place the cursor in the Enable Text Entry Window field on

the System Configuration screen.
2.
Touch the Yes softkey.
Turning Off the Text Entry Window

To turn off the Text Entry Window:
1.
Place the cursor in the Enable Text Entry Window field on

the System Configuration screen.
2.
Touch the No softkey.
File Display Method

Reorganize the way file and directory information is displayed on the
screen. To change the file display:
1.
Place the cursor in the File Display Method field on the

System Configuration screen.
2.
Touch the Sorted Horizontally softkey or Sorted Vertically

softkey.
Video Hardware Type

The Video Hardware Type field identifies the console screen type. For the
Max console, set this field on the System Configuration screen to Single
VGA. Set the field to Dual VGA for the Ultimax 4 console.
Hints and Tricks

If the Ultimax 4 console monitor or video channel breaks down, substitute
it with a PC monitor until its repaired. Set the Video Hardware Type field
for to Single VGA while using the PC monitor. Reset the field after the
Ultimax 4 console is repaired or replaced.
Ultimax System
August, 2002
2-27
Set Network Parameters

Network parameters must be set if the UltiNet Option is installed. Refer to
the UltiNet Option Manual for programming with UltiNet. Information
about this option is available from Hurco or your Hurco distributor.
Set Color Parameters

The Ulitmax dual screen and Max consoles have a color Liquid Crystal
Display (LCD). The display colors may be adjusted for lighting
conditions, or to suit personal preferences. Several possible colors can be
selected for most of the text and graphics displays.
Touch the Set Color Parameters softkey on the System Configuration
screen to set the colors on the text, graphics, and storage function screens.
Text Color Parameters

Change the colors on the Text screen. Color bars at the bottom of each
function key show the color that will appear for each softkey selection.
The chart below lists the Text Color Parameters defaults:
Text Color Parameters
Background Color
Label Color
Data Color
Prompt/Error Area Color
Active Softkey Text Color
Inactive Softkey Text Color
Softkey/Window
Top Frame Color
Softkey/Window
Bottom Frame Color
Softkey Number Color
Cursor Foreground Color
Cursor Background Color
Table2 - 3.
2-28
Color Screen Defaults

Blue
Yellow
Light Green
Light Red
Light Cyan
Light Blue
White
Dark Gray
Black
White
Green
Text Color Parameter Defaults
Revision A
Graphics Color Parameters

Change the colors on the Graphics screen. Color bars at the bottom of
each function key show the color that will appear for each softkey
selection.
The chart below lists the Graphics screen defaults:
Graphics Color Parameters
Background Color
Blue
Part Path Color
Light Cyan
Cutter Path Color
Yellow
Rapid Path Color
Light Red
Axes Color
Light Cyan
Character Color
White
Menu Box Color
Light Cyan
Pointing Device Cursor Color
White
DXF Line Color
Green
DXF Highlight Color
Yellow
DXF Branch Color
Red
DXF Calculator Display Color
Light Green
DXF Calculator Buttons Color
White
DXF Calculator Grid Color
Green
DXF Milled Color
Cyan
Table2 - 4.
Graphics Color Parameter Defaults Defaults
Note
The DXF color options appear on this screen only when the DXF
option is installed on the system.
Ultimax System
August, 2002
2-29
Storage Functions Color Parameters

Change the colors on the Storage Functions screen . Color bars at the
bottom of each function key show the color that will appear for each
softkey selection:
The chart below lists the Storage Functions screen defaults :
Storage Functions
Parameters
Directory Background Color
White
Highlighted Directory Color
Red
Unhighlighted Directory
Color
Light Red
Current Directory Color
Red
File Background Color
White
Highlighted File Color
Cyan
Unhighlighted File Color
Light Cyan
Page Up/Down Arrow Color
Yellow
Table2 - 5.
Storage Function Color Parameter DefaultsDefaults
Display Machine Specifications

Touch the Display Machine Specifications softkey on the System
Configuration screen for a description of the machining center. The
number of axes present, travel limit, maximum spindle motor and tool
speed, and maximum traverse rate are listed on the Display Machine
Specficiations screen.
The Machine Hour Meter field on the Display Machine Specifications
screen displays the current machine hours usage, when control power is
on. Maching usage is not updated while the Display Machine
Specficiations screen is open.
2-30
Revision A
Display Software Configuration

Touch the Display Software Configuration softkey on the System
Configuration screen to display the CNC Configuration screen.
The Ultimax software version and options available for the machining
center are displayed on this screen.
Figure 2 - 6.
CNC Configuration Screen
Note
The software version and options displayed above may be different from
what is displayed on the CNC for your machining center.
Ultimax System
August, 2002
2-31
Display Ladder Configuration

Touch the Display Ladder Configuration softkey on the CNC
Configuration screen to see the individual files that customize the Ultimax
control to a specific machining center model.
The Ladder Configuration screen contains information useful when
contacting Hurco technical assistance about machine problems.
Figure 2 - 7.
2-32
Ladder Configuration Screen
Revision A
Backup Config and Machine Files

Touch the Backup Config and Machine Files softkey on the System
Configuration screen to copy the following files onto a floppy diskette or
the hard drive:
Boot Configuration files
Machine Configuration files
Ladder files
Leadscrew map
Restore Config Machine Files

Touch the Restore Config Machine Files softkey on the System
Configuration screen to restore previously saved Machine Configuration
data stored on the hard drive. Use this feature only if a Machine
Configuration error occurred during power up.
Ultimax System
August, 2002
2-33
Read DXF File

After creating a CAD drawing in AutoCAD, copy the DXF file onto a
diskette. Use the DXF file directly from the diskette, or copy it onto the
CNCs hard drive.
Note
DXF files cannot be downloaded from a serial port.
To access a DXF file stored in the CNCs memory:
1.
Touch the Read DXF File softkey on the Auxiliary screen.
2.
A Current Directory screen is displayed. Move the cursor to

the desired file to highlight it, and press the Enter key.
3.
After a file is selected, a Reading Program message

appears on the screen.
4.
Refer to the UltiDraw DXF Option Manual for DXF files

and part programming.
Change Editor
Touch the Change Editor softkey on the Auxiliary screen to switch the
program editor type between Conversational and NC.
CRT Degauss
The CRT Degauss softkey was used to remove the buildup of magnetic
fields on older monitors with cathode ray tubes (CRT). The CRT Degauss
softkey is not needed for the LCD-based Ultimax and Max consoles.
Change Language
This softkey will only appear if at least two language files are installed.
To change the language file:
2-34
1.
Touch the More softkey on the Auxiliary screen.
2.
Touch the Change Language softkey.
3.
Move the cursor to desired language to highlight it, and

press the Enter key.
4.
The Auxiliary screen reappears in the selected language.

The Graphics screen language will not change until the
Draw console button is pressed.
Revision A
Upgrade System Files

Ultimax software upgrades improve system performance, add new
features, enhance the system or correct system bugs. An upgrade comes on
multiple floppy diskettes, labeled with the CNC type, version number, and
diskette number (e.g., Disk 1 of n, where n is the total number of
diskettes).
Note
Save any part programs before upgrading system files.
To upgrade system files, follow these steps:
1.
2.
Touch the Upgrade System Files softkey.
3.
Touch the Yes softkey. If you touch the No softkey, the

upgrade stops and the Auxiliary screen reappears.
4.
A The current system files on disk will be overwritten. OK

to continue? message appears. Select Yes to continue or No
to abort.
5.
Insert Upgrade Disk #1. Follow screen directions to

complete the upgrade.
Note
If the wrong diskette is inserted, the insert diskette system continues
to display until the correct diskette is inserted into the floppy drive.
6.
After all disks are inserted, switch off the CNC power and
switch it back on again to activate the system upgrade.
Important
Save the system upgrade diskettes in a box away from heat, debris,
and magnetic interference
Ultimax System
August, 2002
2-35
Display Error Messages

Ultimax provides a list of the most recent error messages displayed, up to
a maximum of 200 messages. Review message when troubleshooting or to
determine if a problem reoccurs.
To display the most recent messages, follow these steps:
1.
2.
Touch the Display Error Message Log softkey.
3.
Each screen displays 15 date/time-stamped messages. To

view the entire message, move the cursor to the message to
highlight it, and press the Enter key.
Hints and Tricks

Simultaneously press the F and Home console keys (Ctrl and Home keys
for Max console) to highlight the message at the top of the page.
Simultaneously press the F and End console keys (Ctrl and End keys for
the Max console) to highlight the message at the bottom of the page.
4.
Messages will not update while the Display Error Message

Log screen is displayed.
Note
Touch the Write Error Log to Disk softkey to write the current log to
disk. Message text will not be saved, but can be sent to Hurco for
analysis.
2-36
Revision A
Reset Master
To restart the control (reboot the system) without switching the power to
the machine off and back on again, follow these steps
1.
2.
Touch the Reset Master softkey. Touch the Yes softkey to

reboot the system. Touching the No softkey aborts the
reboot.
Note
If there is a diskette in the floppy drive, it must be removed before
you reboot.
Important
Be sure to save the current part program to the hard disk or a floppy
diskette before rebooting. If you do not save to the hard drive or
floppy diskette:
Ultimax System
A Conversational part program will be restored after the

reboot, but changes made after the last AutoSave will be
lost.
An NC part program will be permanently erased from

memory
August, 2002
2-37
Chapter 3
Programming Basics
Part Programming Setup
There are five main steps to follow before creating a part program on the
Ultimax control
1.
Plan the part programming operations.
2.
Perform the tool-loading and part-fixturing operations.
3.
Enter the Part Setup information.
4.
Enter the Tool Setup information.
5.
Enter the Program Parameters information.
To perform many of the setup functions, use the axis controls to move the
table or spindle and record positions. Refer to the Machine and Console
Basics chapter for information about axis controls.
All machine tool operators need to plan their jobs before they begin
programming. Plan work piece placement, fixturing, and part cutting
operations before cutting a part. Then, load the tools and fixture the work
piece to the table.
Before programming the part on the Ultimax control, use the setup screens
to describe the part and the tools used to cut the part. This information is
necessary for the system to draw the part on the graphics screen.
Important
Part and Tool Setup information is saved with conversational
programs but not with NC programs. Refer to the Restore
Functions section of this chapter for details about restoring HD3
setup information to use with NC programs.
Ultimax System
August, 2002
3-1
Part Fixturing and Tool Loading

Before entering data into the part and tool setup screens for a part
program, first fixture the work piece to the table and load a tool into the
spindle.
In order to determine the starting point (part zero) in the part, first fixture
the work piece (raw material or stock) to the machine tool table. This
process, called fixturing, can be accomplished using a variety of clamping
devices, such as vises and toe clamps. Locate the fixturing device in an
area that will not get in the way of the cutting tool.
You may want to insert a tool in the spindle to use as an edge finder when
identifying part zero. Press the Machine Mode Manual console key to
display the Manual screen. Use the Tool in Spindle field and softkey to
enter the tool number for the edge finder tool.
Part Program Names

Part program names may contain up to eight characters. The current
program can be saved to the current directory with the name given upon
creation or the name can be changed as part of the save operation.
To type in a new program filename:
1.
Select the Input screen by pressing the Input console button.

The cursor is automatically positioned on the current
program name in the Edit Part Program field.
2.
Type the file name and press the Enter console button.
3.
After the program screens are filled in, use the Auxiliary
screens Storage Functions softkey and Write Program to
Disk softkey to save the program to the current directory.
Hints and Tricks

Refer to the Program Storing, Renaming, and Deleting sections in the
this chapter for more information.
This chapter explains basic programming information for Conversational
and NC programming, such as required setup, program checking, editing,
and running.
3-2
Revision A
Programming Basics
Part Setup
The part setup procedures establish the locations of part zero in X and Y
relative to machine absolute zero. Part zero may be located anywhere on
the fixturing or the part. During machine calibration, each axis moves to
its + or - travel limits. Machine zero, identified during machine
calibration, is the location to which each axis moves to determine a fixed
point where the X, Y, and Z axes become tangent. This value does not
change after calibration.
Figure 3-1.
Part Zero Relative to Machine Zero Viewed Looking Down at Table
Program the axes to move within the coordinate system as shown below:
Figure 3-2.
Ultimax System
Axis Motion
August, 2002
3-3
Entering Part Setup Information

Begin the programming setup process with the Part Setup screen. Press the
Part Setup softkey on the Input screen. Definitions for the fields and
softkeys are in the Part Setup Fields and Part Setup Softkeys sections
that follow.
Figure 3-3.
Part Setup Screen
The Digital Read Out (DRO), the top left section of the screen, shows the
position of the axes and machine status. The bottom half of the screen is
the data entry area with fields for entering the values to identify part zero
and the safety work region for the part program.
3-4
Revision A
Programming Basics
There are a number of methods for entering Part Setup information. For
example, you can either manually type values into the fields, or use an
edge finder. If you use an edge finder, follow these steps:
1.
Find the edge of the part in X.
2.
Touch the Store Machine Position softkey or the Store

Position button on the jog unit to set the current axis
position as Part Zero.
3.
Use the CNCs calculator feature to add or subtract the

radius of the edge finder and make adjustments to the X and
Y Part Zero values.
4.
Repeat this process for Y.
Note
The Offset Z field establishes a relative Z offset and should not be
used during initial part setup or with the Store Machine Position
softkey.
There are other methods to use depending on the equipment available in
your shop, such as electronic edge finders and probes.
Hints and Tricks

Create a Conversational Part Setup template that can be saved for
NC part programs.
1.
Restore the template in Conversational programming using

the Restore Part Setup feature before switching editors to
NC.
2.
Load the NC program. The Part Setup template remains in

temporary memory and transfers to the NC program.
Refer to the Restore Functions section in this chapter for details

about restoring program setup information.
Ultimax System
August, 2002
3-5

Part Setup Fields
The Part Setup fields are defined as follows:
Fields
Part Zero X
Y
Offset Z
Definitions
the X location in machine coordinates for part zero.
the Y location in machine coordinates for part zero.
the Z dimension offset for part zero. This field is
usually left at 0 and the Tool Calibration field in Tool
Setup is used to determine each tools part zero.
To store the Z values using the Store Position
button, a reference tool previously defined in Tool
Setup for this program must be in the spindle.
Entering a value in the Offset Z field adds or
subtracts the amount of the offset to the Tool
Calibration value. For example, you can adjust all
Tool Calibration values in the Z axis and Z Start to
compensate for part thickness by changing the
Offset Z value.
Safety Work Region these fields define a part-relative safety area to
prevent the cutting tool from colliding with fixtures
or other equipment.
The defaults are +99.0000 or -99.0000 inches
(+9999.000 or -9999.000 mm).
The remaining Part Setup fields only apply if the Part Probing option is
installed:
Probe Z the distance from Z Zero to the top of the part (i.e.,
the height, or Z Plane), with a reference tool or part
probe in the spindle. This field is used only with the
Probing option. Refer to the Probing Option Manual
for details.
Skew Angle the distance, in degrees, the part is from square
alignment with the table. This field is used only with
the Probing option.
3-6
Revision A
Programming Basics
Part Setup Softkeys
The Part Setup softkeys provide the following options:
Ultimax System
Tool Setup allows access to fields to enter the descriptions of

the tools that will be used in this part program.
Part Programming allows access to fields to enter the exact

description of how the part will be cut.
Program Parameters displays the screens on which the data

common to all of the program data blocks can be entered. Refer to
the Program Parameters section in this chapter for more
information.
Probing allows access to the probing parameters. Probing is

available only with bed mill machines.
Orient Spindle rotates and locks the spindle to its home

position (i.e., for a tool change or a Bore Orient cycle). Orient
Spindle is available only with bed mill machines.
Store Machine Position sets the current axis position as a Part

Zero location. The cursor location defines which axis (X or Y) will
be set. The current axis position appears in the DRO Part column
as zero.
Exit exits the setup process and returns to the Input screen.
August, 2002
3-7
Safety Work Region

Establish the dimensions of the Safety Work Region to prevent the cutting
tool from moving into areas where it might collide with other equipment
or the work piece and fixturing. The Safety Work Region values are
relative to Part Zero.
Figure 3-4.
Safety Work Region Fields on the Part Setup Screen
To enter values into the safety work region fields, use one of these two
methods:
Use the number keys on the keyboard to enter the

dimensional values of the safety region into the appropriate
Safety Work Region field.
Or...
Use the axis jog functions on the jog controls to identify the
X, Y, and Z safety region. With the cursor in the appropriate
Safety Work Region field, jog each axis to the desired safety
region and press the Store Position button on the jog unit.
Hints and Tricks

The Part Limit Z(-) parameter helps prevent the tool from drilling
through the part and into the fixturing or machine table.
When a Position block is programmed, the tool always retracts to the
safety plane programmed as Safety Work Region Z (+).

Touch the Exit softkey to return to the Input screen or touch the Tool
Setup softkey to describe the tools used in the part program.
3-8
Revision A
Programming Basics
NC Work Offsets
When in the NC mode, the Part Setup screen has the Work Offsets softkey
to display up to six work coordinates (G54-G59) and a set of shift offset
values. These are used to set multiple part zeroes for multiple parts
fixtured to the table and milled consecutively using the same program.
The X, Y, and Z work offset values can be entered for G54 to G59 codes.
The coordinates defining G54 are the part zero coordinates for the original
part defined on the Part Setup screen. When the G54 coordinates are
changed on this screen, the part setup is also changed.
Figure 3-5.
Work Offsets for NC Programs
The shift coordinates, which follow the six work coordinates on the
screen, move all of the part zero coordinates as a group. This incremental
value is useful when you place part fixtures on the table in a different
location and want to shift all of the work offsets to the newly fixtured
location. G54-G59 offset values do not change on the screen when shift
offset values are entered.
Ultimax System
August, 2002
3-9
NC Probing Part Setup

It is possible to perform a part probe setup using calls to a set of
predefined subprograms. A subprogram s a group of commands stored
under one name. These probing subprogram calls mimic the probe part
setup conversational data block. The first five subprogram calls (P1000
through P5000) are used to set internal reference locations that perform
the probing function. The sixth subprogram, P6000, performs the probing
operation. In addition, an NC program utilizing G31 commands can be
used to perform a probing part setup.
Important
Probing is used for setting up part zero for G54 only.
3-10
Revision A
Programming Basics
Tool Setup
Use the Tool Setup screen to describe the tools that will be used for the
part program. You can access this screen from either the Input screen or
the Part Setup screen by touching the Tool Setup softkey.
Each tool used in the part program must be described on the Tool Setup
screens; otherwise, the machine will not be able to cut the part when you
run the program.
If the Tool Number, Type, and Diameter are not entered for
a tool, the system will not have enough information to draw
the part properly on the graphics screen.
If the Zero Calibration value is not entered, the spindle will

not switch on when you try to run the part program, and the
system will display the Tool is not calibrated error
message.
Caution
When running a previously created part program, the Tool Setup
must be carefully checked to be certain the tools described for the
old program match the tools planned for the new program. If a tool
breaks or is not available when running a previously created part
program, the Tool Setup information must be changed.
Hints and Tricks

Create tool setup templates to simplify program development.
Ultimax System
To create a tool setup template, enter the tool description.

Save the information as a program, using a program name
that indicates the type of tools described.
To use the saved standard setup, recall the tool setup

program, make any necessary changes for the new part
program, and save the changed setup under a new name.
Renaming preserves the original template file for later use.
August, 2002
3-11
Entering Tool Setup Information

You must enter data on a Tool Setup screen for each tool that will be used
in the part program. Definitions for the fields and softkeys are in the Tool
Setup Fields and Tool Setup Softkeys sections that follow.
Figure 3-6.
Tool Setup Screen
The DRO (top left of the screen) shows the real-time position of the axes
and machine status. The fields in the bottom part of the screen describe the
tool. The Machine and Part position information in the DRO will not
appear if the machine is not calibrated, or is in concurrent programming.
To enter information for a specific tool, or to find out whether any data
already exists for that tool, type the tool number into the Tool field and
press Enter. For example, if you enter a 1 in the Tool field, the screen will
update to show existing data for tool number 1. If no data had been saved
previously for tool 1, the Type field is empty and the remaining fields
contain default values. This means that tool number 1 is currently
available to be programmed.
3-12
Revision A
Programming Basics
Note
If your Hurco machine is equipped with a swing arm ATC and a
vertically positioned tool disk, the tool number will not always
match the pocket (pot) number of the magazine. Refer to the
Important notice at the beginning of Tool Setup.
Use the Arrow keys to move the cursor to each Tool Setup field and use
the softkeys or type in data to set up the tool descriptions for your part
program. Touching the Exit softkey displays the Input screen.
To enter tool descriptions, follow these steps:
1.
Enter the tool number for the tool using the number keys on
the console. If there should be no tool in the spindle, enter a
zero (0) for the tool number.
2.
When you enter the tool number, the cursor is automatically

positioned in the Type field and the softkeys change to tool
type selections. Select the appropriate tool type softkey.
Note
The More softkey displays additional tool types available for this
machine (e.g., Ball Nosed End Mill, Back Spotface, Probe, and Gun
Drill).
Ultimax System
3.
If the tool is a tap, a Threads per Inch value must be

programmed (or Pitch in millimeters per thread, if metric is
the unit of measure).
4.
Enter the Diameter of the tool. The Diameter field gives the
graphics system the information needed to draw the part and
ensures that the program does not cause the machine to
violate any Safety Work Region limits.
August, 2002
3-13

Ultimax uses the information in the Diameter field to
automatically determine cutter compensation during milling
operations. Ultimax software calculates the radius of the
cutting tool and automatically allows for this distance when
performing milling operations. This means you do not need
to remember the size of the cutting tool and manually
calculate tool offsets when programming the part.
A
Path compensating for

cutter radius
Programmed
Path
Cutting tool
Cutter radius = amount

of cutter compensation
offset
B
Figure 3-7.
5.
Cutter Compensation
Use jog functions to calibrate the tool to the part or

reference surface.
a.
Move the tool in the spindle down until the tool

touches part zero.
b.
Press the Store Position button on the jog unit and

the position of the Z axis appears in the Zero
Calibration field.
c.
The position of the Z axis can also be stored using

the Set Tool Zero softkey.
Use the calculator functions on the console to add or

subtract shim stock dimensions (if used). For example, after
touching the Set Tool Zero softkey, enter the thickness of
the shim, press the plus key (+), and then press Enter to add
the shim thickness.
3-14
Revision A
Programming Basics
6.
If the correct speed to be used for this tool is known, enter it

into the Speed field. This value will be copied into each new
data block in the part program (but only for part program
data blocks created after Tool Setup) which use this tool. If
necessary, this parameter can be changed within the new
data block when programming the part. The direction the
spindle turns (clockwise for right-hand cutters) is also part
of this parameter.
7.
The Coolant field defines the coolant type to be used for the
tool and is programmable on a tool-by-tool basis.
8.
For drills or milling tools, the Surface Speed, Flutes, and

Feed/Flute (Tooth) fields also appear on the screen.
a.
Enter a Surface Speed in inches or millimeters per

minute. Then the Flutes and Feed/Flute fields
appear.
b.
Enter values that indicate the number of the flutes

(teeth) on the tool and the feedrate per flute. The
system uses these values to calculate the feeds and
speeds for the tool.
Refer to the following Automatic Feeds and Speeds Calculations section

for more information about automatic calculation.
You may also wish to consult Machinerys Handbook or the feeds and
speeds material in the Appendix of this manual for more information.
Important
When a value is entered into the Speed (RPM) field, the system
ignores any data entered in the Surface Speed field. If the automatic
speed calculation is wanted, enter a value of zero (0) in the Speed
(RPM) field.
You can use the Spindle RPM dial on the front of the tool spindle
plate to override this preset speed.
Ultimax System
August, 2002
3-15

Tool Setup Fields
The standard fields on the Tool Setup screen are defined as follows.
Fields
Tool
Type
Diameter
Diameter Comp
3-16
Definitions
the programmed tool number.
the type of tool.
the diameter of the tools cutting surface.
applies only to BNC and corresponds to the D
code in an NC program block.
If the program specifies the D code in a block
with a tool change (M06 with a T code), the
system uses the D code.
If the D code is not included in the NC program,
the system uses the Diameter Compensation
value entered on this screen.
This value is only used when cutter
compensation is On (G41 or G42 active).
If the tool used to cut the programmed part
differs in diameter from the diameter specified
in the program (or the diameter specified in the
Diameter field), enter the difference between the
programs tool diameter data and the diameter of
the actual tool.
Diameter Comp = Actual Tool Diameter Program Tool Diameter.
Note
An actual tool that is larger than the programmed
tool results in a positive value; an actual tool that
is smaller results in a negative value. For negative
compensation, the control performs the cutter
compensation on the opposite side of the
programmed path.
Revision A
Programming Basics
The remaining Tool Setup fields are defined as follows:
Zero Calibration a valid, calibrated Z axis position (i.e., the distance
between the tool and the top of the part).
For NC programs, The Zero Calibration field
corresponds to the L code in an NC program block
If the program specifies the L code in a block
with a tool change (M06 with a T code), the
system uses the L code.
If there is no L code, the system uses the
specified Zero Calibration value. Enter an L code
in the NC program to set the Zero Calibration
value.
For ISNC, this field can be ignored and left at the
default value.
Speed (RPM) the speed, if known, to be used for this tool. The
and Direction system uses this value to automatically calculate
spindle speeds for the tool.
The spindle Direction (CW or CCW) is also set
here.
For NC programs, the Speed (RPM) field
corresponds to the S code in an NC program block.
If the program specifies an S code in a block
with a Spindle On command (M03 or M04), the
system uses the speed in the S code.
If there is no S code, the system uses the Speed
(RPM) value from the tool setup.
Coolant the type of coolant to be used for this tool.
The choices are Both Off, Primary, Secondary, and
Both On.
Surface Speed the distance a single tooth on a cutter travels in
linear feet or meters per revolution of spindle in
surface feet per minute units, if programming and
not using Automatic Feed and Speed Calculations.
Flutes the number of cutting flutes for the tool.
Feed/Flute (Tooth) the tools chipload.
Ultimax System
August, 2002
3-17

Tool Setup Softkeys
The softkeys on the Tool Setup screen provide the following options:
3-18
Delete Tool deletes all program settings for the tool number
entered in the Tool field.
Probing accesses the probing parameters. Probing is available

only with bed mill machines.
Part Programming accesses fields to enter the exact

description of how the part will be cut.
Tool Offsets available only for NC programs. The tool length

offsets appear on the screen. Tool offsets are used to compensate
tool length without altering the NC program.
Use the Positive Tool Length Compensation (G43) or

Negative Tool Length Compensation (G44) codes. A G49
code specifies tool offset cancel. An H00 also cancels an
offset.
The G43 and G44 codes set a mode of operation within the
program that is in effect until a G49 or H00 is used. If an H
code is used without a G43 or G44, in effect, the value
stored in the tool length offset table is used as the calibrated
tool length.
The four keyboard arrows, Page Up, and Page Down keys
scroll through the 01 to 200 offsets.
When the Store Machine Position softkey is pressed, a

negative Z value reflecting the Z axis machine position is
entered on the screen.
Tool offsets are not saved with the NC program.
Part Setup returns to the Part Setup and make changes.
Tool Home allows you to move the tool quickly away from the
part. Using this softkey after Tool Calibration is much faster than
pressing the axis jog buttons on the jog unit. Press this softkey and
then press the Start Cycle button to move the spindle to tool
change height.
Revision A
Programming Basics
Set Tool Zero To use this softkey, carefully jog the tool in the
spindle down to the top of the part or to the fixture defined at the
Tool Calibration point and then press the softkey. The system
stores the position of the tool into the current part program and the
number appears in the Zero Calibration field on the Tool Setup
screen. This can also be accomplished by pressing the Store
Position button on the jog unit. On the screen the part display for
Z changes to zero.
Warning
Be certain that the tool number in the Tool in Spindle
field matches the tool being edited when the zero
calibration is stored.
Ultimax System
Exit exits the tool setup process and allows return to the Input
screen.
August, 2002
3-19
Automatic Feed and Speed Calculations

During Tool Setup, the control can calculate the appropriate feedrates and
spindle speeds for drilling and milling operations. Here are some
important points concerning automatic calculations of feeds and speeds:
The operator can manually change all feed and speed values
calculated by the control.
Plunge feedrates (Z) are not calculated by the control.
Important
The tool must be a drill, end mill, face mill, or ball nosed end mill.
The control will not automatically calculate feeds for boring and
back spotfacing.
Entering Zero for Speed (RPM) Value
In order for the control to calculate spindle speed and axis feedrate for a
tool during Tool Setup and carry those values forward throughout all the
blocks that use that tool number, follow these steps:
1.
Enter a 0 in the Speed (RPM) field.
2.
Enter a value in the Surface Speed field. The Flutes and

Feed/Flute (Tooth) (i.e., chip load) fields will appear. The
units are Surface Feet per Minute or Surface Meters per
Minute.
3.
Enter values for the Flutes and Feed/Flute (Tooth) (i.e., chip
load) fields.
4.
If the tool diameter is changed for a milling type tool (not a

drill), a message is displayed on the Tool Setup screen
asking if the feeds and speeds should be recalculated. Yes
and No softkeys appear. If you choose Yes, the control
recalculates and updates the feeds and speeds into the part
program for that particular tool.
Caution
The control uses nominal feeds and speeds for mile steel in
calculating the initial feed and speed values. The control does
not take into account material hardness and depth of cut. Be
sure to check computed feeds and speeds to ensure they are
appropriate and make any necessary adjustments.
3-20
Revision A
Programming Basics
Entering Actual Speed (RPM) Value
If you enter Speed (RPM) in Tool Setup, this value is transferred to all
data blocks using this tool. The feedrates must be entered manually in the
data blocks.
Important
You can override the spindle speed in each program block. If the
Speed (RPM) field is changed in Tool Setup, the tool number must
be re-entered in the data blocks in order to force the control to
update the value. Refer to the Changing a Part ProgramBlock
Editor section in this chapter for information about changing
multiple blocks using the same tool.
Note
Do not enter the Surface Speed value in the Tool Setup screen if the
Speed (RPM) value is entered.
Formulas for Automatic Calculations
The Ultimax control automatically calculates spindle speeds using this
formula:
RPM =
SurfaceSpeed
Diameter
The control uses this equation to compute the milling feedrates:

Feedrate = Feed per Flute # of Flutes RPM
When performing a drilling operation, the control uses this equation to
calculate the feedrate:
Feedrate = Feed per Flute RPM
Important
When using larger tools (5/8" or larger diameter), the feeds and
speeds for drilling and milling should be manually reduced by
approximately 15% to 20% based on the machinists experience.
Refer to the Appendix or Machinerys Handbook for more feeds and
speeds information.
Ultimax System
August, 2002
3-21
Program Parameters
Access groups of parameters with the Program Parameters softkey.
Figure 3-8.
Input Screen
A description of each of the program parameters follows:
3-22
Generalretract clearance, rapid traverse, peck clearance plane,

chord error, depletion retract, interrupt cycle Z retract, first peck
offset, override lookout, program protect, tool change position,
automatic tool monitoring and NC optional program stop.
Holesbore orient retract, drill dwell, and bore dwell.
Millingblend offset, blend overlap, finish feed, finish speed,

finish XY, finish Z, milling direction, pocket overlap, cutter
compensation parameter, plunge parameters, operator pocket start,
and inward pocket plunge.
Performancesurface finish quality, precision cornering, NC tool

path tolerance and NC block smoothing. You must have the AVC
or ASF option installed on your machine to access NC Tool Path
Tolerance or NC Block Smoothing.
Revision A
Programming Basics
General Parameters
To display the General Parameters screen, press the console Input key to
display the Input screen. Touch the Program Parameters softkey. Then the
General Parameters screen appears:
Figure 3-9.
General Parameters Screen
Note
The NC Parameters softkey is only available with NC programming.
Refer to the NC Parameters section for information about using
this softkey.
Some of the options listed on the screen above are machine specific.
You may not see these machine-specific options on the General
Parameters screen for your machine.
Ultimax System
August, 2002
3-23

These fields appear on the General Parameters screen:
General Parameters Definitions
Retract Clearance
(Conversational)
-ORClearance Plane (NC)
distance the tool should retract above the Z Start

dimension before rapid table positioning (Rapid
Traverse) between machining operations. This includes
a tool moving from one drilled hole to another, from one
milling operation to another (programmed in separate
data blocks or generated as a patterns operation). The
default values are 99.0000 inches and 999.000 mm. The
minimum value is 0.0.
If the next operation has a different Z Start dimension,
the control always retracts to the highest dimension.
Rapid Traverse Feedrate that all axes move between data blocks or holes
operations (rapid positioning; G00 for NC programs).
When programming offline, be sure the Rapid
Traverse field is set to the appropriate value for the
machine or application before converting the file to
NC or transmitting the Conversational part program.
Peck Clearance Plane distance above the previous peck level to which the Z
(Conversational only) axis returns at rapid traverse.
Chord Error maximum distance the cutter deviates from the true arc
path. This value determines the method the control uses
to generate information for executing arcs. If you enter
0.0 in this field, the control will automatically calculate
a chord error that maintains the programmed feedrate
through the arcs. This field displays 6 decimal places for
inch mode and 5 decimal places for metric mode.
Interrupt Cycle Z allows the Z axis to retract all the way up when the
Retract console Interrupt Cycle button is pressed. Selecting No
for this field means that the spindle will stay in its
current position when either the Interrupt Cycle button
or the Restart button is pressed. The default value is
Yes.
3-24
Revision A
Programming Basics
The remaining General Parameters fields are defined below:
General Parameters Definitions (Continued)
First Peck Offset modify the depth of the first peck in milling and hole
operations. Use this feature whenever a first peck needs
to be different than subsequent pecks. The range is
9.9999 to + 9.9999 in. (254.00 to +254.000 mm). This
value is added to the peck depth in calculating the first
peck only.
Use a positive Fist Peck Offset value for deeper peck;
negative for shallower peck. A First Peck Offset of
0.000 runs pecks without any First Peck Offset.
Example: If the peck depth is set to 0.2000 inches and
First Peck Offset is set to +0.0500 inches, the first peck
will be 0.2500 inches down from Z start plane and all
subsequent pecks will be 0.2000 inches deep. If the First
Peck Offset is set to 0.0500 inches, only the first peck
is 0.1500 inches down from Z start plane and every
subsequent peck will be 0.2000 inches deep.
Override Lockout disables the Axis Feed dial when On is selected. The
default is Off.
Program Protect protects part programs from alteration, if available. To
prevent programs from being changed, select either Full
or Partial access. When set to Full, the operator will not
be able to change the part program or its tool and part
setup information. If partial access is given, the operator
will be able to change a part programs tool and part
setup only, but not the program itself. Partial is the
default.
Tool Change Position indicates whether the table will move to the right/front
of the machine when the operator is changing a tool. If
this field contains Yes when a part program block calls
for a tool change, the table will move out of the way.
The default is No.
Automatic Tool Enables/disables automatic checking of probed tools. If
Monitoring the tool probe option is enabled, the auto tool monitor
field and length and diameter tolerance fields will be
displayed. If set to Yes, a tool previously calibrated with
the probe will be checked to determine if the tool has
worn outside of a specified tolerance. If set to No, the
tool will not be automatically checked for wear. The
default is No.
Ultimax System
August, 2002
3-25
Figure 3-10. Positive First Peck Offset
Figure 3-11. Negative First Peck Offset
3-26
Revision A
Programming Basics
General Parameters Ranges and Default Values
Parameter
Range
Default Value
Retract Clearance
Clearance Plane (NC)
0.0000 - 99.9999 inches

0.000 - 999.999 mm
99.0000 inches
999.000 mm
Rapid Traverse
This range is set at the factory

for each machine.
Minimum is 0.0.
Highest value in
factory-set range.
Peck Clearance Plane

(Conversational only)
0.0000 - 99.9999 inches

0.00 - 999.999 mm
0.0500 inches
0.127 mm
Chord Error
0.0000 -1.0000 inches

0.000 - 25.4 mm
0.000100 inches
0.00250 mm
Depletion Retract
0.0000 - 99.9999 inches

0.000 - 999.999 mm
0.0050 inches
0.127 mm
Interrupt Cycle Z
Retract
Yes and No
Yes
Optional Program Stop

(NC only)
Enabled or Disabled
Enabled
First Peck Offset
-9.9999 to + 9.9999 inches

-254.000 mm to +254.000 mm
0.0000 inches
0.000 mm
Override Lockout
On and Off
Off
Program Protect
Partial and Full
Partial
Tool Change Position
Yes and No
No
Automatic Tool
Monitoring
Yes and No
No
Table 3-1.
General Parameters Ranges and Default Values
When calculating the chord error value for the General Parameters screen,
remember that the chord error for arcs is the maximum distance that the
cutter deviates from the actual arc. As shown below, the machine actually
cuts a series of very small lines when cutting an arc. However, these lines
are indistinguishable from an arc when the machining is complete.
Ultimax System
August, 2002
3-27
Hints and Tricks

Programming a non-zero but very small Chord Error will provide a
better finish but will slow feedrate during the arc. The control will
accept up to eight decimal places. You can enter up to 8 decimal
places for more precision, but the control rounds off to 6 or 5
decimal places for inch or metric, respectively.
Figure 3-12.
Chord Error
Holes Parameters
Touch the Holes Parameters softkey to change any of the Holes
Parameters fields. The most often changed field on this screen is Drill
Dwell. This field controls the length of time the drill stays at the bottom of
a hole after it has drilled the hole.
3-28
Revision A
Programming Basics
Figure 3-13.
Ultimax System
Holes Parameters Screen
August, 2002
3-29

The fields for the Holes Parameters are defined as follows:
Holes
Parameters Definitions
Bore Orient Applies only to machines with mechanical or electronic
Retract spindle orient features.
The value in this field specifies the distance the table travels
in the XY plane before the tool retracts from the part surface
at the end of a Conversational Boring Cycle when a Bore
Orient data block is included in the part program.
during an NC Bore Orient Cycle (Basic NC G76 or G86;
ISNC G76).
The default is 0.02 " or 0.5 mm.
Drill Dwell Controls the dwell time in seconds before the tool retracts
at the bottom of a Conversational Drill Operation.
during an NC Drill with Dwell, Counter Boring canned
cycle (G82).
The default value is 0.5 seconds. Many operators change this
to 0.0 seconds so that the drill will rapid out of the hole after it
is drilled.
Bore Dwell Controls the dwell time in seconds before the tool retracts
at the bottom of a Conversational Bore operation
during an NC Bore with Dwell canned cycle (G89), and
Bore with Manual Feed Out canned cycle (ISNC G88).
during conversational and ISNC Non-Rigid Tapping
canned cycles (ISNC G74 and ISNC G84).
The default value is 1.0 seconds.
3-30
Revision A
Programming Basics
Milling Parameters
Touch the Milling Parameters softkey to access the Milling Parameters
screen. The milling parameters do not apply to NC programs. They only
affect cutter motions during Conversational milling operations.
Figure 3-14.
Ultimax System
Milling Parameters Screen
August, 2002
3-31

Following are definitions for the Milling Parameters:
Milling Parameters Fields
Definitions
Blend Offset XY Distance from the entry point of the part surface
and the Z plunge point where the tool enters the work
piece. This parameter is used for the lead-in move in
milling circles, frames, and ellipses. It is also used for
the lead-out move from the part surface to the Z Retract
point. The default values are 0.1250 inches or 3.000
mm.
Blend Overlap distance the tool travels past the entry point before
exiting from the part. This parameter is used in milling
circles, frames, and ellipses. The default values are
0.1250 inches or 3.000 mm.
Finish Feed percentage of the programmed feedrate of the roughing
tool used for the finish tool, if the finish pass is
programmed for the part. The default is 100%.
Finish Speed percentage of the programmed spindle speed of the
roughing tool used for the finish tool, if the finish pass
is programmed for the part. The range is 10-250%. The
default is 100%.
Finish XY amount of material in the X-Y axis direction to be
removed by the finish pass, if the finish pass is
programmed for the part. The default values are 0.0100
inches or 0.200 mm.
Finish Z amount of material in the Z axis dimension to be
removed by the finish pass, if the finish pass is
programmed for the part. The default values are 0.0050
inches or 0.100 mm.
Milling Direction allows selection of either Conventional or Climb
milling for canned milling cycles (e.g., frame, circle,
and ellipse). Climb milling is the default. This field
does not apply to lines and arcs.
Pocket Overlap percentage of tool diameter overlap for each pass in a
pocket milling operation. The range is 0-99%. The
default is 10%.
Cutter Comp Parameter see the description for this parameter in the Cutter
Comp Parameter section of this chapter.
Mill Plunge Type specifies the plunging strategy to use for the milling
pass. Choose Straight or Helix. The default setting is
Straight. Additional fields will appear. See the Helical
Plunge Option Manual for more details.
3-32
Revision A
Programming Basics
Milling Parameters Fields
Definitions
Finish Plunge Type specifies the plunging strategy to use for the finish
phase. Choose Straight or Helix. The default setting is
Straight. Additional fields will appear. See the Helical
Plunge Option Manual for more details.
Operator Specify Pocket Start this option is available only if the UltiPocket option is
installed on the machine. If set to YES, the pocket start
location fields will appear on pocket boundary screens,
when spiral inward pocketing is selected. The default
setting is No. See the UltiPocket Option Manua lfor
more information.
Inward Pocket Plunge Near this option is available only if the UltiPocket option is
Center installed on the machine. If set to YES, UltiPocket will
attempt to perform a plunge near the center of the
pocket. Using this parameter may help prevent
interferences with pocket islands and boundaries. The
default setting is No. See the UltiPocket Option Manual
for more information.
Ultimax System
August, 2002
3-33
Cutter Comp Parameter

When the cursor is at the Cutter Comp Parameter field, Insert Arc and
Insert Lines softkeys appear:
Figure 3-15.
Milling Parameters Screen with Insert Arc and Insert Line Softkeys
The Cutter Comp softkeys provide these functions:
3-34
Insert Arc set the Cutter Comp field to insert an arc.
Insert Lines set the Cutter Comp field to insert a line.
Revision A
Programming Basics
Touch the Insert Arc or the Insert Lines softkey, and the field connects
these milling segments as follows:
1.
Figure 3-16.
If Insert Arc is selected, a tangent arc is inserted to connect

two line segments, or a line segment and an arc segment
(when the two cutter compensated segments are offset and
do not intersect). When using the Insert Arc method, the
system creates the cutter compensated path as shown below:
Cutter Compensation Using the Insert Arc Parameter
Note
Some operators find the Insert Arc method inappropriate for their
applications because the cutter remains in contact with the work
piece and may drag a chip across a sharp angle on the part. In such
circumstances, operators select the Insert Line field.
Ultimax System
August, 2002
3-35

2.
If the Insert Lines softkey is selected, the cutter

compensated lines and arcs are joined as described below:
Figure 3-17.
3-36
Two line segments are extended until they intersect

(provided they form a 90 or greater angle). If the
lines form an angle of less than 90, a line is
inserted to connect them.
Line and arc segments have the line segment
extended, and a tangent line to the arc segment
inserted and extended until the lines intersect
(provided they form a 90 or greater angle). If the
segments form an angle of less than 90, a line is
inserted to connect them.
Two arc segments have tangent lines (to the arcs)
inserted and extended until the lines intersect
(provided the extended tangent lines form a 90 or
greater angle). If the extended tangent lines form
an angle of less than 90, a line or arc is inserted to
connect them.
Cutter Compensation Using the Insert Line Parameter
Revision A
Programming Basics
NC Parameters
The NC Parameters softkey is available when you use NC programming.
From the Input screen, touch the NC Parameters softkey, and the NC
Parameters screen appears:
Figure 3-18.
NC Parameters Screen
From this softkey menu, you can access the NC Configuration Parameters,
NC M and G Code Program Numbers, and NC Program Variables screens.
See the NC Part Programming Manual for more information about NC
part programming.
Ultimax System
August, 2002
3-37

NC Configuration Parameters
Touch the NC Configuration Parameters softkey and this screen appears:
Figure 3-19.
NC ParametersConfiguration Parameters Screen
Enable or disable Macro Mode B and user defined M, G, S, B, and T

codes by moving the cursor to the appropriate field and selecting the Yes
or No softkey.
3-38
Revision A
Programming Basics
The remaining NC Configuration Parameters fields are defined as follows:
NC Configuration
Parameters Fields Definitions
Linear Positioning specifies the type of move produced in the XY plane
when rapid positioning. The default is Yes. When this
field is set to Yes, the move is in a straight line. Selecting
No causes a 45 move to the nearest X or Y axis and then
moves to the end point along one axis. Linear positioning
applies only to ISNC programming.
Least Dwell Units specifies the dwell units when using an integer to specify
Dwell. Set this field to either 0.001 or 0.0001 to be
compatible with different Fanuc controls. The default is
0.0001. Refer to the Dwell Mode (G04) section in the
NC Part Programming Manual for more information
about using this field. Least Dwell Units applies only to
ISNC programming.
Least Scaling Factor specifies the units of the scaling factor when an integer is
used with the scaling command and contains either 0.001
or 0.00001 to be compatible with different Fanuc
controls. The default is 0.001. Least Scaling Factor
applies only to ISNC programming.
Disable X Y Z Scaling disables any scaling being performed in the respective
axis. The default is No.
Reference Point X Y Z specifies the reference point for the G28 command. The
default is 0.000.
Tool Length Tolerance used for tool probing. Refer to the Probing Option
Manual for details. The default is 0.0000.
M6 Initiates Tool Change initiates a tool change if Yes is selected. If No is selected,
the T code initiates a tool change. Yes is the default.
Allow Vacant Variables enable or disable by selecting the Yes or No softkeys. A
vacant variable is a variable that has been defined, but
has not been initialized. If the Allow Vacant Variables
feature is enabled, any variable that has not been
initialized will be assumed to have a value of zero. If this
feature is disabled, then any variable that is not initialized
will produce an error message when the program is run.
No is the default and should be used in most cases. This
feature is provided for compatibility with NC programs
written using vacant variables. No is the default.
Assume Feed Rate .1 Incr. value is displayed in increments of 0.1 for values entered
without a decimal point if set to yes. This field applies to
ISNC only. No is the default.
Ultimax System
August, 2002
3-39

M and G Code Program Numbers
If the NCPP option is installed, from the NC Parameters screen, touch the
NC M and G Code Program Numbers softkey and this screen appears:
Figure 3-20.
NC ParametersM and G Code Program Numbers Screen
To associate the M code with the subprogram number in the Program

Number column, enter positive M codes into the M-Code column.
Similarly, enter G codes in the G-Code column to associate the G code
with the subprogram number.
Entering a negative number in the G-Code column creates modal
subprograms. Multiple negative numbers can be entered in the G-Code
column, but only the first negative number in the column is made modal.
3-40
Revision A
Programming Basics
NC Variables
Refer to the NC Part Programming Manual for details about the NC
Variables.

After entering the tool and part setup information, you may begin
programming the data blocks describing the cutting operations.
Refer to the appropriate part programming description
(Conversational or NC).
Or...
You may want to save the program to the hard drive or to a diskette.
Refer to the Program Storing, Renaming, and Deleting section of
the System Basics chapter for more information about saving
programs.
Or...
You may want to switch off the machine tool. Refer to the Shut
Down Techniques section of the Machine Basics chapter.
Ultimax System
August, 2002
3-41
Erase Functions
While a Conversational or NC part program is being created or used, it is
stored in a temporary memory area on the control. This is not the
permanent memory where programs are stored for later access.
The erase functions do not affect the permanently stored programs. These
functions only remove copies of programs and portions of programs in
temporary memory.
Erase Current Program

Use these functions to perform the following tasks:
Throw away changes to a copy of a program that are no

longer needed.
Clear the entire work area to start fresh (using the Erase All
softkey).
Clear the part program and keep the part setup and/or tool
setup to use for a new program.
Access these options by touching the Erase Functions softkey on the Input
screen:
Figure 3-21.
3-42
Input Screen with Erase Functions Softkey
Revision A
Programming Basics
The Input screen softkeys change to list the erase functions, as shown
below:
Figure 3-22.
Erase Functions
The erase functions will only affect the part program currently displayed
on the Input screen:
Ultimax System
Erase Part Setup - resets all of the Part Setup to their default
values.
Erase Tool Setup - deletes all tool data defined for the part.
Reset Program Parameters - resets the Program Parameters to

their default values.
Erase Program - deletes the part program data blocks from

program memory.
Erase All - deletes the part program and its tool setup from
program memory and then resets the Part Setup values and the
Program Parameters to their default values.
August, 2002
3-43

After you select one of the erase functions, the system displays the
message shown on the screen below and, therefore, allows you to confirm
the erase operation:
Figure 3-23.
Input Screen with Do you really want to Erase? Message
The erase functions only erase program descriptions from the temporary
memory. This does not affect the stored version of the program on the
hard drive. For an explanation of permanent program storage and deletion,
refer to the Program Storage Functions section in the System Basics
chapter.
3-44
Revision A
Programming Basics
Erase Running Program

If you have been using Concurrent Programming and have two programs
in temporary memory, you may erase the running program if you have
done any of the following:
Completed the running program.
Stopped the running program by pressing the Emergency

Stop button.
Aborted the running program by pressing the Feed Hold or

Motion Hold and Spindle Off buttons.
With the program still in memory, press the console Input key and then
touch the Erase Functions softkey. The following screen displays:
Figure 3-24.
Input Screen with Erase Running Program Softkey
Pressing the Erase Running Program softkey causes the system to display
the Do you really want to ERASE (Y/N)? prompt. Touch the Yes
softkey to remove the running program from temporary memory.
Refer to the Concurrent Programming section in this chapter for
information about concurrent programming.
Ultimax System
August, 2002
3-45
Restore Functions
While a part program is being created or used, it is stored in a temporary
memory area on the control. This is not the permanent memory where
programs are stored for later access.
The restore functions copy portions of programs from the permanently
stored programs into temporary memory. Restore functions are used with
Part Setup, Tool Setup, and Program Parameters. The Restore All function
restores the part setup, tool setup, and program parameters from the
selected HD3 file into temporary storage. Operators use these functions to
perform the following tasks on HD3 files only:
Restore particular sections from existing files into the

current part program.
Read an entire tool setup into an existing part program file

and still retain the part program created.
Load in different program parameter setups based on

personal preferences and retain part program and tool setup.
Use as part of maintaining a tool library.
Access these options by pressing the Restore Functions softkey on the

Input screen:
Figure 3-25.
3-46
Input Screen with Restore Functions Softkey
Revision A
Programming Basics
The Input screen softkeys change to the restore menu, as shown below:
Figure 3-26.
Input Screen with Restore Functions
The restore functions will only affect the part program currently displayed
on the Input screen:
Ultimax System
Restore Part Setup - reads the part setup from the selected HD3
file into memory.
Restore Tool Setup - deletes all tool data defined for the part and
replaces it with the tool setup stored in the selected HD3 file.
Restore Part & Tool Setup - restores the part and tool setup from
the selected HD3 file.
Restore Program Parameters - restores all program parameters

from the selected HD3 file. .
Restore Part Program - .restores the part program portion of the

selected HD3 file into memory. May be used to restore the saved
version of a part program into memory eliminating any changes
made to the current version.
Restore All - .restores part program, program parameters, tool

setup, and part setup from the selected HD3 file.
August, 2002
3-47
Hints and Tricks

Restoring the Tool or Part Setup is useful when using NC files or
DXF files that do not store part and tool information.
Important
The CNC will not allow an operator to perform a restore function
from a program that was created and saved with different
measurement units than the one in memory (i.e., mm in memory and
restore program in inches, or, vice versa). An error message displays
and the restore action aborts when this type of restore is attempted.
Hints and Tricks

For machines equipped with an optional rotary table, you may
initiate and name a new rotary program on the Input screen and then
touch the Restore All softkey to pull in all programming blocks and
setups of an existing standard program. Insert rotary blocks where
needed and save the file with a different name to have a rotary and
non-rotary version of the same program and setup.
3-48
Revision A
Programming Basics
After you select one of the restore functions, the system displays the
message shown on the screen below and allows you to confirm the restore
operation. The term erase is used in this message to indicate
modification of the program in temporary memory:
Figure 3-27.
Input Screen with Do you really want to Erase? Message
The restore functions do not affect the stored version of the program on
the hard drive. For an explanation of permanent program storage and
deletion, refer to the Program Storage Functions section in the System
Basics chapter.
Ultimax System
August, 2002
3-49

If you choose the Yes softkey from the previous screen, the Current
Directory screen appears with the softkeys shown below:
Figure 3-28.
Current Directory Screen After Selecting a Restore Function
Choose from these functions for each of the restore functions on the
previous Input screen:
3-50
Change to Directory - allows you to change to a different

directory.
Rename Program - allows you to rename a program.
Delete Program - allows you to delete a program.
Copy Program - allows you to copy a program.
Change Program Mask - allows you to create a directory.
Select Current Storage Drive - allows you to choose the storage

drive.
More- allows access to more softkeys.
Exit - Returns to the Input screen and does not erase or modify the
sections in program memory.
Revision A
Programming Basics
Graphics
Drawing stops when a data block has incomplete (or incorrect) data and
when new data blocks are being created. Before appearing on the screen,
the scale of the part drawing is computed for the maximum that fits on the
screen. The message Autoscaling part program will be displayed on the
screen during this scaling process.
To switch the graphics display on and off within a part program, press the
Miscellaneous softkey on the New Block screen. The graphics softkeys
then appear as shown below:
Figure 3-29.
New Block Screen with Miscellaneous Functions
The Graphics Off and Graphics On softkeys allow viewing selected part
features in complex programs where certain operations tend to obliterate
others such as facing and pocketing.
Pressing either the Graphics Off or Graphics On softkey stores the
selected function as a data block in the part program. The graphic drawing
of the part is turned off and turned on at the point the block is encountered
in the program.
Caution
Blocks that are hidden by Graphics Off are still cut when the
program is run.
Ultimax System
August, 2002
3-51
Views
Graphics can be displayed in five views:
XY Plane (XY projection)
XZ Plane (XZ projection)
YZ Plane (YZ projection)
Isometric (three-dimensional)
All Planes (all four of the views)
Access any of these views by positioning the crosshair cursor on the View
screen button and pressing the console Select key. Then using the same
method, select the appropriate screen button for the desired view from the
next displayed set of screen buttons.
The following is a screen showing an isometric view of a bolt circle
program:
Figure 3-30.
Graphics Screen with Isometric View
Scaled views appear to the left and at the bottom of the screen, except
when using the isometric view. The displayed views are automatically
proportioned by the control according to the programmed dimensions of
the part.
3-52
Revision A
Programming Basics
The following is a screen showing four views (All Planes option) of a bolt
circle:
Figure 3-31.
Graphics Screen Showing All Planes
Views may be eliminated from the screen using one of the parameters
described later in this section.
Ultimax System
August, 2002
3-53
Zoom
The Zoom function enlarges a selected portion of the drawing. A zoomed
screen remains in that state until the Full Scale option is selected.
Selecting the Zoom function for a plane view does not zoom the other
plane views (i.e., zoom on XY plane does not zoom the XZ plane).
Graphics Parameters
To change the graphics display parameters, position the crosshair cursor
on the Parameters screen button and press the console Select key. This
selection displays a screen with the following options:
Figure 3-32.
Graphics Parameters Screen
To change the Yes/No entry for a field, move the cursor to the box in front
of the field and press the Select key until the desired response appears
after the equal sign.
3-54
Revision A
Programming Basics
The menu selections displayed on the Graphics Parameters screen are
defined as follows:
Parameter Fields
Draw Scales
controls the display of scales that normally

appear to the left and at the bottom of the
screen(s). These scales can be removed by
selecting the No response for this parameter.
Draw Tool Path
controls the display of the tool path (center line),

shown as dashed lines on the graphics screen.
This path is removed from the drawing
representation by selecting the No response. Do
not shut off both the Draw Tool Path field and
the Draw Part Surface field.
Draw Part Surface
controls the finished part surface, shown as solid

lines on the screen drawing. This view is
removed by selecting the No response. Do not
shut off both the Draw Tool Path field and the
Draw Part Surface field.
Draw Rapid Moves

Exit Parameter
Entry
Draw Plunge
Moves
Ultimax System
Definitions
functions only when operating in NC.

move the crosshair cursor to the box before this
parameter and press the console Select key to exit
the screen and save parameter changes.
shows the plunge feed tool path for both helical
and straight plunges. All conversational blocks
with milling have the capability of displaying
plunge feed tool paths. The color default is light
green, but can be changed using the Graphics
Colors Parameters screen.
August, 2002
3-55
Data Block Search

The data block search feature allows you to move directly from a portion
of the drawing that looks incorrect to the data block where it is
programmed. To use this helpful function, follow these steps:
1.
Figure 3-33.
3-56
Rotate the trackball to move the crosshair cursor to the DB

Search screen button in the lower right corner of the
graphics screen. Press the console Select key, and the
message shown in the following illustration appears:
Identifying a Portion for the Search
Revision A
Programming Basics
2.
To select the search area, move the crosshair cursor to the

desired point in the graphic view and press the Select key.
The data block used to execute the area indicated by the
crosshair cursor appears on the text screen, in the figure
below.
3.
If the cursor is located near a point executed by two

adjoining data blocks, the first data block in the program
representing the operation nearest the cursor is displayed on
the text screen.
Figure 3-34.
Data Block Displayed After the Search
4.
To stop the search, move the crosshair cursor to the Exit box
and press the Select key.
5.
To return to the drawing, press the console Draw key.
Important
The data block search function can only be used for the XY Plane
view and is inoperative when viewing a running part program.
Ultimax System
August, 2002
3-57
Graphics Error Checking

If the graphics system encounters an error while drawing the part, an error
message appears in the lower area of the graphics screen, as shown below:
Figure 3-35.
Graphics Screen Error Message
To respond to a drawing error message, follow one of these procedures:
Ignore the indicated error, place the cursor on the Exit

parameter, and press the Select key.
To find the indicated error, position the cursor on the Find

option, and press the Select key. The control automatically
activates the edit functions and displays the data block with
the error.
Hints and Tricks

After correcting the error, you can press the Draw button again to be
certain the part can be drawn without errors.
3-58
Revision A
Programming Basics
Running Part Programs

To run program, either Conversational or NC, the program must be loaded
into the controls memory. Refer to the File Storage Facilities section of
the System Basics chapter for information about reading programs from
disk.
After the machine is calibrated and warmed up, you can perform the
operations described in this section.
The Ultimax system has a variety of options for running programs. You
may wish to run an entire program or only a portion of it. You can also use
the test run facilities, error checking, and program run time estimate
features that are available.
Warning
When running part programs, always follow these rules:
Do not leave the machine unattended.

Never press the console Start Cycle button without
knowing exactly what the machine will do!
Never start the machine when the cutter is in
contact with the work piece.
Stand away while the machine is running a part
program.
Never lean on the machine while the spindle is
moving.
You must work within reach of an Emergency Stop button and be able to
observe the operation of the spindle. If you are running a part program and
cannot reach an Emergency Stop button nor observe the spindle, that is
considered unattended operation and is viewed as a foreseeable misuse of
the machine.
Ultimax System
August, 2002
3-59
European Manual Safety Override Mode

For machines sold in Europe with CE2000 enabled, the Manual Safety
Override mode allows the enclosure doors to be opened when the system
is in Manual mode so the operator or supervisor can perform manual
machine functions.
While the doors are open, manual functions such as adjusting the fixture
can be performed. However, the jog feed is restricted. The jog feed is
limited to 80 inches per minute (2 meters per minute).
Note
A Door Open Fault can occur at the end of a program if the doors are
opened for part inspection or removal but the Tool Magazine is rotating to
the next tool in anticipation of the program restarting. To avoid this Door
Open Fault, do not engage the Manual Safety Override until all machine
movement has ceased - including movement of the Tool Magazine that
could occur at the end of a program.
Important
No spindle operation is allowed when the doors are open.
When the Manual Safety Override mode is enabled, it remains enabled
until control power is turned off, the Emergency Stop button is pressed, or
machine power is turned off. A fault will disable the Manual Safety
Override mode also.
If you try to jog the axes with the doors open without enabling the safety
mode using the Access Code, this message appears on the screen:
Figure 3-36.
3-60
Access Code Message on Manual Screen
Revision A
Programming Basics
To enable the Safety Override mode, access the CE Status & Diagnostics
screen.
1.
From the Manual mode screen, touch the Manual Function

Setup softkey.
2.
Touch the CE Diagnostics softkey. This screen appears:
Figure 3-37.
CE Status & Diagnostics Screen
The fields on the CE Status & Diagnostics screen are defined as follows:
Field
CE Configuration
Door Lock Status
Door Switch Status
Definition
displays CE logic configuration.
displays status as Unlocked or Locked.
displays status as Closed or Open. The switch must be
Closed when the Door Lock Status is Locked.
Limited Manual displays status as Not Enabled or Enabled. Enabled
Operations controls all movement when the chip doors are open.
Status is Enabled after using the Enter Code softkey and
entering an access code. Enabled allows limited safe
motion with the doors open.
Ultimax System
August, 2002
3-61
Entering the Access Code

A numeric access code is required to enable Limited Manual Operations.
Follow these steps to enter the access code:
1.
Touch the Enter Code softkey. A message appears with a

prompt for entering a 4 digit code.
2.
Enter a numeric code using the console keypad. Asterisks

(*) appear representing each entered digit. When the fourth
digit is entered, the asterisks and message disappear.
Note
Using a non-numeric key cancels the operation.
Figure 3-38.
Figure 3-39.
3-62
A message appears if the 4-digit code is entered incorrectly,

and Limited Manual Operations will not be enabled:
Incorrect Code Message on CE Status & Diagnostics Screen
When the code is successfully entered, the Limited Manual

Operations feature is enabled, as indicated in the status field:
Enabled Field on CE Status & Diagnostics Screen
Revision A
Programming Basics
Entering a New Access Code

When a machine is first commissioned, no Access Code is set. A numeric
access code, entered from the console keypad, is required to enable
Limited Manual Operations.
Follow these steps to enter an access code for the first time:
1.
Touch the Enter Code softkey. A message appears asking

you to enter a new code.
2.
Enter the new access code and a prompt appears asking you
to re-enter the code for confirmation.
If the same code is not entered, the code will not be

changed and a message appears prompting you to
enter the correct code.
When the new code is re-entered, the code is saved
and a message appears verifying the code has been
changed.
Changing an Existing Access Code

To change an existing access code, follow these steps:
1.
Touch the Change Code softkey. A message appears asking

you to enter the current code.
2.
Enter the current numeric code from the console keypad. A

message appears asking you to enter the new code.
3.
Enter the new code. A message appears asking you to reenter the new code for confirmation.
Ultimax System
If the new code is not re-entered, the code is not

changed.
When the new code is verified, the code will
change and a message appears to confirm the
action.
August, 2002
3-63
Error Conditions
If the control detects an error during the execution of the program, it clears
the softkeys and stops the spindle and program execution. An error
message is displayed on the bottom of the screen as shown below:
Figure 3-40.
Error Message on the Auto Screen
Pressing the Enter key displays the program editor and positions the
flashing cursor at the block containing the error.
If the control is loading from a remote device while running the program
and the internal buffers become starved, the Z axis retracts from the part
surface by the amount specified by the Depletion Retract parameter in the
Program Parameters. The following message is displayed:
Reloading Buffer...
The Tool has been raised from the part surface. When the program
memory has been refilled, the Z axis is fed into the part and the run
resumes.
3-64
Revision A
Programming Basics
Stop Motion
If you observe a problem during the cutting process or simply want to stop
the machine to make some adjustments, you may press one of three
buttons to stop motion:
Feed Hold - stops all axes movement (except a tapping operation

in progress), when the tool is in the programmed feedrate region.
Pressing the button a second time allows machine positioning to
resume without loss of position, provided no other button or key
has been pressed.
Interrupt Cycle - halts machine operation during automatic

execution of a program to allow manual functions such as cleaning
the work piece. Pressing the Interrupt Cycle button performs the
following actions:
1.
Stops all motion except the spindle.
2.
Pulls the tool straight up and out of the part.
3.
Stops the spindle.
4.
Displays the manual screen on the console.
To restart the part program, press the Auto button followed by the
Start Cycle button.
Important
If any key other than the Auto button is pressed to restart the
program, the system cancels the execution of the part program.
Ultimax System
Emergency Stop - all motion stops and power is shut off to the
spindle, relay control, and servo systems. An emergency stop
message with recovery instructions appears at the bottom of the
text screen. To release an Emergency Stop button, twist the button
in the direction indicated by the arrows and pull the button up.
August, 2002
3-65
Important
After the last choice is selected, the following sequence occurs:
1.
A prompt is displayed to press the Start button while the

console Start Cycle button flashes.
2.
When the Start Cycle button is pressed, the program begins

running at the specified point of the Start Block.
3.
When the specified End Block is reached, the display

indicates that Recovery Restart mode is complete and the
Start Cycle button flashes again.
4.
If the Start Cycle button is pressed again, then the program

will re-run using the same Start and End Blocks.
Re-Run Entire Program

To re-run the program in its entirety after a Recovery Restart, follow these
steps:
1.
2.
3-66
Press the console Auto button.

a.
The softkey selections reappear on the Auto

screen.
b.
The Start Block default is 1, and the End Block

default is the last block of the program.
Touch the Run Program softkey to run the program.
Revision A
Programming Basics
Concurrent Programming
Concurrent Programming allows you to create or edit a Conversational
part program and/or read a part program from disk into memory, while
simultaneously machining a part using a different part program.
Concurrent Programming is possible only when using the Auto screen to
run the program.
Important
Before beginning Concurrent Programming, save each program to
the hard drive or floppy diskette. If the machine power is shut off,
the control will only save the program that is in the editor. The
running program will not be restored and changes made to it prior to
beginning Concurrent Programming will not be saved by the
AutoSave feature.
When using Concurrent Programming, two part programs are
simultaneously available. To enter Concurrent Programming while
machining a part, press the console Input key. The Auto screen is replaced
by the Input screen.
Figure 3-41.
Ultimax System
Input Screen with Concurrent Running Program
August, 2002
3-67

The Running Part Program field identifies the program currently running.
This screen lists the program names for both the running part program and
the edit part program. The graphics screen becomes blank to prepare for
the new part program graphics. The filename of the new part program may
be entered in the Edit Part Program field. Use the part programming
features to create or change data blocks.
To run the new edit part program or to edit the running part program,
follow these steps:
1.
Wait for the running program to finish, or stop this program

from being executed by pressing the console Feed Hold
button, then the Spindle Off key, followed by the Feed Hold
button. The input screen displays the Edit and Run Part
Program names.
2.
Press the Input key.
3.
Touch the Exchange Edit/Run Programs softkey.
Figure 3-42.
3-68
Input Screen with Exchange Edit/Run Programs Softkey
Revision A
Programming Basics
4.
The program names for the Edit and Running Part Programs
are switched. The program now in Edit Part Program can be
edited.
5.
Touch the Exchange Edit/Run Programs softkey and the

program names are switched again.
6.
Select the Auto button to run the program that was

originally running when the program was interrupted.
Important
Editing tool or program information without switching the editor
means that the changes are not being made to the running part
program. You cannot abort Auto, edit the program in Input, and
return to Auto because the control will be running the part program
in the Running Part Program field, not the Edit Part Program field.
Ultimax System
August, 2002
3-69
Software Options
The Ultimax control contains software used to process data and display
screens in much the same manner that personal computers use software
programs. As with other software systems, Ultimax has additional
software options that can be purchased for the system.
Contact Hurco or your Hurco distributor for details about purchasing
software options.
Ultimax Programming Training

Learn how to create part programs in minutes on the easy-to-use Ultimax
control. Hurco offers hands-on training classes to demonstrate the
powerful programming capabilities of Ultimax. Every customer will gain
an advantage by attending Ultimax training classes.
Ultimax training classes teach the machine operator to:
Create part programs from blueprints.
Minimize programming time.
Decrease or eliminate programming mistakes reducing

scrap and programming downtime, and extending tool life.
Increase productivity.
Enhance part programming capability with Ultimax options.
For additional information or to register for an Ultimax Program Training

class, call Hurco at (800) 638-1849.
3-70
Revision A
Appendix A
This Appendix includes the following supplemental material:
Ultimax System
Data Transfer Protocols Usage/Handshaking
Suggested Cutting Speeds in Feet-per-Minute for High

Speed Steel End Mills
Recommended Feed/Flute (Chip Loads)
Feeds and Speeds for High Speed Drills
August, 2002
A-1
Appendix
Protocols Usage or Handshaking

The term protocol or handshaking refers to the method by which data is
transferred between two devices. Without protocols, the sender may send
characters faster than the receiver can handle them. The receivers internal
buffers will probably overflow causing characters to disappear. The
Ultimax control uses two types of protocols:
Hardware
Software
Hardware handshaking physically connects the RTS and CTS pins of one
device to the CTS and RTS pins of another device via a cable. With
hardware handshaking, the receiver uses electronic signals to tell the
sender when the sender can and cannot send characters. This method
usually reacts quickly to the signals but requires that the cabling contain
enough wires to accommodate the additional signals.
Software handshaking uses the software programmable XON and XOFF
control characters embedded in the 7-bit ASCII code. Using software
handshaking, the receiver sends a special character to the sender
instructing the sender to stop until further notice. When the receiver is
ready to receive characters, it sends another special character that instructs
the sender to continue sending. This method requires fewer signal wires
than the hardware handshaking, but reaction time is slower.
A-2
Revision A
Appendix
CTS/RTS Protocol
The CTS/RTS protocol is described from the Ultimax control side of the
connection. The following Control As Sender section describes what
happens when the control sends a program; the Control As Receiver
section describes what happens when the control receives a program. With
this information and the knowledge of the remote device, you can adjust
the remote equipment to communicate with the control.
When the controls ports are initialized, the TD, RTS and DTR (if
available) signals are held in the low state (from -3 to -15 volts or
disasserted). When you start a load or save operation at the control
console, the control brings the RTS and DTR lines into a high state (from
+3 to +15 volts or asserted). This tells the remote device that the control is
ready to communicate.
CTS is an input to the control. Its state depends on the state of the
handshake lines attached to it from the remote device. If the remote device
is ready to communicate, it should be high; if not, it should be low.
Control As Sender
When the control is Saving (sending) a program to the remote device,
setting RTS and DTR to HIGH means that the control is READY to
transmit. No transmission occurs until the remote device sets its
handshake signal to HIGH (which should set the controls CTS to HIGH).
As soon as the control sees a HIGH CTS signal, it begins to transmit as
long as the CTS input stays HIGH or until all the data has been
transmitted.
Figure A-4.
Order of Events when the Control Sends
These are the Control as Senders order of events:

Ultimax System
August, 2002
A-3
Appendix
1.
The Save operation is initiated at the Ultimax control

console.
2.
A program is started at the remote device that receives the

characters sent by the control.
3.
The Remote devices internal buffers fill up. The handshake

line is reset LOW to stop the flow of characters.
4.
The Remote device is able to receive characters again so it

sets the handshake signal HIGH to resume character flow.
5.
The control reaches the end of the file and has no more
characters to transmit. The End Of File (E) character is
transmitted.
6.
The remote device acknowledges the E character and closes

its port. The control ensures that the last character in the file
has been sent, and then closes its port. Both the control and
the remote device return to an idle state shown by their
handshake signals returning LOW.
With this method, the remote device can regulate the controls character
flow by periodically resetting its handshake output LOW causing a LOW
control CTS input, thus suspending the flow of characters from the
control. When the remote device is able to receive characters again, the
device sets its handshake signals HIGH causing a HIGH control CTS, thus
resuming the flow of characters.
A-4
Revision A
Appendix
Control As Receiver
When the control is receiving a program, it signals the remote device that
it is ready to receive characters, by setting its RTS and DTR lines HIGH.
No communication can occur until the remote device is ready to transmit.
When the remote device is ready, it sets its handshake lines HIGH which
should set the controls CTS to HIGH. The remote device will begin
transmitting when it sees that both the control and the remote device are
ready.
Figure A-5.
Order of Events when the Control Receives
The system follows these steps when receiving a transmitted file:
Ultimax System
1.
A program is started at the remote device that transmits the

characters to the Ultimax control.
2.
The load operation begins at the control console.
3.
The controls internal buffers fill up. Its RTS and DTR lines
are reset LOW to stop the flow of characters.
4.
The control is able to receive characters again, so it sets

RTS and DTR HIGH to resume character flow.
5.
The remote device reaches the end of the file and has no
more characters to transmit. The End Of File (E) character is
transmitted.
6.
The control acknowledges the E character and closes its

port. The remote device ensures that the last character in the
file has been sent and closes its port. Both the control and
the remote device return into an idle state shown by their
handshake signals returning LOW.
August, 2002
A-5
Appendix
XON/XOFF Protocol
The XON/XOFF protocol is a software flow control method. It is the
preferred transfer protocol for NC programs. The only wires that must be
in the cable are TD, RD, SG, and the shield (PG). This method uses three
special control characters to start and stop the flow of data characters. The
characters that control the character flow follow:
Mnemonic
DC1
DC2
DC3
HEX
11H
12H
13H
Char Name
XON
PUNCH ON
XOFF
CTRL
CTRL Q
CTRL R
CTRL S
The XON/XOFF protocol begins with a synchronization phase. It consists

of the sender announcing its presence by sending DC2 one time every
250 msec for five seconds, until it receives DC1 (XON), from the
receiver or until the operator aborts the sending operation. If the sender
receives XON or the five second timer expires, it sends DC2 to the
receiver and begins to send the file.
Meanwhile, the receiver advertises its presence by sending XON one time
every 250 msec. The receiver continues to send XONs until it receives a
character from the sender or until the operator aborts the receiving
operation.
A-6
Revision A
Appendix
Once the sender begins to send the file, it continues until the receiver
sends the XOFF signal, the end of file is reached, or the operator aborts
the sending operation. If the sender receives XOFF, it stops transmission
and waits for XON before it resumes. The receiver sends XOFF if its
internal buffers are full. This buffer level is usually calculated so the
receiver sends the XOFF signal early enough for the sender to process the
message and stop transmission before the receivers buffers overflow.
After the receiver is able to handle more characters, it sends an XON
signal.
Figure A-6.
Ultimax System
XON/XOFF Protocol Transmission Order
August, 2002
A-7
Appendix
The XON/XOFF protocol follows these transmission steps:
1.
The receive sequence is started at the receiver. The receiver

sends XONs at 250 msec intervals.
2.
The transmit sequence is started at the sender. The sender

sends a DC2. It sees one of the receivers XONs and then
begins to send characters.
3.
The receivers internal buffer fills up. The receiver sends an

XOFF to stop the sender.
4.
The sender receives the XOFF and stops transmission.
5.
The receiver is able to receive characters again so it sends

the sender an XON.
6.
The sender receives the XON and resumes transmission.
7.
The sender reaches the end of the file, sends the End Of File
(E) character and then has no more characters to transmit. It
closes the port after it ensures that no more control
characters are transmitted from the receiver. The receiver
receives the E and then closes its port.
Note
Between steps 34 and 56, there are time lags as the receiver sends
the control characters and the sender responds to them.
When using XON/XOFF protocol, initiate the receiver first so that it is
immediately ready to receive. After it starts, you may start the sender. If
you do not initiate the receiver and the sender in this order, the senders
five-second timer may expire and characters will be sent without a
receiver.
A-8
Revision A
Appendix
Full Handshake
As with XON/XOFF, full handshake is a software protocol differing from
XON/XOFF only in the beginning synchronization stage. Full handshake
uses the same type of cabling as XON/XOFF.
With full handshake, the sender does not have a five-second time-out.
Instead, DC2s are sent every 250 msec until the confirming that the DC1
is received, or the sender aborts the operation. Once the sender receives
the DC1, it sends the confirming DC2 and begins the file transmission.
This protocol makes it easy to start both the sender and the receiver at the
operators leisure and in whichever order is appropriate for the
application.
During the actual transmission of the file, XON/XOFF and full handshake
operate identically.
Ultimax System
August, 2002
A-9
Appendix
Suggested Cutting Speeds in Feet-per-Minute

For High Speed Steel End Mills
Material
Steel
Up to 240 Brinell (24Rc)
240 to 320 Brinell (2435 Rc)
320 to 500 Brinell (3550 Rc)
Cast
Stainless
Cast Iron
Regular
Hard
Non-Ferrous
Brass
Magnesium
Copper
Regular
Hard
Titanium
Unalloyed
Alloyed
Ultimax System
Cutting Speed (FPM)

90175
5090
550
6090
3080
Formulas:
80120
530
150500
1501000
100500
90150
3070
Surface Ft. Per Minute = (RPM x 3.14 x Tool Diameter) / 12

Chip Load = Feed in IPM / (RPM x Number of Teeth)
Feed in IPM = Chip Load x RPM x Number of Teeth
RPM = (12 x SFPM) / (3.14 x Tool Diameter)
3555
1535
August, 2002
A-10
Appendix
Recommended Feed/Flute (Chip Loads)

Materials
Face Mills
Helical Mills
.010
Slotting & Side

Mills
.008
End
Mills
.007
Form Relieved
Cutters
.004
Plastic
.013
Magnesium Alloys
.022
.018
.013
.011
.007
Aluminum Alloys
.022
.018
.013
.011
.007
Free Cutting Brass and Bronze
.022
.018
.013
.011
.007
Medium Brass and Bronze
.014
.011
.008
.007
.004
Hard Brass and Bronze
.009
.007
.006
.005
.003
Copper
.013
.010
.007
.006
.004
Cast Iron, soft (150180 BH)
.016
.013
.009
.008
.005
Cast Iron, med. (180220 BH)
.013
.010
.007
.007
.004
Cast Iron, hard (220300 BH)
.010
.008
.006
.006
.003
Cast Steel
.012
.010
.007
.006
.004
Med. Carbon Steel
.010
.008
.006
.005
.003
Alloy Steel (180220 BH)
.008
.007
.005
.004
.003
.006
.005
.004
.003
.002
.004
.003
.003
.002
.002
Stainless Steels
.006
.005
.004
.003
.002
Ultimax System
August, 2002
A-11
Appendix
Feed and Speeds for High Speed Drills

The feeds and speeds in the following tables apply to average working conditions and materials. They are
recommended with due regard to conserving drills and avoiding excessive machine tool wear. Under many
conditions, these feeds and speeds may be considerably increased (increase in feed often helps break up chips),
while under other conditions they must be decreased. In order to secure the best results, both the speed and feed
should be increased or decreased in proper proportion. The liberal use of cooling compound will increase the
life of tools. Always keep drills sharp.
Feed per Revolution
Drill Diameter
Feed per Revolution
Material and Surface Feet per Minute

Alloy Steel
2030
up to 1/8
0.0010.003
Aluminum and its alloys
200300
1/8 to 1/4
0.0020.006
Brass, Bronze
1020
1/4 to 1/2
0.0040010
Hard Chilled Cast Iron
1020
1/2 to 1
0.0070.015
Monel
3050
1 and over
0.0150.025
Magnesium
250400
Mild Steel
80110
Soft Cast Iron
70125
Stainless Steel
50
Tool Steel
5060
Titanium
1060
Ultimax System
August, 2002
A-12
Index
B (continued)
Bore Orient Retract, NC, 3-30

Brightness control, 1-3
Abort operation, 2-21

Absolute zero, 1-33
Access code, 3-62
changing, 3-63
Allow Vacant Variables, NC, 3-39
Arcs
chord error, 3-27
Arrow keys, 1-6
Assume Feed Rate, NC, 3-39
ATC, 1-35
large tools, 1-39
loading, 1-37
tool removal, 1-38
ATC Map, 1-40
resetting, 1-41
ATC Map screen, 1-40
Auto button, 3-65
Auto console key, 1-16
Auto cycle mode softkeys, 1-17
Auto cycle run program, 1-18
Auto cycle screen, 1-17
Automatic tool monitoring, 3-27
AutoSave time, 2-25
Autoscaling, 3-51
Auxiliary console key, 2-23
Auxiliary key, 1-5
Axes calibration, 1-34
Axis
calibration, 1-34
feed rate dial, 3-25
select switch, 1-13
Axis control, 1-11
Axis Feed Rate dial, 1-11
Axis limit switches, 1-34
Axis motion figure, 3-3
B
Backup Config and Machine Files, 2-33
Baud rate, 2-14
Bore Dwell, NC, 3-30
Ultimax System
C console key, 1-6

Calculator
shim stock dimensions, 3-14
Calibrate Machine softkey, 1-34
Calibrate the machine, 1-33
Calibration
machine, 1-33
tool, 3-14
Cancel the warm up cycle, 1-34
CE Safety override mode, 3-60
CE Status & Diagnostics screen, 3-61
CE2000, 3-60
Change editor, 2-34
Change language, 2-34
Change to directory, 2-7
Change to Directory softkey, 2-5
Changing access code, 3-63
Changing serial port settings, 2-22
Changing the DRO character size, 2-26
Check for errors, 1-18
Chip Removal Forward, 1-20, 1-23
Chip Removal Reverse, 1-20, 1-23
Chord error, 3-24, 3-27
Chord error figure, 3-28
Cleaning the work piece, 3-65
Climb milling, 3-32
CNC configuration screen, 2-31
Color parameters, 2-28
text, 2-28
Coolant Washdown Off, 1-20, 1-23
Coolant Washdown On, 1-20, 1-23
Communications panel, 1-29
Communications panel figure, 1-29
Compute estimated run time, 1-18
Concurrent programming, 3-67
access from Input screen, 3-67
Concurrent programming screen, 3-67
August, 2002
I-1

C (continued)
C (continued)
Console, 1-2
Console buttons
Emergency Stop, 3-65
Feed hold, 1-15, 3-65, 3-68
Interrupt cycle, 3-24, 3-65
Machine operations, 1-16
motion control buttons, 1-15
Motion hold, 1-15
Spindle Off, 3-68
Console keys
Alt, 1-7
arrow keys, 3-13
Auto, 1-16, 1-28
C, 1-6
Coolant
Auto, 1-28
Secondary, 1-28
Delete, 1-6
End, 1-6
Enter, 1-6
F, 1-6, 1-7
Home, 1-6
Insert, 1-6
Interrupt cycle, 1-16
Machine Mode, 1-16
Auto, 1-16
Manual, 1-16
Single, 1-16
Test, 1-16
Machine operations
Spindle
On/Off, 1-28
Manual, 1-16
Page Down, 1-6
Page Up, 1-6
Primary coolant, 1-28
Single, 1-16
Spindle Off, 1-28
Spindle On, 1-28
Start Cycle, 1-28, 3-59
Test, 1-16
Tool changer, 1-28
Console knobs
Axis Feed Rate, 1-11
Rapid Override, 1-11
I-2
Console knobs (continued)

Spindle Speed, 1-11
Consoles, 1-2
Contrast control, 1-3
Control panel, 1-3
Control power off time, 1-43
Conversational, 1-24
Conversational part program
running, 3-59
Conversational part programming
concurrent, 3-67
manual run, 1-26
milling parameters, 3-31
single cycle, 1-21
Conversational programming
recovery restart, 1-18
Coolant, 1-28, 3-15, 3-17
Auto, 1-28
primary, 1-28
copy all tagged programs, 2-12
Copy part programs, 2-8
Crash prevention, 3-8
Create directory, 2-10
Crosshair cursor, 3-52, 3-54, 3-56
CRT degauss, 2-34
Current directory screen, 3-50
Current program screen, 2-3
Cursor control, 1-6
Cutter Comp using Insert Arc figure, 335
Cutter Comp using Insert Line, 3-36
Cutter compensation, 3-14
UltiPocket parameters
Insert Arc, 3-35
Insert Line, 3-36
Cutter compensation figure, 3-14
D
Data block, 3-57
graphics on/off, 3-51
search, 1-10
search from graphics, 3-56
Revision A
Index
D (continued)
Data block displayed after search screen,
3-57
Date, 2-24
Default communication settings table, 2-21
Default communications settings, 2-21
delete all tagged programs, 2-12
Delete directory, 2-10
Delete key, 1-6
Delete part programs, 2-8
Delete tool
softkey, 3-18
Depletion retract, 3-27
Diameter, 3-16
Diameter Comp, 3-16
Digital Read Out, 2-26
Direction), 3-17
Directories
reorganize, 2-8
Directory
change, 2-7
creating, 2-10
delete, 2-10
structure figure, 2-2
Directory program names, 2-6
Disable X Scaling, NC, 3-39
Disable Z Scaling, NC, 3-39
Disk operations, 2-7
Disk Operations
List Directory softkey, 2-7
Disk operations list directory, 2-7
Diskette
storage, 2-35
Diskette in drive before reboot, 2-37
Diskette in drive during reboot, 2-37
Display
color defaults, 2-30
Door Open Fault, 3-60
Download from current drive to
peripheral device, 2-20
Download from memory to peripheral
device, 2-19
Download programs, 2-14
Download send, 2-19
Download/upload, 2-14
Ultimax System
D (continued)
Download/upload screen, 2-15
Drill Dwell, NC, 3-30
Drilling
dwell parameter, 3-28
feedrate, 3-21
Drives
program storage, 2-9, 2-13
DRO, 3-4
DRO display units, 2-26
DXF option
color settings, 2-29
E
Enter key, 1-6
button release, 1-32
Emergency Stop button, 1-4
Emergency Stop for shut down, 1-42
End Block, 1-17
End key, 1-6
Entering the access code, 3-62
Erase current program, 3-42
Erase functions, 3-42
part setup, 3-43
program, 3-43
reset program parameters, 3-43
tool setup, 3-43
Erase functions screen, 3-43
Erase message, 3-49
Erase running program, 3-45
Erase running program screen, 3-45
Error checking, 1-10, 1-18
using graphics, 3-58
Error messages
on graphics screen, 3-58
Establishing servo power, 1-32
estimate run time, 1-18
European machines, 1-1
Exchange Edit/Run Programs softkey, 3-68
Export program as text file, 2-13
August, 2002
I-3

G
F
F console key, 1-6
Feed Hold button, 1-15, 3-65, 3-68
Feed Hold console button, 1-34
Feed/Flute (Tooth), 3-15, 3-17
Feedrate
finish, 3-32
plunge, 3-20
Feeds and speeds
automatic calculation of, 3-20, 3-21
Figures
Axis motion, 3-3
Chord error, 3-28
Communications panel, 1-29
Cutter Comp using Insert Arc, 3-35
Cutter Comp using Insert Line, 3-36
Cutter compensation, 3-14
Directory structure, 2-2
Jog unit, 1-12
Machining, 1-1
Max console panel groups, 1-4
Negative first peck offset, 3-26
Part zero relative to machine zero, 3-3
Positive first peck offset, 3-26
Ultimax 4 and Max consoles, 1-2
Ultimax 4 console panel groups, 1-3
File display method, 2-27
File extension
wildcard), 2-9
File Management, 2-2
Find, 3-58
Finish
feed, 3-32
speed, 3-32
XY, 3-32
Z, 3-32
Finish plunge type, 3-33
First Peck Offset, 3-27
Floppy drive, 2-9, 2-13
Flutes, 3-15, 3-17
Foreseeable misuse
unattended operation, 3-59
Format diskette, 2-13
Full DRO, 1-20, 1-23
Full Status, 1-20, 1-23
I-4
General Parameters, 3-23, 3-24

defaults and ranges, 3-27
ranges and defaults, 3-27
General parameters ranges and default
values table, 3-27
General parameters screen, 3-23
Graphics, 3-11, 3-51
data block search, 1-10, 3-56
drawing stops, 3-51
error checking, 1-10, 3-58
isometric view, 3-52
on or off block, 3-51
parameters, 3-54, 3-55
screen buttons, 1-9
views, 3-52
XY plane view, 3-57
zoom, 3-54
Graphics color parameter defaults table, 2-29
Graphics color parameters, 2-29
Graphics parameters screen, 3-54
Graphics screen, 1-9
Graphics screen error message, 3-58
Graphics screen with all planes view, 3-53
Graphics screen with isometric view, 3-52
H
Handshaking, 2-22
Hardware options, 1-1
Help key, 1-5
Holes Parameters, 3-28
Holes parameters screen, 3-29
Home key, 1-6
Hurco
telephone numbers, training, 3-70
I
Identify portion of graphic for search
screen, 3-56
Inch
Revision A
Index
M
I (continued)
Threads per, 3-13
Input key, 1-5
Input screen, 1-31, 3-22, 3-42
Exchange Edit/Run Programs
softkey, 3-68
tool setup, 3-11
Insert Arc and Insert Lines softkeys 3-34
Insert key, 1-6
Interrupt console key, 1-16
Interrupt Cycle button, 3-24, 3-65
Interrupt cycle Z retract, 3-24, 3-27
Inward pocket plunge near center, 3-33
Isometric view, 3-52
J
Jog
control buttons, 1-12
parameters, 1-14
Jog unit
axes jog buttons, 3-8
manual operation for, 1-16
Store Position button, 3-8, 3-14, 3-19
Jog Unit, 1-12
Jog unit figure, 1-12
K
Keyboard, 1-5
optional, 1-8
L
Ladder configuration screen, 2-32
Language files, 1-30
change, 2-34
Large tools in the ATC magazine, 1-39
Lead-in move, 3-32
Lead-out move, 3-32
Least Dwell Units, NC, 3-39
Least Scaling Factor, NC, 3-39
Limit switches, 1-34
Linear positioning, NC, 3-39
Loading a tool in the spindle, 1-35
Loading tools in ATC magazine, 1-37
Ultimax System
M6 Initiates Tool Change, NC, 3-39

Machine
calibrate, 1-33
control buttons, 1-15
major components, 1-1
mode buttons
Manual, 1-26
mode console key
Single, 1-16
mode console keys
Manual, 1-16
Test, 1-16
mode keys
Auto, 1-16
operations
buttons, 1-16
Coolant
Auto, 1-28
Secondary, 1-28
Primary Coolant, 1-28
powering up, 1-30
Machine calibration screen, 1-33
Machine components, 1-1
Machine control, 1-11
Machine mode console keys, 1-16
Machine zero, 3-3
Maching center figure, 1-1
Manual Function Setup softkey, 1-27
Manual Jog
Feed keys, 1-13
hand wheel, 1-13
hand wheel multiplier keys, 1-13
Manual Jog Feed parameter, 1-14
Manual key, 1-16
Manual mode button, 1-26
Manual screen, 1-26
loading tools, 3-2
park machine, 1-43
Manual Spindle Speed parameter, 1-14
Max console
console keys, 1-4
Max console panel group figure, 1-4
August, 2002
I-5

M (continued)
Memory
permanent, 3-42, 3-46
temporary, 3-42, 3-44, 3-46
Metric
pitch in mm per thread, 3-13
Milling
direction, 3-32
feedrate, 3-21
parameters, 3-32
blend offset, 3-32
blend overlap, 3-32
finish feed, 3-32
finish speed, 3-32
finish X-Y, 3-32
finish Z, 3-32
milling direction, 3-32
pocket overlap, 3-32
Milling Parameters, 3-31
Milling parameters screen, 3-31
Miscellaneous functions screen, 3-51
Motion
stop, 3-65
Motion Hold button, 1-15
Multiple parts, 3-9
N
Naming directory, 2-6
Naming part program, 2-6
Naming subdirectory, 2-6
Naming part programs, 3-2
NC Auto screen, 3-64
NC codes
G41, 3-16
G42, 3-16
G54-59, 3-9
G86, 3-30
G89, 3-30
M06, 3-16
NC Parameters
Configuration, 3-38
M and G Code Program No., 3-40
NC Variables, 3-41
NC Parameters, 3-37
I-6
N (continued)
NC parameters - M and G code program
numbers, 3-40
NC parameters screen, 3-37
NC Configuration parameters, 3-38
NC part program
running, 3-59
error conditions, 3-64
NC part programming
Allow Vacant Variables, 3-39
Assume Feed Rate, 3-39
Bore Dwell, 3-30
Bore Orient Retract, 3-30
Disable X Scaling, 3-39
Disable Z Scaling, 3-39
Drill Dwell, 3-30
least dwell units, 3-39
least scaling factor, 3-39
linear positioning, 3-39
M6 Initiates Tool Change, 3-39
probing part setup, 3-10
Reference Point X, 3-39
Reference Point Z, 3-39
shift offsets, 3-9
Tool Length Tolerance, 3-39
NC programming
test run mode, 1-24
NC Variables, 3-41
NC Work Offsets, 3-9
Negative first peck offset figure, 3-26
Network parameters, 2-28
New access code, 3-63
Numeric keypad, 1-7
O
Offset, 3-6
blend, 3-32
Offset Z, 3-6
Operator specify pocket start, 3-33
Optional keyboard, 1-8
Optional program stop, 3-27
Options
hardware and software, 1-1
Orient Spindle softkey, 1-27
Revision A
Index
P (continued)
O (continued)
Orientation hole, 1-35
Orientation key, 1-35
Overlap
blend, 3-32
pocket, 3-32
Override Knobs, 1-11
Override lockout, 3-25, 3-27
P
Page Down key, 1-6
Page Up key, 1-6
Parameters
blend offset, 3-32
blend overlap, 3-32
cutter compensation, 3-34
erase program, 3-43
finish feed, 3-32
finish speed, 3-32
finish X-Y, 3-32
finish Z, 3-32
graphics, 3-54, 3-55
jog unit, 1-14
manual jog feed, 1-14
manual spindle speed, 1-14
milling, 3-32
milling direction, 3-32
Override lockout, 3-25
pocket overlap, 3-32
Program protect, 3-25
Tool change position, 3-25
Park Machine softkey, 1-27
Park the machine, 1-43
Part fixturing, 3-2
Part program
copying, 2-8
deleting, 2-8
erase copy of, 3-42
exporting as text file, 2-13
load from current directory, 2-4
loading, 1-30
part setup, 3-4
erase, 3-43
restore, 3-47
Ultimax System
permanent storage, 2-5

renaming, 2-7
restore, 3-46
storage, 2-9, 2-13
tagging, 2-11
templates, 3-11
tool setup, 3-11
erase, 3-43
restore, 3-47
Part program names, 2-6, 3-2
Part programming
concurrent, 3-67
general parameters
ranges and defaults, 3-27
part setup, 3-3
planning, 3-1
program parameters, 3-22
Part programming and graphics, 3-51
Part Programming softkey, 3-7, 3-18
Part setup, 3-3, 3-4
erase, 3-43
restore, 3-47
softkey, 3-18
Part Setup fields, 3-6
Part setup screen, 3-4
Part Setup softkeys, 3-7
Part Tool Setup
restore all, 3-47
restore part program, 3-47
restore program, 3-47
restore program parameters, 3-47
Part zero, 3-2, 3-3
Part zero relative to machine zero, 3-3
Part Zero X and Y, 3-6
Peck
clearance plane, 3-24, 3-27
Pop-up text window, 1-8
Ports
loading programs from, 2-18
serial, 2-21
Positive first peck offset figure, 3-26
Power
off, 1-42
Power On button, 1-15
August, 2002
I-7

P (continued)
Power On console button, 1-32
Power up, 1-30
daily checks, 1-30
machine, 1-30
Probe Z, 3-6
Probing
softkey, 3-18
Probing option
part probing
in NC, 3-10
Program
copy, 2-8
delete, 2-8
Program mask, 2-8
Program parameters, 3-22
General Parameters, 3-23
Program Parameters
NC Parameters
Configuration, 3-38
M & G Code Numbers, 3-40
NC Variables, 3-41
NC Parameters, 3-37
Program Parameters softkey, 3-7
Program protect, 3-25, 3-27
Programming Mode keys, 1-5
R
Rapid Override dial, 1-11
Rapid traverse, 3-27
for X, Y, & Z axes, 3-24
Read DXF file, 2-34
Read program from disk, 2-4
Reboot, 2-37
Recovery restart, 1-18
mill contour, 1-18
Reference Point X, NC, 3-39
Reference Point Z, NC, 3-39
Remote Jog Unit, 1-12
Remote jog unit figure, 1-12
Removing tools from the ATC, 1-38
I-8
R (continued)
Rename part programs, 2-7
Rename program, 2-7
Reset master, 2-37
Reset Master softkey, 2-37
Reset Part Count, 1-20, 1-23
Reset port parameters, 2-21
Reset Servos & Spindle softkey, 1-27, 1-32
Resetting ATC Map, 1-41
Restart, 1-4
Restart machine after Power Off, 1-43
Restart machine after E-Stop, 1-42
Restart parked machine, 1-43
Restore all, 3-47
Restore Config Machine Files, 2-33
Restore functions, 3-46
change current directory, 3-50
copy program, 3-50
create directory, 3-50
current storage drive directory, 3-50
delete program, 3-50
part setup, 3-47
part tool setup, 3-47
rename program, 3-50
tool setup, 3-47
Restore functions screens, 3-47
Restore part program, 3-47
Restore program parameters, 3-47
Retract Clearance, 3-24, 3-27
Review key, 1-5
Root directory, 2-2
RS-232-C serial port settings, 2-21
Run, 3-59
conversational part program, 1-17
manual, 1-26
time estimate, 1-18
Run program
Auto cycle, 1-18
single cycle, 1-22
Run program screen, 1-19
Revision A
Index
S (continued)
S
Safety
CE2000, 3-60
override mode, 3-60
while running program, 3-59
work region, 3-24
Safety Work Region, 3-6, 3-8
Safety work region screen, 3-8
Saving a program
to hard drive, 2-5
with date/time stamp, 2-24
Screen
Download/upload, 2-15
Screen blank time, 2-25
Screens
ATC map, 1-40
Auto Cycle, 1-17
CE Status & Diagnostics, 3-61
CNC configuration, 2-31
Concurrent programming, 3-67
Current directory, 3-50
Current program, 2-3
Data block after search, 3-57
Erase functions, 3-43
Erase running program, 3-45
General parameters, 3-23
Graphic with isometric view, 3-52
Graphics, 1-9
Graphics all planes view, 3-53
Graphics error message, 3-58
Graphics parameters, 3-54
Holes parameters, 3-29
Identify graphic for search, 3-56
Input, 1-31, 3-22, 3-42
Insert Arc & Lines softkeys, 3-34
Ladder configuration, 2-32
Machine calibration, 1-33
Manual, 1-26, 3-2
Miscellaneous functions, 3-51
NC
NC Program Parameters, 3-40
Part Setup with work offsets, 3-9
NC Auto, 3-64
NC parameters, 3-37
Ultimax System
Screens (continued)
M and G codes, 3-40
NC Configuration parameters, 3-38
Part Setup, 3-4
Restore Functions, 3-47
Run program, 1-19
Safety work region, 3-8
Single Cycle, 1-21, 1-22
System configuration, 2-23
Test Run, 1-24
Text entry window, 1-8
Tool Setup, 3-12
Select a storage drive, 2-9, 2-13
Select DRO, 1-20, 1-23
Select Current Storage Directory, 2-5
Select port, 2-21
Send a part program, 2-19
Serial port setup, 2-22
Serial Port status messages, 2-16
Set Current System Time softkey, 2-24
Set Feed softkey, 1-25
Set network parameters, 2-28
Set Plunge or Segment Feed, 1-25
Set Tool Zero softkey, 3-19
Setting Serial Port, 2-22
Setting the DRO Display Units, 2-26
Shift (NC), 3-9
shut down
control power off time, 1-43
Shut down, 1-42
park machine, 1-43
Single cycle
run program, 1-22
Single cycle mode, 1-21
Single cycle mode softkeys, 1-17
Single cycle screen, 1-21, 1-22
Single key, 1-16
Skew Angle, 3-6
August, 2002
I-9

S (continued)
S (continued)
Softkeys, 1-5, 1-7
Delete Tool, 3-18
Exit, 3-7, 3-19
Insert Arc, 3-34
Insert Lines, 3-34
Orient Spindle, 3-7
Part Programming, 3-7, 3-18
Part Setup, 3-18
Probing, 3-7, 3-18
Program Parameters, 3-7
Store Machine Position, 3-7
Tool Home, 3-18
Tool Setup, 3-7
Tool Zero, 3-19
Software options, 1-1, 3-70
Special function keys, 1-6
Speed, 3-15, 3-20
finish, 3-32
Speed (RPM), 3-17
Speed RPM, 3-21
Spindle
manual speed, 1-14
on/off buttons, 3-68
On/Off keys, 1-28
orient, 1-27
RPM dial, 3-15
speed, 3-21
tool removal, 1-36
Spindle control, 1-11
Spindle On, 1-28
Spindle Speed dial, 1-11
Spindle unclamp button, 1-36
Start block, 1-17
Start Cycle button, 1-15
Start Cycle console button, 1-32
Stop Cycle button, 1-15
Stop motion, 3-65
Stop reading programs from a disk, 2-4
Storage drive
selecting, 2-9, 2-13
Storage function color parameter
defaults table, 2-30
Storage Functions, 2-3
I-10
Storage functions color parameters, 2-30

Storage Functions softkey, 2-3
Store Machine Position softkey, 3-7
Store Position key, 1-13
Storing part programs, 2-5
Subdirectory names, 2-6
Subprograms
part probing
in NC, 3-10
Surface speed, 3-15, 3-17
System Configuration, 2-23
System configuration screen, 2-23
T
Table
fixturing part, 3-2
protection, 1-43, 3-8
Tables
Default communication setting, 2-21
Default parameter values, 3-27
General parameter ranges, 3-27
Graphics color defaults, 2-29
Storage function color defaults, 2-30
Text color parameter defaults, 2-28
Tag part programs, 2-11
Tap
threads per inch, 3-13
Test key, 1-16
Test run mode, 1-24
Test run screen, 1-24
Test run softkeys, 1-17
Text
Text color parameter defaults table, 2-28
Text entry window, 1-8, 2-27
Text entry window screen, 1-8
Text screen, 1-5
Time, 2-24
Toggle program tag, 2-11
Toggle Rapid Override Enable, 1-20, 1-23
Revision A
Index
U
T (continued)
Tool
broken, 3-11
calibration, 3-6, 3-14
changer keys, 1-28
descriptions in the system, 3-12
diameter, 3-11, 3-14, 3-20, 3-21
in Spindle, 1-35
in Spindle softkey, 1-27
number, 3-11, 3-13
setup, 3-11, 3-43, 3-47
activate coolant, 1-28
checking, 3-11
screen, 3-12
templates, 3-11
Setup softkey, 3-7
types, 3-11, 3-13
zero, 3-19
Tool, 3-16
Tool change position, 3-25, 3-27
Tool changer
orientation key, 1-35
Tool changers, 1-35
Tool holder
orientation hole, 1-35
Tool Home
softkey, 3-18
Tool Length Tolerance, NC, 3-39
Tool loading
machine spindle, 1-35
Tool Offsets, NC, 3-18
Tool removal from ATC magazine, 1-38
Tool removal from spindle, 1-36
Tool Setup fields, 3-16
Tool setup screen, 3-12
Tool Setup softkeys, 3-18
Tool setup with tool types, 3-13
Tool Type, 3-16
Trackball, 1-9, 3-56
Training classes, 3-70
Turning off the text entry window, 2-27
Turning on the text entry window, 2-27
Ultimax System
Ultimax
software
options, 3-70
upgrade, 2-35
Ultimax 4 and Max consoles figure, 1-2
Ultimax 4 panel groups figure, 1-3
Ultimax training, 3-70
Unattended operation, 3-59
Untag all programs, 2-11
Upgrade system files, 2-35
Upload from peripheral device, 2-18
Upload programs, 2-14
Upload receive, 2-17
Uploading a part program, 2-17
V
Video hardware type, 2-27
W
Warm Up Machine softkey, 1-34
Warm up the machine, 1-34
Wildcard
file extension), 2-9
Work offsets for NC programming, 3-9
Work Offsets softkey, 3-9
Work piece, 3-6
cleaning, 3-65
fixturing, 3-2
safety region, 3-8
Write part programs to disk, 2-5
Z
Z Bottom parameter, 3-8
Zero calibration, 3-11, 3-14, 3-19
Zero Calibration, 3-17
Zoom, 3-54
Zero calibration
in NC, 87
August, 2002
I-11

Get Started With Ultimax4

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704-0111-101

Getting Started with

Hurco Machining Centers

Hurco Manufacturing Company reserves the right to incorporate any

Patents: U.S. Patents B14,477,754; 5,453,933; Canadian Patent 1,102,434;

Getting Started with Ultimax Manual

Hurco Machining Centers

Using This Manual

Hints and Tricks

Where can we go from here?

Getting Started with Ultimax Manual

Ultimax screens have three areas of primary interest:

Softkeys on the right side of the touch screen. Available

Fields to the left of the softkeys. A field is an area that

Prompt and error message area at the bottom of the screen.

Hurco Machining Centers

Getting Started with Ultimax Manual

Hurco Machining Centers

File Management and System Configuration

Getting Started with Ultimax Manual

Hurco Machining Centers

Getting Started with Ultimax Manual

Hurco Machining Centers

Hurco Machine with the Ultimax 4 Console....................................... 1-1

Directory Structure.............................................................................. 2-2

Part Zero Relative to Machine Zero Viewed Looking Down at Table3-3

Getting Started with Ultimax Manual

Hurco Machining Centers

Transfer Types for Conversational and NC Programs...................... 2-15

General Parameter Ranges and Default Values ................................ 3-27

Machine and Console Basics

Hurco Machine with the Ultimax 4 Console

Getting Started with Ultimax Manual

Ultimax 4 Console and Max Console

Hurco Machining Centers

Machine and Console Basics

Control Panel Function Groups

Ultimax 4 Console Panel Groups

Getting Started with Ultimax Manual

Figure 1-4. Max Console Panel Groups

Emergency Stop Buttons

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Machine and Console Basics

Text Screen Data Entry

Pop-up Text Entry Window

Graphics Screen Data Entry

Text Screen Data Entry

Input displays the main programming screen used to create and

Auxiliary accesses program storage management, system

Review for Conversational programs, provides an outline view

Help displays help text. Place the cursor on a field in question

Getting Started with Ultimax Manual

Insert - type over and replace current text.

Delete - delete the character to the right of the cursor.

Home - position the cursor before a line of text.

End - position the cursor at the end of a line of text.

Page Up - position the cursor at the beginning of the previous

Text Screen Cursor Control Keys

Enter key () - accept the information typed in a text field, or

Special Function keys

C console key - Use the C console and Clear keys to delete

Delete console key - Use the F console and Delete keys

Arrow console key - Use the F console key in combination

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