Line Model: RAPID 25 T

Serial number: 34393

Programming
and operating manual
Programming and operating manual Model RAPID 25 T

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2 FICEP S.p.A.
Model RAPID 25 T Programming and operating manual

INTRODUCTION

This manual provides people involved with all information about operating use and programming of the
machine or of the production line which refers to. It has to be considered like an important part of the ma-
chine supply and must follow the machine until its demolition.
This manual has to be kept with care in a place near by the machine and within reach of all operating and
programming people concerned, who have to be aware of its contents, provided that it can’t substitute the
experience and common sense of a qualified and well trained staff.
Keep this manual for all future references; in the event of loss or damage, ask for a new copy to FICEP
After Sales Service.

The technical information included in this manual are property of FICEP S.p.A. and must be considered
reserved. Law forbids the reproduction, even if partial, of the graphic work, the text or the images.
Some details described in the texts and/or represented in the illustrations of this manual could be slightly
different from the machine which refers to, or in the figures some element could have been omitted to en-
sure the illustrations understanding.
This manual has been divided into chapters to make the consultation easier.
The subjects covered in this manual are exactly the ones required by “Machine Directive 2006/42/CE”.

The manual reflects the technological development at the moment the machine is manufactured and
could not be considered obsolete and incomplete only because it has been updated in a consequent
date. Ficep S.p.A., with the aim of a continuous technical and technologic improvement of its products,
reserves the right to modify the production and the manual without being bound to update previous edi-
tions.

READ CAREFULLY THIS MANUAL BEFORE OPERATING WITH THE MACHINE OR THE LINE.

STRUCTURAL STEEL WORK DIVISION

SALES DEPARTMENT – AFTER-SALES SERVICE
21045 - GAZZADA - SCHIANNO (VA) ITALY
Tel +39 (0332) 876111 - Fax +39 (0332) 462459

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Programming and operating manual Model RAPID 25 T

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Model RAPID 25 T Programming and operating manual

Symbols used in this manual

Subjects and concepts expressed in the

paragraphs marked by this symbol are
particularly important.

Warnings included in the paragraphs

marked by this symbol, if disregarded
can be dangerous for things and/or per-
sons.

Subjects dealt with in the paragraphs

marked by this symbol are particularly
important and related to programming.

Subjects dealt with in the paragraphs

marked by this symbol are particularly
important and related to machine setup.

Subjects dealt with in the paragraphs

marked by this symbol attain to proce-
dures and represent the practical opera-
tive guide.

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Model RAPID 25 T Programming and operating manual

INDEX
INDEX ............................................................................................................................................................7
CHAPTER 1: SYSTEM DESCRIPTION .......................................................................................................9
Introduction of the system .....................................................................................................................9
Possible layout of a standard system ...................................................................................................9
Electrical data plate ...............................................................................................................................9
Machine identification data plate .........................................................................................................10
How the line can be put together ........................................................................................................10
C.N.C. controlled positioning ...............................................................................................................11
Introduction..........................................................................................................................................11
Axes table of the RAPID 25 T line ......................................................................................................11
Control panel .........................................................................................................................................13
Note .....................................................................................................................................................15
Switching ON procedure ......................................................................................................................17
CHAPTER 2: C.N.C. DESCRIPTION .........................................................................................................19
Introduction of the C.N.C. operating environment ............................................................................19
Touch screen .........................................................................................................................................19
Fixed elements for all screen pages ...................................................................................................20
C.N.C. Software sections ......................................................................................................................20
Line start up ...........................................................................................................................................21
CHAPTER 3: PROCEDURES FOR THE LINE OPERATION ....................................................................23
Line starting operations .......................................................................................................................23
Preliminary remarks ............................................................................................................................23
Axes zero cycle .....................................................................................................................................23
Manual control of the axes ...................................................................................................................24
CHAPTER 4: LINE SETUP AND MANUAL ADJUSTMENTS ...................................................................27
Preliminary remark ................................................................................................................................27
Drilling tools data flowchart .................................................................................................................27
Tables .....................................................................................................................................................28
Tables – Drilling Tab ...........................................................................................................................28
Insert/modify a tool in the drilling table ................................................................................................29
List of the tool types ............................................................................................................................31
Setup ......................................................................................................................................................33
Setup - General tab .............................................................................................................................33
Setup – ToolF tab ................................................................................................................................34
Setup – Drilling tab ..............................................................................................................................37
Summarizing procedure to insert tools ..............................................................................................38
Machine setup .......................................................................................................................................40
Soft-keys for adjustment and setup operations of the machine ..........................................................40
Portable push buttons panel for service operations ............................................................................42
CHAPTER 5: PROGRAMMING..................................................................................................................43
Preliminary remarks ..............................................................................................................................43
Terminology.........................................................................................................................................43
The programming window ...................................................................................................................44
To input a new program ......................................................................................................................45
Editing a program: preliminary remark ...............................................................................................48
General rules to edit or modify a part program ...................................................................................48
Note on the examples of this manual ..................................................................................................48
Programming: single hole ...................................................................................................................49
Programming: linear pattern of holes with same diameter .................................................................50
Programming: matrix pattern of holes with same diameter ................................................................51
Programming: pattern of holes with same diameter arranged on an arc of circle or a whole circle ...52
Milling operations ................................................................................................................................53
Programming: special functions .........................................................................................................55

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Programming and operating manual Model RAPID 25 T

Use of the absolute and incremental coordinates .............................................................................. 55

Permanent repositioning of the piece origin ....................................................................................... 56
Temporary repositioning of the part origin .......................................................................................... 57
Programming of special functions ...................................................................................................... 58
CHAPTER 6: PROGRAM EXECUTION .................................................................................................... 61
Execution of working operations: introduction ................................................................................ 61
Procedure to execute a program of a single piece ............................................................................. 61
Execution parameters for “cut-to-lenght” pieces ................................................................................ 65
The execution window ........................................................................................................................ 66
Operator controls during automatic execution.................................................................................... 67
Restart of working process after an emergency stop ......................................................................... 68
Restart of working process after a drop of voltage ............................................................................. 68
3D View .................................................................................................................................................. 69
Example .............................................................................................................................................. 69
Commands menu ............................................................................................................................... 72
CHAPTER 7: SPECIAL AND ADDITIONAL OPERATIONS .................................................................... 73
Working in test mode .......................................................................................................................... 73
Operator parameters adjustment for processing ................................................................................ 73
CHAPTER 8: ARCHIVE OPERATIONS .................................................................................................... 75
File management operations ............................................................................................................... 75
Import operations ................................................................................................................................. 75
Import of part program in DSTV format .............................................................................................. 75
Import of part programs generated by third applications .................................................................... 76
Statistics final balance of the line ....................................................................................................... 78
CHAPTER 9: MAINTENANCE AND TROUBLE SHOOTING ................................................................... 79
Signalling and messages ..................................................................................................................... 79
Display of the Input/Output (I/O) signals condition .......................................................................... 80
Summary of the commands of “View” and “Setup” menu .............................................................. 82
Use of the “Debug” window ................................................................................................................ 83
“Installation-Servicing” graphic push-button ................................................................................... 83
General rule ........................................................................................................................................ 83
Tabs contents ..................................................................................................................................... 84
CHAPTER 10: PROCEDURE TO SHUT OFF THE LINE ......................................................................... 87
APPENDIX A – DIAGNOSTIC ................................................................................................................... 89
List of signals that are more frequent ................................................................................................ 89
Service messages class 200 – Operator Messages .......................................................................... 90
ATTACHMENT – OPTIONAL MARKING UNITS ...................................................................................... 91
Marking operations setup window ...................................................................................................... 91
Programming: marking operations ..................................................................................................... 92
Programming: tracing operations ....................................................................................................... 94
ATTACHMENT – OPTIONAL CUTTING UNITS ....................................................................................... 95
Tables – Cutting unit Tab ................................................................................................................... 95
Setup – Saw Tab ................................................................................................................................ 97
Bar nesting ............................................................................................................................................ 98
Basic procedure for nesting execution ............................................................................................. 100
Changes to the basic nesting procedure: how to use the push-button “Rotation” ........................... 101
Changes to the basic nesting procedure: manual nesting ............................................................... 102
Changes to the basic nesting procedure: automatic nesting ........................................................... 103
Bars list ............................................................................................................................................. 104
Execution parameters for nesting ..................................................................................................... 105
Procedure to execute a program of a nesting .................................................................................. 106

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Model RAPID 25 T Programming and operating manual

CHAPTER 1: SYSTEM DESCRIPTION

Introduction of the system

Possible layout of a standard system

The system can be completed with:
1) rollerway with idle rolls for infeed material handling
2) rollerway with idle or motorised rolls or others devices for outfeed material handling (optional)
3) carriage sliding guide
4) carriage to move the profiles
5) pincher arm
6) pincher
7) drilling unit
8) marking unit (optional)
9) cutting unit (optional)
10) rotating loading system (optional)
11) C.N.C. and Operator’s position
12) electrical cabinet
13) main switch

11
7 6
9 10
8 5
2 1

4
3

12

13

Electrical data plate

GAZZADA SCHIANNO (VA) - ITALY

Type XXXXX Serial Number XXXXX

Drawing number DES XXXXX Year XXXX

Voltage Frequency Phases Max load

XXX V XX Hz 3~ XX A

Max load current

XXX A

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Programming and operating manual Model RAPID 25 T

Machine identification data plate

+39(0332)-876111 FAX +39(0332)-462459

● GAZZADA SCHIANNO ● VARESE ● ITALIA ●

MACHINE MODEL
XXXXX

SERIAL NUMBER YEAR OF CONSTRUCTION V/Hz

XXXXX XXXXX XXXXX

SECTIONS TO BE PROCESSED

MAX Ø MAX THICKNESS MAX WEIGHT TENSILE STRENGTH

mm mm Kg N/mm2

WORKING PRESSURES

HYDRAULIC SYSTEM PNEUMATIC SYSTEM CUTTING GAS

BAR BAR BAR

The serial number identifies the system all over the world; for any spare-parts, assistance or technical
support requests use this number as reference.

How the line can be put together

Option and alternative choices

Standard
configuration Material
Material loading Cutting Marking
unloading
- rollerway with • rotating loading • rollerway with • single cut shear • 38 characters
idle rolls for in- system idle rolls • double cut shear disc marking unit
feed material • infeed transfer • rollerway with • disc sawing unit • marking unit with
handling table motorized rolls • band sawing unit four or eight
- carriage with • belt type con- drawers
pincher veyor
- drilling unit

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Model RAPID 25 T Programming and operating manual

C.N.C. controlled positioning

Introduction

1. In this manual the expressions “side A” and “side B” refer to the profile sides; particularly, standing at
the material entry side, the “side A” is the one on the right.

Side “A”

Side “B”

2. In this manual, we call “axes” all the C.N.C. automatic controlled movements.

Axes table of the RAPID 25 T line

Name Description Function

Material
AXX Carriage axis for longitudinal positioning of material
handling
Traverse axis (gaugeline) for the positioning of the “side A” drilling
AXV
unit
Auxiliary short axis for longitudinal positioning of the drilling head on
AVX
side "A"
AXC Forward axis of the “side A” drilling unit

MDV Spindle rotation axis of the “side A” drilling unit

Drilling
Traverse axis (gaugeline) for the positioning of the “side B” drilling
AXW
unit
Auxiliary short axis for longitudinal positioning of the drilling head on
AWX
side "B"
AXD Forward axis of the “side B” drilling unit

MDW Spindle rotation axis of the “side B” drilling unit

ADM Characters disc holder rotation axis of the marking unit (optional)
Marking
AAH Positioning axis of the drawer-type marking unit (optional)

AXS Disc or band rise/descent axis of the sawing unit (optional) Cutting

All axes tagged with a star are showed in the following pictures

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Programming and operating manual Model RAPID 25 T

AXX
+ - 0

B side AXS
A side

0
-

+
ADM

AAH

+ -
- AVX,
AWX

B side A side

MDW MDV

- -
AXD AXC
+ +

+ +

AXW AXV

0 - -
0

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Model RAPID 25 T Programming and operating manual

Control panel
The operator’s workstation has a colour video and some push-button stations.

01 02 03 04 05 06 07 08 09 10
- + A

+
0

11 12 13 14 15 16 17 18 19 20 21 22

23 24 25 26 27 28 29 30 31 32 33 34

RESET CONT

35 36 37 38 39 40 41 42

43

45
44

RESET

RESET
D

46 47 48 49

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Programming and operating manual Model RAPID 25 T

Through screen and keyboards, the operator can program and control the line completely.
A) Main push-button panel: push-button and selectors switches necessary for the manual or au-
tomatic operative functions execution
B) Touch screen colour video
C) Auxiliary push-button panel: number, disposition and meaning of the push buttons are strictly
referred to the line configuration supplied; in this manual a general push-button station is showed
(refer to the “Controls” chapter of the Instruction Manual).
In this zone, there is also an emergency push-button with mechanical reset. When activated, all
actuators on the machine and the auxiliary circuits are immediately switched OFF. To restore the
normal operation, it is necessary to unlock the push-button (depending on the different models it
is required to pull or to rotate clockwise the red head) and to push again the “RESET” push-
button with blue warning light. Some others emergency push-buttons are placed along the line
where the operator stays more frequently.
D) Controls and protections zone: push-button and selectors switches necessary for the line and
the safety protections management.
Main push-button panel: keys function
Number Function
01 Switching OFF of the line auxiliary circuits (ex. the oil pump)
02 Switching ON of the line auxiliary circuits
Stand-by mode: axes are not qualified to operate. Programming and setup operations are
03
enabled
Manual mode: it enables the axes manual control by means of the push-buttons 07 “-” and 08
04
“+“
05 Modo Automatic mode, single execution (step by step)
06 Automatic mode, continuous execution
JOG -: manual movement of the selected axis towards negative direction (decreasing coordi-
07
nates)
JOG +: manual movement of the selected axis towards positive direction (increasing coordi-
08
nates)
09 CYCLE HOLD: The program is arrested and all the axes keep the actual position
10 CYS: automatic cycle start; the selected cycle is started (part process, zero cycle, etc…)
Auxiliary push-button panel: keys function
Number Function
11 Manual rotation control of the bar rotating loading system (option)
12 Request for the tool length pick-up sensitive cycle (option)
Activation of the material vertical hold-down placed before the sawing unit in manual mode
13
(option)
14 Not used
15 Not used
16 Not used
17 It enables the scraps unloading automatic cycle under the cutting unit (option)
18 Unloading table rolls motorisation manual control (option)
19 Push button of exit table tilted over on the L. H. side in manual mode (option)
20 Push button of exit table tilted over on the R. H. side in manual mode (option)
21 Lifting/lowering of the unloading area zero zone (option)
Disc-type marking unit inclusion/exclusion after the manual adjustment to verify the effective
22
marking height (line is setup mode) (option)
23 Manual push button for slow forward of catch type loading table (option)
24 Manual push button for fast forward of catch type loading table (option)
25 Push button for automatic management of catch type loading table (option)
26 Manual push button for slow backward of catch type loading table (option)
27 Manual push button for fast backward of catch type loading table (option)

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Model RAPID 25 T Programming and operating manual

Number Function
It activates, in manual mode, the device for part separation placed at the exit side of the saw-
28
ing unit (option)
29 Inclusion of the automatic short pieces unloading device (option)
30 Exclusion of the automatic short pieces unloading device (option)
31 Not used
32 Not used
33 It activates the scrap and short pieces unloading conveyor belt (option)
Selection of slow/fast speed of the scrap and short pieces unloading conveyor belt
34
(ON = fast) (option)
35 It activates the saw disc rotation in manual mode (option)
36 Alarms and messages reset or operator negative answer
37 Operator answer to confirm
38 Axis positioning at tool change position
39 Pincher lowering (only with opened pincher) (option)
40 Pincher lifting (only with opened pincher) (option)
41 It enables the automatic device to grip the bar in pincher (option)
Pincher opening/closing; this push-button is present also on board before the processing unit
42
on the material loading side
43 Opening screw to USB port
44 USB port
45 Emergency push-button with mechanical reset
Controls and protections zone: controls function
Number Function
Key type selector to select three operative modes:
the C.N.C. is switched in setup mode. No operation is possible in this mode; the op-
erator can extract the key to avoid any unexpected control and then operate directly
on the machine in safety way
46
all controls are available for the operator who has the full control of the line

it is allowed only to pass from the current operating mode to stand-by mode and vice
versa (only the last selected mode is kept active)
47 Protecting barriers alarm reset (if present)
RESET: push button to activate electric safety devices. At the system start-up the blue light is
48 illuminated.
Refer to the system start-up procedure
CYCLE STOP: when pressed, this push button stops the program in progress and the drilling
49
heads are moved back in safety position

Note
all push buttons, except 47, 48 and 49, are of the holding type: pushing once the relevant operation is ac-
tivated, pushing twice it is deactivated.
Meaning of push buttons LED:
If the LED is not illuminated, the selector switch is in OFF position and the relevant command is not
activated. To move the selector switch to ON position, just press the push button and wait till when
the LED is illuminated.
If the LED is illuminated, the selector switch is in ON position and the relevant command is activat-
ed. To move the selector switch to OFF position, just press the push button and wait till when the
LED is no more illuminated.
If the LED is blinking, it signals the system availability to accept the command from the push-
button.

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Programming and operating manual Model RAPID 25 T

Alphanumeric PC keyboard

Some keys have particulars functions:

ESC: To escape from an application, coming back to the previous level.

TAB: To move the cursor on different boxes.
ENTER: To open the selecting window evidenced by the cursor, or to confirm the execution
of a common request (OK).
ARROWS: To move the cursor in the selected direction, on a field or on a list.
F2: To modify data already input or to confirm modifications executed.
F4: To open lists of options to be used when programming or in processing operations
(Aided programming).
INSERT: To move the cursor on a blank table, and input new working data (it is named INS
in the example).
+/- : To increase (+) or decrease (-) the axes speed, or to program negative/positive in-
cremental or absolute coordinates.
DELETE To delete characters on the right of the cursor position
BACKSPACE To delete characters on the left of the cursor position

Keys combinations:

ALT+H: Opens the windows describing messages

ALT+TAB: Enables to select one of the already opened applications or activates the actual
page on the video
CTRL+ESC: Opens the Windows menu list (ESC to close)
CTRL+X: Stores and removes the data evidenced by the cursor
CTRL+C: Stores the data evidenced by the cursor to be copied
CTRL+V: Paste the stored data in the actual position of the cursor

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Model RAPID 25 T Programming and operating manual

Switching ON procedure

Electrical cabinet

ON ON
OFF

OFF
Operator’s workstation

Operator’s workstation

or

Operator’s workstation

RESET

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Model RAPID 25 T Programming and operating manual

CHAPTER 2: C.N.C. DESCRIPTION

Introduction of the C.N.C. operating environment

The C.N.C. operating environment is called “Minosse” and the picture above represents the opening
screen page.
The five graphic push buttons define four different working sections (Programming, Execution, Installation
and Servicing, Communication CAM) and the system shut down (“OFF”).
To enter one of the four main pages or to shut down the system, it is sufficient to touch the screen in the
graphic push-button corresponding area.

Press the ESC key on the PC keyboard to return to the first page.

Touch screen

To carry out a touch screen command, just gently touch the area on the screen where the relevant push-
button is displayed.

Clean the screen only when the system is shut down to avoid wrong commands.

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Programming and operating manual Model RAPID 25 T

Fixed elements for all screen pages

The lower part of all screen pages is the one shown in the following picture.

1 2 3 4

Number Function
1 Error or message graphic signalling
2 Numeric code and type of the active signalling
3 System clock in the format hh:mm:ss
4 Graphic bar of the X axis movement speed; it is possible to change the value by steps of
10% by means of the “-“ and “+” graphic push-button

C.N.C. Software sections

The operating environment of the C.N.C is divided into four sections + the system shut down push-button.
Main activities of each section are listed in the following table:

SECTION ACTIVITIES

Programming - programming of new pieces

editing of existing pieces
-
pieces archive management: import/export, copy, delete, print, etc…
-
graphic dimensional check
-
nesting of pieces into long bars (only if a cutting unit is present)
-
Execution -display of the axes coordinates
axes manual positioning
-
setup/confirmation of the tools required to execute the programmed piece
-
setup of the tools used on the system
-
display of the program in execution
-
Installation/ -
display/modification of machine cycles parameters
Servicing -display/modification of axes parameters
information about predefined working cycles
-
information about C.N.C internal configuration
-
diagnostic information
-
Communication - graphic and textual information about execution data of a working order
CAM -statistical information, in graphic format, about the system working time alloca-
tion
- connection to optional external programs (WinCN) to import part programs
from PC office and/or with different programs
OFF - system shut down and switching OFF

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Model RAPID 25 T Programming and operating manual

Line start up

When switched ON, the PC on the operator panel starts loading the “Windows” operating system and
then the C.N.C operating environment. Anyway, to operate, it is necessary to press the RESET push-
button with blue warning light placed on the operator’s control panel. If the procedure has positive result,
the blue lamp is not illuminated.

At the start-up, after a thirty seconds wait…

…, a window appears with diagnostic information about the system bootstrap.

All the items have to result “OK”; if any “NOT OK” appears; the C.N.C has hardware or software prob-
lems.

End the procedure pressing the “OK” push-button.

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Model RAPID 25 T Programming and operating manual

CHAPTER 3: PROCEDURES FOR THE LINE OPERATION

Line starting operations

Preliminary remarks

Just after the line has been started up and before a program execution or a manual positioning
of the axes, it is necessary to perform the preset program called “axes zero cycle”.

The C.N.C when switched on is unacquainted on the true physical position of the axes; it is therefore
necessary to move each axis to reference points, having limit switch and apposite signals coming from
the motor sensor (encoder), which are known by the C.N.C.

Axes zero cycle

Command Meaning Remark

Starting position System start-up procedure ended correctly; main C.N.C

windows displayed.

Execution Select the “Execution” section It enables the display of the C.N.C environment window
of the C.N.C software envi- with the main axes numerical coordinates.
ronment All coordinates values are red. That means it is neces-
sary to execute the axes zero cycle.

Rotate the key-type selector The operator can control the system.
switch in central position.

RESET
Reset of protecting barriers The alarm of protecting barriers interruption (if provided)
alarm is RESET

Switch the auxiliary circuits The oil pump starts and the oil pipes goes under pres-
on. sure; the LED of the push button remains illuminated and
the line is in stand-by mode

Select the automatic execu- The continuous execution mode is selected. The LED
tion push button remains illuminated, whereas the LED of Cycle Start push
button is blinking to signal that the system is ready to
Start.

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Programming and operating manual Model RAPID 25 T

Command Meaning Remark

Axes zero cycle start The axes start to move and reach the relevant reference
points; the sequence of axes movement is predetermined
and cannot be modified; on the video axes coordinates
values changes accordingly. During the execution, the
LED is illuminated.
ATTENTION: the execution time of the whole zero cycle
changes according to the starting position of each axis at
the starting up of the line.

Condition at the end of axes Axes coordinates becomes blue and the LED of the Cycle
zero cycle Start push button is blinking to signal that system is ready
to start the execution of a program.
Zero cycle executed. The line is ready to operate.

Manual control of the axes

Command Meaning Remark

Start condition System start-up procedure ended correctly; axes zero cycle
performed; main C.N.C windows displayed.

Execution Selection of the “Exe- The “Execution” window with the axis coordinates is dis-
cution” window played. All coordinates values are blue.

Key-type selector The operator can control the system.

switch in central posi-
tion

Switching ON of the The LED of the push button remains illuminated and the
auxiliary circuits line is in stand-by mode.

Selection of the manu- The manual execution mode is selected; the LED remains
al mode illuminated.

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Model RAPID 25 T Programming and operating manual

Command Meaning Remark

JOG Selection of the JOG- The “JOG” window is displayed. The “JOG +” and “JOG -
mode “push-buttons LED of the main push buttons panel blink to
signal that the system is ready to accept a displacement
command towards the positive or negative direction.

Selection of the axis Touch the screen on the L. H. side list to select the axis to
be manually moved

Selection of the dis- Touch the “Positioning” pull-down menu to select incre-
placement type mental movement from 0,01 mm up to 1000mm (selecting
the corresponding value) or continuous movement (select-
ing “Barrier”)

Adjustment of the The axes maximum speed rate is adjust by step of 10%
maximum speed rate

As long as the operator presses one of the push-buttons

+ - the axis moves, the LED of the pressed push-button re-
mains illuminated and the axis coordinate value on the
screen changes accordingly.
When the operator releases the push-button, the axis stops
and the LED of both push buttons blink.

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Model RAPID 25 T Programming and operating manual

CHAPTER 4: LINE SETUP AND MANUAL ADJUSTMENTS

Preliminary remark

The tool management is based on two different databases:

• “TABLES”: it is the “catalogue” of all the tools used and it is the general database of the system. To
open this database, press the push-button “TABLES” in the “Execution” window.
• “SETUP”: it contains the technological and geometric information of the tools
- set on the line and used to execute the program in progress
- that can be set on the line to execute a program which required some tools different from the
ones already on the line
To open this database, press the push-button “SETUP” in the “Execution” window.

Drilling tools data flowchart

The following flowchart is valid:

Tables Setup Setup

Drilling tab Examples ToolF tab Examples Drilling tab

Tool Ø 10.0 1 Tool Ø 10.0 1 Tool n. 3

Tool Ø 11.0 Type A
Tool Ø 11.0 Type B 2 Tool Ø 11.0 Type C
Side
2 Tool n. 1
Tool Ø 11.0 Type C A
Tool Ø 12.0 3 Tool Ø 12.5 3 Tool n. 18
Tool Ø 12.2
Tool Ø 12.5 4 Tool Ø 11.0 Type A 1 Tool n. 4
Tool Ø 13.8
.
. 5 Tool Ø 12.2 2 Tool n. - Side
. B
.
.
. ... … 3 Tool n. 191

General set of all Set of the tools available Set of the tools fitted on
the tools that can be for the line; it is compa- the line; for each drill-
used on the line. It rable to a tools-holder ing head, the tab de-
represents the tools truck aside the line; it scribes the tools fitted
magazine of the contains maximum 200 on the automatic tools-
manufacturing de- tools. holder; the tools num-
partment. ber depends on the line
configuration.

3 2 1

The tool installation on the line needs a double passage:

1) “Drawing” from the “magazine of the manufacturing department”
and “insertion” into the “tools-holder truck”
2) “Drawing” from the “tools-holder truck” and fitting on the drilling unit
tools-holder

The tools data have to be input only the first time into the drilling table; then, the C.N.C. transfers them
where they are necessary.

FICEP S.p.A. 27
Programming and operating manual Model RAPID 25 T

Tables

Tables – Drilling Tab

It is possible to use a tool only if it has been input in the drilling table.

02
08

01

03 04 05 06 07

Controls function

Number Function
01 List of all tools stored in the C.N.C memory
02 Display of the ordering type of the tools listed in the zone 01; touch the push-button 07 to
change it
03 To modify the tool selected in the zone 01; it is possible to select the tool touching the name
on the screen ; the selection is identified by a blue bar
04 To delete the selected tool
05 To insert a new tool
06 To duplicate a tool
07 To order the tools listed in the zone 01; in the window displayed, the operator has to choose
the ordering type
08 To exit from the “Tables” window and return to the “Execution” window

28 FICEP S.p.A.
Model RAPID 25 T Programming and operating manual

Insert/modify a tool in the drilling table

The following window will be displayed touching the “F2 modify” push-button, to modify the data of a tool
already inserted in the table, or the “INS New” push-button, to insert the data of a new one.

42
01 02 03 04 05 06 07 08

09 22 30
10 31
11
12
23 32
13
24
14 33
25
15
26 34
27 35
16
28 36
17
29 37
18
19
20
21

38 39 40 41

NOTE: the display of the fields depends on the operation/tool type.

Number Operation Function
01 Tool type; refer to the following paragraph.
02 Any Minimum diameter of a non-cylindrical tool (i.e. countersink tool).
03 Any Maximum diameter of a non-cylindrical tool (i.e. countersink tool).
04 Any Nominal diameter (working) of the tool; the C.N.C. uses this value to carry out
its calculations.
05 Any Material to be drilled with the tool; touch F4 to select a material. When a mate-
rial is specified in this field, this tool is available only for it.
06 Any Field available for further specification (i.e. the supplier).
07 Drilling Minimum thickness that can be drilled; when a value is specified in this field
and/or in the following one, the tool can be used only for profile with thickness
included in this range.
08 Drilling Maximum thickness that can be drilled; refer to the previous field.
09 Any Tool cutting speed; the operator can insert this datum and the C.N.C. calcu-
lates automatically the value of the following field according to the nominal di-
ameter or vice versa. Refer to the picture on page 31 for fields from 09 to 30.
10 Any Tool rotating speed.
11 Drilling Tool forward speed inside the material in mm/revolution; the operator can in-
sert this datum and the C.N.C. calculates automatically the value of the follow-
ing field or vice versa.
12 Drilling Tool forward speed inside the material in mm/min.
13 Drilling Tool forward speed entering the material in mm/revolution; the operator can
insert this datum and the C.N.C. calculates automatically the value of the fol-
lowing field or vice versa.

FICEP S.p.A. 29
Programming and operating manual Model RAPID 25 T

Number Operation Function

14 Drilling Tool forward speed entering the material in mm/min.
15 Drilling The C.N.C changes the spindle speed from item 14 to item 12 when the tool
reaches this distance (mm from the material surface).
16 Any Drill total width, from cutting edge to cutting edge.
17 Any Tool lubrication type; the interval (“T”) selected shows an intermittent working
of the lubrication with TON = TOFF = T.
18 Drilling Maximum distance covered by the drill inside the material before its replace-
ment with a similar one to allow its cooling; the drill turnover has to be enabled
into the “Execution Parameters” window.
19 Drilling Tool life use percent value.
20 Drilling First tool use limit; when this value is reached, the C.N.C. software generates
a message for the operator asking for tool sharpening.
21 Drilling Second tool use limit; when this value is reached, the C.N.C. software gener-
ates a message for the operator asking for tool replacement.
22 Any Tool length; refer to the following picture:

22

23 Any Distance from material to be reached by the tool before the positioning for the
subsequent operation.
24 Any Distance from material to be reached by the tool where the spindle change
from fast approach speed to spindle forward speed (field 14).
25 Any Hole end coordinate (out of material).
Drilling: real end of hole coordinate automatically calculated by C.N.C ac-
cording to the grinding angle.
Milling: coordinate where the spindle arrives at fast approach speed be-
fore starts the contouring movement.
Pocketing: real coordinate of the working depth.
This value is always negative.
26 Any Drilling: First stop coordinate of the tool forward to break the chip.
Pocketing: Tool positioning coordinate inside the material to execute the first
pass.
This value is always negative.
27 Drilling Drilling: Incremental step for subsequent stops to break the chip.
Pocketing: Incremental step for subsequent passes.
This data represents an increment in the same direction; therefore its
value is positive.
28 Drilling Coordinate where the C.N.C increases the forward speed to break the materi-
al.
This value is always negative.
29 Drilling It enables the drill backward to unload the chips.
30 Countersink Minimum diameter for countersink operations.
31 Countersink Maximum diameter for countersink operations.
32 Milling Contouring speed.
33 Milling Maximum depth for each pass.
34 Milling Tool inserts diameter.
35 Milling Bending radius of the tool inserts corners.

30 FICEP S.p.A.
Model RAPID 25 T Programming and operating manual

Number Operation Function

36 Milling Tool shank diameter.
37 Milling Tool shank height.
38 To confirm the input data.
40 To pass to the preceding tool tab.
41 To pass to the following tool tab.
39 or 42 To exit from the “Drilling” window and return to the “Execution” window.

25, 26 and 28 are negatives!

28

27 13
11 14
12
26
15
25

09
10
23 17

24

23 is a distance evaluated
Coordinates during the spindle backward!

Speeds

List of the tool types

In succession the list of the tool types to define the field 01 editing a new tool into the drilling table.

ATTENTION: the availability of the following codes depends on the configuration of the
line.

Tool type
Working cycle Description
Operation Code
DRILL Sensitive drilling Execution of a passing through hole with normal twist drills.
with a twist drill
ATTENTION: only for the “DRILL” working cycle, if necessary, the sensitive
cycle for the drill length automatic pick-up can be set.
DRILL_32 Programmed drill- Execution of a passing through hole with inserts or special tools.
ing with insert type
drill
DRILL_33 Programmed drill- Execution of dead holes or with tools for high-speed rotation.
ing with a twist drill

FICEP S.p.A. 31
Programming and operating manual Model RAPID 25 T

Tool type
Working cycle Description
Operation Code
FLARE Countersink The cycle requires a tool with 90° cutting angle.
ATTENTION: this operation can be performed only in an al-
ready made passing through hole.
SPOT_FACING Spot facing This cycle is used to make the seat for cheese-headed screws; it
is similar to POCKET operation but without contouring.
DEBURR Traditional debur- The tool reaches the material surface, waits the time set by the
ring operator and, then, goes back until the start coordinate.
ATTENTION: this operation can be performed only in an al-
ready made passing through hole.
DEBURR_36 Deburring with When coming out from the material (it works on the opposite side
special NBT tool respect to the drill entry one), the tool waits the time set by the
operator and then returns to the starting coordinate.
ATTENTION: this operation can be performed only in an al-
ready made passing through hole.
POINT Pointing with point- The cycle executes a mark on the material with proper tool. The
ing tool working depth depends on a time set by the operator.
POINT_37 Timed sensitive Pointing cycle similar to “POINT” but with twist drill. The working
pointing with twist depth depends on a time set by the operator.
drill
TAP ISO metric tapping The tool forwards in the material and goes back with the same
speed but with reversal rotation direction.
Note that the forward speed must be equal to the thread pitch
(see “Drilling table” field 11).
This cycle requires a tool holder suitable for reversal of rotation
direction.
ATTENTION: this operation can be performed only in an al-
ready made passing through hole.
TAP_42 Fine ISO metric See TAP
tapping
TAP_43 Whitworth tapping See TAP
TAP_44 Fine Whitworth See TAP
tapping
TAP_45 UNF tapping See TAP
TAP_46 Gas tapping See TAP
TAP_47 UNC tapping See TAP
TAP_48 Left tapping Similar to TAP but with left helix
MILL Milling The tool goes down into the material until the coordinate of first
pass at the maximum speed; then the tool starts the programmed
contouring movements. It is necessary to pay the utmost atten-
tion to avoid collisions.
ATTENTION: this operation can be performed only in an al-
ready made passing through hole.
POCKET Pocketing The tool approaches the material surface at front cutting speed
(this value is a percentage of contouring speed); when the tool
reaches the coordinate of first pass the contouring movement
starts. If required the C.N.C repeats the cycle to get the pro-
grammed depth.
POCKET_68 Pocketing Carrying out scribing on the material. It is necessary a special
scribing tool.

32 FICEP S.p.A.
Model RAPID 25 T Programming and operating manual

Setup

The setup information, that is the line setup, can be called up in two ways:
- automatically from the C.N.C, if the program execution needs a different setup; in this case, the fields
with correct setup are displayed with green background whereas the fields with setup to be changed
are displayed with red background. Once the operator ends the setup operation, he has to confirm the
C.N.C requests by means of the “OK” push-button.
- manually from the operator by means of the “SETUP” push-button in the “Execution” window.

ATTENTION: In any case, when the operator presses the OK push-button, the C.N.C cannot
verify if the required setup corresponds exactly to the one of the machine. To
avoid damages it is required that the operator checks with the utmost attention
before confirmation is given.

Setup - General tab

This is a summarizing tab of the data of the working in progress.

01

All fields shown in this page are only displayed; the only field that can be modified is the “Measuring unit”,
follow this procedure to change it:
1) F2 Modify
2) F4 to set the measuring unit (mm, inches, fractions of inch)
3) F2 Confirm
4) “OK”

FICEP S.p.A. 33
Programming and operating manual Model RAPID 25 T

Setup – ToolF tab

This tab is the equivalent of a “tools-holder truck” aside the line containing maximum two-hundred tools.
The tools to be inserted into the optional automatic tools-holder magazines will be selected from this tab.

06

01

02 03 04 05

Commands function

Number Function
01 List of the available tools; each row is completed with the following field:
No. number of the tool position
ABCD information about the site occupied from the tool into the tools-holder mag-
azine. Example: C3 means that the tool is in the site n.3 of the “side A”
tools-holder magazine.
This information could be completed also with the indication of the drilling
head in which magazine the tool is installed (C for side “A” and D for side
“B”). Example: “C3 - C” specifies that the tool is in the site nr. 3 of the side
A tools-holder magazine and that it is used to drill the side A.
The “ABCD” label is also a push-button: the C.N.C shows or all the availa-
ble tools or the ones loaded on the line each time this push-button is
touched.
Tool tool description of the tool as defined in the drilling table
Diameter tool nominal diameter as defined in the drilling table
Type tool type as defined in the drilling table
Life quantity of material drilled from the tools from its first use
02 To open a window to modify the data of the selected tool; see following “Details” window
03 To delete a tool from the ToolF tab; it is not possible to delete a tool if it is loaded into a
tools-holder magazine
04 To insert a new tool in the ToolF tab; the tool to be inserted is selected from the drilling table;
the same tool can be used more times in several position
05 To exclude the selected tool
06 To exit from the ToolF tab and return to the “Execution” window

34 FICEP S.p.A.
Model RAPID 25 T Programming and operating manual

To insert a new tool into the ToolF tab, touch the push-button 04; the “Drilling Table” opens (see page 28)
where it is possible to select the tool.
To modify one or more characteristic of a tool already inserted in the ToolF tab, touch the push-button 02,
the “Details” window opens. The “Details” window can contains different field according to the tool type;
hereafter the Details window of a drilling tool is shown as example.

NOTE: the modifications made in this window do not change the original characteristics stored into the
“Drilling table”.

01 02 03 04
33
05
06 20
07 21
08
09 22

10 23

11

12 24
25
13 26

14 27
28
15 29
16 30
17
18
19

31 32

Meaning of the fields

Number Function
01 Number of the position occupied from the tool into the ToolF tab; only displaying field
02 Tool type (see the “List of the tool types”, page 31); only displaying field
03 Tool nominal diameter (field 04, drilling table)
04 Field available for other user specification (field 06, drilling table)
05 Specification of the working plane where the tool can be used
06 Tool cutting speed (field 09, drilling table)
07 Tool rotation speed (field 10, drilling table)
08 Tool forward speed inside the material in mm/revolution (field 11, drilling table)
09 Tool forward speed inside the material in mm/min. (field 12, drilling table)
10 Tool forward speed entering the material in mm/revolution (field 13, drilling table)
11 Tool forward speed entering the material in mm/min. (field 14, drilling table)
12 The C.N.C changes the spindle speed from item 11 to item 09 when the tool reaches this
distance (mm from the material surface) - (field 15, drilling table)
13 Drill total width, from cutting edge to cutting edge (field 17, drilling table)
14 Tool lubrication type (field 18, drilling table)

FICEP S.p.A. 35
Programming and operating manual Model RAPID 25 T

Number Function
15 Maximum distance covered by the drill inside the material before its replacement with a simi-
lar one to allow its cooling (field 19, drilling table)
16 Tool life use percent value (field 20, drilling table)
17 Total distance covered by the tool inside the material from its first insertion into the ToolF
tab
18 First tool use limit (field 21, drilling table)
19 Second tool use limit (field 22, drilling table)
20 Tool length; see the following picture

23

21

22

20

21 Real tool diameter; see previous picture

22 Tool-holder length; see previous picture
23 Tool-holder diameter; see previous picture
24 Distance from material to be reached by the tool before the positioning for the subsequent
operation (field 24, drilling table)
25 Distance from material to be reached by the tool where the spindle change from fast ap-
proach speed to spindle forward speed (field 25, drilling table)
26 Hole end coordinate (out of material) (field 26, drilling table)
27 First stop coordinate of the tool forward to break the chip (field 27, drilling table)
28 Incremental step for subsequent stops to break the chip (field 28, drilling table)
29 Coordinate where the C.N.C increases the forward speed to break the material (field 29,
drilling table)
30 It enables the drill backward to unload the chips (field 30, drilling table)
31 To confirm the data
32 or 33 To exit from the “Details” window and return to the “Setup - ToolF” window

36 FICEP S.p.A.
Model RAPID 25 T Programming and operating manual

Setup – Drilling tab

13
01
02
03

04

05 06 07 08

09 10

12
11

Number Function
01, 02, … Each row represents a site of the automatic tools-holder magazine; the row number depends
on the line configuration.
To insert a tool into a site, the operator has to select one of the six box F1 ÷ F6 and touch
the “INS New” push-button. The window with the list of all tools available into the ToolF tab
opens; the operator selects the tool to be installed and confirms with “OK”.
For each installed tool the following entries are displayed:
n° number of the position occupied from the tool into the ToolF tab
Tool type tool type (code as per table on page 31)
Diameter tool nominal diameter, as defined into the drilling table
Tool code additional identification code, as defined into the drilling table
Life Total distance drilled by the tool from its insertion into the ToolF tab
04 Some operational values of the tools are displayed in this box
05 Tool loaded into the spindle; touching this push-button a window opens where the operator
has to input the site number of the tool loaded into the spindle.
The corresponding row will be marked by a tool icon and the site must be obviously empty.
If the zero value is typed in, it means that the spindle is empty and all tools are loaded in
their respective site.
06 To request the execution of the sensitive cycle for the tool length automatic pick-up; the
background of the value in the box 04 becomes yellow and the approaching to the material
during the first drilling is executed at low speed to allow the C.N.C to automatic pick-up the
length.
The sensitive cycle can be executed only with twist drill.
07 To select a tool from the ToolF tab and to load it into a site of the magazine
08 To remove a tool from the magazine

FICEP S.p.A. 37
Programming and operating manual Model RAPID 25 T

Number Function
09 To modify the data displayed into the box 04
10 To modify the data not displayed in the box 04 but available into the “Details” window
11 To make permanent the modifications saving them into the Drilling table
12 To confirm the line setup
13 To close the window and come back to the “Execution” one.

Summarizing procedure to insert tools

To use a tool on the line follow the subsequent procedure starting from step 01 if the tool is a new one or
from step 05 if the tool is already inserted into the “tools magazine of the manufacturing department” (drill-
ing table) but not into the ToolF (Setup).

Command Meaning Remark

01 “Execution” Condizione di partenza

window

02 Tables To page to the data- “Tables” window opens, it is comparable to the “tools
base of all tools magazine of the manufacturing department“.

03 INS New To insert a new tool The “Drilling” window opens; the operator inputs all
into the “tools maga- necessary fields and, at the end, confirms with the “F2
zine of the manufac- Confirm” push-button; the “Drilling” window closes and
turing department“ the tool appears in the list of the “Tables” window. The
tool is inserted into the “tools magazine of the manu-
facturing department “.
The operator can repeat this step for all tools to be in-
serted into the “Drilling table”.

04 To close the “Tables” “Tables” window closes and the C.N.C returns to the
window “Execution” window

05 Setup To page to the work- The “Setup” window opens which contains all data of
ing database the line setup

06 “ToolF” tab To page to the ToolF The “ToolF” tab, which is comparable to a “tools-
tab holder truck aside the line”, is displayed

38 FICEP S.p.A.
Model RAPID 25 T Programming and operating manual

Command Meaning Remark

07 Touch screen To select an empty The operator selects an empty position where add a
position new tool

08 INS New To insert a tool into The “Tables” window with the list of all available tools
the ToolF tab opens

09 Touch screen To select a tool The operator select the tool to add.

10 The operator confirms, the “Tables” window closes

OK
and the C.N.C returns to the ToolF tab of the “Setup”
window.

11 F2 Modify The “Details” window opens where the operator de-

fines some special values for the inserted tool as, for
example, length and diameter of the tools-holder and
ends the modifications touching the “F2 Confirm”
push-button. The “Details” window closes automatical-
ly.
The operator can repeat the steps from 07 to 11 to in-
sert all the necessary tools. The tools can be also
doubled.

11 To close the “Setup” The “Setup” window closes and the C.N.C returns to
window the “Execution” window

When the procedure is ended the tool can be used on the line. When a program execution needs a differ-
ent tool, the C.N.C opens the Setup window automatically and displays the correct tools with green back-
ground and the ones to be changed with red background.

FICEP S.p.A. 39
Programming and operating manual Model RAPID 25 T

Machine setup
Each drilling unit of the RAPID 25 T line is equipped with an automatic tool-changer device; the following
pictures show an exemple of three tool-holders magazine and of an HSK-A80 tool-holder.

The HSK-A80 tool-holder has two slots with same width and depth; the tool-holder has to be inserted into
the magazine so that the triangular slot is turned toward the drilling head (see the following picture).

Soft-keys for adjustment and setup operations of the machine

During the setup operations or for adjustment, maintenance, cleaning etc… purposes, it could be neces-
sary to manually operate on single parts of the line. In the Execution window, the “Operator” graphic
push-button allows paging to some commands that can be activated by means of the graphic pushbut-
tons (softkeys).

ATTENTION: the picture shows all possible controls and can partially correspond
to the soft keys of the machine supplied.

40 FICEP S.p.A.
Model RAPID 25 T Programming and operating manual

01 02 03

04 05 06 07 08 09 10

11 12 13 14 15 16 17 18

19 20 21 22 23
24 25

26 27

28 29 30

01: It enables the TEST mode to check a program without any material and without execute the opera-
tions
02: It enables the programmed stops (M01 function) in the program in progress
03: It enables the bar length pick-up automatic cycle; the measurement is taken by photocells placed at
the entry side of the line
04: It activates the shear cutting cycle in manual mode; avalaible only if the optional shear is present
05: It excludes the rotating loading system; available only if the rotating loading system is present
06: It selects the hold-downs working mode: always together or separated
07: It enables the material loading with the rotating loading system and pincher beyond the rotating load-
ing system position towards the machine; available only if the rotating loading system is present
08: Not used
09: Loading table at slow speed only; available only if the rotating loading system is present
10: Not used
11: Tool deposit for the “A” side drilling unit (line in manual mode)
12: Tool deposit for the “B” side drilling unit (line in manual mode)
13: Tool load for the “A” side drilling unit (line in manual mode)
14: Tool load for the “B” side drilling unit (line in manual mode)
15: It enables the cutting cycle in manual mode
16: It enables to stop the band underneath the material after the cutting execution
17: It actuates the band rotation in manual mode
18: It enables the C.N.C to use the right parameters when the saw is equipped with high-speed cutting
band
19: It actuates the lifting of the vertical hold-down, which stands in the sector of the positive mitering, in
manual mode (optional)
20: It actuates the lowering of the vertical hold-down, which stands in the sector of the positive mitering,
in manual mode (optional)
21: It actuates the lifting of the vertical hold-down, which stands in the sector of the negative mitering, in
manual mode (optional)
22: It actuates the lowering of the vertical hold-down, which stands in the sector of the negative mitering,
in manual mode (optional)
23: It enables the use of the vertical hold-downs in automatic mode (optional)
24: It displays the current drawn of the band rotation motor
25: It displays the preset current drawn of the band rotation motor. This value is automatically calculated
by the C.N.C software according to the profile type. If the actual current drawn is greater than this
value, the C.N.C automatically decreases the rotation speed
26: It displays the actual band feedrate speed during cutting operations
27: It displays the time of cutting operation
28: It changes in manual mode the band feedrate speed percen
29: Display of short textual descriptions under each softkey by means of a safety password

FICEP S.p.A. 41
Programming and operating manual Model RAPID 25 T

30: Exit from soft-keys window and return to the C.N.C execution one

Portable push buttons panel for service operations

A portable push-buttons panel allows carrying out maintenance and/or restore manual operations. To use
this panel it is necessary to put the line in setup mode rotating in left position the key selector (Setup).
On the portable push buttons panel an emergency push-button, as the one on the operator’s control pan-
el, is available.
In case of activation, to restore the normal functioning, it is necessary to unlock the push-button and to
push again the “RESET” push-button with blue warning light on the operator’s control panel.

TC TD
01 02 03

06
04 05

Number Function
01 Selects the A side (TC) or B side (TD) drilling head and/or tools-holder magazine.
02 Moves the tools-holder magazine of the selected head to the tool-change position
03 Moves away the tools-holder magazine of the selected head from the tool-change position
04 Releases the tool from the spindle of the selected head
05 Activates the tool lubrication circuits; the selection of the internal or external lubrication is au-
tomatic depending on the tool type inserted into the spindle as per the line setup
06 Emergency push-button

If the line is equipped with 6-positions tools holder magazines, there are two three-position
selector switches instead of the nr. 01; each switch refers to a drilling head and the opera-
tor can select the first or the second group of three tools.

TC TD
1-2-3 4-5-6 1-2-3 4-5-6

42 FICEP S.p.A.
Model RAPID 25 T Programming and operating manual

CHAPTER 5: PROGRAMMING

Preliminary remarks

“Programming” means translate the drawing of the piece to be processed into C.N.C executive instruc-
tions.
A program can be inserted into the C.N.C by:
- importing files from an external PC, in this case the program could be generated with other pro-
grams like, for instance, Winsteel
- direct editing on the touch screen of C.N.C; in this case display the “Programming” screen page

Anyway, these agreements are valid:

- side “A”: right side of the profile standing at the material entry side; we shall call it, “flange A”
- side “B”: left side of the profile standing at the material entry side; we shall call it, “flange B”

NOTE: To program, the activation of auxiliary circuits (oil pump, etc…) is not required.

Terminology

Piece: instructions list to program a piece into the C.N.C software

Parts list: list of all pieces programmed in the C.N.C software (available in the pro-
gramming window)
Bar: row material to be cut to get the programmed pieces
Nesting: optimization of the pieces into a bar; only if an optional cutting unit is present
Bars list: list of all the nested bars; only if an optional cutting unit is present
Canonic program: executing program of the C.N.C generated starting from
- piece program to execute a single piece
- bars list to execute one ore more nested bar of a production lot; only if an
optional cutting unit is present

FICEP S.p.A. 43
Programming and operating manual Model RAPID 25 T

The programming window

1
2 3

Programming window zones

Zone 1: general information about the part program selected in the zone n. 5
Zone 2: profile type and relevant geometric measures of the part program selected in the zone n. 5
Zone 3: drawing not in scale of the part program selected in the zone n. 5
Zone 4: controls to select and put in order the part programs according to the selected criteria
Zone 5: list of the part program stored in the C.N.C
Zone 6: operator controls

Remarks on the contents of the zones

Zone 2, profile: the symbol identifies the datum line side or the “A flange” of the profile, whereas the
symbol identifies the part origin.

Zone 3, drawing: the profile is represented “open” on the plane and the symbols determine the origin of
each side of the profile; the profile sides are identified with “A” and “B”. In the drawing, also the position of
the pincher is represented in blue colour.

Zone 4, selecting controls: pressing the “Filter” push-button, a window is displayed where it is possible to
choose the selection criteria for the pieces listed in the zone n. 5. Pressing the “Order” push-button, a
window is displayed where it is possible to choose the order criteria for the pieces listed in the zone n. 5
or for the selected pieces. The chosen criterion is identified by a selection mark.

Zone 5, parts list: to select a particular part program touch directly the screen or use the arrow keys of the
PC keyboard; the selected part is identified by a blue bar.

Zone 6, operator controls: the push buttons of this zone allows operating with files and nesting programs,
in detail:
“New” push-button: to edit a new part program
“Open” push-button: to modify an already existing part program selected in zone n. 5

44 FICEP S.p.A.
Model RAPID 25 T Programming and operating manual

“Execute” push-button: to generate the canonic program for the part selected in the zone n. 5 as
“piece cut to length”
“Graphic” push-button: to display a window with a scaled graphic view of the part selected in the zone
n. 5
“Archive” push-button: to import/export, copy, delete, rename, etc. a part program
“Nesting” push-button: to nest in bars the parts selected in the zone n. 5 (available only if the line is
equipped with an optional cutting unit)
“Bars list” push-button: to open the list of the nested bars (available only if the line is equipped with an
optional cutting unit)
“Print” push-button: to print the selected part program, choosing between full printout and simpli-
fied printout. Full printout gives all details of each instruction whereas the sim-
plified one gives only macroinstructions. To have full printout it is necessary to
select the “single operations” option in the window displayed pressing the
“print” push-button
“Information” push-button: to display a window with summarized information of a part: profile type, size,
dimensions, tools list, operations for each side, etc. This push-button is in the
zone “1”.
“Quantity” push-button to adjust the parts quantity set without modify directly the part program

To input a new program

Pressing the “New” push-button in the programming section, a window to compile the part program is dis-
played:

17
01
02
03
04
05
06
07
08
09
10
11 18

12
13

16

14 15

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Description of the data to be inserted

FIELD MEANING
01 Alphanumeric string, which identifies the contract (for example the final customer’s name,
the work code, etc.). Max 12 characters.
02 Alphanumeric string, which identifies the drawing. Max 12 characters.
03 Alphanumeric string, which identifies the piece; if the part program contains marking oper-
ations with no other specifications, this is the text that will be marked. Max 12 characters.
04 Alphanumeric string, which identifies the particular of an assembly drawing. Max 12 char-
acters.
Note: it is not necessary to fill in all previous fields; it is possible to put in only one (better
the field n. 3).
05 Quantity of piece to be produced
06 Type of material: to select a material, press F4 and choose it from the list in the selection
window. In the same window, it is possible to insert a new material or to modify an already
existing one.

07 Type of profile: to select a profile type, press F4 and choose it from the list in the selection
window.

08 Dimensions of profile: to select standard dimensions (or to insert/modify dimensions),

press F4 and choose it from the list in the selection window.

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FIELD MEANING

09 Length of the piece.

10 Not used
11 Not used
12 Not used
13 Not used
14 Free remark field; max 30 characters.
15 Choice of measuring unit; press F4 to select (mm - inches – fractions of inch).
NOTE the measuring unit has to be selected before inserting the programming lines.
16 Selected profile section with the relevant dimensions; this is the same drawing displayed in
the selection window described at point n. 08.
17 The profile is represented open on the plane and not to scale.
18 List of program instructions; each instruction is so composed:
- LINE: progressive number of the instructions automatically provided by the C.N.C
software
- TYPE: operation code (operation to be performed)
- SIDE side code (side where to perform the operation)
- DIAMETER: tool diameter (or other parameter of the tool to be used)
- X: X coordinate (horizontal) of the operation point
- Y: Y coordinate (vertical) of the operation point
- DETAILS: tool type or other special enhanced information

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Programming and operating manual Model RAPID 25 T

Editing a program: preliminary remark

General rules to edit or modify a part program

To edit a program line, it is necessary to press the F4 key of the PC keyboard to open the selection win-
dow with the different options for each field of the instruction.

LINE TYPE SIDE DIAMETER X Y DETAILS

001

F4 F4 F4

Pressing F4 when the cursor is in the diameter field, a window with the list of all tools present in the tool
table (the C.N.C general database) is displayed.

Note on the examples of this manual

In the following examples all the drilling operations are programmed with the standard twist tool using the
DRILL operation in the details field of each instruction; therefore, the examples are valid even if DRILL is
replaced with DRILL 32 or DRILL 33.

Different possibilities of programming are shown in the following sections; the values of X and Y coordi-
nates in the following examples are not binding and are given only to illustrate the instructions.

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Programming: single hole

Y
X

Meaning of the fields and possible choices

FIELD CONTENT MEANING

TYPE No code (empty) Single hole
SIDE

DA

│◄
►

DB

│◄
►

DA+DB

│◄
►
DETAILS DRILL Twist tool; sensitive cycle allowed
DRILL_32 Tool with inserts; sensitive cycle not allowed
DRILL_33 High speed tool; sensitive cycle not allowed

Example: single hole with diameter 20 mm to be performed with twist tool on the flange “A”
LINE TYPE SIDE DIAMETER X Y DETAILS
001 DA 20.000 75 75 DRILL

NOTE The values of X and Y coordinates are for example only.

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Programming: linear pattern of holes with same diameter

Meaning of the fields and possible choices

FIELD CONTENT MEANING
TYPE LIN Pattern of holes with same diameter aligned on a same line
SIDE See “single hole”
DETAILS See “single hole”

Selecting “LIN” in the “TYPE” field, a window is displayed to insert the parameters of the holes pattern
configuration and of the other field of the programming line.

Example: four holes with diameter 22 mm horizontally aligned, spaced 40 mm and executed on both
flanges with standard twist tool

LINE TYPE SIDE DIAMETER X Y DETAILS

001 LIN DA+DB 22.000 200 40 DRILL

NOTE: The values of X and Y coordinates are for example only.

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Programming: matrix pattern of holes with same diameter

Meaning of the fields and possible choices

FIELD CONTENT MEANING
TYPE MAT Pattern of holes with same diameter arranged in echelon formation
SIDE See “single hole”
DETAILS See “single hole”

Selecting “MAT” in the “TYPE” field, a window is displayed to insert the parameters of the holes pattern
configuration and of the other field of the programming line.

Example: matrix of twelve holes with diameter 20 mm executed on the flange A with standard twist tool,
spaced 50 mm along one direction (3 repetitions) and spaced 40 mm in the orthogonal direction (2 repeti-
tions). In this example, the matrix has a 7° angle as to the longitudinal X-axis

LINE TYPE SIDE DIAMETER X Y DETAILS

001 MAT DA 20.000 500 75 DRILL

NOTE The values of X and Y coordinates are for example only.

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Programming: pattern of holes with same diameter arranged on an arc of circle or a whole circle

Meaning of the fields and possible choices

FIELD CONTENT MEANING
TYPE FLA Pattern of holes with same diameter arranged on an arc of circle (flange
pattern)
SIDE See “single hole”
DETAILS See “single hole”

Selecting “FLA” in the “TYPE” field, a window is displayed to insert the parameters of the holes pattern
configuration and of the other field of the programming line.

Example: seven holes with diameter 20 mm executed on the flange B with standard twist tool and ar-
ranged on an arc of circle of 270°, spaced 45° and with radius 45 mm; the first hole must be at 45° as to
the X-axis.

LINE TYPE SIDE DIAMETER X Y DETAILS

001 MAT DB 20.000 1000 80 DRILL

NOTE The values of X and Y coordinates are for example only.

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Milling operations

OPERATION PROGRAMMING
EXAMPLE
TYPE CODE

Pocketing POCKET

Milling MILL

The pocketing operation executes the approach to the material at reduced speed to perform a first pass
with material removal and further passes to get the programmed depth.

The milling operation, instead, executes the fast approach until a predetermined coordinate under the ma-
terial surface and the subsequent transversal movement at working speed to remove the material. There-
fore, the milling operation has to start from a hole with at least the same diameter of the milling tool.

Both operations are programmed with two instructions: “LEAD” which defines the starting point coordi-
nates and the operation type (POCKET or MILL) and “CUT” which defines point-to-point the tool path.

Example of program for milling or pocketing operations: execution of a slot

LINE TYPE SIDE RADIUS X Y DETAILS REMARK

001 LEAD DC 100 50 POCKET / MILL Start from point nr 1

002 CUT DC 400 50 Removal up to point nr 2

003 CUT DC 400 150 Removal up to point nr 3

004 CUT DC 100 150 Removal up to point nr 4

005 CUT DC 100 50 Removal up to point nr 1

4 3

150
1 2

50 100
400

When the cursor is in the “DETAILS” field of the “LEAD” instruction, pressing “Enter” of the PC keyboard
a window, where it is possible to define the working parameters is displayed.

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Programming and operating manual Model RAPID 25 T

01
16
02

03

04

05

06
07 09

08 10

11

12 13 14 15

FIELD MEANING
01 How the overall dimensions of the tool is taken into consideration during the working op-
erations.

Left compensation No compensation

Right compensation No compensation

02 Not used
03 Tool tangential (cutting) rotation speed; it is the same data of the field 09 of the “In-
sert/modify a tool in the drilling table” window (page 29); if no other value is specified the
C.N.C. software uses the one stored into the table
04 Tool nominal diameter; it is necessary to select it among the ones available inside the
ToolF table pressing the “three dots” push-button …

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FIELD MEANING
05 Optional user code to identify the tool; it is the same data of the field 06 of the “In-
sert/modify a tool in the drilling table” window (page 29)
06 Working total depth: it is the same data of the field 26 of the “Insert/modify a tool in the
drilling table” window (page 29). This value is always negative because it represents a
coordinate on the opposite side of material with reference to the tool.
POCKET operation: total depth of the pocket
MILL operation: value bigger than material thickness
07 Depth of the first pass of the tool; it is the same data of the field 27 of the “Insert/modify a
tool in the drilling table” window (page 29).
POCKET operation: real value of the first pass depth; positive value
MILL operation: this operation is carried out in just one pass field 07 = field 06
08 Step between two subsequent passes; it is the same data of the field 28 of the “In-
sert/modify a tool in the drilling table” window (page 29). This value is always positive be-
cause it is an increment value and not a coordinate.
POCKET operation: real increment between two subsequent passes
MILL operation: field 07 = field 06 field 08 not used
09 ÷ 15 Not used
16 Close the window and return to programming operations

Programming: special functions

According to the drawing dimensioning of the piece, it is possible to use several rules.

Use of the absolute and incremental coordinates

It is possible to use the absolute coordinates, as per all previous examples, or the incremental coordi-
nates as per the following one where the operation is programmed in the two different ways:

Program with absolute coordinates

LINE TYPE SIDE DIAMETER X Y DETAILS
001 DB 22.000 500 75 DRILL
002 DB 22.000 600 75 DRILL

Program with absolute and incremental coordinates

LINE TYPE SIDE DIAMETER X Y DETAILS
001 DB 22.000 500 75 DRILL
002 DB 22.000 100+ 0+ DRILL

In the second program the coordinates of the second hole are not defined as absolute coordinates ac-
cording to the part origin but as incremental displacement according to the first hole position.
The position of both holes in both examples is the same.

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Permanent repositioning of the piece origin

If it is necessary to repeat the same operation, it is possible to write the needed instructions the first time
and then copy them changing the origin point.

Example: the following picture shows a part program with five repetitions of the same group of holes.

1 2 3 4 5

925

50 150
125
100
75 50
25 1 3 5

2 4

200 200 200 200

LINE TYPE SIDE DIAMETER X Y DETAILS REMARK

001 DA 20.000 50 75 DRILL

1st Group of holes; the piece
002 DA 20.000 75 100 DRILL origin is defined by C.N.C
software (point 1)
003 DA 20.000 50 125 DRILL
004 ORG DA 200 -100 New origin (point 2)
005 DA 20.000 50 75 DRILL
2nd Group of holes; the holes
006 DA 20.000 75 100 DRILL coordinates are the same of
the first one
007 DA 20.000 50 125 DRILL
008 ORG DA 200 100 New origin (point 3)
009 DA 20.000 50 75 DRILL
3rd Group of holes; the holes
010 DA 20.000 75 100 DRILL coordinates are the same of
the first one
011 DA 20.000 50 125 DRILL
012 ORG DA 200 -100 New origin (point 4)
013 DA 20.000 50 75 DRILL
4th Group of holes; the holes
014 DA 20.000 75 100 DRILL coordinates are the same of
the first one
015 DA 20.000 50 125 DRILL
016 ORG DA 200 100 New origin (point 5)
017 DA 20.000 50 75 DRILL
5th Group of holes; the holes
018 DA 20.000 75 100 DRILL coordinates are the same of
the first one
019 DA 20.000 50 125 DRILL
Origin displacement is reset
020 ORG DA
(back to point 1)

Note:
- each origin displacement is incremental according to previous origin and not to the one set by the
C.N.C software
- the displacement of X origin coordinate is suitable for all sides of the piece whereas the displacement
of Y origin coordinate is suitable only for the one where it is defined
- the “ORG” instruction without X and Y coordinates resets all the displacements and it takes again the
origin in the initial position set by the C.N.C software

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Temporary repositioning of the part origin

Pressing F4 with the cursor in the SIDE field, the window for the choice of working side is displayed
where it is also possible to select the repositioning of the X and Y coordinates origin. This repositioning is
valid only for the program line where it is defined.

Y origin repositioning

Y/2

Y/2

X origin repositioning

X X

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Programming of special functions

Put the cursor in the “TYPE” field, press F4 and choose the command “MISC” (Miscellaneous), move the
cursor in the “DETAILS” field and press F4 to open the list of all programmable special functions:

Functions to modify the execution order

The C.N.C. can execute the program instructions following different criteria. For example:
- to reduce the material handling
- to reduce the tool change operation
Therefore it is possible to set the instructions execution order using the couples of functions M51-M50,
M52-M50 … till M59-M50. Each couple M5… - M50 identifies an instructions group.
The C.N.C. executes the instructions with the following order:
- instructions group between the M51-M50 functions
- instructions group between the M52-M50 functions
- instructions group between the M53-M50 functions
- instructions group between …
- instructions group between …
- instructions group between the M59-M50 functions
- instructions not included between M functions; those are executed following the order
which reduces the tool changes

In the following example the M functions change the instruction execution order:
EXECUTION
LINE TYPE SIDE DIAMETER X Y DETAILS REMARK
ORDER
001 DB 20.000 100 100 DRILL 7 Tool Ø 20 mm
002 MISC M52
003 DB 20,000 200 100 DRILL 3 The M52 group instructions are
004 DB 16.000 300 100 DRILL 4 executed per second
005 MISC M50
006 DB 20.000 400 100 DRILL 6 Tool Ø 20 mm
007 DB 16.000 500 100 DRILL 9 Tool Ø 16 mm
008 MISC M51
009 DB 20.000 600 100 DRILL 1 The M51 group instructions are
010 DB 16.000 700 100 DRILL 2 the first to be executed
012 MISC M50
013 DB 20.000 800 100 DRILL 5 Tool Ø 20 mm
014 DB 16.000 900 100 DRILL 8 Tool Ø 16 mm

NOTE The values of X and Y coordinates are for example only.

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Mirroring function (G74 ÷ G75)

The G74 and G75 special functions start and finish, respectively, the mirroring mode of an operation with
reference to X coordinate.

In the following program, two mirror-likes holes are obtained with an only drilling instruction.
LINE TYPE SIDE DIAMETER X Y DETAILS
001 MISC G74
002 DA 22.000 100 50 DRILL
003 MISC G75

NOTE The values of X and Y coordinates are for example only.

The following picture shows the execution output of the mirroring operation.

50

100 100

Vertex angle milling - MHTA

The MHTA macro-instruction, if available, allows to mill the vertex of an L profile.To program this type of
operation type F4 when the cursor is in the "TYPE" field of a programming line and choose the operation
MHTA. A window opens to allow to parametrise the operation.

REMARK: the tool must have a grinding angle of 45°

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Model RAPID 25 T Programming and operating manual

CHAPTER 6: PROGRAM EXECUTION

Execution of working operations: introduction

The RAPID 25 T line can execute:

- single pieces, already cut to length, with drilling operations only

- group of pieces from a bar (or many bars) by means of the optional cutting unit (see relevant attach-
ment)

Hereby the procedure to execute a piece cut-to-length is described.

Procedure to execute a program of a single piece

Command Meaning Remark

Start condition Line powered, axes zero cycle performed, auxiliary cir-
cuits ON (oil pump, etc…), no active alarm, main page of
C.N.C software displayed, part program already edited
and ready to be executed.

Programming Programming window In this window the part program of the programmed piec-
displayed es are listed.

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Command Meaning Remark

Selection of the piece to By means of the arrow keys, select in the list the piece to
be processed be processed. The selected one is highlighted by a line
with blue background.

Execute Start the execution of A window with some information about the piece is dis-
the selected piece played to allow the operator to check if everything is OK.
Note that the upper drawing of the following picture
shows the programmed piece while the lower one shows
how to load the piece

Optional

Parameters Check and adjustment Adjust, if needed, the execution parameters opening the
of the execution param- window by pressing the “Parameters” push-button.
eters

To know the meaning of the execution parameters see

on page 65.
At the end of the operation touch the exit push-
button to go back to the previous window

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Command Meaning Remark

Execute The canonic program is For few seconds a processing service window is dis-
generated played. Then the previous window with the parts list is
shown again.
It means that the canonic program has been correctly
generated.
If an error occurs (for instance, the program needs a tool
not present in the tool tables, programming errors, etc.)
an error message is displayed. Press again the “Execute”
push-button after having removed the problem.

To supervise the execu- The Execution window is displayed; the operator can
+ tion of the program. read dynamic information.
Execution

Selection of automatic Choice of required automatic cycle (continuous or step

cycle by step)

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Command Meaning Remark

Start The execution of the program is started. If the line setup

is suitable to the required one, the pincher moves to
clamp the material, the LED into START push-button is
ON and the coordinates change dynamically: the line is
working.
If the line setup is not the one required, the C.N.C stops
the execution after few seconds and automatically dis-
plays the setup window. In this page, correct tools have
green background while incorrect tools have a red one.

Setup mode to fit the The operator must switch the line in setup mode rotating
line on the left the key selector of the control and safety push-
button panel and pulling out the key to avoid any control
by third person.

Machine fitting The operator executes all fitting operations required

checking carefully that type and position of all fitted tools
are exactly the ones requested from the C.N.C.
At the end of operations, the operator confirms pressing
“OK”.

Restart The operator inserts the key into the selector and switch-
es the machine in working mode

RESET

Alarms reset The operator resets the system pressing the push-button
to clear the alarm of protection barriers interruption (if
provided).

The operator starts again the execution of the automatic

cycle; the pincher moves to clamp the material, the LED
into START push-button is ON and the coordinates
change dynamically: the line is working.

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Execution parameters for “cut-to-lenght” pieces

13
01

09

02

03

04
05
06
07

08
11
10

12

Reference Meaning
01 “Piece cut to length”: the selected piece doesn’t need cuts (it is already cut-to-length)
02 - Standard: the instructions are executed following the X order to reduce the materi-
al movements
- Passes: the instructions are grouped per tool to reduce the tool changes
03 Not used
04 Not used
05 Not used
06 Selecting this option the C.N.C automatically performs the tool turnover (tools with same
diameter) depending on the quantity of material worked
07 Cooling limit for drilling tools; if this field is left empty the C.N.C takes the datum from tool
tables
08 Not used
09 Not used
10 Drilling tools optimize for - options:
- “Tool life maximum”: if in the ToolF tab identical tools are available, the CNC uses
the one with the more remaining life to reduce the tool changes.
- “Tool life minimum”: if in the ToolF tab identical tools are available, the CNC uses
the one with the less remaining life to finish their use
11 This push-button allows activating all the standard options and values.
12 This push-button allows modifying the values and options in the window. At the end of
operations, it is necessary to press again F2 to confirm the selections made.
13 To close the window and come back to the “Execution” one.

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The execution window

01

05
06
07
08
09
10
02
03
11
12

04

Reference Meaning
01 Taskbar
02 Display of main axes coordinates
03 Graphic information about the profile in process
04 The program is in execution (canonic): the display of program is in textual under-
standable form and the content of the box changes rolling according to the pro-
gramming line in execution.
Each program line is marked by
a smile which could be
white = setup line without movement instructions
red = line to be executed
☺ green = line already executed
After a stop, this allows to the CNC to restart the program exactly from
the interruption (first red smile)
Lxxx line number
X… Y… positioning coordinates
Operation clear description of the operation executed and tool used
05 Measuring unit of the program in execution
06 This push-button opens the axes manual controls
07 This push-button opens the setup tables
08 This push-button opens the operator parameters to adjust some basic operations
(see page 73)
09 This push-button allows the display of the canonic program; pressing the “Open”
push-button in the window displayed, a text window with the CNC working code is
displayed where it is not possible to made modifications.

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Reference Meaning

10 This push-button opens the tools tables (tools general database)

11 This push-button opens a window where it is possible to execute a new part, a new
bar or a special cycle. The special cycles are programs stored in the CNC to test
and adjust the line.
12 This push-button opens the soft-keys window for machine adjustment and direct
control of some devices (see page 40)

Operator controls during automatic execution

“Hold” The operator can press the push-button on the main push-
buttons panel at any time to temporary halt the program execu-
tion.
“Start Cycle” When pressed, this push-button placed on the main push-
buttons panel starts the program or restarts the program in pro-
gress from the interruption point.
“Stop Cycle” At any time, the operator could press the push-button, placed in
the control and protections zone, to stop immediately the cycle
and put the tools in safety position without put the line in
emergency mode. When the “Start Cycle” push button is
pressed: if the last operation was ended, the execution starts
from the next instruction, otherwise the operation interrupted is
re-executed.
“Emergency” In case of danger, the operator must press immediately one of
the available emergency push buttons. The program execution
stops, the auxiliary circuits are switched OFF and the tools stay
in the current position. The line is in emergency condition.

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Restart of working process after an emergency stop

The procedure, to restart the system after an emergency stop has been pressed, requires well-trained
personnel because it is necessary to pay the utmost attention to protect devices and tools from collisions,
tearings, etc.
The correct sequence of operations to be carried out to restart the system depends from the position of
the system at the moment of the interruption; here below find a possible sequence of operation to restore
the system as follows:

1) remove the source of danger or solve the problem which has generated the interruption
2) release the mechanical reset of used emergency push buttons
3) reset electrically the system by pressing the blue push button on the operator’s workstation. After
the reset, the blue lamp of the push button must be switched off.
4) reset, if active, the alarm caused by the interruption of the protecting barriers (if present)
5) restart the auxiliary circuits
6) select manual mode
7) if the drilling tools (and/or the optional cutting tool) can be moved, press the “cycle stop” push but-
ton to move the tools out from the working area (fully retracted). If a tool seems to be jammed into
the material act in manual mode, and select very small incremental movements and at a very
slow speed and try to set the tool free moving the axes manually by means of “+” and “-“ keys.
Before manually move a tool, check carefully that it is not locked into the material.
8) when the tools are out of material, select the automatic cycle (step by step)
9) press the “Start cycle” push-button verifying if the cycle starts properly
10) if the operations have been resumed without problems, pass to the automatic continuous cycle

Restart of working process after a drop of voltage

In the event of an interruption of the system working process due to a voltage drop, the restart procedure
is the same as stated above except for the axes zero cycle execution.
ATTENTION: In the event of voltage drop, the C.N.C looses the axes position.
It means that manual movements can be made by operator but acting with the utmost attention, as the
axes electronic barriers are not active, and the operator must execute an axes zero cycle before the
start of the interrupted program.

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3D View

To view a piece in three-dimensional graphics tap the "3D" in the general programming window; in the
new window that opens, you can see the selected piece in his final appearance after processing.

Example

09 08 07 06 05 04 03 02 01

10

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Function of the graphic push-buttons

Number Function
01 Minimizes the 3D window
02 Opens a side panel with the list of working operations for the piece represented

Tapping a list item, the corresponding representation in 3D design is highlighted

03 “Whole screen”: the representation is magnified to the size of the screen
04 This orientates the representation of the piece. The point where the operator touches the
screen constitutes the center of rotation. In the following picture:
represents the point where the operator touches the 3D drawing
represent the directions of movement of the finger of the operator
represents the type of rotation of the workpiece

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Number Function
In the following picture:
represents the point where the operator touches the 3D drawing

represent the directions of movement of the finger of the operator

represents the type of rotation of the workpiece

05 Allows to translate the representation of the workpiece. The point where the operator touch-
es the screen constitutes the gripping point of the piece. In the following picture:
represents the point where the operator touches the 3D drawing

represent the directions of movement of the finger of the operator and the corre-
sponding type of movement of the piece

06 "Zoom": allows to change the dimensions of the 3D representation of the piece, the operator
touches the workpiece and move your finger to the

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Number Function
- Up to increase the size
- Down to decrease the size
07 "Zoom Window": the operator enlarges only the desired part of the 3D representation by
drawing a rectangle on the screen; by tapping the button 03, the piece is again fully dis-
played
08 "Menu" makes visible the command bar that is not displayed normally

09 3D image reconstruction
10 Cartesian reference system of the 3D representation

Commands menu
The menu commands are not useful for the operator with the exception of the command "Display - Views"
with which the operator can recall a number of predefined views of the piece.

Top = Top view Bottom = Bottom view

Left = Left view Right = Right view
Front = Front view Rear = Rear view
Isometrica = Isometric view

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CHAPTER 7: SPECIAL AND ADDITIONAL OPERATIONS

Working in test mode

The RAPID 25 T can execute a program in test mode without the material, however, it is necessary that
the bar length automatic pick-up is not active.
To test a program, follow this procedure:
1) Select TEST ON by pressing the soft-key n. 01
2) Disable, if activated, the bar length automatic pick-up by pressing the soft-key n.03
3) Press “Cycle Start” on the main push-button panel

Note When the line is in Test mode, in the execution window at the beginning of the canonic program a
yellow bar displays a clearly message.

Operator parameters adjustment for processing

Pressing the “Parameters” graphic push-button in the “Execution” window, a sub-window is displayed
where it is possible to adjust some values regarding the line basic functioning.

ATTENTION: the following parameters could partially correspond to the ones displayed on
the line supplied because their number and function are strictly referred to the
line configuration

Name of Measuring Meaning

parameter unit
TMP017 s Stop time required for scrap breakage during the drilling head forward.
TMP018 s Time required for a pointing operation executed with the drill (tool type
POINT_37)
TMP257 s Available only if the line is fitted with the optional disc marking unit: Writing
marking time for the first characters of the marking string
TMP261 s Available only if the line is fitted with the optional disc marking unit: Writing
marking time for the characters following the first of the marking string
TMP281 s Available only if the line is fitted with the optional marking unit with drawers:
marking time with the drawer n° 1 of the marking unit with drawers; the bigger
is this time the bigger is the marking depth.
TMP282 s Available only if the line is fitted with the optional marking unit with drawers:
nd
as above but for the 2 drawer
TMP283 s Available only if the line is fitted with the optional marking unit with drawers:
rd
as above but for the 3 drawer
TMP284 s Available only if the line is fitted with the optional marking unit with drawers:
th
as above but for the 4 drawer
TMP285 s Available only if the line is fitted with the optional marking unit with drawers:
th
as above but for the 5 drawer
TMP286 s Available only if the line is fitted with the optional marking unit with drawers:
th
as above but for the 6 drawer
TMP287 s Available only if the line is fitted with the optional marking unit with drawers:
th
as above but for the 7 drawer
TMP288 s Available only if the line is fitted with the optional marking unit with drawers:
th
as above but for the 8 drawer
DBL001 number Special field to input a numerical code to unlock some protections of the ma-
chine (reserved to FICEP technicians)
GEN1016 Max length tolerance for cut to length parts

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CHAPTER 8: ARCHIVE OPERATIONS

File management operations

In the main programming window, the graphic push-button “Archive” allows to display a window for file
management operations.

Command “Copy”: allows creating a copy of the selected part program; the copy must have at
least one of the four fields contract, drawing, mark and position different from
the original
Command “Rename”: allows changing the content of one or more of the four fields contract, drawing,
mark and position
Command “Delete”: allows deleting the part of the list according to the selection keys (contract
name, material type, etc…) set by the operator.
Command “Delete all”: allows deleting all part programs, all profiles or all materials
Command “Recovery”: allows cancelling the last file deletion; only the last part deleted can be re-
stored from a safety backup copy created automatically by the C.N.C software
Command “Export”: allows exporting a part program in “.FNC” format (C.N.C exchange format)
Command “Import”: allows importing a part program generated with an external program as file
with extension “.NC” or “.NC1” according to the DSTV specifications or C.N.C
files with extension “.FNC”.
Attention: the path of a DSTV format file has to be a name without spaces.

Import operations

Import of part program in DSTV format

Pressing the “Import” graphic push-button, a part import window is displayed.

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Pressing the “DSTV Options” graphic push-button, a window is displayed, where defines the parameters
of the DSTV format import operation, made up of three tabs: “General” (F1), “Drilling” (F2) and “Scribing”
(F3).

01
02
03
04

05
07
08
09
10
11
06

Reference Meaning
01 Possible new name for the field “Contract”
02 Like above but for field “Drawing”
03 Like above but for field “Mark”
04 Like above but for field “Position”
05 This option allows the automatic generation of working longitudinal symmetry (along
the X axis)
06 Graphic push-button for the automatic set of default import parameters
07 This option allows importing Q profiles if the line could process them; it has to be
deactivated for the RAPID 25 T
08 This option allows the generation of programs with “F” (Flat) profiles rather than of
“P” (Plate) profiles when importing program with flat profiles; it is normally enabled
for RAPID 25 T line
09 Not used
10 Not used
11 Not used

N.B. All the fields without numerical reference are not used

The “Drilling” tab contains the parameters for drilling operations with the optional drilling head; if neces-
sary the relative values can be generated by pressing the graphic push-button n. 06.
The “Scribing” tab contains some parameters not important for the RAPID 25 T line.

Import of part programs generated by third applications

The import of part programs edited with CAD software of third suppliers needs a sequence of import-
export operations for which it is necessary to purchase a specific license from FICEP. For its documenta-
tion, refer to the supplier manuals.
In this manual, only the final step of import process is shown; this is performed directly on the machine by
means of import package software called “WinCN”.
It is possible to have access to this optional software by means of the “Custom” graphic push-button
which is available pressing the “Communication CAM” graphic push-button in the C.N.C main window.

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Pressing the “Custom” push-button, the window in figure below is displayed where the list of the part pro-
grams that can be imported is present; the part programs has to be stored before in a directory known by
“WinCN”.

ATTENTION: If the supply not includes at least one import licence, the “WinCN” software
package is not installed and the “Custom” graphic push-button is not pre-
sent. If in the C.N.C software main window the “Communication CAM” is
pressed, the statistics final balance of the line described in the following par-
agraph are directly displayed.

To achieve import operations, it is necessary to:

- select the part programs of the list with a lateral tick (to tick off, just double click the part or press the
space bar of the PC keyboard)
- press F4

If the import process ends without errors, each imported program is marked by the icon of an envelope;
that means the program has been “sent” to the C.N.C.
Pressing the “ESC” push-button to come back from the WinCN to the C.N.C software, all the imported
part programs are available in the parts or bars list.
In addition, the WinCN package needs the right adjustment of the importing parameters; the input of the
correct values is normally made by FICEP technicians during the line setting up.

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Statistics final balance of the line

It is possible to page to some numerical and graphic information about the order realization times and the
line utilization times pressing the “RegCam” push-button.

As example, in the picture below shows the percentage distribution of the line utilization times which is
displayed with the command “Graphics” “Machine times” in the taskbar.

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CHAPTER 9: MAINTENANCE AND TROUBLE SHOOTING

Signalling and messages

The C.N.C software, when particular events happen, displays a clear informative message for the opera-
tor; depending on the situation importance and danger, the C.N.C stops the processing. The messages
displayed are codified with a numeric coding (error code) probably followed by a second number (cause
code); this numbers are divided by “:” and respect a colour coding.

Alarm Informative message Wait Error

(Red) (Yellow) (Green) (Grey)

?
An alarm shuts off the pow- A message informs the A waiting message at- An error message
er to the machine auxiliary operator about a par- tests that the C.N.C normally occurs after a
circuits leaving connected ticular condition of the software needs time to particular action, a
only the C.N.C; the result is line stopping the work- execute some opera- wrong set-up, a non-
the same of pressing the ing in progress without tions, during which it correct operation of
emergency push-button; an shut off the power. cannot accept any the operator, etc.
alarm message normally controls from operator.
happens when something i.e. “Specific consent i.e. “Selection not
dangerous occurs, as a to “n“ axis move- i.e. “Dwell for end of possible”
probably collision, a dam- ment is missing” zero cycle 02
aged driver, the emergency phase”
push-button activation, etc.

i.e. “axis “n” encoder

signals alarm”

The description window of a message is like the one in the following picture:

01

03
02
04

05
06

07 08 09 10

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1) error identification on the title bar of the error window

2) icon that identifies the type of error; it follows the colour coding described before
3) signalling numeric code and , maybe, cause code
4) type of signalling
5) description of the problem type
6) description of the possible cause(s)
7) opening the machine events register (alarms)
8) returning to the description window of the current alarm
9) opening the summarizing windows with the list of all active signalling
10) push-button to reset the active signalling; it has effect only if the cause of the signalling is being
removed

N.B. the indications present on the grey part of the window (02, 03 and 04) are also available on the
fixed lower part of all windows.

It could happen that the signalling window is not foreground but under other opened window;
to call it up it is sufficient to press the key combination “ALT” + “H” of the PC keyboard; to
consult the signalling and alarm list, see “Appendix – Diagnostic”.

Display of the Input/Output (I/O) signals condition

The C.N.C software allows paging directly to the input/output elementary signals of the control both digi-
tals and analogues to verify the correct functioning of the sensors and actuators on board.

Mitrol MINOSSE - Execution X

View Setup
Axes coordinates
The display window of the I/O signals condition Channels
(called “Channels”) can be called up from the “Ex- Synoptic
ecution” window pressing in the control bar the Comment
command “View” “Channels”. Debug

Alarm/messages
The “execution” window changes and displays the
I/O signals condition instead of the axes coordi-
nates.

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Layout and function of the graphic push buttons are the same whereas a matrix of oval graphic symbols,
each of them represent an I/O channel, is displayed instead of the axes coordinates.

The condition of the following object is represented:

INP input channels (helpful for factory maintenance service)

OUT output channels (helpful for factory maintenance service)
RIN internal relays (helpful for FICEP installers and technicians)

The first row of the matrix, called “INP01 (1 - 40)”, displays the condition of the digital inputs with “ad-
dress” from 1 to 40, the second one the condition of the digital inputs with “address” from 41 to 80 and so
on.

The rule used is the following:

- green graphic symbol for an input channel: low level condition (i.e. sensor on board normally
opened not activated)
- red graphic symbol for an input channel: high level condition (i.e. sensor on board normally
opened activated)
- green graphic symbol for an output channel: low level condition (i.e. coil of a solenoid valve not
activated)
- red graphic symbol for an output channel: high level condition (i.e. coil of a solenoid valve activat-
ed)

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Mitrol MINOSSE - Execution X

View Setup
Axes coord.►
It is possible to customize the number and the type Canonic ►
of the channels to be displayed by means of the Channels ► Configure
command “Setup” “Channels” “Configure”: Set/Reset

This command opens a window where it is possi-

ble to configure the content of each row of the ma-
trix with intuitive manner.

For the function and the address of each input and output signal, it is necessary to refer to
electric, pneumatic and hydraulic drawings of the line supplied.

Summary of the commands of “View” and “Setup” menu

Command View
Axis coordinates
Axes Displays the normal “Execution” window
Channels coordinates
Synoptic Channels Displays the “Execution” window with I/O condition
Comment Comment Enables/disables the display of the programming comment
Debug
inserted in the canonic program
Alarm/messages Debug It allows gaining access to a window where it is possible to
display and control directly a limited number of channel se-
lected by the operator.
Alarm/messages If a message is active, it calls up the relative window (same
function as “ALT” + “H”)
Command Setup
Axes coord ► It allows gaining access to an under-menu where it is possible
Axis coord. ►
Canonic ► to choose the display format of the axes coordinates. Only for
Channels ► FICEP technicians. Default: “User“.
Canonic ► It allows gaining access to an under-menu where it is possible
to choose the display format of the canonic program. Only for
FICEP technicians. Default: “User“.
Channels ► It allows gaining access to two different windows:
- in the first one (called “Configuration”) the operator can con-
figure which channels he wants to display in the “execution”
window
- in the second one (called “Set/Reset”) the operator can di-
rectly control the activation (“+”) and the deactivation (“-“) of
each channel by pressing the “+” and “-“ push buttons of the
main push-button panel.

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Use of the “Debug” window

Debug window
(Menu “View” “Debug”)

The lower part of the window displays

twelve signals condition by means of
the address of the signal itself and a
green/red little bar or the correspond-
ing numerical value. Positioning the
cursor in one of the box and pressing
F2, the window “Choose of the data
to be displayed” opens where it is
possible to change the type and the
address of the displayed signal.
By means of the graphic push-button
“Set/Reset” the condition of the se-
lected signal is changed after an at-
tention message.
ATTENTION

Any given order is under the direct

responsibility of the operator; the
C.N.C software executes only what
requested without make any control.
An incorrect command of I/O
channels could be very dangerous
for the line and the operators.

“Installation-Servicing” graphic push-button

If the “Installation – Servicing” graphic push-button is pressed in the C.N.C software main page, a window
with several tabs will be displayed.
In these windows, it is possible to perform the line “tuning” procedure like, in example, the pre-setting of
all functional parameters, the dynamic regulation of all axes, the locating of the limit switches coordinates,
etc...
All these operations are executed in the factory and adjusted during the installation.
Thus, the user does not need to gain access to the window, which will be displayed pressing the “Installa-
tion-Servicing” graphic push-button.
In succession for completeness, the contents and the function of all tabs of the windows are briefly de-
scribed.

General rule
Pressing the “Installation-Servicing” graphic push-button, a window with the following tabs opens:
- Parameters
- Axis
- Analogue
- Cycles
- Configuration
- Info I/O
- PLC
The modification of the values displayed in some tabs or the activation of some push buttons command in
other tabs are protected function; in this case, to make the modification or accept the command the C.N.C
ask to insert a password in the window displayed pressing the “Password” graphic push button (where
present).

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The following agreement is valid:

If there are some tables of values and the colour of the selection bar the modifications are
of the value to be modified is
Blue Enabled
Grey Disabled

Each time that the “Password” graphic push-button (where present) is pressed and the correct password
is typed in, the colour of the selection bar or the activation condition of some push-buttons change.

The FICEP technician during the line installation gives the password to the factory responsible and it can
be modified on customer demand or directly during installation or, afterwards, via teleservice.

ATTENTION: any parameter modification carried out by unskilled personnel can be very
dangerous for the operators and the line.

Tabs contents

“Parameters” Tab
This tab allows displaying and modifying the working parameters of some sub-systems of the line. To
modify a parameter, it is necessary to select the category in the right frame and the element to modify in
the left frame; with the modifications enabled, use the PC keyboard to type in directly the new value in the
selected numerical field and press “Enter” to confirm.

“Axes” Tab
This tab allows displaying and modifying the working parameters per each axis. If an axis in the left frame
is selected, it is possible to read its parameters in the right one.
In the right lower area of the tab, the coordinate of the selected axis is displayed, whereas in the left box
the graphic information on the axis dynamics are specified.

“Analogue” Tab
The “Analogue” tab contains the display fields of the infeed or outfeed analog signals.

“Cycles” Tab
This tab contains a list of functionality test programs (called “cycles”), which are inserted into the C.N.C
during the assembly in FICEP.

“Configuration” Tab
This tab contains summarizing information about the machine’s hardware, the C.N.C software version,
the configuration of the internal logic relays, the IP address assigned to the line if it is connected to the
factory net, etc..., )
The most helpful commands for the operator are:
Push-button “Time”: call up the Windows’ calendar-clock application to adjust the data and
the time of the system.
Push-button “Teleassist”: starts the connection with the FICEP After Sales Service (SAT) for ma-
chine remote diagnostics in case of malfunction. The C.N.C has to be
connected to the factory LAN by cable or wireless and have a valid IP
address with Internet access.
Push-button “Alarm”: call up the window of the active alarms.
Push-button “Times zero setting”: all the system time counters used to compose the statistics final bal-
ance of the line are reset (see page n. 78).
Pull-down menu “Language”: allow changing the language used in the C.N.C software among those
fixed by contract.

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“Info I/O” Tab

In this tab, the conditions of all devices that, inside the C.N.C, are connected each other’s via CAN bus
(Controller Area Network) are displayed.
The tab is in table format and each row corresponds to a CAN device; each row reports the following in-
formation:
ID: device logic address on the CAN bus
LINE: number of the CAN line on which the device is connected
TYPE: this word identifies the type of device
STATE: logic condition of the device (activated, deactivated, etc…)
ALL: possible alarm condition in progress

Example:
ID LINE TYPE STATE ALL
6 L2 CDI 20 OPER. OK

Meaning: electronic board to manage twenty digital inputs (TYPE=CDI 20) with CAN address “6” (ID=6),
connected on CAN line n. 2 (LINE=L2), operative state (STATE=OPER.), no alarm in progress (ALL=OK).

All the fields of a correctly configured and functioning device are displayed with green background; if a
device presents a defect, the corresponding fields are displayed with red background and the word
changed consequently.

Example:
ID LINE TYPE STATE ALL
6 CDI 20 NO PRES .

Meaning: electronic board to manage twenty digital inputs with address “6” not present; CAN line interrup-
tion possible.

In the tab, there are five push buttons with the following meaning:
(F2) Download: it allows modifying the parameters of the motor drives; only for FICEP technicians
(F3) Chg ID: it allows reconfiguring the CAN bus; only for FICEP technicians
(F5) Debug: it allows displaying the propriety of each device connected to the CAN bus
(F8) Resync: CAN bus restart command (new synchronization); to be used in case of communication
problems on the machine due to the CAN bus

“Plc” Tab – only for FICEP technicians

This tab contains functioning information and access commands to the Software of the internal PLC.

Reset time: reset of all monitored PLC cycle time (unit ms); only for FICEP technicians

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CHAPTER 10: PROCEDURE TO SHUT OFF THE LINE

Respect the following procedure that assures a correct restart of the interrupted job:

Command Meaning Remark

Start condition Line working; part program or bar program (nesting)

in execution; “Execution” window displayed.
Select the automatic mode single When the line is in automatic mode single execution
execution (step by step) the C.N.C stops at the end of an operation execu-
tion.

Stop cycle and repositioning of When the line is stopped and the LED of the start
the tool axes in safety position push-button is blinking waiting for the command,
pressing the push-button all the tool axes (drilling
tools and blade if present) are moved in safety posi-
tion far from material.

OPERATOR Access to the softkeys windows; Press the push button of release of the tool in its
select the drilling unit soft-keys place in the magazine (soft-keys 11 and 12, page
window 40)

Closing the drilling unit soft-keys Quit the softkeys window and come back to the exe-
window cution window.

Coming back to the C.N.C soft- Quit the execution window and come back to the
ware main window C.N.C software main window, in the lower R. H. cor-
ner there is the push-button “OFF”.

Switch OFF of the auxiliary cir- Switching OFF the auxiliary circuits the line pass to
cuits the stand-by mode.

OFF Start the line shut down The C.N.C shut down procedure starts; the C.N.C
asks the operator to put down in the tools magazine
the drilling tools present into the spindle; the opera-
tor presses “OK” and the C.N.C. asks for another
confirmation of the shut down.

OK + OK Shut down the C.N.C Wait until all the LED of the push-button panels are
switched off and the message displayed on the
screen gives the authorization to switch off the pow-
er.

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Programming and operating manual Model RAPID 25 T

Command Meaning Remark

Main switch Power off Anticlockwise rotate the main switch on the electrical
cabinet to switch off the power

ATTENTION: the installation of the operative system and of all software applications is car-
ried out in protect mode directly in FICEP and, normally, an unexpected volt-
age drop does not create problems.
Anyway, we suggest following the correct shut down procedure to avoid any
problem.

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APPENDIX A – DIAGNOSTIC

List of signals that are more frequent

Some Alarms (red messages) between the more frequent ones:

009 A value of the parameters or of the cycles has been modified by keyboard; it is necessary
switch off and switch on again the C.N.C
030:n "n" axis encoder signals alarm; lack of 24 V DC power supply of the encoder or encoder con-
nection interrupted or encoder damaged
037:n CAN Bus alarm of the “n” node; resynchronization required
038:n CAN Bus alarm of the “n” node; reset with “RESET” push button on the operator’s control panel
040:n "n" axis servo alarm; bar excessive weight for the X axis or axis driver damaged
046:n “n” axis not answering to the C.N.C.; check the “n” axis drive power supply
050:n lack of 24 V DC power supply on the “n” Output electronic board; burnt fuse or interrupted wire
070 Carriage telescopic collision
077:04 Thermal protections on
077:05 Minimum oil level
077:07 One of the emergency push-buttons pressed
077:41 Hydraulic power pack not ok
077:77 Oil temperature too high
080:00 Power circuits not activated; automatically cleared when auxiliary circuits are activated

Some Messages (yellow messages) between the more frequent ones:

010:n “n” axis minimum barrier; it is required a positioning to a coordinate lower than the minimum
possible (end of stroke)
013:n “n” selected program not OK
015 OK to zero cycle is missing; an axis is probably in an extra-stroke position
020:n “n” axis maximum barrier; it is required a positioning to a coordinate bigger than the maximum
possible (end of stroke)
023:n Timeout for service movement (n = cause, i.e. hold-downs not closed in the preset time)
034:n Timeout for marking operations (n = cause, i.e. end of work, character not possible, etc…)
036 Required update of machine setup; the operator has to set up the machine
038:n “n” pre-phase NOT OK during the zero cycle (n = number of the zero cycle operative phase)
104 System under TEST
115:n Bar wrong position while the pincher is clamping the material (n = possible matters, i.e. cycle
required with photocell engaged during bar length pick-up cycle)
118:n “Start cycle” command with pincher not OK (n = possible matters, i.e. pincher opened, pincher
lifted, etc…)
220:n Marking cycle not possible for barrier X/LP

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Some Errors (grey messages) between the more frequent ones:

012 Data not correct

013 Request of STAND-BY
036 Tool selection not OK
039 Tool not configured
067 Selection not possible
096 Canonic program cannot be executed with remaining bars (BR value) equal to zero
151 Nesting not OK
280 Profile already existing
281 Material already existing
340 Tool not found; the programmed tool is not present in the table

Service messages class 200 – Operator Messages

Message number Meaning
200.001 Min. lubricating grease level.
200.002 Air pressure insufficient; this message is displayed if the line is not under pressure
for more than five seconds.
200.003 Oil filter dirty.
200.004 Pincher lifting/lowering operation not allowed when pincher is closed; this message
is displayed if the operator tries to lift or lower the pincher when it is closed.
200.006 Carriage in loading area
200.007 Loading zone occupied
200.008 Rotating loading system in error; the rotation is not finished in the preset time
200.034 Stop of machine inlet coolant pump during drilling
200.036 Rotating loading system stops
200.046 Cycle start (CYS) when pincer opened
200.057 Bar length NOT OK
200.065 Saw cooling pump motor thermal protection operated (option)
200.081 Chips unloader emergency.
200.085 Thermal protections activated on electric motors of exit side table
200.091 Min. lubricating oil level
200.098 Remove pincher scrap from shear entry side (option)
200.101 Tool selected in V plane arrived at its max. working life (profile “A” side)
200.102 Tool selected in W plane arrived at its max. working life (profile “B” side)
200.111 Blade life is on pre-alarm limit (option)
200.112 Blade life is on alarm limit (option)
200.113 Carriage axis positioning required beyond barriers. (This positioning is not correct).
200.129 Outfeed table motor inverter not ok
200.136 Outfeed piece conveyor overloaded
200.137 Electrical cabinet air filter dirty; this message is displayed every 100 hours of work
200.138 Lubricate the system; this message is displayed every 60 hours of work
200.144 Disassemble the mobile upper blade and the fixed lower blades to allow the pinch-
er passing trough (option)
200.153 The selected tool has reached the max. limit of drill cooling
201.012 Drilling tool too long

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ATTACHMENT – OPTIONAL MARKING UNITS

The RAPID 25 T line can be equipped with one or more optional marking unit, the possibilities are:

- 38-positions disc marking unit; the “ADM” axis is added for the characters disc holder rotation
- marking unit with four or eight drawers, each one containing 13 maximum characters; the “AAH” axis
is added for the drawer selection
- scribing device with relevant tool for the drilling unit; this device allows also to trace the profile

Marking operations setup window

The following window is available only if the line is equipped with the drawers marking unit. In the follow-
ing picture the marking unit is with eight drawers. In this window the characters strings composed or to be
composed into the drawers has to be indicated if the content of the part program “Mark” field is not used.

To verify the real marking position, the operator can put the line in stand-by mode and then:

- press the nr.22 push-button of the C.N.C. auxiliary push-buttons panel (see on page 14) for the
disc marking unit
- put the selector switch 1 of the control panel placed near the marking unit with drawers in ON po-
sition (see following picture)

OFF 0 ON 0

1 2

After the test, the operator brings the marking unit in safety position by means of the same nr.22 push-
button for the disc marking unit and by means of the same selector switch 1 in OFF position for the units
with drawers. For this kind of unit, the selector switch 2 controls the drawers sliding for their fitting out;
aside the two selector switches an emergency push-button is available.

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Programming: marking operations

FICEP

Meaning of the fields and possible choices

FIELD CONTENT MEANING
TYPE MARK Marking
SIDE DB with optional disc mark- The disc marking unit is normally positioned to mark the B flange
ing unit

DA or DB with optional The marking unit with drawers is normally placed on the operator side to al-
marking unit with drawers, low a quick access to the drawers
depending on the assembly
side

DA or DB with optional scrib- The optional scribing tool is necessary

ing device

DETAILS A string with max 12 charac- The content of this field will be marked on the piece; otherwise, if the field is
ters or blank empty, the piece will be marked with the first twelve carachters of the “Mark”
field of the programming window.

Selecting “MARK” in the “TYPE” field, a window is displayed to insert the marking parameters and the
other field of the programming line.

01 10

02
03
04
05

06

07

08
09

FIELD MEANING

01 Marking X coordinate
02 Marking Y coordinate (gaugeline)
03 Marking angle according to the X axis. Not used with marking unit with drawers.
04 Marking string; if the field is empty, the C.N.C. uses the first twelve characters of the
“Mark” field of the programming window

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Model RAPID 25 T Programming and operating manual

FIELD MEANING

05 Marking type; the pull-down menu allows choosing between:

- Standard marking = Optional disc marking unit
- Marking with drawers = Optional marking unit with drawers
- Marking with scribing = Marking with the optional scribing device.
The scribing tool has to be inserted into the ToolF table.
The available types depend on the line configuration; other possible choices can not be
used.
06 Marking characters dimensions; to be defined only for marking with scribing tool.
07 Scribing tool diameter; use the push-button … to select the tool into the ToolF table.
08 Scribing tool tangential speed. The value is valid only for the current operation. If the field
is left empty, the value of the ToolF table will be used.
09 Characters depth for marking with scribing tool. This value must be negative.
10 Close the window and come back to the program.

Examples: Marking of the content of “Mark” field by the disc marking unit on the B flange (1) + marking of
“FICEP” string using the scribing tool (2).

1 2

To mark with disc or drawers marking unit, it is necessary to specify only the X coordinate because the Y
coordinate is manually adjusted and is valid for all marking operations of the same type.

LINE TYPE SIDE ANGLE X Y DETAILS

001 MARK DB 0 300
002 MARK DA/DB 0 700 100 FICEP

NOTE The values of X and Y coordinates are for example only.

FICEP S.p.A. 93
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Programming: tracing operations

If the line is equipped with the optional scribing device, it is also possible to realize tracing lines on the
profile.
The “LEAD” instruction is used to define the tracing starting point and the “CUT” instruction to define the
subsequent points; the scribing tool is identified with “POCKET_68”.
Press F4, as usual, to input the instructions.

Example: realization of a tracing of a 200 x 100 mm rectangle on a profile “A” side

LINE TYPE SIDE ANGLE X Y DETAILS

001 LEAD DA 0 300 50 POCKET_68
002 CUT DA 500 50
003 CUT DA 500 150
004 CUT DA 300 150
005 CUT DA 300 50

NOTE The values of X and Y coordinates are for example only.

300 200

100

50

The operator has to press “Enter” of the PC keyboard after having input the ““POCKET_68” tools code in-
to the “DETAILS” field keeping here the cursor. The following window opens:

The operator touches the … graphic push-button to select the scribing tool diameter into the ToolF table
and defines into the “Depth” field the tracing depth value. The value is negative. Example: -1.5 means
that the tracing will have a depth of 1.5 mm.

Tool diameter and tracing depth has to be specified for each “LEAD” instruction.

94 FICEP S.p.A.
Model RAPID 25 T Programming and operating manual

ATTACHMENT – OPTIONAL CUTTING UNITS

The RAPID 25 T line could be equipped with an optional cutting unit; the possible options are:

- single cut shear

- double cut shear
- disc sawing unit
- band sawing unit

Tables – Cutting unit Tab

The following window is available only if the line is equipped with a disc or a band sawing unit and allows
defining the blades to be used.

01 10
02
03
04
05
09

08

06 07

FIELD MEANING

01 Minimum thickness of the material that can be cut with the selected blade
02 Maximum thickness of the material that can be cut with the selected blade
03 Material that can be cut with the selected blade
04 Blade rotation optimum speed, it can be assumed from the supplier’s data
05 Optimum speed of blade forward when enters into the material, it can be assumed from
the supplier’s data
06 To delete the selected blade
07 To insert a new blade
08 To modify the selected blade
09 List of all available blades
10 To close the window and return to the “Execution” window

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Programming and operating manual Model RAPID 25 T

The following window is available only if the line is equipped with a shear cutting unit and allows defining
the material deformation data which is caused by shearing.

12

02
03
04
05
06
01
07
08

09 10 11

Fields description

Number Function
01 List of lengthening data sets stored into the table
02 Material minimum thickness which the lengthening data set refers to
03 Material maximum thickness which the lengthening data set refers to
04 Not used; this value is always 0
05 Not used; this value is always 0
06 Material type which the lengthening data set refers to
07 Lengthening of the material remaining before the shear (see following picture)
08 Lengthening of the cut material after the shear (see following picture)
09 Deletion of a lengthening data set
10 Insertion of a new lengthening data set
11 Modification of a lengthening data set
12 Exit from “Tables” window and come back to “Execution” window

07
08

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Model RAPID 25 T Programming and operating manual

Setup – Saw Tab

The following window is available only if the line is equipped with a disc or a band sawing unit and allows
displaying the life parameters of the band used at the moment.

13
01
08 09
02

03
10
04
05
11
06
07

12

Number Function
01 Blade rotation speed; the C.N.C. automatically picks up this value from the sawing unit
table. The operator can modify it for the cut in progress without modify the table original
data.
02 As per field 01 but for the band forward speed.
03 Display of the full working time of the band.
04 Display of the remaining working time of the band.
05 Maximum lifetime of the band: after this time, the band replacement is required.
06 Percentage threshold of the band life: when the band reaches this value, the C.N.C
software generates a message for the operator to advice that the band has to be re-
placed soon.
07 Material section that the band has to cut at reduced speed during the first phase of band
use.
08 Percent decrease by steps of 5% of the band rotation speed.
09 Percent increase by steps of 5% of the band rotation speed.
10 Display of the actual value of band rotation speed.
11 When this push-button is pressed, the timers are reset and the last set value is input in-
to the field nr 05
12 To make modifications and confirm them.
13 To exit from the “Saw” tab and return to the “Execution” window.

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Programming and operating manual Model RAPID 25 T

Bar nesting

If the line is equipped with an optional cutting unit (of any type), it could produce many pieces cutting long
bars of material.
The operator, after he has edited the programs for single pieces, can “insert” them into bars of material by
pressing the push-button “NESTING” in the general programming window.
When the operator presses the push-button “NESTING” the C.N.C software chooses all pieces to be real-
ized with the same material and the same profile. If the operator would like to nest only some particular
pieces, he can filter the listed pieces choosing the needed criteria.

Generally, four “zones” are defined in a single bar:

- zone n. 1: starting scrap to eliminate initial defects of the bar

- zone n. 2: material to be used to make pieces
- zone n. 3: material not usable of the bar (its length is shorter than the smaller piece to nest)
- zone n. 4: pincher scrap; this is the clamping zone of the pincher

A A A A B B

1 2 3 4

Position of zone n. 3 (material not usable) and type of pieces to be nested in a bar could be automatically
decided by the C.N.C software or manually realized/modified by the operator.
To start the nesting operations select the pieces to be nested in the pieces listed in the general program-
ming window and press the “NESTING” push-button.
The following window will be displayed; in the lower part all pieces with same profile and same material,
that is to say that can be nested, are listed.

02

01

03 04 05 06 07 08

09 10 11 12 29
13
15 16 17 18

14

19

20 21 22 23 24 25 26 27 28

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Model RAPID 25 T Programming and operating manual

Reference Meaning
01 Graphic information of the selected profile
02 Drawing not in scale of the nesting carried out
03 Measuring unit
04 Selected nesting type (see execution parameters)
05 Pincher scrap (zone nr. 4 of the nesting)
06 If in the “Parameters” window “Pincher scrap” is selected, this field contains the total
scrap (zone n. 3 + zone n. 1 of the nesting)
If in the “Parameters” window “Leading edge scrap” is selected, this field contains
the total length of the nesting (zone n. 2 of the nesting)
07 If in the “Parameters” window “Pincher scrap” is selected, this field contains the total
length of the nesting (zone n. 2 of the nesting)
If in the “Parameters” window “Leading edge scrap” is selected, this field contains
the total scrap (zone n. 3 + zone n. 1 of the nesting)
08 Possible initial cut of the bar to get perfect initial squaring (zone n. 1 of the nesting)
09 Type of material of the nesting in progress
10 Type of profile of the nesting in progress
11 Length of the bar of the nesting in progress
12 Number of bars for the nesting in progress as described in zone n. 14 (calculated by
the C.N.C.)
13 Signal area of the sorting criteria of the pieces to be nested
14 Nesting in progress
15 Remaining pieces to be processed (this field is only displayed and is updated during
the execution)
16 Remaining pieces to be nested into extra bars similar to the one in the zone 14
which includes the number of pieces specified in the field 17
17 Number of the pieces nested in a single bar of the nesting in progress
18 Initial quantity of the pieces to be processed
19 List of the pieces to be nested with relative quantities
20 Not used on a RAPID 25 T line
21 Push-button to choose the execution parameters (see next window “execution pa-
rameters”)
22 Push-button to execute the nesting displayed in the zone n. 14
23 Push-button to delete a row in the zones n. 14 or 19
24 Push-button to save the nested bars into the bars list (see next window “bars list”)
25 Push-button to get the automatic nesting; pressing this push-button the system
doesn’t calculate the number of needed bars and the quantity is set to 9999; during
the execution, the C.N.C software calculates the needed bars according to the real
measured length of the bars
26 Push-button to open the “Ordering” window where the operator can decide the crite-
rion to order the pieces to be nested (for instance increasing or decreasing order for
length, mark, contract, etc…)
27 Push-button to get the Nesting of the pieces selected in the zone n. 19
28 Push-button to rotate the pieces
29 Signal box for the scrap percentage; green background: OK, red background: ex-
cessive scrap. To define the threshold limit see the paragraph “Execution parame-
ters” page 105

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Programming and operating manual Model RAPID 25 T

Basic procedure for nesting execution

Command Meaning Remark

Start condition Bar nesting window displayed with the list of the piec-
es to be nested listed in the zone n. 19. Otherwise,
press “ESC” to return to the programming general
window and select the pieces to nest.

Parameters Verify/modify the nesting execu- The window with execution parameters is displayed;
tion parameters the operator must change the desired values. To fin-
ish the operator must press the “F2” key of PC key-
board or the graphic push-button “Confirm” on the
screen. If no modification is required, the operator
can press “ESC” to close the window.
To know the meaning of each execution parameter
refer to next paragraph “Execution parameters” page
105.

Input a value in field n. 11 Set the bars length to be processed.

OK The system requires the authorization to nest pieces

with quantity different from zero

OK Press the “OK” graphic push- The quantities “QTA” in the zone n. 19 decrease as
button in the subsequent window the pieces are nested in the zone n. 14 in one or
to continue more line.
Note In case of contradiction or programming errors,
the nesting is not executed and the line number
of the piece selected in the zone n. 19 becomes
red; the operator must remove the fault and re-
start the nesting procedure.
Be sure that the nesting operation does not
need more tools than the line can use and/or to
eliminate the errors of the part program.

Save Save the realized nesting A window will be displayed with the number of re-
quired bars for this nesting; it is necessary to confirm
pressing the “OK” push-button, reject pressing the
“Cancel” push-button or decrease the number of bars
if the total quantity is not in stock.

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Model RAPID 25 T Programming and operating manual

Command Meaning Remark

If needed, the operator can define When the zone n. 19 is empty all pieces are “ar-
a new length for the bars in the ranged” in bars of material; the operator can close the
field 11 and press the “OK” push- nesting windows pressing “ESC” of the PC keyboard
button (n. 27) to re-execute the to come back to general programming window..
nesting procedure for the remain-
ing pieces until zone n. 19 is emp-
ty.

Bars list Check of the programmed bars As soon as the nesting is completed, it could be
list checked and/or executed from the windows displayed
pressing the “BARS LIST” graphic push-button in the
general programming window.

Changes to the basic nesting procedure: how to use the push-button “Rotation”

According to the selection made, the nesting of the part in rotated position is obtained:

NOT USABLE

NOT USABLE

The longitudinal rotation creates part as per the original and could be set only for profile with
equal flanges.
The longitudinal rotation is useful only to mark the flange which otherwise can not be marked
(the one opposite to the marking unit installation side).

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Programming and operating manual Model RAPID 25 T

Nesting example of a part without rotation and with longitudinal rotation

150 A
80 Original part to be
nested in a bar (the
40 holes pitch is 20
mm)
150 B

150
600
850
Nesting without rota-
tion

A A
80

40

B B

150 150
600 600

Nesting with longitudinal ro-

tation

A A
40

80
B B

210 210
700 700

Changes to the basic nesting procedure: manual nesting

The operator can carry out a manual nesting procedure fixing quantity, position and possible rotation for
each type of piece.

Command Meaning Remark

Start condition Bar nesting window displayed with the list of the piec-
es to be nested in the zone n. 19. Otherwise, press
“ESC” to return to the programming general window
and select the pieces to nest.

A cell n. 17 (quantity) in the The operator selects the “QTA” quantity field of the
zone n. 19 (pieces to nest) is first piece he wants to nest.
in blue colour

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Model RAPID 25 T Programming and operating manual

Command Meaning Remark

Optional

Rotation
If needed, the operator presses the push-button “Ro-
tation” and decides the rotation of the chosen piece.
This setup is valid for all pieces of the same type in-
serted in the bar. The rotated piece is marked by
green line number.

By the PC keyboard, the operator inserts the number

of pieces to be nested in the bar shown in the zone
n.2 and confirms pressing the “Enter” push-button.
The value of cell n. 17 (quantity) in the zone n. 14
(pieces arranged in the bar) is increased of the num-
ber of inserted pieces and, at the same time, the
drawing in the zone n. 2 is updated.

Select a cell n. 17 (quantity) in The operator continues to select and nest the pieces
the zone n. 19 (pieces to until the bar surplus is less than the smallest piece to
nest) be nested or until the pieces are finished.

Save
Press the “Save” graphic When a bar is completed, the operator can press the
push-button “Save” push-button so the system displays the re-
quired number of bars and the operator must confirm
pressing the “OK” push-button.
If some pieces remain to be nested, the operator can
start a new manual nesting. In this case, quantities
and drawing are cleared and the nesting operations
continue until the pieces to be nested are finished.

Bars list
Check the bars list As soon as the nesting is completed, it could be
checked and/or executed from the windows displayed
pressing the “BARS LIST” graphic push-button in the
general programming window.

Changes to the basic nesting procedure: automatic nesting

If the operator wants to use bars having different lengths for the same nesting, he has to realize the nest-
ing in automatic mode. In this case, the C.N.C software cannot predetermine the number of the needed
bars and leaves it at the maximum (9999): the production ends when the pieces quantity to be produced
is finished.
In the “Bars list” window, all automatic nestings are marked by a star on the R. H. side.
To perform an automatic nesting, it is sufficient to press the push-button “Automatic” in the nesting win-
dow and confirm the number of bars “9999”. Save in the bars list is automatic and it is not necessary to
press the “Save” push-button.
When an automatic nesting is performed neither quantities in the zones n. 14 and n. 19
nor the drawing in the zone n. 2 are updated.

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Programming and operating manual Model RAPID 25 T

Bars list
When it is necessary to process the nested bar, it is sufficient to press the “Esc” push-button to close the
nesting window, to come back to general programming window (parts list) and, then, press the “Bars list”
push-button. The window with the list of bars to be processed is displayed.

01

02
03

06 07

05

04

08

09 10 11 12 13

Reference Meaning
01 Drawing not in scale of the nesting selected in the zone n. 05
02 Pressing this push-button, a window opens where some general information about the
nesting selected in the zone n. 05: profile type, contract data, and required tools, etc
are displayed.
03 Display of the nesting type:
- True cuts
- Simulated cuts
This selection is performed in the “Execution parameters” window (see page 105)
04 Graphic information on the selected profile
05 Nesting list.
06 Number of the total required bars per each nesting
07 Number of the remaining bars per each nesting
08 Push-button to open the softkeys windows for line adjustment and management of
some devices (see on page 40)
09 Not used
10 Push-button to execute the selected nesting
11 Push-button to open a window where the operator can delete the selected nesting or all
the nesting of the list; there is also the possibility to select to delete automatically a
nesting when remaining bars are ended.
12 Push-button to open the nesting window for the selected nesting (to display the pieces
nested)
13 Push-button to modify the bar quantity after having insert the password.

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Model RAPID 25 T Programming and operating manual

Execution parameters for nesting

Pressing the push-button n. 21 of the nesting window (see page 98) a window is displayed where the op-
erator can set some parameters used by the C.N.C software during the nesting.

01 08
09 18
10
11
12
13
02 14

03

04

05
06

07
17 15

16

Reference Meaning
01 Select the type of nesting:
- True cuts: when the nesting is processed the line really cuts the material
- Simulated cuts: when the nesting is processed the line doesn’t cut the material;
so it is possible to execute all the other operations and cut the bars in a second
time or by means of other machines
- Other possible choices: not used
02 Select the position for material surplus; available options:
- surplus at the start of the profile (leading edge scrap)
- surplus at the end of the profile (pincher scrap)
03 See Execution parameters for “cut-to-lenght” pieces, on page 65
04 See Execution parameters for “cut-to-lenght” pieces, on page 65
05 See Execution parameters for “cut-to-lenght” pieces, on page 65
06 See Execution parameters for “cut-to-lenght” pieces, on page 65
07 See Execution parameters for “cut-to-lenght” pieces, on page 65
08 Length threshold of the pincher scrap:
- if it is shorter than this value the machine unload the material
- if it is longer than this value the C.N.C ask the operator to confirm the unloading
operation (pressing the “CONT” push-button of the auxiliary push-button panel
the operator confirms the operation, pressing the “RESET” push-button the op-
erator reject to use the surplus as a new bar for another automatic nesting)

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Programming and operating manual Model RAPID 25 T

Reference Meaning
09 Like parameter n. 08 but in percentage of the bar length; it could be used to evalu-
ate the quality of a nesting; if the scrap percentage is bigger than this value the sig-
nal box n. 29 in the nesting window becomes red.
Note: 100% = surplus control disabled
10 Not used
11 Leading edge scrap: this material will be cut to face the profile (standard 30 mm).
12 Cut scrap: Material which is lost due to the cutting unit tool thickness (for single cut
shear it is usually 0,00; for double cut shear it is the distance between the two
blades; for the disc or band saw it is the blade thickness)
13 Pincher scrap: Material which can not be processed due to the pincher dimensions
(standard 50 mm)
14 Not used
15 See Execution parameters for “cut-to-lenght” pieces, on page 65
16 See Execution parameters for “cut-to-lenght” pieces, on page 65
17 See Execution parameters for “cut-to-lenght” pieces, on page 65
18 Close the window and return to the nesting one

Procedure to execute a program of a nesting

Command Meaning Remark

Start condition Line powered, axes zero cycle performed, auxiliary cir-
cuits ON (oil pump, etc…), no active alarm, main page of
C.N.C software displayed, nesting program already edit-
ed and ready to execute.

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Model RAPID 25 T Programming and operating manual

Command Meaning Remark

Programming Programming window In this window the part program of the programmed
displayed pieces are listed.

Selection of the nest- By means of the arrow keys, select in the list the nesting
Bars list
ing to process to process. The selected one is highlighted by a line with
blue background

Start the execution of A window with confirmation request is displayed. It is

Execute
the selected nesting necessary to confirm pressing “OK” or to abort pressing
“Cancel”.

Return to the parts list The canonic program has been correctly generated.
If an error occurs (for instance, the program needs a tool
not present in the tool tables, programming errors, etc.)
an error message is displayed. Press again the “Exe-
cute” push-button after having removed the problem.

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Programming and operating manual Model RAPID 25 T

Command Meaning Remark

To supervise the exe- The Execution window is displayed; the operator can
cution of the program read dynamic information.

+
Execution

Selection of automatic Choice of required automatic cycle (continuous or step

cycle by step)

Start The execution of the program is started. If the line setup

is suitable to the required one, the pincher moves to
clamp the material, the LED into START push-button is
ON and the coordinates change dynamically: the line is
working.
If the line setup is not the one required, the C.N.C stops
the execution after few seconds and automatically dis-
plays the setup window. In this page, correct tools have
green background while incorrect tools have a red one.

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Model RAPID 25 T Programming and operating manual

Command Meaning Remark

Setup mode to fit the The operator must switch the line in setup mode rotating
line on the left the key selector in the control and safety
push-button panel and pulling out the key to avoid any
control by third person.

Machine fitting The operator executes all fitting operations requested

checking carefully that type and position of all fitted tools
are exactly the ones requested from the C.N.C.
At the end of operations, the operator confirms pressing
“OK”.

Restart The operator inserts the key into the selector and
switches the machine in working mode.

RESET
Alarms reset The operator resets the system pressing the push-button
to clear the alarm of protecting barriers interruption (if
provided).

The operator starts again the execution of the automatic

cycle; the pincher moves to clamp the material, the LED
into START push-button is ON and the coordinates
change dynamically: the line is working.

FICEP S.p.A. 109