KCAM4
CNC CONTROL SOFTWARE
USERMANUAL
Revision4.0.25
Introduction
Thank you for choosing KCam. KCam is designed to make your CNC experience simple and enjoyable. A wide variety of features are available to perform functions typically only found in more expensive CNC packages. Typical CNC applications for KCam include Routing, Signage, 3D Milling, PCB Milling and Drilling, and Plasma Cutting. KCam is designed to read files created by your design applications and control the CNC equipment attached to your PC Printerport.
Features
File formats supported: GCode, DXF, HPGL, Excellon, Gerber Parallel Port motor controlleraccess
Serial Port motor controller access( MaxStepper hardwareonly) 2D and 3D graphical plots ofdata
Gcode data entry Gcode dataconversions
Gcode macro sub programs Manual jogging controls Keyboard jogging controls Manual gcodeinput
Estimated CNC processingcalculation Tool position statusindicators
Dual cutting depths for signengraving Multiple motor enablingoptions
PCB Isolation Plots fromGerber(RS274X)
Quick Start withKCam
There are 4 steps to setting up your CNC table for use with KCam. Step 1 allocates a filefor KCam to store your custom parameters. Step 2 includes entering in your machine axis parameters in the Table Setup window. Step 3 includes entering your communication port information in the Port Setup window. Step 4 is determining the timing parameters using the System Timingwindow.
Step 1 Create a New Machine Setup Select the Machine drop down menu Select Create New MachineSetup
Select a folder on your hard drive to store your machine setups Enter a name for your CNC machine setup in the File Name box Select the Savebutton
Step 2 Table Setup window
Select the Units of Measurement you use (Metric orImperial). Select the Numerical Format (ex.000.0000).
Enter the Steps per in for each Axis (ex 4000IPM). Enter the Lengths for each Axis (ex. 10Inches).
Enter the Backlash distance(ex. .0125 Inches) for each axis(optional). Enter the Feed Rates. (Traveling, Cutting andJogging).
Enter a Travel Depth for the Z Axis(ex. 0.50 for 2D DXF and HPGLimporting).
Enter a Normal Cut Depth for the Z Axis(ex. 0.125 for 2D DXF and HPGLimporting). Enter a Deep Cut Depth for the Z Axis(ex. 0.00 for 2D DXF and HPGLimporting).
Select Backlash to True if the Backlash distances areknown(optional). Select Ramping to True if you wish Ramp Up/Down function to occur. Enter a Ramp Start IPM (5recommended).
Select a Ramp Rate (50 recommended). Enter the Maximum Feed Rates for eachaxis. Select the OKbutton.
Step 3 Port Setup window
Select the Port I/O ControlsTab.
Select Port Type (LPT or Serial Port) depending on your controllertype.
Select Parallel Port I/O DLL (InpOut32 or DLPort) depending on your Operating System. Select the Applybutton.
Select the LPT Setup Tab. Select the Pin Setupoption.
Select the Pin Address(typically &H378 for LPT1).
Enter the Output Pins associated with your motor controller stepfunctions.
Invert each Pin as necessary to acquire the desired normal state when not moving an axis.
Enter the Input Pins associated with your limitswitches.
Invert each Pin as necessary to acquire the desired normal state when Limit/E-Stop switches are notengaged.
Select the OKbutton.
Step 4 System Timing window Select the StartButton.
Wait until the timing is complete and selectOK.
Press the Esc key on the keyboard if the process takes longer than 2minutes.
Open the CNC Controls window and select the Manual tab. You can test the motors by using the Jog Arrowbuttons.
Pull downMenus
File
Edit View
New Gcode file Open Gcode file Save Gcode file Import
DXF HPGL
Excellon Gerber
Export
DXF HPGL
Recent File List Print
Exit
Find Replace
Plot(F4) Gcode(F5) CNC Controls(F6) Parallel I/O Display Save FormView
Load Default FormPositions
MachineSetups
Create New Machine Setup Load MachineSetup
Setup
Options
System Timing Table Setup Port Setup Macro Files Tool List EventSounds
Functions
Scale Gcode Offset Gcode Convert toAbsolute
Convert to Incremental Window
WindowList
Help
File
HelpContents About
New GcodeFile
Erases current GCode data in the GCode window. A message box window will appear to confirm your intentions to erase all the current data loaded in KCam’s Gcode window. This function will only erase data in memory, not any data stored in gcode file on the storage media.
Open GcodeFile
Opens an ASCII file which contain G and M codes. A browsing window will appear to enter the file name andlocation.
Save GcodeFile
Saves the current GCode data in the editor window to an ASCII file. A browsing window will appear to enter the file name andlocation.
Import
Import DXFfile
Imports a DXF ASCII file using the R12 format from AutoCAD. A browsing window will appear to enter the file name and location. See Supported DXF Formats for further DXF importinformation
ImportHPGL
Imports a HPGL ASCII file. A HPGL ASCII file contains 2D plotting data. A browsing window will appear to enter the file name andlocation.
ImportExcellon
Imports an Excellon ASCII drill file. Excellon ASCII drill files contain data for drilling holes in printed circuit boards. Excellon ASCII files contain drill hole location and bit sizes. A browsing window will appear to enter the file name and location. Some programs do not add the Drill Size header. If your files are missing the header, check for options to add it in your CAD software. Below is a sample file with the header and drill positioncoordinates:
M48 INCH,LZ
T01F00S00C0.125 [drill size header for tool 1, bit size=.125] T02F00S00C0.028 [drill size header for tool 2,bitsize=.028]T03F00S00C0.035 [drill size header for tool 3,bitsize=.035]T04F00S00C0.042 [drill size header for tool 4, bitsize=.042]
% G90
T01 [select drillsize1(.125)]X+03851Y+04226 [move to coordinate X,Y and drill] X+03851Y+01163 [move to coordinate X,Y and drill] T02 [select drillsize2(.028)]X+02456Y+03415 [move to coordinate X,Y and drill] X+02556Y+03415 [move to coordinate X,Y and drill] T03[select drillsize3(.035)]X+03469Y+02238 [move to coordinate X,Y and drill] X+03569Y+02238 [move to coordinate X,Y and drill] T04 [select drillsize4(.042)]X+03171Y+01538 [move to coordinate X,Y and drill] X+03371Y+01538 [move to coordinate X,Y and drill] T00
M30
ImportGerber
Imports a Gerber ASCII file. An Isolation Plot will be created if the Isolation option isChecked in Options(Gerber Tab). A Gerber ASCII file contains 2D plotting data. A browsing window will appear to enter the file name and location. If the file contains more than one layer, a layer selection window will appear. In that window you can select which layers you want to import.
See GerberOptions
Note: The Gerber Import function only works with Gerber(RS274X) single layer files. A Gerber(RS274X) file has the aperture list in the file included with the line data. If a file is imported without a correct aperture list the resultant gcode data will not becorrect.
Note: For trial purposes the Gerber entities will be limited to 100. Pleasesenduscomments and suggestions pertaining to the isolation importprocess.
Known Issues with IsolationImports:
When a corner or side of a polygon is inside two or more other polygons, extra cutlines areproduced.
Speed, the isolation import function is slow. The number of calculations are exponential with polygoncount.
When two intersecting lines have the same slope, extra cutting lines areproduced.
Export
Export DXFfile
Exports a DXF ASCII file from the data in the GCode editor. The exported DXF file format will be AutoCAD R12. A browsing window will appear to enter the file name and location. Line and arc elements in the DXF file will be represented by line segments. See Supported DXF Formats for further DXF Exportinformation
Export HPGLfile
Exports a HPGL ASCII file from the data in the GCode editor. A browsing window will appear to enter the file name andlocation.
Recent FileList
The Recent File List is located in the File pull down menu. Files which have been opened before can be quickly accessed by selecting them in the Recent FileList.
Prints the currentwindow.
Note: Currently only the Plot and Gcode windows aresupported.
Exit
ExitsKCam.
EDIT
Find
Finds a text string in the Gcode Editorwindow.
Replace
Replaces text strings in the Gcode Editorwindow.
VIEW
Plot
This function opens the Plot Window for viewing ourgcode
The Plot window has additional buttons for changing the viewpoint of your graphicalplot.
The Zoom Tools allow changes to the way the plot is displayed. The button functionsare
Zoom In, Zoom Out, Zoom Window, Zoom Table, Zoom All, Pan, RefreshPlot.
The Zoom In tool will decrease the view point distance from the plot. To use it, select the function button and click the mouse on a desired point in the plot window. The area of interest will appear larger in the plot window and show a smaller area of thetable.
The Zoom Out tool will increase the view point distance from the plot. To use it, select the function button. The plot elements will appear smaller in the plot window and show a wider view of elements and thetable.
The Zoom Window tool will allow exact selection of the area of interest to be displayed in the plot window. To use it, select the function button and draw a rectangle on the plot window over the area of interest. The plot window will zoom in to the area youselected.
The Zoom Table tool will force the zoom level to show the whole table dimensions. To use it, select the function button. The plot display will be adjusted to show the wholetable.
The Zoom All tool will adjust the zoom level so the plot window shows all the elements. To use it, select the function. The plot display will adjust its zoom level to the extents of all the elements.
The Pan tool allows sliding the view point on the X and Y axis. To use it, select thefunction and click on the center of the area of interest in the plot window. The plot will be adjusted so that the location selected will now be in the center of the plotwindow.
The Refresh Plot tool will erase and draw all the elements back onto the plot window. To use it, select the function button. The plot window display will berefreshed.
The 3D Viewpoint Tools allow the plot view to be displayed in a 3 dimensional fashion. The button functions are Top View, Bottom View, Front View, Rear View, Left SideView, Right Side View, Isometric Right View, Isometric Left View. There are also 3 rotational parameters that can be adjusted by using the associated up/down buttons. These will change to 3D viewaxis’.
GCode Highlighting
Another feature of the Plot window is the GCode Highlight If no zoom functions are selected and the plot viewpoint is in Top View mode, a line may be drawn using the mouse that intersects one plot line or arc. This will line will tell KCam which element you are interested in and KCam will highlight the GCode in the Gcode window thatcorresponds with the intersected element. Conversely, you can double click on GCode in the GCode window to highlight the corresponding plotelement.
Gcode
This function opens the Gcode Editor window. The Gcode Editor window allows viewing and editing of the gcode data. The text window operates similar to a normal windows text editor. Functions like Cut, Paste, Find and Replace work in the text box. As described in the Plot section, double clicking on Gcode in the Gcode Editor window will enable the highlighting function in the Plot window. The line or arc element corresponding the selected code will be shown in a different color(black).
Find Function
This function will open a text search box to allow searching through the Gcode for similar text
Reset to Beginning of Gcode
This function resets the Graphic Test Pointer to the beginning of the Gcode.
Advance to Next Gcode
This function advances the Graphic Test pointer to the next Gcode line and plots the associated Gcode.
Feed Rates
These entry boxes allow feed rates tobe adjusted prior to compiling theGcode.
Remove Nxx
This function removes line numbersfrom all of the Gcode lines in the Gcode text box.
Add Nxx
This function adds line numbers to allof the Gcode lines in the Gcode textbox.
Compile
This function Compiles all of the Gcode lines in the Gcode text box. This needs to be done prior to scaling, plotting or executing the Gcode.
Decimal Format
This function formats all of the Gcodedata
in the Gcode text box to conform with the decimal format parameter. The decimal format parameter can be modified in the Table Setupwindow.
Cnvrt Metric
This function converts all of the Gcode data in the Gcode text box to Metric data by multiplying the data with the metric scale parameter. The metric scale parameters can be modified in the Optionswindow.
Cnvrt Imperial
This function converts all of the Gcode data in the Gcode text box to Imperial data by multiplying the data with the imperial scale parameter. The imperial scale parameters can be modified in the Optionswindow.
CNCControl
This function opens the CNC Control window. The CNC control window allows manual and automatic motion control for your axis along with specific information about motion characteristics.
CNC CONTROLS WINDOW – MANUAL TAB
Arrow buttons
The Arrow buttons will move the Axiswhen pressed. If the Single Step button is engaged, the moves will continue for a distance equal to the distancebox.
Single Step button
When the Single Step button is engaged, the Arrow button movements will continue forthe distance specified. The distance is specified in the Distance Entrybox.
Distance Entry combo box
The distance entered in this box is used for Single Step moves. You can use the predetermined numbers or type in yourown.
Move to Home button
When the Move to Home button is pressed, the CNC tool will move to the Home position for all axis .The Home position is specified in the Table Setup window. If the Home position entry boxes are blank, those axiswill not move from their currentposition.
Move to Re-Tool button
When the Move to Re-Tool button ispressed, the CNC tool will move to the Re-Tool position for all axis. The Re-Tool position is specified in the Table Setup window. If the Re-Tool position entry boxes are blank,those axis will not move from their currentposition.
Keyboard Jog button
The Keyboard Jog button will open the Keyboard Jog window. When theKeyboard
Jog window is open, the arrow keys allow jog movements while those keys aredepressed. See the Keyboard Jog window for moredetails.
Goto button
When the Goto button is pressed, the Gcode data in the Goto Data Entry box willbe immediatelyprocessed.
Goto Data Entry box
The Goto Data Entry box is used for entering Gcode commands to be performed whenthe Goto button is pressed. Only single line commands are allowed to beentered.
Feed box
The Feed Rate box displays the feed rate the motors are moving at. This value is calculated from the timing signals sent out theports.
Override box
The Throttle Override box adjusts the feed rate the motors are moving at in real time. This can be used to slow down cutting feed rates during anoperation.
Auto Tune button
The Auto tune button performs "on the fly" System Time Constant adjustments for parallel port users. It should only be used when the tool is not cutting material. Make sure it is not engaged while cutting materials or motor positions may be compromised. After use the axis positions should be Zeroed foraccuracy.
Motor Enable button
The Motor Enable button is a software E-Stop. It will halt all movements immediatly.
E-Sto Switch
The E-Stop Switch indicator displays the current status of the external E-Stop input.
CNC CONTROLS WINDOW – AUTOTAB
StartingStep
This is the first Gcode line that will be executed when the automatic process isstarted.
Ending Step
This is the last Gcode line that will be executed when the automatic process isrunning.
CNC Start Process
This buttons starts the automaticCNC process.
CNC Pause Process
This buttons pauses the automatic CNC process.
CNC Step Process
This buttons steps the automatic CNC process after apause.
CNC Stop Process
This buttons stops and resets theautomatic CNCprocess.
CNC Process Status Box
This indicates the current CNCprocess.
AUTORETOOL
This buttons pauses the automaticCNC process and moves the axis to the ReTool position.
Step Status
This displays the current step number tobe executed.
Step Gcode
This displays the current step Gcode to beexecuted.
Spindle Status
This displays the current Spindlestate.
EnableTMR
This displays the motor enable timervalues.
Feed Ratebox
The Feed Rate box displays the feed rate the motors are moving at. This value is calculated from the timing signals sent out theports.
Auto Tune button
The Auto tune button performs "on the fly" System Time Constant adjustments. It should only be used when the tool is not cutting material. Make sure it is not engaged while cutting materials or motor positions may be compromised. After use the axis positions should be Zeroed foraccuracy.
Motor Enable button
The Motor Enable button is a software E-Stop. It will halt all movementsimmediately.
E-Stop Switch
The E-Stop Switch indicator displaysthe current status of the external E-Stopinput.
CNC CONTROLS WINDOW – TIMING TAB
Get Time Constant button
This function determines the necessary time constant for the current feedrate.
Time Constant box
This displays the current Time Constant. Clicking on this box allows manualchanging of the TimeConstant.
Time Constant +/-buttons
Clicking on these buttons increments or decrements the TimeConstant.
Feed Rate box
The Feed Rate box displays the feed ratethe motors are moving at. This value is calculated from the timing signals sent out theports.
Auto Tune button
The Auto tune button performs "on the fly" System Time Constant adjustments. It should only be used when the tool is not cutting material. Make sure it is not engaged while cutting materials or motor positions may be compromised. After use the axis positions should be Zeroed foraccuracy.
Motor Enable button
The Motor Enable button is a software E-Stop. It will halt all movementsimmediately.
E-Stop Switch
The E-Stop Switch indicator displaysthe current status of the external E-Stopinput.
CNC CONTROLS WINDOW –PROCESS STATUS TAB
Timer
This displays the current process timervalue. The process time value is reset when the CNC Process isstarted.
Estimated Material Process Time
This displays the estimated process completion time for the current Gcode. The estimated time is calculated during a plot redraw.
Feed Rate box
The Feed Rate box displays the feed ratethe motors are moving at. This value is calculated from the timing signals sent out theports.
Auto Tune button
The Auto tune button performs "on the fly" System Time Constant adjustments. It should only be used when the tool is not cutting material. Make sure it is not engaged while cutting materials or motor positions may be compromised. After use the axis positions should be Zeroed foraccuracy.
Motor Enable button
The Motor Enable button is a softwareE- Stop. It will halt all movementsimmediately.
E-Stop Switch
The E-Stop Switch indicator displaysthe current status of the external E-Stopinput.
Keyboard Jog Window
While this window is open, arrow key presses will move the axis. The Axis will only move while the keys are depressed. When the keys are released the axis will stop immediately.
Parallel I/O Display
This function opens the Parallel I/O Display window. The Parallel I/O Display shows the current logic states of the parallel port pins. This function may be helpful when diagnosing I/O problems.
Save Form View
This function saves the current Plot, Gcode and CNC Controls window size and positions. When KCam is started again, the forms will be loaded at the save size andposition.
Load Default FormPositions
This function loads the default form size and positions. This may be useful if a form is positioned out of reach after a screen resolutionchange.
MACHINE SETUPS
Create New MachineSetup
This function saves the machine setup to a storage file for later use.
Load MachineSetup
This function loads a saved machine setup file.
Machine Setupdefinition:
Machine setup files are the parameter files for different machines. An unlimited number of Machine setups can be stored and reloaded. All parameter information like Table Setup, Port Setup, Options, and Tool Lists are stored in the machine setup ASCII file. An example use would be to store parameters for two different CNC machines. Another use would be to store different parameters for different uses on the same machine, like drilling and routingPCB's.
Setup
Options
Options Generaltab
Arc Resolution
The number of individual lines in a 360 degree arc. A higher number yields an arc or circle with a smoother edge butslower plotupdates.
Force Plot Bit Radius
When checked the radius of plot lines will be forced to Bit radius (below) regardless of the Tool size currently selected in the GCode. If unchecked the GCode and the Tool Size setup will determine the plot radius of cutting lines in the Plotwindow..
Bit Radius
The width of the default tool bit. This is used in displaying line width on the Plot window. If tool bits are specified in the Tool List window and tool commands are used in Gcode, this default value is not used unless the Force Plot Bit Radius(above) isselected.
Plot Fast Draw
When checked, the Plot window data is drawn quickly. If Unchecked, the tool path can be viewed more easily as the data is slowlyredrawn.
Plot after Load/Import
When checked, the Plot window data is drawn following a Load, Import, or processfunction. If Unchecked, the tool path will not be plotted automatically. This setting is useful for very large programs where plotting time can be anissue.
Execute Dwells
When checked, the Plot window redraw functions will execute dwell commands. This function should be left unchecked except when verifying dwell times for plasma cuttingor similarapplications.
Plot Table Grid
When checked, the Plot window will show the CNC table in the form of a grid. When unchecked the Plot window will only show the GCode plot lines. The Z axis display is also effected by thissetting.
Display Line Nodes
When checked, the Plot window data will show small circles at the end of each line. This is designed for diagnostic purposes where adjoining lines must be detected. Normally this should remain unchecked for plot speedpurposes.
Def. X Offset
The default axis offset value used when the Offset Gcode function isperformed.
Def. Y Offset
The default axis offset value used when the Offset Gcode function isperformed.
Def. Z Offset
The default axis offset value used when the Offset Gcode function isperformed.
Duplicate
When Checked, creates duplicate Gcode at the offset position when the OffsetGcode function isperformed.
Def. X Scale
The default axis scale value used when the Scale Gcode function isperformed.
Def. Y Scale
The default axis scale value used when the Scale Gcode function isperformed.
Clear Error Log File on Start up
Clears the contents of the Error Log File every time KCam is started. The Error Log file contains information about any errors that may have occurred in KCam’sfunctions.
Error File button
This button opens the error log file in NotePad.exe forviewing.
Reset Parameters
This button resets all parameters to factory values.
Options Gcode tab Add Dwell Commands
When Checked, import functions will insert dwell time anddwell execution commands into theGcode.
Add Spindle On/Offs
When Checked, import functions will insert M03 and M05commands into the Gcode to control the spindle before and after each Z axis plunge. This feature is designed for torch users to engage the torch prior to eachcut.
Default Dwell Time
This is the dwell time parameter that importing functions use for inserting dwellinstructions into theGcode.
Cnvrt Metric
These X,Y and Z values are used to scale the Gcode from Imperial toMetric.
Cnvrt Imperial
These X,Y and Z values are used to scale the Gcode from Metric toImperial.
I and J are Incremental
When Checked the Gcode Arc commands use the I and J values in an incrementalformat. This effects importing DXF, HPGL files and plotting Gcodedata.
Colors
The Plot window colors can be modified by setting the color values for the associatedcolor boxes.
Options DX F tab
Sort Entities
When Checked, Entities are sorted by position prior to generatingthe
Gcode data during a DXF file import process. Using this feature with large files will severely increase the import time, but the Gcode willbe moreefficient.
Sort Layers
When Checked, layers are sorted alphabetically prior to generating the Gcode data duringa DXF file importprocess.
Ignore Z Depth
When Checked, Z axis coordinates in the DXF file are ignored and parameters from the Multi Depth are used for setting the depths. If unchecked, Z coordinates from the DXF file are used if they arepresent.
Line Tolerance
This parameter joins non connected lines together during a DXF Import. Lines with adjacent end points that are closer than this parameter will be joined together. This function is useful when CAD programs used to create the DXF files do not snap the end points together, but instead leave very small gaps between lines. If this parameter if too small (.000001) it will not join lines. If it is too large(.1), it may join unwanted lines together. It is recommended that its value be small until it isneeded.
Multi Depths
Are parameters that allow you to set the depths at which different DXF entities arecut.
Layer Name
Is used to match the entities you wish to set certain depthvalues.
Passes to Depth
This is the number of times or passes the entities are cut into the material. When set to 1, only one pass is used to get to final depth. When set to 3, three passes are done incrementally to get to finaldepth.
Starting Depth
This is the z position for the first cutpass
Final Depth
This is the z depth used in the last cutpass.
All Rows
When checked, changing any cell of data will change all values in thecolumn.
Options Excellon tab
Sort by Size
When Checked, drill holes are sorted by size prior to generating theGcode
data during a Excellon file importprocess.
Sort by Location
When Checked, drill holes are sorted by position prior to generatingthe Gcode data during a DXF file importprocess.
When both size and location sorts are selected, holes will be sorted by location first andthen size. Example: all .028 holes will be drilled first(sorted by location) and then the .040 holes will be drilled(sorted bylocation)...
Default Bit Size
This is the tool size that will be used if no tool sizes are available in the files toolheader.
Leading Zeros
This parameter sets the numeric format for reading the coordinates from the excellonfile. When selected it will expect a leading zero format from the datacoordinates.
Trailing Zeros
This parameter sets the numeric format for reading the coordinates from the excellonfile. When selected it will expect a trailing zero format from the datacoordinates.
Integers and Decimals
These two parameters set numerical format of the coordinate data from the Excellon datafile. Typically Excellon files use 2:3 format which represents 2 digits for the integer portion and 3 digits for the decimal portion of the data. Leading and Trailing Zero formats work with this to assign the proper numerical format for the imported data. Check the output options in your CAD application to determine the proper settings for theseparameters.
Def. PenSize
This is the default pen size when importing a HPGLfile.
Sort Entities
When Checked, Entities are sorted by position prior to generating the Gcode data during a HPGL file import process. Using this feature with large files will severely increase the import time, but the Gcode will be moreefficient.
Ignore Z Depth
When Checked, Z axis coordinates in the HPGL file are ignored and parameters from the Table Setup are used for setting the depths. If unchecked, Z coordinates from the HPGL file are used if they arepresent.
Passes to Depth
This is the number of times or passes the entities are cut into the material. When set to 1, only one pass is used to get to final depth. When set to 3, three passes are done incrementally to get to finaldepth.
Multiple Pen Support
When Checked, this parameter allows unique cutting parameters to be applied to linesfrom specific HPGLpens.
Retool Pen Change
When Checked, the spindle will go to the retool position and pause when the Gcode processor completes executing data from one pen and is ready to change to anotherHPGL pensdata.
Pen Number
This is used to match HPGL pen data with particular cuttingparameters.
CuttingI PM
When matching pen data is read, the generated Gcode with cut at thisvelocity.
Plunge Depth
When matching pen data is read, the generated Gcode with plunge to thisdepth.
PlungeI PM
When matching pen data is read, the generated Gcode with plunge at thisvelocity.
Options Gerber tab
Clean up Gerber Data
When selected the Gerber Import will remove redundant andoverlapping objects.
TraceI solation
When selected the Gerber Import will convert Gerber(RS274X) photoplot lines to grouped polygons for PCB tracemilling.
Cleanup Lines
This option will remove some unwanted lines the polygon isolating program leaves behind. It can also reduce poly lines to single lines when the slopesmatch.
Sort Entities
When selected the Gerber Import function will sort the isolated polygons by location. This option reduces cuttingtime.
Multi pass
When Checked, the path will be copied with an increasing radius from the originalpath.
# of Passes
The number of increasing radiuspasses.
Multi Cut Gap
The value of the radius increase from the previouspass.
Tool Radius
This option adds a tool radius to the Gerber polygon diameters. It can enlarge the plot entities to increase pad and line thickness. changing this value can also reduce the isolation imperfections on some Gerberfiles.
Minimum Line Size
Line sizes the same or smaller than this parameter are processed using the following functions.
Discard Minimum Line soption
This option forces the isolation process to ignore objects this diameter and smaller. It decreases import time by ignoring small entities such astext.
Draw as Line soption
This option forces the isolation process convert objects this diameter and smaller tosingle line entities not outlinedentities.
Note: Gerber(RS274X) format is the only gerber format supported. If your filesdonotimport properly, check to ensure they have a valid apertureheader.
SystemTiming
This function opens the System Timing window. The System Timing window determines calibration data specific to the PC in use. This calibration data adjusts the axis velocities for accuratemotion.
Table Setup
This function opens the Table setup window. The Table setup window allows editing of CNC tableparameters.
Table SetupParameters:
Units Of Measurement
The numerical measurementtype.
Millimeters orInches
Numeral Format
Pre and Post zeros used in formatting numbers in the Gcode Editor.
Steps/Inch or Steps/mm
The number of steps required to move an axis one inch or one millimeter.
Axis Length
The maximum mechanical travel of anaxis.
Axis Invert
The axis direction is normal when set to False. The axis direction is reversed when set toTrue.
Back lash
The distance necessary to overcome play or errors in the axis mechanics due to wear or looseness of components. Backlash errors are most visible when an axis changesdirection.
Travel Depth
The default Z axis depth for rapid movements. Used in engraving for rapid movements without cuttingmaterial.
Normal Cut Depth
The default Z axis depth for cutting with 2D imported files. Used in engraving for cutting letters anddesigns.
Deep Cut Depth
The default Z axis depth for cutting through the material with 2D imported files. Used in engraving for cutting holes andborders.
Backla shoption
When set to False, backlash compensation is not used. When set to True, backlash compensation isused.
Ramping
When set to false, the axis start and run at the specified feedrate.
When set to true, the axis start slowly, increase speed, and finishslowly.
This functions allows greater axis speeds, due to inertial limits of steppers andaxis mechanics.
Ramp Start
This sets the starting and ending speed of the axis if ramping is enabled. The number represents an absolute feedrate.
Ramp Rate
This sets the ramp up and down time or velocity envelope. This number represents the amount of IPM change in an Inch or mm ofmovement.
Feed Rates
These are the default feed rates for moving the axis. Travel Feed Rate is for high speed moves such as G00 commands. The Cutting Feed Rate is for G01 commands. The Jogging Feed Rate is for Jog buttons or keyboardmovements.
Note: The Cutting Feed Rate is overridden when Gcode program feed rate commands specify the feedrate.
Maximum Feed Rates
These are the maximum Feed Rates allowed per axis. These parameters are useful when certain axis are unable to operate at the same rate as the rest. For example, the Z axis may not operate as fast as the X and Y. In this case the Z axis Maximum Feed Rate would be set lower the X andY.
Invert Z Coordinates
This reverses the Z axis coordinate system.
Hide AxisCursor
When Checked the milling cursor will not be displayed on the Plot window. This function improves the step pulse trainuniformity.
Disable PositionUpdate
When Checked the axis positions will not update until the movement is complete. This function improves the step pulse trainuniformity.
Enable Z Axis Jog Step
When Checked the Z axis can be jogged specific distances. When unchecked the Z axis can only be jogged while the jog keys are pressed. This is a safety feature to avoid jogging the Z axis into the table when using JogDistances.
Hide A Axis Position
When Checked the A axis will not be shown in the CNC Controls window. This feature allows the use of lower screen resolutions (800 by 600) when the A Axis is not needed. Otherwise a screen resolution of 1024 x 768 or greater isrecommended
DRO Format
This parameter changes the CNC Controls window DRO (digital read out) format. This feature allows the user to customize how numerals are displayed on the DRO for axis positions.
Limit Switches Disabled
When Checked the Limit Switches are not polled during operation and will not stop theAxis. It will speed up the maximum step rate. This function is useful when you do not have limit switches available or want faster step rates. When it is set or reset(changed) the System Timing function should beperformed.
Limits Stop CNC Run
When Checked, the Limit Switches will stop the CNC run mode iftripped.
Application Priority
These options determine how KCam operates within the Microsoft Windows environment. When normal priority is selected, KCam operates like any standard window. When high priority is selected, KCam will operate with more priority than other programs and steppulse streaming may improve. When Realtime priority is selected, KCam will have much more priority than other applications or processes within Windows. Be aware that Realtime mode can make KCam seem unresponsive while axis are inmotion.
Table Setup Parameters:
HomePosition
The position the axis will return to when the HomeButton has executed. If the Home position is blank, the axis will remain in its current position for the Homefunction.
The Homing(without validation) axis sequence isas follows:
Z axis moves to the Travel position X and Y move to their Homeposition Z moves to its Homeposition
HomeValidation:
Validate Position checkbox enables the home validation process. Direction Parameters are the positions the axis will traveltowards. Target Parameters are the positions the axis will be setto.
Fast IPM is the rate the axis will find the limit switchesat.
Slow IPM is the feed rate the axis will recheck the limitpositions.
Home Validation is the process of reseting the position counters by finding the limitswitches. When selected the axis will validate their positions using the limit switches when the Home button is pressed. Typically the Direction positions should be -1,-1,4 for the X,Y,Z axis and the Target positions are 0,0,3 for the X,Y,Zaxis.
Below is an explanation of what happens during validation process using the abovesettings:
The "Validate Position" option must bechecked.The Z axis moves towards position 4(Direction) at the Fast IPM rate until a limit switchis found.It taps the limit switch 3 times using the Slow IPM rate and sets the current Z positionto 0(Target).
The user presses the "Home" button in the CNC Controlwindow.
The X axis moves towards position -1(Direction) at the Fast IPM rate until a limit switchis found.
It taps the limit switch 3 times using the Slow IPM rate and sets the current X position to 0(Target).
The Y axis moves towards position -1(Direction) at the Fast IPM rate until a limit switchis found.
It taps the limit switch 3 times using the Slow IPM rate and sets the current Y positionto 0(Target).
The Z axis moves to the HomePosition
The X and Y axis move towards the HomePosition
Re-Tool Position
The position the axis will return to when a tool change command is executed. If the Re-Tool position is blank, the axis will remain in its current position for the toolchange.
The Re-Tool axis sequence is asfollows: Z axis moves to the Travelposition
X and Y move to their Re-Toolposition Z moves to its Re-Toolposition
Table SetupParameters:
Jog KeyAssignment:
The Manual Jog Keys can be reassigned for custom keyboard. To assign a new key, select an axis direction button and press the key to activate thataxis direction. A Key Test window opens during the key assignment to grab the desired key press and determine its ASCIIvalue.
Restore Defaults
This function will return the Jog Keys to the Numerical Keypad keys forjogging. DefaultKeys:
Numerical Keypad Arrows move the X and Y axis. Keys 7,9,1,3 move the X and Y axis together.
The Numerical Keypad - and + keys move the Z axis up and down respectively. The < and > keys change the feedrate.
Check Key Value
This function will open a test window that shows the ASCII value of keyspressed.
PortSetup
This function opens the port setup window. The Port setup window allows editing of the communication portparameters.
Port I/O Controls:
Port Type
The Port Type selects the communication portfor accessing the stepper motorcontrollers.
Parallel Port I/O DLLused
The Parallel Port I/O DLL used selects to DLL windows uses to access the parallel port. Either can be used under Windows 95 and 98. If Windows NT operating system is used then DlPort.dll must beused.
Max Stepper Setup:
Port Status:
Max Stepper Com Port: Determines which serialport KCam uses to communicate with MaxStepper. The serial port choices are 1 through15.
Model Type: Sets which model of MaxStepperis connected.
SASF: Sets secondary axis smoothing factor. This value can be used to smooth secondary axis step aliasing. The higher the value, the lower the maximum frequency MaxStepper can produce. Use with caution! The default value isone.
Communication: Displays the status of the serial connection to MaxStepper.
Comms: Total number of communication attempts by KCam to MaxStepper.
Errors: Number of erroneous communication attempts by KCam toMaxStepper.
CS Er: Number of Check-Sum type communicationerrors.
Len Er: Number of bad length type communicationerrors.
Buffer: Number of motion command strings waiting in the commandbuffer.
Rev: Firmware revision inMaxStepper
Date: Date of firmware inMaxstepper
Hz: Current pulse rate in Hertz that Maxstepper is applying to the steppermotors.
CByte1: Displays the control byte for Axis X,Y,Z andA
CByte2: Displays the control byte for futureaxis.
Watchdog: Is reserved for futureuse.
SASF: Displays the secondary axis smoothingfactor.
Status Message: Information on Maxstepper Communicationstatus
Ramp Rate: The hz per step increment used whenramping
Min Arc Length: The smallest arc length allowed. Set to a value that reduces buffer overrun with Gcode programs containing extremely shortarcs.
Maximum Spindle Value: This is the Gcode value used to set a 100 percent duty cycle scaleon the PWMoutput.
LPT Setup:
Pin SetupPort: BitSetup
When this option is selected, the bit setupparameters areenabled.
Pin Setup
When this option is selected, the pin setupparameters areenabled.
Pin Address
The address of the LPT port used to communicate to the stepper motor controllers forPin Setup. The address is used to convert the Pin Setup to the more advanced BitSetup.
Output Setup: Pin
The pin number on the 25 pin D-Sub LPT connector used to perform the specifiedmotor controllerfunction.
Port
The port address of the bit used to access the specified controllerfunction.
Bit
The Bit used to access the specified controllerfunction.
Inverted
Specifies the normal state of the outputpins.
Input Setup: Pin
The pin number on the 25 pin D-Sub LPT connector used to perform the specified Limit orE- Stop switchfunction.
Port
The port address of the bit used to access the specified controllerfunction.
Bit
The Bit used to access the specified controllerfunction.
Inverted
This function inverts normal state of the bit for thecontroller.
Auxiliary M Code Output Setup: Pin
The pin number on the 25 pin D-Sub LPT connector used to perform the specifiedmotor controllerfunction.
Port
The port address of the bit used to access a user defined controllerfunction.
Bit
The Bit used to access the a user defined controller function.
MotorEnable:
This function defines how the motor controller axis enable bits are controlled.
On with Step turns the enable bits on only while a stepping process is in progress.
Always On turns on the enable bits with the first stepping process and leaves them onuntil KCam isexited.
Timed (off delay) turns the enable bits on during stepping process and turns the bits offa specified time ( in seconds) after the last stepping process hascompleted.
LPT Info:
This window gives general information on the parallelport. This information can be used for determining how to connect a stepper motor controller to aPC.
Macro Files
This function opens the Macro Files window. The Macro Files window allows editing of the macro file namesand
macro file numbers. Macro Files are used for sub program calls within your main gcode program to perform repetitive functions with code efficiency. Macro files are called using M98 in the gcode file. The format is M98 x, where x is the macro file number stored in the Macro Filelist.
Example:
N001 [MACROEXAMPLE]
N002 [DRAW THE SERIAL NUMBER 99633524] N003 [USINGMACROS]
N004G90
N005 G00 Z1.000 N006 X0Y0
N007 M98 9 [CALL MACRO FILE 9] N008X.11
N009 M98 9 [CALL MACRO FILE 9] N010X.11
N011 M98 6 [CALL MACRO FILE 6] N012X.11
N013 M98 3 [CALL MACRO FILE 3] N014X.11
N015 M98 8 [CALL MACRO FILE8]
N016X.11
N017 M98 5 [CALL MACRO FILE 5 N018X.11
N019 M98 2 [CALL MACRO FILE 2] N020X.11
N021 M98 4 [CALL MACRO FILE 4] N022X.11
N023 G00 X0Y0
ToolList
The Tool List allows editing of tool bit diameters. Tool bits are accessed through the Gcode by using the T command. A maximum of 200 tool sizes can be saved in each file. When Importing an Excellon file, tool diameters are automatically generated from the aperture list. Tool Offsets are also edited here. The Tool Offset function is not yetimplemented.
Clear All
The Clear All button clears all the tool diameters in the list. When the tool list is cleared, the Plot window uses the Bit Radius in Options (General Tab) for displaying plotlines
Using the Load or Save buttons, different tool files can be stored and reloaded forvarious machinesetups.
EventSounds:
The list shows the available events that sounds can be assigned to. To change a sound for an event, double click on theevent to open a browse window for fileselection.
You can right click on a selected event tohear the assignedsound.
FUNCTIONS
Scale Gcode
This function scales the gcode in the editor window. A pop up entry box will appear to enter X and Y scale data. If the X or Y Scale data is blank or 0, no scaling will beperformed.
Offset Gcode
This function offsets the gcode in the editor window. A pop up entry box will appear to enter offset data for each axis. If the offset data is blank or 0, no offset will be performed for thataxis.
Convert Gcode toAbsolute
This function converts the gcode in the editor window to absoluteformat.
Convert Gcode toIncremental
This function converts the gcode in the editor window to incrementalformat.
WINDOW
Window List
Displays the open child windows. If a window is underneath another, it can be brought forward by selecting it from the windowlist.
HELP
Help Contents
Opens the help contentsfile.
About
This function opens the About window. The About window shows the software version, Registration button and System Informationbutton.
Registration
Registration information can be entered to allow full use of the software and remove time limits. In order to register your version of KCam you must obtain a Key Code fromKellyware.
Supported GCodes
G Code Description
G00 RapidTraverse
G01 NormalTraverse
G02 CWArc
G03 CCWArc
G04 Execute DwellTime
G17 XY PlaneSelection
G18 XZ PlaneSelection
G19 YZ PlaneSelection
G40 Cancel CutterDiameterCompensationG41 Start Cutter DiameterCompensationLeftG42 Start Cutter DiameterCompensationRightG45 NormalTraverse
G73 DrillCycle
G80 End DrillCycle
G81 DrillCycle
G82 Drill Cycle withDwell
G83 DrillCycle
G90 Sets AbsoluteMode
G91 Sets IncrementalMode
Pxxx Sets Dwell Time to xxx (example: P2.125 will set dwell to 2.125seconds)FxxxSets Feed Rate to xxx (example: F45 will set the feed rate to 45 IPM)
Supported MCodes
M Code Description
M00 ProgramStop
M01 Optional ProgramStop
M02 ProgramEnd
M03 Engage SpindleCW
M04 Engage SpindleCCW
M05 Disengage SpindleRelays
M06 ToolChange
M07 Mist CoolantOn
M08 Flood CoolantOn
M09 Mist and Flood CoolantOff
M13 Engage Spindle CW andCoolantMistM30 Program End andReset
M60 ProgramStop
M98 Call Macrosubroutine
User Defined Mcodes
Mxx Engage userdefinedoutputMxx Disengage user definedoutput
xx is the number given by theuser
Supported DXF version R12Formats
Entity Description
Line Single Line X1,Y1,Z1 TOX2,Y2,Z2
Poly-line Multiple Line X1,Y1,Z1 tofollowingvertexesVertex Multiple Line toX2,Y2,Z2
Point Single PointX1,Y1,Z1
Arc CCW ArcEntity
Circle Full CircleEntity
Note:
Text items do not import. TurboCAD v5.0 and v6.0 have a text property call FLEXIBLE which will convert the text entity into poly-lines. Some CAD programs have a Save-Option to explode text. Some newer DXF formats are compatible with KCam but notguaranteed.
HardwareConnections
KCam has two motor control port options, Parallel and Serial. In Parallel Port mode KCam requires step and direction motor drivers. In order to get movements from the PC to the CNC table KCam pulses or changes the state of pins on the parallel port on your PC. In Serial Port mode the MaxStepper needs to be connected to the serial port and step and direction motor drivers toMaxStepper.
Parallel ModeInformation:
Each motor controller needs to have a Step input connected to a Pin on the parallel port. This input on the controller advances(rotates) the stepper motor when pulsed. A Direction input is also required to tell the controller which direction to move when the step input is pulsed. An Enable input is used to tell the controller to apply current to the motor. The Enable function is optional and some controller don't use it. If you have a controller that has an Enable input, you should use it. It will shutdown the motors when they are not in use and protect them fromoverheating.
Parallel port mode can be used with port cards other than just a parallel port. The Parallel Port Setup allows Bit Mode for assigning access for the step and direction addresses in a unique card. Each brand of I/O Card has different port addressing schemes and correct settings in KCam must be determined by the end user using documentation for thecard.
Typical Parallel Port Connections
Glossary
Axis Backlash CNC
Ramp Rate IPM
An Axis is a motorized portion of amachine.
Backlash is the play in the threads between the drive nut and threaded rod on an axis. This play causes a loss of distance in a movement when the directionchanges.
CNC is the abbreviation of Computer Numerical Control. Or simplified its the computer control of machines.
The Ramp Rate is the acceleration and deceleration rate of the stepping velocity. Its value is given in change of IPM perInch.
IPM is the measurement of velocity or speed for an axis. It is the abbreviation of Inches Per Minute which is a rate ofmovement.
RegisteringKCam
To register your copy of KCam please visit our web site www.kellyware.com fordetails.
To obtain your registration code, open http://www.kellyware.com/kcam/kcam_registration.htm in an internet browser. Click on the Purchase hyperlink and select a payment option for an KCam. You can enter your credit card information and a VALID email address. Please make sure your Email Address is correct and that there or no spam blocking settings in your email client that will interfere with receiving your registration information. Once Kellyware has received notice of your payment a personal registration code will be generated and sent to the email address given to PayPal. You need to enter the user name and registration code into KCam's Registration form. You can find this form by clicking on "Help/About/Registration". Your registration code is typically sent to you in about 1 to 5 business days. Registration response times may vary due to business activity andholidays.
Note:
If PayPal does not support your country, you can try a nearby country or mail paymentto Kellyware. Details on sending payment are available at http://www.kellyware.com/kcam/kcam_registration.htm
Shareware
KCam is shareware until a valid registration code is entered. Until KCam is registered, a user has a 60 day or 60 execution trial period until the software becomes limited. During the trial period KCam has no limitations. After the trial period has finished, some functions are disabled or limited.
After Trial Limitations include: Gcode saving is disabled Gcode lines are limited to500
Gerber Isolation lines are limited to100
