2000 Series Centerless Grinder Setup Manual

Below is the standard setup for any 2000 series centerless Grinder:

 

PLC

Outputs

PLC Output Name

Function (Also description IO in Mach4)

Safety Relay

Configuration in Mach4

Mach4 Signal Assignment 

Q00.0

7202M - Hydraulic Pump

 

PMC with time delay after enable turns off

Output# 10

Q00.1

7203M - Coolant Pump

 

Config-> coolant

Output# 11

Q00.2

2011CON - Grind Wheel Motor Contactor

 

MM plugin - Grind wheel

Output# 12

Q00.3

Q00.3 - Reg Wheel Forward

 

MM plugin - Reg wheel on

Output# 13

Q00.4

Q00.4 - Reg Wheel Enable

 

PMC -> enable

Output# 14

Q00.5

Q00.5 - Work Light (Above Safety Circuit)

Above

MM plugin - Work light

Output# 15

Q00.6

Q00.6 - Unused (Above Safety Circuit)

Above

 

Output# 16

Q00.7

Q00.7- Unused (Above Safety Circuit)

 

Above

 

Output# 17

Q01.0

Q01.0- Unused (Above Safety Circuit)

 

Above

 

Output# 18

Q01.1

7211CR - Reset Safety Estop Circuit (Above Safety Circuit)

Above

MM plugin - Safety circuit

Output# 19

 

 

 

 

 

Q08.0

7501CR - Lube

 

MM plugin - lube - on with spindle

Output# 20

Q08.1

7502CR - Grind Wheel Coolant

 

MM plugin - Grind wheel coolant

Output# 21

Q08.2

7503CR - Reg Dresser Coolant

 

MM plugin - reg wheel coolant

Output# 22

Q08.3

7504CR - Grind Dresser Coolant

 

MM plugin - grind dresser coolant

Output# 23

Q08.4

7506CR - Grind Wheel Lube

 

PMC -> enable

Output# 24

Q08.5

7507CR - Main Air

 

PMC -> enable

Output# 25

Q08.6

7508CR - Unused

 

 

Output# 26

Q08.7

7509CR - Unused

 

 

Output# 27

 

 

 

 

 

Q09.0

7511CR - Grind Dresser Front

 

MM Plugin - centerless

Output# 28

Q09.1

7512CR - Grind Dresser Back

 

MM Plugin - centerless

Output# 29

Q09.2

7513CR - Grind Dresser Diamond

 

MM Plugin - centerless

Output# 30

Q09.3

7514CR - Reg Dresser Front

 

MM Plugin - centerless

Output# 31

Q09.4

7516CR - Reg Dresser Back

 

MM Plugin - centerless

Output# 32

Q09.5

7517CR - Reg Dresser Diamond

 

MM Plugin - centerless

Output# 33

Q09.6

7518CR - Unused

 

 

Output# 34

Q09.7

7519CR - Unused

 

 

Output# 35

 

Inputs

PLC Input Name

Function (Also description IO in Mach4)

Active Low

Configuration in Mach4

Mach4 Signal Assignment 

MachMotinoModbusDevice

I00.0

I00.0 - E-Stop Okay

Low Active

MM plugin - Safety circuit

Input #10

Input0

I00.1

I00.1 - Overloads Okay

 

GMS - disable

Input #11

Input1

I00.2

I00.2 - Air Pressure Low

 

GMS - disable

Input #12

Input2

I00.3

I00.3 - Way Lube Pressure Low

 

GMS - disable

Input #13

Input3

I00.4

I00.4 - Way Lube Level Low

 

GMS - warning

Input #14

Input4

I00.5

I00.5 - Coolant Filter Dirty

 

GMS - disable

Input #15

Input5

I00.6

I00.6 - Main Hydraulic Filter Dirty

 

GMS - disable

Input #16

Input6

I00.7

I00.7 - Grind Wheel Hydraulic Filter Dirty

 

GMS - disable

Input #17

Input7

I01.0

I01.0 - Main Coolant Flow Okay

 

GMS - disable

Input #18

Input8

I01.1

I01.1 - Hydraulic Pressure Okay

 

GMS - warning if hydraulics on (Output# 10) for 5 seconds

Input #19

Input9

I01.2

I01.2 - Reg Wheel Axis Drive Fault

 

GMS - disable

Input #20

Input10

I01.3

I01.3 - Grind Wheel Bearing at Pressure

 

GMS - disable

 

Input #21

Input11

I01.4

I01.4 - Unused

 

 

Input #22

Input12

I01.5

I01.5 - Unused

 

 

Input #23

Input13

 

 

 

 

 

 

I08.0

I08.0 - Grind Dresser Front

 

MM Plugin - centerless

Input #24

Input16

I08.1

I08.1 - Grind Dresser Back

 

MM Plugin - centerless

Input #25

Input17

I08.2

I08.2 - Reg Dresser Front

 

MM Plugin - centerless

Input #26

Input18

I08.3

I08.3 - Reg Dresser Back

 

MM Plugin - centerless

Input #27

Input19

I08.4

I08.4 - Wheel Guard

 

 

GMS - warning

 

Input #28

Input20

I08.5

I08.5 - Wheel Balancer Fault

 

GMS - disable

 

Input #29

Input21

I08.6

I08.6 - Unused

 

 

Input #30

Input22

I08.7

I08.7 - Unused

 

 

Input #31

Input23

I09.0

I09.0 - Grind Dresser Speed Low Push Button

 

MM Plugin - centerless

Input #32

Input24

I09.1

I09.1 - Grind Dresser Speed Medium Push Button

 

MM Plugin - centerless

Input #33

Input25

I09.2

I09.2 - Grind Dresser Speed High Push Button

 

MM Plugin - centerless

Input #34

Input26

I09.3

I09.3 - Grind Dresser Out Push Button

 

MM Plugin - centerless

Input #35

Input27

I09.4

I09.4 - Grind Dresser In Push Button

 

MM Plugin - centerless

Input #36

Input28

I09.5

I09.5 - Grind Dresser Front Push Button

 

MM Plugin - centerless

Input #37

Input29

I09.6

I09.6 - Grind Dresser Back Push Button

 

MM Plugin - centerless

Input #38

Input30

I09.7

I09.7 - Dresser Coolant Flow Okay

 

GMS - disable if coolant on for 5 sec

Input #39

Input31

 

 

 

Regulating Wheel Setup

Siemens PLC Setup

Wire up the regulating wheel to Analog Output 0 or Analog Output 1 of the PLC as shown here: Siemens PLC - Wiring SM1234 Analog Card

Set up the regulating wheel in MachMotion Parameters as shown:

image-1589904849070.png

Command the regulating wheel to go max RPM for Speed Range 0 and use a tachometer to confirm it goes the correct speed. If it doesn't, calculate the new Regulating Wheel Max Speed Range 0 as follows:

Actual RPM / Commanded RPM * Range 0 = New Regulating Wheel Max Speed Range 0

 

 

Grind Wheel Setup

V1000 Setup

Set Control Source to Auxiliary. 

Set the V1000 Auxiliary Control Max RPM to the max RPM you want the grind wheel to go. 

image-1589903000781.png

Next set the Grind Wheel Max Speed Range 0 to the same as the Auxiliary Control Max RPM. Configure the other parameters as follows:

Parameter Name Value Description
Grind Wheel Enabled Yes Enables the grind wheel.
Grind Wheel Input IO -> Yaskawa-V1000_0->Motor_At_Speed Tells the control when the grind wheel is up to speed.
Grind Wheel Output Speed Mode RPM Tells the grind wheel to send a RPM value to the V1000. 
Grind Wheel Output Speed Multiplier 1 Should always be 1. 
Grind Wheel Output IO -> Yaskawa-V1000_0_Auxiliary->FWD Tells the V1000 to start rotating
Grind Wheel Speed Register Register -> Yaskawa-V1000_0_Auxiliary->Command_RPM Tells the V1000 what speed to rotate at.

 

image-1589904685796.png

Now test the grinding wheel speed. Enter in a speed command and monitor the actual speed with a tachometer. Make sure your Max Wheel RPM is high enough to allow the commanded speed you want to command. 

image-1589903658254.png

If it isn't correct, calculate the new Max RPM as follows:

Actual RPM / Commanded RPM * V1000 Auxiliary Control Max RPM = New Max RPM. 

Now set the V1000 Auxiliary Control Max RPM and the Grind Wheel Max Speed Range 0 to the new Max RPM. 

 


Revision #6
Created Thu, Feb 13, 2020 10:12 PM by Carl
Updated Tue, May 19, 2020 4:37 PM by Carl