Process

• Electric review checklist
• • Check brake circuit
  • Compare VFD and Drive Voltage against incoming power
  • 24V Control power output correct Polarity after power on.
  • Before powering on the panel make sure B2 and B3 are jumped on the drives (Not needed if resistors are connected to B1 B2)
• Keyence safety  https://support.machmotion.com/books/safety-relays/page/keyence-safety-relay
• • For Onsrud use single channel parameters
  • Setup Keyence Safety (Password 1111)
  • Connect to Keyence using Ethernet
• UPS Battery Backup
• • Install fuse at power up
  • Connect control to panel and test shutdown
• Motion Controller Rapid Path https://support.machmotion.com/books/motion-controllers-and-breakout-boards/page/2000-series-rapidpath-operating-manual
• • Test Inputs 
  • Test Output
• Motion Controller Apollo III https://support.machmotion.com/books/motion-controllers-and-breakout-boards/page/2000-series-apollo-iii-operating-manual
• • Test Inputs (C0+ to x0-x15). Along with checking connection on PLC and Beckhoff also
  • Test Output
  • Update HiCON Firmware and FPGA to latest.
  • Quality Control (Screws, Wires, Labels, Jumpers, and RJ45 plugs on unused axis and HiCON ports)
  • Apollo has two 2 position Phoenix connectors
  • Jumpers Setup (Move X0 Jumper up for Drive Fault)
  • Add HiCON SN# to Mach (Log in notes below
  • Test enable
  • Test HiCON graph
  • Check the BOM for any HiCON Feature codes that may need to be purchased
  • Test spindle
• Machine I/O Software NEEDS BOOKSTACK ARTICLE WRITTEN FINISHED https://support.machmotion.com/books/quality-control-and-testing-knowledge-base/page/import-io-into-mach/edit
• • Import IO to Mach https://support.machmotion.com/books/quality-control-and-testing-knowledge-base/page/import-io-into-mach
  • Add "Setter" to any tool I/O descriptions https://support.machmotion.com/books/qc-g0W/page/mach4-io-formatting-for-production-setup
• Safety circuit https://support.machmotion.com/books/qc-g0W/page/safety-setup-for-rapidpath-system
• Drives and Motors set up in mach..axis mapping rotation counts consolidate
• • Stepper Drive Dip Switch Settings (if not in an electrical panel)
  • (Apollo III only) Check that Yaskawa control boards are seated properly
  • Set Resistor wattage in drive Yaskawa PN600 = (Wattage x 0.02) 
  • Program Drives
  • Jog All Motors All Directions
  • Is there a break motor? Hit Estop and see if the the brake engaged on the motor.
  • Apollo III Check Drive Fault (Doesn’t always work on Knee Mill kits.  That’s okay) 
    
  • JOG RATE knob changes motor jog rate
  • Test the wireless pendent *if applicable
  • Set homing method to "Home to current position" (Config/plug-ins/Rapid Path/Drives)
  • Calibration CHECK WITH INSTALL TO SEE HOW NECESSARY
  • • Motor calibration
• (Rapid Path) Motor rotation encoder counts (Rapid Path)
• • Set "Counts per unit" according to motor type. (Motor tab and Aux. Positions tab)
  • Turn each motor one rotation to match the count (or close to it) on the chart below
  • Mach/diagnostics/rapidpath/motor
  • • Yaskawa - 131072.00
    • Everelcteonica - 4000
    • Leadshine - 10000
    • Mitsubishi - 131,072
    • CTB – 131,072
• (Apollo III) Motor rotation encoder counts 
• • Turn each motor one rotation to match the count (or close to it) on the chart below
  • Mach/diagnostics/hicon status/encoder
  • • TECO - 10,000
    •  Yaskawa - 16384
• VFD
• • If Hitachi install the program for programming drives  NEED PROGRAM LOCATION
  • •  https://support.machmotion.com/books/motors-drives-and-vfds/chapter/vfd-hitachi
  • VFD Programmed 
  • • If regen resistor for yaskawa VFD set L3.04 to 3.
    • Custom VFD parameters (use data collection form)
    • Check manual for extra settings (A1000, GA500, GA800, Safety relay) https://support.machmotion.com/books/motors-drives-and-vfds/page/yaskawa-v1000-a1000-ga500-ga800-tcp-modbus-or-ethercat-communication-setup
    • VFD Communication settings configured on VFD https://support.machmotion.com/books/motors-drives-and-vfds/page/on-site-yaskawa-v1000-a1000-ga500-modbus-vfd-installation
  • Change HiCON Spindle Feedback to undefined (Config>Plugins>HICON)
  • Run VFD FWD and REV and check that the at speed signals work correctly
  • On the VFD.  off, flashing, then on solid
  • On the Mach4 screen, off, yellow, then green
  • Confirm full speed on the face
  • Run half speed and verify Hz or RPM drops by half
  • Set IO and spindle settings. This is in the rapidpath plugin, under control IO, and MachMotion plugin. (To start with)...pathway...and description
  • Add watchdog to I/O widget
  • Set VFD Control to "Mach" (imaging?) (Rapidpath Only)
  • Set VFD Feedback "Mach" (imaging?) (Rapidpath Only)
  • Set VFD Command Mode to "Percentage" (imaging?) (Rapidpath Only)
• PLC  https://support.machmotion.com/books/plc/page/siemens-plc-modbus-setup
• • Reference the BOM for the PLC program number and download the PLC program from the server.  Put the PLC program in https://support.machmotion.com/books/qc-g0W/page/downloading-and-installing-siemens-licenses
  • Program PLC with Program number on BOM C:\Mach4_Development\PLCs\PLC-Program-Generic-Waterjet-Intensifier-Pump-Control_V15
  • Put PLC in Run mode
  • Test communication (Diags/Modbus – Green)
• Lathe
• • Disable Spindle Speed check for testing and re-enable when done before it ships
  • If spindle encoder: Set HiCON spindle feedback source to encoder
  • If spindle encoder: Set MachMotion parameter in Yaskawa V1000_0 Use RPM Feedback to “No"
• Automated Precision Equipment
• • Check the Beckhoff slice SN to make sure its EK1101
  • Select APE when running Machmotion setup Mach4.bat
  • Delete APE profile folder on the control and Copy APE profile folder from\\svr1\MachMotion\Production\Customer Backups\Automated Precision Equipment_Kurt Norgaard_OEM\_Production Information\Master Control Files\2000 Series Drywall
  • Do all testing on APE_MM_TESTING
  • If no absolute battery check for option card on drive
  • If absolute check the CN1 board that jumpers are on pins 2&3 CN1 board
  • On the breakout board, ensure only the X0 is in the up position
  • MM/Production/Quality control/APE 1. Screens  2. Modules  3. Profiles21214
• Centerless Grinder https://support.machmotion.com/books/cnc-machine-operator-manuals/page/2000-series-centerless-grinder-setup-manual-rapidpath
• • If a centerless grinder check to see if any axis (except reg wheel) have absolute encoder **And do what**
  • Check loads
• Final
• • Turn off production testing
  • Review and update redlines
  • Take Pictures/video and upload to server
  • Scan and upload redlined electrical drawing M:\Production\Customer (or send redlines through Eplan)