Launch 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 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
- 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)
NEEDS UPDATED (PICS)https://support.machmotion.com/books/cnc-machine-operator-manuals/page/2000-series-waterjet-setup-manual