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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 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. While the project is in QC, the control should be powered by the control stand and not the panel. The reason being that the panel itself may need to be powered down when the control does not. This will shorten the wait time after power cycles.
  • Rapidpath
    • Test Inputs 
    • Test Output
  • Motion Controller Apollo III Apollo III
    • 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
    • Import IO to Mach Import I/O
    • Add "Setter" to any tool I/O descriptions 
  • Safety Circuit Set-Up
  • 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 
    • 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
  • 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)

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