machine specific supplemental...

Comm‐instr_MAZAK_VCP_DOK‐0303‐EN(05) 2019‐06‐05 Translated doc. in accordance with MRL 2006/42/EC 1 / 59

Machine‐specific supplemental instructions

For installation and commissioning of pL LEHMANN CNC rotary tables on a machine tool

MAZAK

VCP Series with FANUC / MAZATROL control systems

(currently applicable only with APC)

Manufacturer: Peter Lehmann AG Bäraustrasse 43

CH‐3552 Bärau

www.lehmann-rotary-tables.com

INFORMATION

2 / 59 Comm‐instr_MAZAK_VCP_DOK‐0303‐EN(05) 2019‐06‐05 Translated doc. in accordance with MRL 2006/42/EC

Table of Contents

1 This is a supplemental document .............................................................................................. 3 1.1 History .............................................................................................................................................................. 3 1.2 Abbreviations ................................................................................................................................................... 4

2 MAZAK Machine Overview PRIMOS .......................................................................................... 4 2.1 Additional information .................................................................................................................................... 4 2.2 Indication of origin ........................................................................................................................................... 4

3 Items included in delivery .......................................................................................................... 6 3.1 Installation material, 1‐axis LOZ.MAZ‐VCP.EA (for Mazak VPS Series without APC) ....................................... 6 3.2 Installation material, 2 x 1‐axis LOZ.MAZ‐VCP.2EA (for Mazak VPS Series with APC) ..................................... 7 3.3 Angular position measuring system (option) (provisional) ............................................................................. 7

4 Installation of VCP400S with APC ............................................................................................... 8 4.1 Installation involves the following steps: ........................................................................................................ 8 4.2 Prepare the machine, check the «OPTION PACK» ........................................................................................... 8 4.3 Install filter/controller for air and oil ............................................................................................................. 11 4.4 Install rotary table, connect wiring harness .................................................................................................. 16

5 VCP with CNC «FANUC» ............................................................................................................ 18 5.1 Commissioning ............................................................................................................................................... 18

5.1.1 Entering parameters ................................................................................................................................................................................... 18 5.1.2 MAZAK VCP400S‐specific parameters ........................................................................................................................................................ 18 5.1.3 M‐functions ................................................................................................................................................................................................ 20 5.1.4 Test run ...................................................................................................................................................................................................... 21

5.2 Operation ....................................................................................................................................................... 23 5.3 Fanuc control FAQs ........................................................................................................................................ 25 5.4 Safety (DCS) ................................................................................................................................................... 28

5.4.1 A few important safety parameters ........................................................................................................................................................... 29

6 VCP with CNC «Mazatrol SMOOTH C» ...................................................................................... 30 6.1 Commissioning ............................................................................................................................................... 30

6.1.1 Entering parameters ................................................................................................................................................................................... 30 6.1.2 MAZAK VCP400S‐specific parameters ........................................................................................................................................................ 30 6.1.3 Installing/removing .................................................................................................................................................................................... 35 6.1.4 Test run ...................................................................................................................................................................................................... 36

6.2 Operation ....................................................................................................................................................... 38 6.2.1 Control 'SMOOTH C' ................................................................................................................................................................................... 38

6.3 SMOOTH C FAQs ............................................................................................................................................ 42

7 Electrical connection of Fanuc control ...................................................................................... 54 7.1 Overview of MAZAK control cabinet (FANUC servos) 2‐axis version (VCP400S with APC) ........................... 54 7.2 VCP Series (with APC) .................................................................................................................................... 55 7.3 «KAB.Fx‐x.x‐MZb‐2» for VCP Series (with APC) (200 V), FANUC servo .......................................................... 56

8 Electrical connection of MAZATROL control .............................................................................. 57 8.1 Overview of MAZAK control cabinet (Mitsubishi servos) 1‐axis version (VCP400S with APC) ...................... 57 8.2 «KAB.MI2‐x.x‐MZb‐2» for MITSUBISHI motor, Type HG‐H ............................................................................ 58

9 Contact ..................................................................................................................................... 59

INFORMATION


1 This is a supplemental document

Dear Customer,

This document contains special technical knowledge that supplements our «Commissioning instructions STANDARD DOK‐0004».

It is intended for trained commissioning technicians.

For complete system documentation, see USB stick at the bottom of the pL rotary table motor add‐on.

IMPORTANT: For this expansion, the machine needs to be prepared in terms of hardware and software.

Weexpressourheartfeltthankstothemachinemanufacturer'steamforitswillingnesstoprovideassistance.

NOTE

Read and heed the STANDARD commissioning manual DOK‐0004. It is binding at all times.

Preventable damage is not covered by warranty!

This manual is only a machine‐specific supplement to the above.

ATTENTION

The diagrams may differ from one another.

Check that the machine and pL LEHMANN diagrams match!

The diagrams may differ on one page or another as the result of continued technical development, modifications, version, etc.

Always compare the electrical diagrams with one another.

If any doubt exists, please contact our customer technical support.

1.1 History

Ix(1) Date of issue(2) Page What of

00 2017‐05‐12 Document prepared. as

01 2017‐06‐13 30 # Motor performance adapter is a new part of the motor assembly. am

02 2017‐09‐13 30 # Motor connector assignment error corrected. cm

03 2018‐03‐13 30 # Added shielding for HF and HG on encoder, cable shown. as

04 2018‐07‐18 div # Added everything new about Mitsubishi/SMOOTH control As

04 2018‐08‐29 55 # Schema für VCP, Blattnummer korrigiert frö

05 2019‐06‐05 56+58 # Entstörung auf blackBOX 120‐3853c eingefügt. as

For change index and date, see footer: …DOK‐xxxx‐xx.00(1)…YYYY‐MM‐DD(2)

INFORMATION


1.2 Abbreviations

pL abbreviation Description

COM. Commissioning

Servo Servo controller, Servo drive, amplifier

TAP Tilting table average performance

TOP Tilting table optimal performance

WDF Wall penetration/wall bushing (mating connector for rotary table, machine side)

2 MAZAK Machine Overview PRIMOS

Vertical machining center with or without (Automatic Pallet Changer) 2 interchangeable pallets

Model MAZAK Primos

Abbrevia‐tion MAZAK

Version Manu‐fac‐tured from

MAZAK FZ(Fanuc 0iMD)

Mazak SMOOTH C (Mitsubishi)

T‐slot width / number / distance

Comments

MAZAK PRIMOS 400S

VCP400S Without APC

< 2017 x x * 14 mm / 3x / 125 mm

MAZAK PRIMOS 400S

VCP400S With APC

< 2017 x x * Threads 18x M16 (distance 125 in Y and 100 mm in X) T‐slots (14 mm) optio‐nal

‐ Maximum last per pallet: 200 kg ‐ Swivel circle 1150 mm

MAZAK PRIMOS 400L

VCP400L ? < 2017 ? ? ? Made in China, in‐tended only for do‐mestic Chinese mar‐ket

- Bold = = system commissioned

- At present, the manual applies primarily to MAZAK PRIMOS 400S with APC

- * = Optionally also available with MAZATROL SMOOTH G

-

2.1 Additional information

Type Drive system

Clamping Control sy‐stem type

Possible rotary tables

Possible motors

Special aspects

VCP400S with APC FANUC

200 V 24 V DC un‐clamp signal

Fanuc 0iMD 507/508510/511 (520)

β1/6000is α2/5000is α2/5000is

507 /508 have ideal size for APC

VCP400S with APC MAZATROL

400 V 24 V DC un‐clamp signal

MAZATROL SMOOTH C

510/511(520)

HG‐H75SHG‐H105S

2.2 Indication of origin

INFORMATION


VCP400S or VCP400SG Made in Singapore VCP400L Made in China

VCP400S with APC, Fanuc control VCP400S with APC, MAZATROL control

VCP400S without APC, Fanuc control

DELIVERY


3 Items included in delivery

The installation kit LOZ.xxx always contains the following components:

Installation material: Maintenance unit, air connection

Rotary table fastening material: (kit for EA or M/T system) without clamping claws; these are supplied with the system.

3.1 Installation material, 1‐axis LOZ.MAZ‐VCP.EA (for Mazak VPS Series without APC)

1. For installation of maintenance unit 1x plate HUR‐0001 2x socket head screw M6x16

2. Fastening material for rotary table. Supplied loose. Number for EA‐: LOZ.Nute14‐EA

3. 5 m plastic hose BU 5 m plastic hose WH

4. Material for air / oil connection 1x T‐connector D8‐6 1x reducer D8‐D6 1x straight push‐in fitting D8‐1/4

5. WDF.lo 6. Alignment T‐slot nuts AUR.St14

7. Corrugated tubing clip

DELIVERY


3.2 Installation material, 2 x 1‐axis LOZ.MAZ‐VCP.2EA (for Mazak VPS Series with APC)

1. For installation of maintenance unit 2x socket head screw M6x16 2x U‐washer

2. WDF.lo 3. 5 m plastic hose WH

4. Material for air/oil connection 1x T‐connector D6 1x T‐connector D6 1x reducer D8‐D6

5. 2x corrugated tubing clip

ATTENTION: This material is sufficient only if the rotary tables are mounted in the manufacturer's plant.

If the rotary tables are retrofitted 'in the field', the following should be ordered: instead of 1 x LOZ.MAZ‐VCP.2EA, better 2 x LOZ.MAZ‐VCP.EA.

3.3 Angular position measuring system (option) (provisional)

In principle, on machines with APC, the angular position measuring system connection could be incorporated into connector X1233/X1243 (encoder signals) Type MS3102A‐28‐21S in addition to the blackBOX and encoder signals.

Because of the limited space, this solution with a separate M23 connector is preferable.

INSTALLATION


4 Installation of VCP400S with APC

4.1 Installation involves the following steps:

Prepare the machine

Install the filter/controller

Install and connect the pL LEHMANN rotary table

Enter parameters

Conduct test run

4.2 Prepare the machine, check the «OPTION PACK»

The expansion kit "Additional Axis 2PC NC Rotary Table" from MAZAK must already be installed for 2x 4th axis.

NOTE: This material is NOT part of the standard items included in the pL delivery! It must be provided by the machine manufacturer/dealer.

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1.

Machine with Fanuc control system Required Fanuc servo controller: Servo controller αiSV20/20‐B A06B‐6240‐H205 (2‐axis)

suitable for β1/6000is suitable for α2/5000is suitable for α4/5000is In order to eliminate the need to re‐ference the axes, the servo is con‐nected to an external buffer battery (mounted on the control cabinet door) Encoder thus functions as an abso‐lute encoder

Drive system, complete (servo rotary axes to the far right)

Rotary axis servo used

INSTALLATION


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2.

Machine with Mazatrol SMOOTH control system Mitsubishi servo controller requi‐red: Servo controller MDS‐EH‐V2‐10 (2‐axis)

suitable for HG‐H75S suitable for HG‐H105S In order to eliminate the need to re‐ference the axes, the servo is con‐nected to an external buffer battery (orange connector) Encoder thus functions as an abso‐lute encoder

Drive system, complete

Rotary axis servo used A402

3.

Rotary table connection to change table connection box (1x per pallet) MIL connectors are always used. The following connector types are in‐volved: MS3102A‐28‐21S (signals + encoder) CE05‐2A18‐10SDB (power) The standard MIL connectors from pL cannot be used, which is why se‐parate cabling had to be prepared for the VCP400S

MAZAK preparation

INSTALLATION


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4. Buttons for manual operation of the rotary table on the loading station

5. JOG buttons for 4th axis present (installed only temporarily in the photo)

6. Clamping relays KA40/KA41 instal‐led

7. Required SW options + PLC for 4th axis installed

NOTE: This material is NOT part of the standard items included in the pL delivery!

WARNING

INSTALLATION


Electric shock.

Danger of serious injury!

Make sure that the machine is disconnected from the electric mains.

Lock the main switch.

Use a voltage tester to check that the intermediate circuit voltage has dropped to 0 V.

ATTENTION

The diagrams may differ from one another.

Check that the machine and pL LEHMANN diagrams match!

The diagrams may differ on one page or another as the result of continued technical development, modifications, version, etc.

Always compare the electrical diagrams with one another.

If any doubt exists, please contact our customer technical service.

4.3 Install filter/controller for air and oil

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1. Ensure that the compressed‐air supply to the machine is turned off.

2.

Install the LEHMANN maintenance unit at the mounting holes provided (remove all three marked screws, substitute a low‐profile screw for the center screw with normal head) Install the MAZAK mounting plate.

Plate organized by MAZAK. (as an alternative, the pL plate HUR‐0001 can be used.)

Mounting position at rear right on machine

INSTALLATION


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Install the maintenance unit

Maintenance unit connection

(in picture with pL plate HUR‐0001)

3.

To connect the compressed air, use either the reducer D8 D6 or replace the coupler D6 with a D8 coupler at the compressed air inlet on the maintenance unit. . The manifold block can be found on the rear side of the MAZAK main pressure regulator. The two air lines that lead to the APC are probably connected to the manifold block; disconnect them from here and connect them to the outlet on the maintenance unit. If there happens to be an open connection, it can be sealed with the supplied blind plug and reducer D8 D6 CAUTION: MAZAK works with 5 bar system pressure (standard). If the full clamping force of the rotary tables is needed, the supply to the maintenance must be tapped in UPSTREAM from the MAZAK main pressure controller or the sy‐stem pressure must be increased to 6 bar. (Acc. to MAZAK, the system pressure can be increased to 6 bar without concern) (At 5 bar, approx. 20% clamping force reduction)

Compressed air manifold block

Overview of main pressure regulator, maintenance unit

INSTALLATION


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4.

If not already prepared by MAZAK ‐ 2 holes must be drilled on each of the WDF mounting plates for the Lehmann oil and air coupler connections 2x Ø10 in mounting plate 2x Ø15 in 'connector box'

Drilled holes

(usually prepared by MAZAK)

5. Fully prepared connection box

6.

Run oil line from Lehmann maintenance unit along the existing airline to the APC Connection to oil/air couplers

2 x ø10

2 x ø15

INSTALLATION


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Hose run along partition APC

Manifold on both rotary axes with T‐pieces

INSTALLATION


NOTE

Route hoses safely.

Kinked or overheated hoses can cause malfunctions!

Pay attention to bending radii.

Hoses should not come into contact with hot chips or aggressive substances.

ATTENTION

Compressed air at least 4 bar at flow rate of 130 L/min.

The clamping does not function below 4 bar!

The rotary table displays a «clamped» error message and the system cannot operate.

The error message is visible on the red LED "ERROR" on the motor cover.

The required pressure is 5‐6 bar. A lower pressure also means reduced clamping force.

Ensure adequate compressed air supply: The pressure must not drop below 4 bar at a flow rate of 130 L/min.

ATTENTION

Only use pL LEHMANN oil, VULCOGEAR V5.

Otherwise, the warranty will be invalidated immediately!

VULCOGEAR V5 was developed specifically for the very demanding requirements of pL LEHMANN gear units.

It must not be mixed with other products.

Ensure that your maintenance service receives this information.

NOTE

The white oil hose must be filled and free of bubbles at all times.

If air finds its way into the clamping system, error messages may be generated.

Check the fill level of the maintenance unit regularly.

Normal oil consumption is hardly indicated by the fill level.

INSTALLATION


4.4 Install rotary table, connect wiring harness

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1.

Place and secure the rotary tables on the machine table

CAUTION: Swivel circle of the pallet 1150 mm must NOT be exceeded

NOTE:

The following rotary tables can be used on machines with Fanuc control:

EA‐507 EA‐508 EA‐510 EA‐511

The following rotary tables can be used on machines with Mazatrol control:

EA‐510 EA‐511

(motors are too large for EA‐507.)

EA‐507 (Fanuc control)

EA‐510 (Mazatrol control)

2.

Connect wiring harness at wall bushing. Make sure that the flexible tubing is not bent too sharply and does not project into the swivel circle of the ATC an‐ywhere so that problem‐free swiveling of the ATC is possible. Attach wiring harness to partition using corrugated tubing clip NW23.

INSTALLATION


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3. Install spray guard connector interface.

4. Only if necessary: Secure wiring harness to rotary table housing by means of retaining clamps.

Example of securing the wiring harness.

5. View of cable outlet on EA‐507

COMMISSIONING


5 VCP with CNC «FANUC»

5.1 Commissioning

5.1.1 Entering parameters

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1.

Enter parameters in accordance with the pL LEHMANN parameter list. A list of parameters specific to your system is saved on the USB stick at the rotary table.

Or at http://www.lehmann-rotary-tables.com Downloads Commissioning.

Fanuc 0iMD control system

VCP400S control panel

5.1.2 MAZAK VCP400S‐specific parameters

Fanuc 0iMD

Axis assignment

Axis number Designation Description

1 X Linear axis

2 Y Linear axis

3 Z Linear axis

4 U Tool changer axis (tool magazine, ATC) not visible on POS screen

5 V Pallet change axis (APC) not visible on POS screen

6 A Rotary axis on Pallet 1 (4th axis in JOG)

7 B Rotary axis on Pallet 2 (4th axis in JOG)

COMMISSIONING


Inputs/Outputs

(For verification of the digital inputs/outputs)

I/O Reg. MAZAK Pallet Axis Designation

Y7.4 Unclamp solenoid valve 1 A Unclamp output, relay KA40

X8.5 Zero return deceleration 1 A Reference cam input (not used)

X8.6 Unclamp 1 A Input for axis unclamped

X8.7 Ignore 1 A Input for axis present

X8.2 Ignore (DCS) 1 A Input for axis present DCS (wire in parallel to X8.7)

Y41.0 Unclamp solenoid valve 2 B Unclamp output, relay KA41

X41.0 Zero return deceleration 2 B Reference cam input (not used)

X41.1 Unclamp 2 B Input for axis unclamped

X41.2 Ignore 2 B Input for axis present

X8.3 Ignore (DCS) 2 B Input for axis present DCS (wire in parallel to X8.7)

Keep relay

K Value Ori Designation Description K6#0 1 Enabling/Disabling

additional axis Pallet 1 Activation/deactivation of A‐axis. (not actually necessary, be‐cause axis is automatically deactivated when disconnected electrically (X8.7))

K6#1 1 Enabling/Disabling additional axis Pallet 2

Activation/deactivation of B‐axis. (not actually necessary, be‐cause axis is automatically deactivated when disconnected electrically (X41.2))

DATA

DATA Value Ori Value pL Unit Description

D1900 1145 3600 [°/min] Indexing of feed axis on setup station. Setup station door must be closed for this. effective value = value * 50% (Pallet 1)

D1904 1145 3600 [°/min] Indexing of feed axis on setup station. Setup station door must be closed for this. effective value = value * 50% (Pallet 2)

D1908 1145 1145 [°/min] JOG feed axis on setup station. Setup station door can be open. (Pallet 1)

D1912 1145 1145 [°/min] JOG feed axis on setup station. Setup station door can be open. (Pallet 2)

D1932 8 8 Dividing factor for indexing value on setup station. 8 = 360°/8 45°

Timer

Timer Original valueMAZAK [ms]

Value pL [ms]

Designation Description

T106 250 100 NC table unclamp timer A A‐axis.Wait time after 'unclamped signal' Can theoretically be reduced to 10 ms

T108 250 200 NC table clamp timer A A‐axisWait time after 'not unclamped' signal

COMMISSIONING


Must correspond to the effective clamping time + a bit extra

T110 250 50 NC inPosition timer A A‐axisWait time after InPosition (re‐adjust time)

T146 250 100 NC table unclamp timer B B‐axisWait time after 'unclamped signal' Can theoretically be reduced to 10 ms

T148 250 200 NC table clamp timer B B‐axisWait time after 'not unclamped' signal Must correspond to the effective clamping time + a bit extra

T150 250 50 NC inPosition timer B‐axisWait time after InPosition (re‐adjust time)

5.1.3 M‐functions

M‐function Designation Description

M46 Auto‐clamping 4th axis in machining compartment OFF Unclamp 4th axis

M47 Auto‐clamping 4th axis in machining compartment ON Clamp 4th axis (standard)

M71 Pallet 1 (with axis A ) in machining compartment Rotate APC Pal1 in work area

M72 Pallet 2 (with axis B ) in machining compartment Rotate APC Pal2 in work area

COMMISSIONING


5.1.4 Test run

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1Main switch ON (on 200 VAC transformer). Ensure that EMERGENCY STOP is released. Control ON

2

Check the Status LED on the motor housings of the pL Lehmann axes. REQUIRED status: Clamped:

LED +24 V illuminated green

LED Clamp illuminated blue

LED clamped illuminated green

3

Check whether it releases when the the 4th axis is selected via the rotary switch. (The clamping control basically functions automatically) Or when the JOG button for the 4th axis +/‐ is pressed (feed potentiometer open only minimally) Unclamped:

LED unclamped illuminated

CAUTION:

The 4th axis is always the axis that is currently in the work area. (In order to test both axes, it is thus necessary to rotate the change table (APC))

A 5th axis cannot be selected

4If OK, select 4th axis and carefully traverse the axis in the manual mode. Motor should not 'sing'

5Set absolute coder to the approximate 0‐positionPRM1815#4 1 0 1 (restart)

COMMISSIONING


6

Checks:

A. If the air pressure is reduced (less than 4 bar at the maintenance unit), the message 'Clamping error' should appear This test is not possible, since MAZAK processes only the 'unclamped' signal

B. Positioning at nmax possible? (CAUTION: Observe duty cycle 20%!)

C. Check rotation directions

D. Install customer‐specific workpiece, test to ensure that axis neither shakes nor vibrates.

E. Prepare NC‐ (or MDI) test program with operating modes G00 (rapid traverse) and G01 (feed) Check whether axis always moves smoothly

F. Check whether positioning of the rotary table at the change station functions correctly using the buttons provided.

For more information see " Commissioning manual DOK‐0004" chap. 3

7

Adaptations:

A. Measure and adjust the gear backlash PRM1851/1852

B. If necessary, activate Pitch error table

C. Set absolute encoder to the 0‐position PRM1815#4 1 0 1

OPERATION


5.2 Operation

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1. Basic screen

Here with deactivated A/B‐axis (A‐axis is always displayed)

2. Some control buttons

(the rotary table in the work area is al‐ways the 4th axis, the 5th axis cannot be selected)

Door switch

I for moving with open door

JOG buttons for 4th axis

3. Special functions

The Machine button can be used (in the

EDIT or MDI operating mode) to open MAZAK‐spec. diagnostic/maintenance function (e.g. for manually locking/un‐locking the change table)

OPERATION


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4. Error acknowledgement, e.g. after EMERGENCY STOP

Simultaneously press buttons MF1 +

MF2 + //

5. Operation at loading station

Release pallet (must illuminate so that pallet can be swiveled into work area) (pressing this button locks and unlocks the loading door)

Lights up when door unlocked.

Buttons A1/B1, A2/B2 for hydraulic workpiece clamping

Indexing selector switch (left) / JOG (right) (indexing only possible when loading door closed)

Buttons to rotate rotary axis UZ / GUZ

6. Rotate pallet The pallets are swiveled into position via an M‐command

M71 = Rotate pallet 1 into work area


It is first necessary to press to release the pallet ('good' symbol must light up)

Since the swivel axis of the pallet is an NC axis, the speed can be adjusted during swiveling by means of the rapid traverse potentiometer.

1

5

3

4

2

COMMISSIONING


5.3 Fanuc control FAQs

No. Question Response

1. Selecting/deselecting an axis

Selecting/activating an axis 1. Switch off the machine 2. Connect the rotary table 3. Restart machine

It is not necessary to adjust the keep relay

Deselecting/deactivating an axis

1. Switch off the machine 2. Disconnect the rotary table 3. Restart machine

When axes disconnected, the B‐axis is not visible and the A‐axis is preceded by 'D' for Detach

2. Referencing If the axis is not programmed for absolute (battery‐buffered), referencing is re‐quired each time the machine is restarted. (MAZAK standard: Battery‐buffered, no referencing necessary) MAZAK expects a normally closed contact for this This means that in the Blackbox switch 1 'Reference Signal' must be set to ON (inverted).

3. How is the reference point of the axis set? (if in absolute mode)

Rotary axis to desired 0‐position (at least 1 revolution of the motor) PRM1815#4 101 RESTART New absolute position is set

4. Sign preceding axis letter Meaning of sign preceding axis letter:

I Axis interlock (axis clamped)

D Axis detached (axis not connected)

* Axis rotates

COMMISSIONING



5. I/O channel The data input/output interface can be selected by means of Parameter 20 (I/O channel):

0.1 RS232C serial interface 4 Memory card interface (CF card) 9 Integrated Ethernet interface 17 USB memory interface (USB stick)

6.

Create screenshots

If the Shift key is pressed and held for a longer period of time (until the clock stops

briefly), a screenshot is saved automatically to the CF card or USB stick (depending on the PRM20 setting) The appropriate storage media must, of course, be plugged into the control system

7. Back up data 1. Select whether to use the CF card or USB stick for backup:

2. EDIT mode

3. System key

'All data' softkey 'Parameter' softkey 'BETR' softkey 'Execute'(AUSGBN) softkey 'AUSF' softkey

8. Additional signals at Black‐BOX

No additional signals such as 'Error' / 'Ready' / 'Service' are evaluated.

9. Motor load is high Since the drive systems have been designed for intermittent operation S3 ED20% with cycle duration of 1 min (positioning mode), it is absolutely nor‐mal that the motor load is greater than 100% during the acceleration/decele‐ration phase. As long as ED20% is not exceeded, this represents a permissible thermal and mechanical load on the motor. If ED exceeds 20%, rotational speed and acceleration must be reduced.

10. Speed inversion The axis direction can be inverted by means of parameter PRM2022 (111 / -111)

11. Released signal missing/flickering

Check ground/shield.

12. Clamping control MAZAK has an 'UNCLAMP' output. This means that DIP Switch 3 'clamp' must be set to ON (inverted) on the Blackbox Only the 'unclamped' signal is processed by MAZAK. Thus, true 'clamped monitoring' cannot be achieved with the control system. Clamping errors are indicated only at the LED strip on the rotary table or found by reading the logfile

COMMISSIONING



Standard for releasing is 24 VDC.

Clamping relay KA40 A‐axis KA41 B‐axis

13. Clamping always disengaged If the clamping mechanism is always disengaged, the reason may be that the fitted clamping relay is a solid‐state relay (SSR). (SSR need a small erasing/reset current on the load side) to switch to OFF again, as of 2017 all pL rotary tables are fitted with a corresponding load resistor. If a pL rotary table with date of manufacture < 2017 is being connected, it may be necessary to retrofit this load resistor)

14. What to check in the case of a clamping error?

Pneumatic pressure at LEHMANN maintenance unit below 4.0 bar

Check clamping status LEDs on motor housing

Axes bled correctly (Caution: Can be checked only with machine swit‐ched off and clamping released. See also standard commissioning manual BR500 DOK‐0004)

15. Direct connection of wiring harness instead of MIL connectors

If there are reservations regarding the leaktightness of the MIL connectors, an alternative is to connect the rotary table directly to the JB60 connection box on the top of the machine. Encoder connectors were Harting X1235, X1245. It would then be necessary to select the cabling variant 'KAB.xx.xx‐o' (= free cable ends). This variant is not described further by pL in this manual

16. Safety error In order to initialize DCS correctly together with the pL rotary axes, the machine must be started ONLY with the EMERGENCY STOP not actuated. Otherwise, the following error messages, which cannot be acknowledged, appear (machine must be restarted)

COMMISSIONING



5.4 Safety (DCS)

Some information about safety functions on the machine

The machine operates basically with DCS (Double Check Safety). In general, DCS is active when the work area door is open

When a door is open, the 'Safe operating stop' and 'Safely limited speed' monitoring functions are always active

Currently (as of April 2017) the control system displays a Safety error message if the machine is started with activated rotary tables and the EMERGENCY STOP actuated. Cause: Faulty DCS initialization in PLC. Elimination: Restart machine with EMERGENCY STOP not actuated

For DCS diagnosis, the specific DCS error can be checked in System DCS Check CROSS CHECK (page 1 shows the active errors (PMC and DCSPMC should always be identical)

Some information G750/G02 VLDV (safely limited speed) G750#0 Axis 1 …. #7 = Axis 8 1 = Safety inactive 0 = Safety active (door open)

X8.4 = EMERGENCY STOP (in the case of MAZAK, the other bits of X8 are not relevant,

COMMISSIONING


(PMC and DCSPMC must be identical only in bit 4)

F750, F751, F752 ‐ Safety status bytes

Using F766, it is possible to see whether safety is active in each axis (Bit 0 = Axis 1… Bit 7 = Axis 8, 1= active)

5.4.1 A few important safety parameters

PRM Designation Value A / B

13822..84 Safety parameter (already preset by Mazak) ‐

1904#6 DCS Dual Check Safety on each axis active = 0 inactive = 1 (may be set to inactive only for test purposes)

0 / 0

10597#0 IDD expanded view of Dual Check Safetyinactive = 0 active = 1

1

COMMISSIONING


6 VCP with CNC «Mazatrol SMOOTH C»

6.1 Commissioning

6.1.1 Entering parameters

No. Text Image

1.

Enter parameters in accordance with the pL LEHMANN parameter list. A list of parameters specific to your system is saved on the USB stick at the rotary table.

Or at http://www.lehmann-rotary-tables.com Downloads Commissioning.

Mazatrol SMOOTH C: Mazatrol SMOOTH G:

Parameter lists:

MAZAK_SMOOTH_400V_EA…..pdf MAZATROL SMOOTH C control

VCP400S control panel

2. Entry of Mazak‐specific PLC options parameters

6.1.2 MAZAK VCP400S‐specific parameters

Mazatrol SMOOTH G

Axis assignment

Axis number Designation Servo No.

DIP Switch Servo

Description

1 X A401 Linear axis

2 Y A401 Linear axis

3 Z A401 Linear axis

4 A A402 SWL = 4 Rotary axis on Pallet 1 (4th axis in JOG)

5 B A402 SWM = 5 Rotary axis on Pallet 2 (4th axis in JOG)

17 ‐ A440 Tool changer axis (tool magazine, ATC) not visible

18 ‐ A441 Pallet change axis (APC, 2PC) not visible

COMMISSIONING


Inputs/Outputs

(For verification of the digital inputs/outputs)

I/O Reg. MAZAK Pallet Axis Designation

? Unclamp solenoid valve 1 A Unclamp output, relay KA40

? Zero return deceleration 1 A Reference cam input (not used)

? Unclamp 1 A Input for axis unclamped

? Ignore 1 A Input for axis present

? Unclamp solenoid valve 2 B Unclamp output, relay KA41

? Zero return deceleration 2 B Reference cam input (not used)

? Unclamp 2 B Input for axis unclamped

? Ignore 2 B Input for axis present

Option VCP400S (Smooth C Control)

O Number Value Description

O1 2x EA = 6 Number of control axes (Axis No‐1)X,Y,Z;MAG = 3 X,Y,Z,A;MAG = 4 X,Y,Z,A,B,MAG,2PC = 6

O3 4 Simultaneous number of control axes

O85 2x EA = 4 Max Servo axis number ‐1only CNC axes, without PLC axes (ATC, MAG, 2PC)

Setting for VCP400S with APC, but only 1xEA

COMMISSIONING


PLC parameters VCP400S (Smooth C Control)

RB No. Value Description

RB1 xxxxxxx1 Bit0: Type of table 1: 4th axis validBit7: Type of feedback 4 1: Absolute, 0: Incremental

RB3 xxxxxx11 Bit0: 2PC spec 0: without APC, 1: with APCBit1: 2PC & 2RT spec 0: without rotary table,1: with 2x rotary table

RB9 xxxxx100 Bit0: Type of Feedback 5 1: Absolute, 0: IncrementalBit1: Type of Feedback 6 1: Absolute, 0: Incremental Bit2: 5th Axis Spec: 1: Available, 0: Unavailable

RB14 x11xxxxx Bit5: 4th Axis Servo OFF 1:active, 0: inactive (Servo immer EIN) Bit6: 5th Axis Servo OFF 1:active, 0: inactive (Servo immer EIN)

RB20 xxxxxx1x Bit1: 4th/5th Axis handle feed *1000 0: inactive, 1: active


RS No. Value Description

RS74 8 2PC setup side rotary table index feed fixed point number(Dividing factor for indexing value on setup station. 8 = 360°/8 = 45°)

RL No. Value Unit Description

RL70 18000 °/min PTP feed speed 4th axis (indexing of feed on setup station)

RL71 18000 °/min PTP feed speed 5th axis (indexing of feed on setup station)

RL74 0 0.0001° 2PC setup side rotary table index angle shift amount

COMMISSIONING



PLC timer VCP‐400S

Timer Value Ori Value pL Unit Designation Description

TIM24 25 (250 ms)

15 [0.01 s]

Unclamp timer 4th axis A‐axisWait time after 'unclamped signal'

Can theoretically be reduced to 10 ms

TIM25 25 20 [0.01 s]

Clamp timer 4th axis A‐axisWait time after 'not unclamped' signal


TIM36 25 10 [0.01 s]

Unclamp Sol on time from servo on 4th axis

A‐axisWait time between servo ON and unclamp

TIM71 5 (500 ms)

2 [0.1 s] Brake on timer 4th axis A‐axisWait time after InPosition (re‐adjust time)

TIM21 25 (250 ms)

15 [0.01 s]

Unclamp timer 5th axis B‐axisWait time after 'unclamped signal'

Can theoretically be reduced to 10 ms

TIM22 25 20 [0.01 s]

Clamp timer 5th axis B‐axisWait time after 'not unclamped' signal


TIM37 25 10 [0.01 s]

Unclamp Sol on time from servo on 5th axis

B‐axisWait time between servo ON and unclamp

TIM38 5 (500 ms)

2 [0.1 s] Brake on timer 5th axis B‐axisWait time after InPosition (re‐adjust time)


COMMISSIONING


Safety Parameters

PRM No. Value Unit Description

#51104 1433 °/min SLS2 (safely limited speed when door open)(2000 mm/min circumferential speed = (2000 / diameter (200) /π) x 360 x 1.25

Recalculate if interference radius is greater than 100 mm

#51105 3583 °/min SLS3 (safely limited speed in mode 3)(5000 mm/min circumferential speed = (5000 / diameter (200) /π) x 360 x 1.25

Recalculate if interference radius is greater than 100 mm

Safety parameters can be found under Diagnostics Version Version

System Mainte

Safety Data

Safety Param

Servo

COMMISSIONING


Safety parameter entry page

M‐Codes VCP‐400S

M‐function Designation Description

M46 (?) Auto‐clamping 4th axis in machining compartment OFF Unclamp 4th axis

M47 (?) Auto‐clamping 4th axis in machining compartment ON Clamp 4th axis (standard)

M71 (?) Pallet 1 (with axis A ) in machining compartment Rotate APC Pal1 in work area

M72 (?) Pallet 2 (with axis B ) in machining compartment Rotate APC Pal2 in work area

6.1.3 Installing/removing

Installing the rotary table

4. Open doors

5. EMERGENCY OFF

6. M17#7 for each axis on 0 (0=if axis removed = alarm) (error message 'Servo problem 1 appears)

7. Switch off the machine

8. Install rotary table(s)/connect electrically

9. Switch on the machine

Removing the rotary table

1. Open doors

2. EMERGENCY OFF

3. M17#7 for each axis on 1 (1=if axis removed = no alarm)

4. Switch off the machine

5. Remove rotary table(s)/disconnect electrically

6. Switch on the machine

COMMISSIONING


6.1.4 Test run

No Text Image

1. Main switch ON Control ON

2.

Check the Status LED on the motor housings of the Leh‐mann axes. Required status: Clamped:

LED +24 V illuminated green

LED Clamp illuminated blue

LED clamped illuminated green

3. Set absolute coder approximately to the 0‐position or run referencing

4.

Check whether it releases when the 4th or 5th axis is selected via the rotary switch. (The clamping control basically functions automatically) Or when the JOG button for the 4th +/‐ is pressed (feed potentiometer open only minimally) Unclamped:

LED unclamped illuminated yellow

CAUTION:

The 4th axis is always the axis that is currently in the work area. (In order to test both axes, it is thus necessary to rotate the change table (APC))

A 5th axis cannot be selected

JOG buttons installed only temporarily here

5. If OK, select 4th axis and carefully traverse the axis in the manual mode. Motor should not 'sing'

COMMISSIONING


No Text Image

6.

Checks:

A. If the air pressure is reduced (less than 4 bar at the maintenance unit), the message 'Clamping error' should appear This test is not possible, since MAZAK processes only the 'unclamped' signal

B. Positioning at nmax possible? (CAUTION: Observe duty cycle 20%!)

C. Check rotation directions

D. Install customer‐specific workpiece, test to ensure that axis neither shakes nor vibrates.

E. Prepare NC‐ (or MDI) test program with operating modes G00 (rapid traverse) and G01 (feed) Check whether axis always moves smoothly

F. Check whether positioning of the rotary table at the change station functions correctly using the buttons provided.

For more information see " Commissioning

manual DOK‐0004" chap. 3

7.

Adaptations:

A. Measure and adjust gear backlash Parameter N12/N13

B. If necessary, activate Pitch error table

C. Set 0‐position Parameter M16

OPERATION


6.2 Operation

6.2.1 Control 'SMOOTH C'

No Text Image

1. Start screen

The control can be shut down/re‐started using the menu at the lower right

2. Basic screen

Operation / menu guidance basically very similar to that on MATRIX SMART/ NEXUS II

3. Menu control

4. Some control buttons

Door switch

Main menu/back 'Scroll' in the current menu

Selector

OPERATION


No Text Image

5. Error acknowledgement, e.g. after EMERGENCY STOP

Usually Reset // suffices

In special cases, also:

Simultaneously press buttons MF1 +

//

6. Executing an NC program (Screens from Mazatrol SMART)

Create an NC program

Select program

I for moving with open

door

OPERATION


No Text Image

Program is executed

7. Executing an NC program (Screens from Mazatrol SMART)

Create an NC program

Select program

OPERATION


No Text Image

Program is executed

8. Operation at loading station

Release pallet (must illuminate so that pallet can be swiveled into work area) (pressing this button locks and unlocks the loading door)

Lights up when door unlocked.

Indexing selector switch (left) / JOG (right) (indexing only possible when loading door closed)

Buttons to rotate rotary axis UZ / GUZ

9. Rotate pallet The pallets are swiveled into position via an M‐command



It is first necessary to press to release the pallet ('good' symbol must light up)

Since the swivel axis of the pallet is an NC axis, the speed can be adjusted during swiveling by means of the rapid traverse potentiometer.

1

4 3

2

OPERATION


6.3 SMOOTH C FAQs

No Question Response

1. Axis vibrates If the axis vibrates because of uneven loading, the parameter SV03 (Speed loop gain 1) must be reduced by approx . 20% under certain circumstances

2. Motor load is high Since the drive systems have been designed for intermittent operation S3 ED20% with cycle duration of 5 min (positioning mode), it is absolutely normal that the motor load is greater than 100% during the acceleration/deceleration phase. As long as ED20% is not exceeded, this represents a permissible thermal and mechanical load on the motor. If ED exceeds 20%, rotational speed and acceleration must be reduced.

3. Referencing MAZAK expects a normally closed contact at the reference cam. For this reason, the reference output on the BlackBox must be inverted (Switch 1 'Reference Switch' set to ON (inverted)) CAUTION: ACTUAL VALUE buffering of the encoder can be retained several hours (3h) during the test even though the motor was electrically disconnected from the machine. Only a longer interruption such as overnight (approx. 12h) 'emptied' the memory of the encoder, which then required re‐referencing. This must be taken into consideration especially in the case of service visits, replacement rotary tables, troubleshooting. To ensure that everything functions correctly in such cases, referencing should always be forced in the event of a service visit: M18#7 to 0 ð PowerON ð M18#7 to 1 ð PowerON ð Reference

4. How is the reference point of the axis set?

The reference point offset is entered in parameter M16 for the desired axis. (Input unit: 0.0001°) M18#7=1 is used to set the axis (battery‐buffered) as an 'Absolute system' this means that – as long as the rotary table is locked – no reference run is required after Power ON In general, we recommend that both the reference cam is evaluated and battery buffering is used. Advantages of this system: As long as the rotary table is not disconnected from the machine there is no need to perform a reference run. If the rotary table has been disconnected from the machine and reconnected, then all that needs to be done is to perform a single reference run via the

HOME function (the cam is active here), after which the system will run in absolute mode again. This means: the reference point offset in M16 always refers to the reference cam.

OPERATION



If one axis is not yet referenced, the machine start automatically in the REF mode. If all axes are referenced, the machine starts in the MEMORY mode

5. Differences between 'incremental' and 'absolute axis'

Param. Absolute Incremental Unit Description

SV17 308C 308C HEX Servo encoder configuration (always absolute)

O66#0 1 1 Bit‐coded

Cam/grid evaluation

RB1#7 0 0 Bit‐coded

Cam present for referencing(0=Yes)

M16 e.g. 3'462'000

e.g. 3'462'000

0.0001° Reference point offset (only positive values allowed)

M18#7 1 0 Bit‐coded

Absolute or incremental mode

M20#6 0 0 Bit‐coded

6. Clamping control MAZAK has an 'UNCLAMP' output. This means that DIP Switch 3 'clamp' must be set to ON (inverted) on the Blackbox Only the 'unclamped' signal is processed by MAZAK. Thus, true 'clamped monitoring' cannot be achieved with the control system. Clamping errors are indicated only at the LED strip on the rotary table or found by reading the logfile Clamping can be activated/deactivated completely only by means of PLC bits. Deactivation/activation by an M‐code is not available

7. Clamping always disengaged

If the clamping mechanism is always disengaged, the reason may be that the clamping relay installed is a solid‐state relay (SSR). If this is the case, replace the SSR with a conventional relay. CAUTION: The machine will not report an error if the clamping mechanism fails to engage. The program will be worked through despite this.

OPERATION



8. Speed inversion The axis direction can be inverted by means of parameter M17 Bit 5

9. How do I access the machine parameters?

Softkeys

'

PARAM

MACHINE PARAM

10. Parameter levels K = Language selection can be found here M = General machine parameters N = Machine parameters acceleration, rotational speed etc. SV = Servo parameters

11. How do I access the servo parameters?

Softkeys Diagnostics

Diagnostics Version

OPERATION



Enter 1131 Enter

Servo Monitor

Param

Attention: Some parameters become active only after the control system reboots

12. Servo diagnostics Softkeys

Diagnostics

Diagnostics Version Enter PW 1131 Enter

Servo monitor

Servo monitor

OPERATION



The servo, motor and encoder type for each axis are visible here

OPERATION



DROOP = Lag error

CYC CNT: Internal current encoder position

13. How do I access the option parameters?

Softkeys

Diagnostics

Diagnostics Version (left)

OPERATION



Diagnostics Version (right)

14. Servo oversized By setting SV017 Bit A a motor can be operated with an oversized servo controller. (at most, the 'next larger servo controller can be used) This change is clearly NOT recommended by Mitsubishi. If this bit is set, it may also be necessary under certain circumstances to change various controller parameters

15. PLC view It is possible to switch to the PLC view mode by means of 'LADDER MONITOR' in the Version menu

OPERATION



16. Mazatrol smart: Error message The messages: 128/129 Interlock axis A should be considered as 'normal' (appear with every clamp/unclamp operation)

OPERATION



17. Max. number of axes for simultaneous operation

On Mazatrol SMOOTH C trix Nexus II maxmax. 4 axes can be programmed simultaneously, no option for 5ax selectable

OPERATION



18. Creating screenshots on the SMOOTH CSmart Control

USB StickCF card must be inserted into control

Then CTRL + .

19. Creating a screenshot on Matrix Nexus 2 (Windows 7 Embedded)

With Windows Tools 'PrintScreen3' under C:\mainte\

OPERATION



20. Adjusting increments for 4th/5th axis.

The adjusting increments for the handwheel or in jog mode are selected via hardware buttons. x 1 = 0.0001° x 10 = 0.0010° x 100 = 0.0100° x 1000 = cannot be selected for round axes

21. Data Backup Several possibilities are conceivable for backing up machine/servo parameters and/or also NC programs. In any case, first insert USB or CF card Password must also be set Complete backup version: Diagnostics NC DATA SAVEEN BACKUP

NC USB DATA SAFE

BACKUP DATA SAVE

OPERATION



Only desired data version: INPUT/OUTPUT

With Ver. selection Select the desired target directory on the USB stick

OUTPUT NC –> USB

Mark desired data for backup A‐PARAM / M‐PARAM / S.DATEN needed for parameter backup

With START the files marked in blue are copied to the USB drive

DIAGRAMS


7 Electrical connection of Fanuc control

7.1 Overview of MAZAK control cabinet (FANUC servos) 2‐axis version (VCP400S with APC)

A240 / A241 Servo A/B axis

A701 / A702 Batteries for buffering the absolute values of encoder

KA40 / KA41 Output relay Unclamp A/B‐axis

DIAGRAMS


7.2 VCP Series (with APC)

DIAGRAMS


7.3 «KAB.Fx‐x.x‐MZb‐2» for VCP Series (with APC) (200 V), FANUC servo

DIAGRAMS


8 Electrical connection of MAZATROL control

8.1 Overview of MAZAK control cabinet (Mitsubishi servos) 1‐axis version (VCP400S with APC)

A402 Servo A/B axis

KA40 / KA41 Output relay Unclamp A/B‐axis

DIAGRAMS


8.2 «KAB.MI2‐x.x‐MZb‐2» for MITSUBISHI motor, Type HG‐H

CONTACT


9 Contact

Manufacturer:

Peter Lehmann AG

Bäraustrasse 43

CH‐3552 Bärau

+41 (0)34 409 66 66

+41 (0)34 409 66 00

[email protected]

www.lehmann‐rotary‐tables.com

Thank you for using pL LEHMANN products!

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