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U
*Ensure regional settings correct - correct date format
*Rename the Ethernet Adaptors to Ethernet and EtherCAT
*Ensure the [https://stuga.dokit.app/wiki/TwinCAT_Issue_-_EtherCAT_Network_Protocol_Missing TwinCAT Protocol is installed] on the EtherCAT adaptor
*Teamviewer setup
*Administrator password set to "Stuga001"
*Add Stuga desktop image
*Latest winMulti in c:\multi
+, Map the network drives
Map customer network connections +, This is important to ensure there have been no mistakes in the remapping +, …
Before the upgrade is despatched to site, the servo system needs to be assembled and pre-wired in its enclosure.
<br/>
*Drill off Fan detail in right hand side of cabinet. A 114mm hole saw and arbor has been purchased for this.
*Drill and fit 4 adjustable feet in the bottom of the cabinet. 4 extra nuts will be in the kit. The height of the feet does not need to be set at this stage.
*Drill off all servo drives. For ZX3 machines, the rack will be as follows: AX8640-AX8118-AX8206-AX8206 and for a ZX4 the will be: AX8640-AX8118-AX8206-AX8206-AX8206 (the extra drive is for the V and W axes).
*Pre-wire the rack (inc STO links) and the cabinet fan with the cable provided in the kit. leave the spare coil of cable in the cabinet ready for running on-site.
*Plug in the 2x15m green etherCAT cables.
*The enclosure bottom plate is left off to allow the cable entry on site.
'''''*for detailed wiring information, please use drawing packs from Monday.com board.*''''' +, '''Parts'''
The parts should arrive on site, packed as a kit. Check the parts for any obvious signs of damage and check through to make sure you have received what was expected.
'''Expectations'''
Before starting any works, check in with the customer and make sure that all parties are aware of the scope of the work being undertaken. It is good to set expectations at this point, to keep clarity between you and the customer.
'''Starting the Job'''
<div class="icon-instructions caution-icon">
<div class="icon-instructions-icon"><i class="fa fa-exclamation-triangle"></i></div>
<div class="icon-instructions-text">...Ensure machine is turned off and properly isolated before starting any work!</div>
</div>
Check machine condition and get pictures before starting any work. It may be useful to run the machine to check any inherent issues before the upgrade begins. After works have been started, it will not be possible to come back to this stage.
<br/> +, It is important to note that although the components are being removed from the machine, they are not to be thrown away. Please keep all parts in good condition and find a place to store them until the end of the upgrade process.
Where wiring needs to be disconnected, try and keep crimped ends attached so that the wires can be reused later in the upgrade process.
'''Parts to be removed from MH cabinet:'''
*Main PC.
*Servo Drives.
*Breakout boards for Servo drives.
*Motion controller.
*Filters and resistors for Servo system.
*Smartdrive control box and associated cards.
*All network switches and modem devices.
<br/> +, …
infeedZeroToX=605
stopZeroToX=595
measureSensorPos1=1554 +, Original TC2 software has the saw and extractors set up as a simple kind of inverter. The should now be removed and the mapping changed for the outputs Y97 and Y98 directly mapped rather than "inverterGoFwd" +, Original TC2 software has the spindle inverter set up as a simple kind of inverter. The should now be removed and the mapping changed for the output Y62directly mapped rather than "inverterGoFwd" +, …
Check the [https://stugaltd.monday.com/boards/304269981 Control Systems Log] board to look up the machine and the control system used
This procedure only applies to TwinCAT2
For TwinCAT3 upgrades use [[Full Version Upgrade TwinCAT3 WinMulti]] +, Latest files are stored in
G:\Builds\Latest Software Versions\Multi.TwinCAT2.
Use teamviewer to copy it across to the machione.
The default folder on machines for the projects is
c:\TwinCAT\Stuga +, The program will prompt that the program has changed. Click Yes +, …
Ask one of the IT team to connect and download it
<br/><div class="icon-instructions caution-icon">
<div class="icon-instructions-icon"><i class="fa fa-exclamation-triangle"></i></div>
<div class="icon-instructions-text">...It is over 1Gb long!</div>
</div>
G:\Design\TwinCAT3\TC31-FULL-Setup.3.1.4024.22.exe
<br/> +, Ensure the box indicated is ticked +, https://github.com/microsoft/Git-Credential-Manager-for-Windows/releases/download/1.20.0/GCMW-1.20.0.exe
There are lots of forms on install - leave all as default +
V
With the machine turned off , find the FE PC and remove it as much as you need to gain access to the top cover.
If you are upgrading the memory try and remove the PC to a flat surface. +,
#Press the blue clips at the front of the disk cradle and slide towards the front of the PC.
#Lift cradle out and turn upside down.
#Place the SSD drive upside down in the cradle and locate the side lugs into the drive screw holes.
#Flip the cradle over and reverse the extraction process ensuring that the SATA edge connector slides into the female connector on the motherboard.
+, After powerup look at "my computer" and ensure that you have an extra Disk drive of 400+GB. +, …
# Install the VM Upgrade hardware [[VM Upgrade Hardware]]
# Check that you have at lease 12GB of memory.
# Check that the extra disk is present (Should be D)
+,
# Open Hyper-V Manager
# Select FE name on the Tree
# Create Virtual switch External
# Name Stuga Virtual Switch
+,
# RMB start the Virtual PC
# RMB Open (or double click the image)
# Sign in with usual passwords
# check and install all updates
# Rename the PC with the same name as the FE but replace the FE with VM
+, …
First, make sure the heater plates are cool enough to work on. If not then gloves will be required to protect your hands from the heat
Put the machine into input/output mode. This will then allow us to move the heater plates into a position to be worked on. Ensure the items highlighted in GREEN are on. +,
# In the I/O screen switch off "Melting". This will activate the cylinder that moves the heater plate from side to side.
# Check to see if the plate is roughly centred. This is not critical to welding, it merely ensures that the plate doesn't catch on anything and rip the Teflon sheets when moving into position. This can be adjusted by screwing the rubber stop in or out.
# This cylinder is OFF during the welding process to allow the plate to centralise itself between the faces of the profile and give an equal amount of weld on each side
+, Remove the 4 CS Hex screws and remove the setting plate to get easy access to the adjusters.
#The adjusters highlighted in RED are for adjusting the plate side to side to change the angle.
#There is one on either side of the plate. Both locknuts need slackened off and then the adjustment screws turned in the same direction as each other ie, one in, and the other out. This will ensure they keep a tight grip on the plate.
#Adjust the angle of the heater plate until it aligns with the bed, and then tighten the lock nuts.
#The Grubscrews circled in GREEN are for adjusting the vertical plane of the plate to ensure they are square to the beds. This can be checked with an engineers square. +
W
# Open Settings->Colours
# Select the colour from the list
# Update the Description if required
# Edit the Top, Core and Face colour by clicking and choosing a colour
<br/><div class="icon-instructions info-icon">
<div class="icon-instructions-icon"><i class="fa fa-info-circle"></i></div>
<div class="icon-instructions-text">...The colour codes are automatically added each time a new colour code is sent to the machine</div>
</div><br/>
+, Click on the Colour Indicator bar next to the profile picture
The colour settings tab will open as Method 1, but the colour will be automatically selected +
Once you have a black screen with a small blue text box in the middle you are safe to press the physical red 'POWER OFF' button on the console. +, Now turn the console isolator anti-clockwise to the off position +, When prompted press 'Yes' to confirm you are wanting to shutdown the machine
The software will now automatically close, windows will also start to shutdown. You may have to wait up to 60 seconds until the PC is shutdown.
<br/>
<div class="icon-instructions info-icon">
<div class="icon-instructions-icon"><i class="fa fa-info-circle"></i></div>
<div class="icon-instructions-text">...Depending on the machine type, the axes may move to a 'clear' position</div>
</div> +, …
X
Select Q1 +, Via IO screen +, • Short circuit: In the event of a short circuit at the sensor output, the green LED flashes with a frequency ofapprox. 4 Hz.
• Teach error: In the event of a teach error, the yellow and green LEDs flash alternately with a frequency of approx. 8 Hz
<br/><div class="icon-instructions idea-icon">
<div class="icon-instructions-icon"><i class="fa fa-lightbulb-o"></i></div>
<div class="icon-instructions-text">...Note!
The difference in the taught-in distance measured values for the switching thresholds A and B must be
greater than the switching hysteresis set in the sensor.
On delivery, the switching hysteresis is 15 mm.
If the difference in the taught-in measured values is the same as or smaller than the set switching
hysteresis, the sensor will visually signal an unsuccessful Teach-In. The last distance measured value
that was taught in will not be adopted by the sensor.
Select a new distance measured value for switching threshold A or B with a greater difference between
the switching thresholds.
Teach in this distance measured value on the sensor again.</div>
</div><br/> +, …
Z
A straight faced piece of profile the same height as the Z section or taller or a piece of steel straight edge or the like; then lastly a Z section profile for measuring. +, Place the long face of the 100 mm set square vertically between the Z section and the straight edge as shown in the picture. Lay the short edge of the 150 mm set square along the top face of the Z section. This will support the 100 mm set square’s short edge and stop it falling over - as shown in the picture. +, You will need a 150mm Vernier caliper, a 150mm set square and a 100mm set square. +, …
Align the infeed roller block so that it is square (check the roller with a straight edge against the other rollers). Fit the bracket using the 2 off M8 x 25 Bolts. Mark through the clearance holes on the bracket onto the roller block. +, Reinstall strengthening bracket with 2x M8 x 16 Bolts (F0000023) into the infeed roller block, and the 2x M8 x 25 Bolts (F0000025) into the infeed arm. +
Locations of jigs required
mounting method +, Levelling jigs
1st level jigs individually
2nd level jigs to each other
<div class="icon-instructions caution-icon">
<div class="icon-instructions-icon"><i class="fa fa-exclamation-triangle"></i></div>
<div class="icon-instructions-text">...Lowest datum point must be held when levelling jigs
explain</div>
</div><br/> +, Use wire to align jigs to each other
Double checks ensure levels are correct after wire alignment
Q/C +, …
If the blades do not meet properly, or form a "W" shape, the mechanical setup is not correct. Please follow procedure:
[[ZX5 V Notch Blade Mechanical Setup|https://stuga.dokit.app/wiki/ZX5_V_Notch_Blade_Mechanical_Setup]]
<br/> +, <br/><div class="icon-instructions pin-icon">
<div class="icon-instructions-icon"><i class="fa fa-thumb-tack"></i></div>
<div class="icon-instructions-text">...Remember that the width of the V notch is HALF the depth
</div>
</div>Open the 'Settings' screen and the 'Notching' tab
# For the front V Notches, the depth is adjusted by changing the dOffsetVI variable
# For the rear V Notches, the depth is adjusted by changing the dOffsetWI variable
+ will make the V notch deeper, - will make it shallower +, Run a manual test with a shallow V notch and datum hole in the same x axis position
The goal is to adjust the 'xOffset' variable to get the datum hole and V notch to line up +, …
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