Upgrade ZX Machine to Beckhoff Drives and Control

This tutorial will provide a step by step guide on how to upgrade a ZX style machine to have Beckhoff drives and control system.

Difficulty

Very hard Very Hard

Duration

5 day(s) day(s)

Upgrade, Beckhoff, ZX3, ZX4, Control System Upgrade_ZX_Machine_to_Beckhoff_Drives_and_Control_ZX4.JPG

Introduction

The ZX3 and ZX4 machines that have control systems that pre-date the Beckhoff hardware now have an upgrade available. The upgrade will bring up-to-date hardware to the machines control system and drives. The control system and drives will be changed to Beckhoff. TwinCAT 3 PLC and AX8000 series drives.

Attention

Refer to instruction manual

Use protective footwear

For maintenance disconnect from mains

Generic warning

High Voltage

Step 1 - Preparation (Base)

Check through all parts lists and make sure that the parts that have been requested are the parts that are in the box. The picked parts should include all the consumable products that are in the BoMs (bolts, tie wraps, wires etc).

Once parts have been checked, they need to be handed to production for pre-assembly.

Ensure all information and drawing packs are available in the service job and in the relevant technical information boards on Monday.com. Link to Monday board for drawing packs here:

https://stugaltd.monday.com/boards/3338864598

Step 2 - First Fix Servo Cabinet

Before the upgrade is despatched to site, the servo system needs to be assembled and pre-wired in its enclosure.

• 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.*

Step 3 - Preperation (On-Site)

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

...Ensure machine is turned off and properly isolated before starting any work!

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.

Step 4 - Remove Components - MH (Electrical)

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.

Step 5 - Remove Components - Saw (Electrical)

Parts to be removed from Saw Cabinet:

• Ace PC
• Nextmove ESB Controller
• Servo Drive
• Breakout board for Servo Drive
• Filter and Resistor for Servo Drive
• 12Vdc Power Supply

Step 6 - Remove Components - Saw Infeed (Electrical)

...This is also known as the 'Transfer Cabinet'

Parts to be removed from Saw Infeed Cabinet:

• B&R PLC (or Omron)
• LEDs on cabinet door

Step 7 - Remove Components - Field Components

Parts to be removed:

• Touchscreen from MH Console
• Keyboard and PS2 cable from MH Console
• Touchscreen from Saw Console
• VGA and any USB or PS2 cables from Saw Consoles
• Printer serial cable
• SX axis servo cablesfrom Saw cabinet through to SX axis motor
• X axis servo cables from MH rear plug join to X axis motor
• X axis servo cables from MH drop down panel to MH rear plug join
• G axis stepper cable from MH drop down panel to MH rear plug join
• Y, Z and R axis servo cables from MH drop down panel to servo motors
• X, Y, Z and R axis servo cables from MH Cabinet to MH drop down panel
• G axis stepper cable from MH cabinet to MH drop down panel

Step 8 - Fit Parts - MH (Electrical)

...When fitting IO slices, try and place them in such a way that existing IO wiring will reach the terminals.

Parts to be fitted in MH cabinet:

• Beckhoff IO Slices
• Beckhoff IPC
• Front End PC
• 24Vdc 10A Power Supply
• 3Pole 10A Breaker for Servo System
• 1Pole 3A Breaker for 24Vdc 10A Power Supply
• Din Mount Network Switch

*For any IO wiring that will not reach the IO slices, terminals are provided in the kit. The terminals can be used to extend the wiring.*

Step 9 - Fit Parts - Saw (Electrical)

...When fitting IO slices, try and place them in such a way that existing IO wiring will reach the terminals.

Parts to be fitted in Saw Cabinet:

• Beckhoff IO Slices
• Din Mount Network Switch

Step 10 - Fit Parts - Transfer (Electrical)

...When fitting IO slices, try and place them in such a way that existing IO wiring will reach the terminals.

Parts to be fitted in Saw Infeed Cabinet:

• Beckhoff IO Slices

Step 11 - Fit Servo Cabinet

Step 12 - Wiring Cabinets

Refer to drawings

Step 13 - Run Machine Cabling

Step 14 - Upgrade Console - MH

Step 15 - Upgrade Console - Saw

Step 16 - Terminate Machine Wiring

Step 17 - Tidying and Checks

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