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- ZX5 Clamp and Gripper Height Changes for Tall Profile + (-Ensure the small black pins on the back o … -Ensure the small black pins on the back of the block and the bushes in the gripper body are still inserted correctly. -Push the gripper pin block into the desired bushes. The top position is for the profiles above 90mm in height -Tighten the Centre bolt back in to fully secure the grip pin block.ack in to fully secure the grip pin block.)
- Stuertz Infeed - Check GY Position Parallelism + ( #Datum the machine and move GY axis to ze … #Datum the machine and move GY axis to zero, GZ to 25 #Place the jig against the backfence and offer it up to the Gripper Jaw #If the GY datum is set correctly, the rear outer face of the jig should be just in contact with the rear serrated jaw #If this is not the case, set GY datum correctly his is not the case, set GY datum correctly )
- TM018B Microline and ZX3 V Notch Blade Setup + (A calibration mnd file has been written to … A calibration mnd file has been written to help line up the x offsets called VTEST. This program creates the following pattern on the bottom of the profile using a 10mm spindle and the notching blades themselves:
Run the VTest operation on a length of large outer frame of at least 1m long. Put the operation at a position of 500mm.
The pattern allows you to measure the offsets required with calipers.
face, Basically turn it over when it comes of the transfer table.</div> </div><br/>) - Hikvision Camera Setup + (<div class="annotatedImageDiv" typeof=" … On the machine open the “SADPTool” . This is our camera finder and IP address modifier for the cameras)
- PLC Source Control - Git Credential Manager for Windows Install + ( # Keep the destination folder as the default # Select Components , keep as defaults # Start Menu Folder keep as default # Chose the default editor ,keep as default # Select Use Git from the windows Command Prompt # Use the Window secure Channel Library )
- ZX5 Installation Procedure + (No hard pipe under the Saw.)
- PC Recovery Process + (- Turn off the PC - Plug in recovery USB. - Turn the PC back on - Keep pressing F12 until the boot selection screen shows. <br/>)
- TB0444 Renewing CF Card on TwinCAT2 Systems + (1. From Camera PC, use System Manager … 1. From Camera PC, use System Manager to activate original configuration
2. From Camera PC, use PLC Editor to login both original projects – PLC_Reset in Port 811, and the other main PLC control project in Port 801.
instructions-text">DO NOT FORGET TO ACTIVATE BOOT PROJECT</div> </div><br/>) - Setting Profile Detection Laser Sensor + (<div class="icon-instructions caution-i … # Turn L/D adjustment clockwise so it is on its maximum "L" # Turn anticlockwise until Yellow light comes on # Turn clockwise until Yellow light goes offurn anticlockwise until Yellow light comes on # Turn clockwise until Yellow light goes off)
- Ecoline - Disabling V axis To Swap Faulty Drive + ([[Archiving a TwinCAT Project]])
- Viewing Camera Footage from Hikvision Cameras + (If this is the first time that this has been attempted on your PC, a Hikvision plugin will be needed. Follow the process to install it)
- Commissioning - Off-Cut Laser Sensor + (Adjust the "'''Light Dark'''" balance on t … Adjust the "'''Light Dark'''" balance on the sensor. To do this, using a small flat head screwdriver, turn the light dark dial '''clockwise''' until the orange light goes off. Then slowly turn '''anti-clockwise''' until the orange light turns on again, when this happens re-turn a '''little clockwise''' to turn off the orange light.clockwise''' to turn off the orange light.)
- ZX4 Infeed Roller Reinforcement + (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.)
- R0015333 Fit Clamp Assembly + (All bolts to have Loctite 243 adhesive applied unless otherwise stated All Threaded Pneumatic connections to have Loctite 570 applied All bolts to be pen marked once adhesive applied and correct tension added)
- R0015335 Mount Electrical Cabinet + (All bolts to have Loctite 243 adhesive applied unless otherwise stated All Threaded Pneumatic connections to have Loctite 570 applied All bolts to be pen marked once adhesive applied and correct tension added)
- ZX5 Installation Procedure 2023 Pneumatic connections + (All control pneumatic connections will be … All control pneumatic connections will be identified with identification numbers All permanently fed supply lines will be identified by the use of Red pneumatic pipe All Emergency stop switched air feeds will be identified by the use of Blue pneumatic pipeentified by the use of Blue pneumatic pipe)
- Setting up an Ecoline Barcode Scanner + (All refurbished Ecolines will now be provi … All refurbished Ecolines will now be provided with USB barcode scanners. This may be a hand held device or an 'Orbital' scanner attached to the infeed table depending on the customer's preference. Use the provided cable to plug the scanner in to the nearest available USB port. There will be 2 USB extension cables coming from the PC inside the cabinet. One will go to the console to control the keyboard and the touchscreen and the other will go to the infeed table junction box to control one or two barcode scanners.ox to control one or two barcode scanners.)
- Changing saw pusher bearings - Standalone Saw + (Bring the Saw pusher to the end where the chain tensioner and sprocket are. Remove the pusher arm by taking out 2 bolts below the arm. Remove the face plate by taking out the 4 bolts in the fron of the plate Take off the top roller bearings.)
- Upgrading Project File on TwinCAT2 System + (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]])
- TB0409 Setting Up Windows 10 PC 2018 + (Connect monitor, network cable, keyboard, mouse/touchpad, and switch on PC.)
- ZX5 Production R0015040 Module F to R0015001B Module E alignment + (Position module F at end of Module E infeed frame Approximately Align Saw roller back fences to Saw infeed back fences Approximately align X axis position by setting the to frames spaced at the distance shown of 20mm)
- Ecoline - Datum and MitreOffset Tests + (Cut 3 lengths of outerframe around 1000mm … Cut 3 lengths of outerframe around 1000mm long
ie no swarf and profile tape is not "flapping" over the end</div> </div><br/>) - R0015099 Guard panel drilling + (Drill hinge panel as detailed 1 Clamp p … Drill hinge panel as detailed 1 Clamp panel in position equalising edges to frame 2 Drill vertical face holes onto frame M6 tapped 3 Mark 4 off holes with M6 pointed grubscrew 4 Drill 4 off to 7.5 mm 5 Check correct drilling by fixing panel with M6 socket capslling by fixing panel with M6 socket caps)
- AX8000 Drives - ES Contactor Wiring + (Find a spare section of DIN rail that the contactor can be placed in. The contactor clips onto the din rail without the need for fixings.)
- Recovery of Bar Queue following winMulti Crash + (First you need to check out the bar queue … First you need to check out the bar queue to see if it is the same as the actual bars on the transfer table #Restart winMulti #Count the total number of bars on the saw infeed and transfer table #Compare with the number of bars on the saw queue If there is '''one more bar''' actually on the table than on the bar queue screen, follow the process below to add the missing bar to the queue.han on the bar queue screen, follow the process below to add the missing bar to the queue.)
- Troubleshoot - Permanent IP Address - Windows 8 + (Go to '''Control Panel > Network and Sh … Go to '''Control Panel > Network and Sharing Centre'''.
the bottom right toolbar on the windows desktop (see picture).</div> </div><br/>) - Troubleshoot - Permanent IP Address - Windows 10 + (Go to '''Control Panel > Network and Sh … Go to '''Control Panel > Network and Sharing Centre'''.
the network icon in the bottom right toolbar on the windows desktop.</div> </div><br/>) - Autoflow Hepco Slewing Ring - Journal Adjustment + (Identify the blank spindles - these are the ones with no machining stations on them.)
- ZX5 Adjusting V Notch Depth and Position + (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/>)
- Setting Motor Overload Relays + (In order to read the motor plate we need t … In order to read the motor plate we need to know 3 pieces of information *Whether the motor is wired in star or delta *The frequency at which the motor is running *The voltage at which the motor is running Whether the motor is wired in star or delta depends on the application. Refer to the electrical diagrams to find out which it is. For example, the saw blade motor is wired in star, whereas most extractor motors are wired in delta. The UK standard for a three phase electrical supply is 415v at 50Hz. Unless the supply to a motor runs through an inverter (i.e the spindles) this is also the standard for our machines. Using the picture on the right as an example, we know the motor will be running at 50Hz (1) so we can disregard the information on the right of the plate as this provides figures for a 60Hz supply. Looking at the box numbered (2) we can work out that this motor would be wired in delta if it were running on a single phase 230v supply. However, we know that this is a three phase supply and will be wired in star. So when we move on to the box numbered (3) we will be looking at the number on the right hand side of the slash. Therefore, this particular motor would need an Overload Relay set to 3.00A.would need an Overload Relay set to 3.00A.)
- ZX5 Gripper Energy Chain & Tray Setup + (Make sure the cables and piped are fixed with cable ties to the fingers of the bracket to avoid movement or twisting inside the energy chain.)
- Installation Procedure - Autoflow Mk4 + (Machining centre distance to infeed between frames =)
- Install markings and measurements ZX5 + (Measure and mark up the distance between t … Measure and mark up the distance between two points (one on each) of the two modules. Mark up the points in a place where it is easy to read the markings and simply practical to get the two modules in a similar position (gap between the two) on installation - preferably on the front and the back of the modules. This makes it easier and closer to adjusting the loadpos and datum on the x-axis once setting up accuracy.um on the x-axis once setting up accuracy.)
- 500mm Saw Blade Upgrade + (Remove the two grub screws from the taper … Remove the two grub screws from the taper lock pulleys and insert one into the hole that was initially empty. Screw in tight to break seal of taperlock and split the two parts. If siezed the outer part can be tapped back with a hammer. These parts are usually very brittle and can shatter with a heavy hammer blow. It can also be useful to have the belts on at this point to stop the pulley from turning.his point to stop the pulley from turning.)
- Easily resizable forms for any screen resolution in Visual Studio + (On the start screen in Visual Studio, click on the "Create a New Project" button.)
- TB0426 Replacement Zebra Printer Setup + (Open box, unwrap printer, plug in power and plug Ethernet connected to network to the printer. As the printer boots up there will be a red light displayed on the front. After around 30 seconds this will turn green as the printer completes boot up.)
- R0015336 Pneumatic Output Testing Part 2 + (Output testing will require valve operatio … Output testing will require valve operation with no e/s circuit Ensure the following Work area is clear from all components not required for testing All colleagues are aware of the procedure being undertaken No additional colleagues are working on the module PCL coupling is accessible to release pressure in case of emergency Testing procedure is fully adhered tocy Testing procedure is fully adhered to)
- Training Laser on Ecoline + (Sensitivity also needs settings 5 full turns after turning anticlockwise until it goes Sensitivity then turn clockwise until on then the 5 turns.)
- TB0451 CX5120 Beckhoff PC Setup + (Go to Control Panel then ‘Region and Language’ and select ’English (United Kingdom)’.)
- Setting Up New Printer - GX420d + (Plug in the power cable and ethernet cable to the back of printer, then turn the printer on with the switch at the back.)
- Allocations + issuing received parts + (Populate the allocate column for each part … Populate the allocate column for each part in accordance to the pick bins that are available. The general rule is to prioritize allocation to the range of Bins of the Build numnber which is next to in line to be Built according to the production schedule. If there is no bin physically available for the Job car number shown it must be zero'd in the allocation quantity column and put into stock normally.antity column and put into stock normally.)
- TB0436 Creating a Backup Through WinMulti + (Press on the “Backup” button on WinMulti)
- Runing MRP + (Press the Planning Tab > Read demand > ok The demand will then read with a load screen. Once this has finished move on to the next step)
- R0000728 R0000729 Stroke Assembly Dismantling + (The stroke assembly must be dismantled in the exact manner stated as many sections can only be removed once mating parts have been extracted Please use the following steps accurately)
- Move SR Datum Sensor to Higher Level R0019217 + (Replace the upper brace plate with D0016338. This has the detection plate for the SR axis added on the top)
- X252 Forward Clamp Out Sensor Setup Stuertz Infeed + (Select Q1)
- Fitting Y Axis energy chain strengthening plate + (Take out the 2 bolts holding the energy chain end bracket to the Aluminium bracket.)
- Laser Setup on Flowline/ZX3 for Laser Holes + (The laser sender needs to have a clear pat … The laser sender needs to have a clear path to the laser receiver, its really important that this is parallel and the beam does not bounce off the inside of any of the aluminium mounting block. Slacken off the Nuts above and below Laser to move up/down and side/side.below Laser to move up/down and side/side.)
- TB0301 Autoflow Saw Head Reinforcement - Additional Enhancements + (The 2 carriage assemblies are as shown. Fi … The 2 carriage assemblies are as shown. First, the rails need to be loosely installed onto the horizontal Maytec extrusion, allowing for lateral adjustment. Parts D0010710, D00010711 and B0000046 are to be assembled, as shown. Two of these sub-assemblies are required. Two of these sub-assemblies are required.)
- Create a TwinCAT Project from Existing Project + (The build needs to be the same machine typ … The build needs to be the same machine type and have an identical EtherCAT box and drive setup You can create a backup in three ways # Create an archive of an open project (you need to run Visual Studio on the desktop of the machine in question) # Copy the contents of the c:\TwinCAT\Stuga\[BuildNo] folder from the "donor" to your new machine setup # Use VPN to connect to the back end of the machine and upload the project from the target, then save it locally. this needs a good internet connection and Teamviewer remote VPN installed on the remote Beckhoff PCte VPN installed on the remote Beckhoff PC)
- Dokit - Creating A Work Instruction + (To create a new Dokit, you need to login as a editor The Username is Gareth Green Password is available from the IT department <br/>)
- ZX3 Counterweight Installation + (Fit all 3 weight plates, and secure with the provided bolts and washers)
- GE Control Components Changeover + (The supplier that we use for the supply of … The supplier that we use for the supply of our control components advised us of the need to changeover. The components that have been made unavailable are all of the GE components. This includes, all MCB's, all contactors (24Vdc, 24Vac, 230Vac), all motor overloads and any auxiliary components to go with these devices. See pictures for reference.these devices. See pictures for reference.)
- Hotswap Beckhoff PLC with Licence Slice Installed + (There are a row of retaining clips on bot the top and bottom of the PC that hold it to the Din rail. Pop them open with a flathead screwdriver)
- Air Pressure Switch Setup + (This is usually called 'AIR'. From this point you will either need to have somebody watch the input on the screen or have means (eg dialled in on a laptop) to be able to watch the output while carrying out he next step.)
- ZX5 V Notch Blade Mechanical Setup + (Using a straight edge placed BETWEEN the t … Using a straight edge placed BETWEEN the teeth of the blade (W/I) you can see we have a gap around 2-3mm. On the opposite blade (W/O) we need to turn the setting bolt anti clockwise until the tips of the teeth just touch the straight edge, as seen in the second picture. If the tips of the teeth were overlapping we would need to increase separation by turning the adjusting bolt clockwise.
Transfer the straight edge to the opposite blade (W/O) and adjust W/I as above.
lade (W/O) and adjust W/I as above. <br/>) - Autocut Piece Jammed + (This will dump the air to the cylinders and probably free off the jammed piece)
- Autoflow Mk1-Mk3 Daily Maintenance + (To check the machine is ready for producti … To check the machine is ready for production, a couple of simple tests can be run
# Datum Test
# Pos Test
olerance is +/0.5mm, so there is no need to adjust if an inaccuracy is less than this tolerance (1mm back to back)</div> </div><br/>) - Units of Measure modification CIM50 + (To make the item status of a product inact … To make the item status of a product inactive it needs to comply with all of the following conditions :
Item has 0 in stock
Item has 0 in quarantine
Item does not exist on any live sales orders
Item does not exist on any live purchase orders
Item does not exist on any live works orders
Item does not exist on a bill of material
e re-entered after the unit of measure has been amended and saved.</div> </div><br/>) - DM - Updating Resources + (To open the document go to the Stuga dropbox (ask admin for permissions): Service > Documentation > Device Magic Resources > DeviceMagic Data v1.xlsx https://www.dropbox.com/s/v7vhxpve9ocm6as/DeviceMagic%20Data%20v1.xlsx?dl=0)
- Autoflow Mk4 Greasing Points + (4 off greasing points for Z axis)
- R0015345 Conveyor Mounting Brackets + (Use Loctite 243 on all fasteners Use Loctite 572 on all threaded pneumatic connection Pen mark all fasteners to show finalised)
- R0010260 Bench Assemble Tool Break Sensor + (Use Loctite 243 on all fasteners Use Loctite 572 on all threaded pneumatic connection Pen mark all fasteners to show finalised)
- R0015091 Mount Outfeed Beam Sensor + (Use Loctite 243 on all fasteners Use Loctite 572 on all threaded pneumatic connection Pen mark all fasteners to show finalised)
- R0015277 Set Drive pinions in position + (Use Loctite 243 on all fasteners Use Loctite 572 on all threaded pneumatic connections Pen mark all fasteners to show finalised)
- R0015322 Remove Electrical Control Cabinet Assembly + (Use Loctite 243 on all fasteners Use Loctite 572 on all threaded pneumatic connection Pen mark all fasteners to show finalised)
- R0015296 Bench Assemble Bearing Assemblies + (Use Loctite 243 on all fasteners Use Loctite 572 on all threaded pneumatic connection Pen mark all fasteners to show finalised)
- R0015071 Bench Assemble Pneumatics Rail + (Use Loctite 243 on all fasteners Use Loctite 572 on all pneumatic threaded connections Pen mark all fasteners to show finalised)
- R0015084 Bench assemble and Drill Off Swarf chutes + (Use Loctite 243 on all fasteners Use Loctite 572 on all threaded pneumatic connection Pen mark all fasteners to show finalised)
- R0015285 Bench Assemble Pneumatic Rail + (Use Loctite 243 on all fasteners Use Loctite 572 on all threaded pneumatic connections Pen mark all bolts to show finalised)
- R0015346 Conveyor blower system + (Use Loctite 243 on all fasteners Use Loctite 572 on all threaded pneumatic connection Pen mark all fasteners to show finalised)
- R0015101 Bench Assemble Take Up Assembly + (Use locktite 243 on all fasteners Use loctite 572 on all threaded pneumatic connection Pen mark all fasteners to show finalised)
- R0015319 Fit Guards and Doors + (Use locktite 243 on all fasteners Use loctite 572 on all threaded pneumatic connection Pen mark all fasteners to show finalised)
- R0015270 Bench assemble Shafts, bearings and sprockets + (Use loctite 243 on all fasteners Use Loctite 572 on all threaded pneumatic connections Pen mark all bolts to show finalised)
- R0015271 Mount buffer bars + (Check D0015464B Infeed Rear Endfence has been drilled for m6 countersinks If not rework and note rework time)
- R0015265 Mount Infeed arm covers and End guards + (Use loctite 243 on all fasteners Use Loctite 572 on all threaded pneumatic connections Pen mark all bolts to show finalised)
- Troubleshoot - Permanent IP Addresses - UVision Cameras + (Using any Stuga PC on the same network as the target machines, search for the program '''CameraSetup.exe'''.)
- Omron E5CVS PV Shift + (H0 = No offset. Temp at Plate =230 degrees - Display on E5CSV = 240 Degrees L10 = - 10 degree. Temp at plate = 230 degrees - Display E5CSV = 230 Degrees H10 = +10 degree . Temp at plate = 230 degrees - Display E5CSV = 250 Degrees)
- Z Transom Width Measurement + (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.)
- Changing Version Control to Visual Studio + (Delete the versionControl folder completel … Delete the versionControl folder completely
prevents confusion in the future of where the project exists</div> </div><br/>) - Full Version Upgrade TwinCAT3 WinMulti + ([[Create a TwinCAT Project from Scratch]] This procedure ensures that the front end PC has the latest TwinCAT version, and that the PLC source control program is correctly integrated, meaning the latest PLC code version will be available)
- Setting Gripper Nose + (when it is in this position - Fully bottom … when it is in this position - Fully bottomed make sure the Grip on comes down but doesn't catch the Grip nose. Notice the Dead stop bolt at bottom is hard up then set grip switch bolt so that the dead stop bolt gap is no more than 1mm when grip switch goes off.o more than 1mm when grip switch goes off.)
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