S80 Door Safety Spindle Interlock - Rottler Manufacturing

S80 Series Door Safety Spindle Interlock

September 18, 2023

APPLICATION BULLETIN: AB007

Applicable Machines

S80 Series: S85A, S86A

Download PDF

Relevant Parts

7345: Door Safety Spindle Interlock, Surfacer
- Safety Limit Switch, Compact, Roller Plunger Actuator, NEMA 4 and IP65 Rated
- Mounting Hardware, with Wiring
- Software Upgrade, on USB Drive
Installation Documentation, including Wiring Diagram

Overview

Rottler Manufacturing has made another development in the S80 Series by adding the option to include a door safety spindle interlock on the surfacing machines – both S85A and S86A.

The surfacing machines already feature a full enclosure for the safety of personnel. The door safety interlock adds an additional measure of safety to the machine. By including this switch, when the door of the machine is opened, the spindle motor drive is in a safety disabled state. This means that there is no way for the hardware of the machine to allow motor-controlled movement of the spindle. The software has also been upgraded as another safety measure. With the switch installed, if the door is opened, the Start Spindle and Autocycle buttons are completely deactivated.

Because both software and hardware are handling the spindle interlock, there is redundancy which further increases the safety of the machine. Unlike the ESTOP, the spindle interlock only restricts the spindle movement. The column is free to move, and the X and Z axis motors are powered. This is helpful when setting up the starting location of the machine or manually touching off the cutterhead insert. This door safety spindle interlock can be easily installed on any current or future machine

Figure 1: S86A shown with Spindle Interlock Switch

Sections

Installation Notes

ALWAYS USE CAUTION WHEN DEALING WITH MACHINERY. IMPROPER CARE CAN LEAD TO MACHINE DAMAGE, PERSONAL INJURY, OR DEATH.

NOTE: Always follow the safety protocols as written in the Safety section of the S85A S86A Operation Manual. This includes, but is not limited to, wearing proper attire, using safety glasses, and keeping hands and all other body parts completely away from the machine during operation. Do not operate the machine without having fully read and understood all sections of the S85A S86A Operation Manual.

Follow the instructions below to correctly wire and mount the safety limit switch and install the software upgrade. Be sure to turn the main breaker of the machine off while wiring the switch. Restart the machine after installation of the software; the new software should start automatically on reboot and the safety limit switch will be active.

Software Installation

To use the spindle interlock switch, your machine must be updated to software version 0.999.4 or newer. You can find the version number on the lower right-hand corner of the Program Select screen, as shown in Figure 2.

Figure 2: Program Select Screen with Version Number

You can find the procedure for updating your software in Applications Bulletin 006.

Hardware Installation

The following is a procedure for installing the hardware. Follow all relevant safety guidelines while completing the installation. See the above section Installation Notes for more safety instructions.

Ensure the main breaker of the machine is switched off.
Take off the electrical box door.
Check that the safety switch is wired internally. The safety switch should be wired internally from factory, but in the case that it is not, or that it needs to be rewired:
- Open the safety switch cover.
- Feed one end of the red and black wires through the base of the switch and screw them in terminals 13 and 14, as shown in Figure 3 below.
  Figure 3: Safety Limit Switch Internal Wiring
- Close the safety switch cover.
Once the switch is wired internally, feed the loose end of the wire in-between the machine control panel and the sheet metal into the wire tunnel as shown in Figure 4.
Figure 4: Wire Route from Switch to Wire Tunnel
Push the wire down the wire tunnel to the bottom of the sheet metal.
Take off the horizontal wire tunnel, shown in Figure 5, by removing the cap screws in the machine.
Figure 5: Horizontal Wire Tunnel with One Screw Cap Highlighted
Route the wire through the horizontal wire tunnel and through the electrical box wire access hole shown in Figure 6.
Figure 6: Electrical Box Wire Access Hole
Take the cover off the Yaskawa V1000 VFD shown in Figure 7. If your machine has a different VFD, please seek assistance from one of the contacts in the Contact section below.
Figure 7: Yaskawa V1000 VFD
Locate the HC and H1 terminals on the VFD. There should be a length of wire between these terminals to connect them from factory, remove this wire prior to inserting the switch wires. Wire the red and black wires from the switch into the HC and H1 terminals as shown in Figure 8.
Figure 8: Terminals Correctly Wired in VFD
Put the cover back on the VFD and close the electrical box.
Close the enclosure door and hold the safety switch against the top right corner of the door so that the switch is in the closed position as shown in Figure 9. The switch should open when the door is open.
Figure 9: Switch in Closed and Open Positions
With the switch in the correct position, use the provided self-tapping sheet metal screws (#8, 11/4”, qty. 2) to mount the switch in the correct location.
Verify that the door can open and close freely while triggering the switch to the closed position when the door is closed.

Functional Testing

NOTE: Treat the machine as though the safety switch is not active during testing. Never place your hands or any other body part near the machine during operation or testing. See above note for more safety details.

With the new software and switch is installed, the switch is automatically active. Test the proper function of the switch by following the steps below.

Turn on the machine and select a program to get to the Program Screen.
Open the enclosure door. You should see a red notice in the lower middle section of the screen that reads AC DRIVE ALARM as shown in Figure 10. Note that if the machine has its ESTOP in, the AC DRIVE ALARM notice will not appear as the machine is already in emergency stop state.
Figure 10: AC Drive Alarm Notice

If you do not see this notice on the screen with the door open, the switch or the software is not installed correctly. Some common issues and solutions are mentioned below:

Situation	Solution
AC DRIVE ALARM shows when door is closed, disappears when door is opened.	The switch has been wired backwards internally. Open the switch cover and rewire to the other set of terminals.
AC DRIVE ALARM never appears, neither door open nor closed.	Check the version from the Program Select screen by looking in the bottom right-hand corner. The version should be 0.999.4 (or later). If the version is earlier, the software was not installed correctly. If the version is correct, check the wiring at the spindle drive and ensure the correct terminals have been used.
AC DRIVE ALARM is always on, with both door open and closed.	Check the wiring at the spindle drive and ensure the correct terminals have been used and that no wires are lose. Check the internal wiring of the safety limit switch for a lose wire. Check for a pinched or cut safety switch wire.

Situation

Solution

AC DRIVE ALARM shows when door is closed, disappears when door is opened.

The switch has been wired backwards internally. Open the switch cover and rewire to the other set of terminals.

AC DRIVE ALARM never appears, neither door open nor closed.

Check the version from the Program Select screen by looking in the bottom right-hand corner. The version should be 0.999.4 (or later). If the version is earlier, the software was not installed correctly.

If the version is correct, check the wiring at the spindle drive and ensure the correct terminals have been used.

AC DRIVE ALARM is always on, with both door open and closed.

Check the wiring at the spindle drive and ensure the correct terminals have been used and that no wires are lose.

Check the internal wiring of the safety limit switch for a lose wire.

Check for a pinched or cut safety switch wire.

With the door open:

The AC DRIVE ALARM notice should be on the screen.
Attempt to turn on the spindle. The spindle should not be able to turn on with the door open.
Attempt to start the autocycle. The autocycle should not be able to run with the door open.
Using the slide control, attempt to move the column in all directions. The column should be able to move freely.
Using the increment buttons, and/or handwheel, attempt to move the column in all directions. The column should be able to move freely.

With the door closed:

The AC DRIVE ALARM notice should disappear.
Enter cutting parameters for the testing of switch operation. Do not use operational speeds and feeds. Use a low RPM and a feed rate that results in a reasonable IPM travel – recommended parameters are listed below and shown in Figure 11
- RPM: 100 RPM
- Feed Rate: 0.100 in/rev
- Depth/Cut: 0.001″
- Total Depth: 0.001″
- Horizontal Travel: 2″

Figure 11: Program Screen with Test Parameters

Be sure to zero your Horizontal and Vertical Program Start to begin the cut at the current location. Be sure that there are no workpieces, fixtures, or obstacles in the path of the cutterhead or column prior to starting the spindle or autocycle.
Attempt to turn on the spindle. The spindle should be able to turn freely. Open the door. The spindle should automatically turn off. Note that there is not a spindle brake, so the spindle slows down gradually using the force of the motor. This is the proper function. Close the door again. The spindle should not restart without user intervention.
Attempt to start an autocycle – if using the above parameters, the autocycle (when started) will make one pass that is 0.001” deep and 2” long, and takes approximately 12 seconds to complete. The autocycle should run freely. Once the autocycle is complete, attempt to start another autocycle. This time, open the door in the middle of the cycle. The spindle should automatically turn off and the feeding of the machine should be halted. Close the door again. The autocycle should not restart without user intervention.

Operation

Operational notes are listed below.

Do not push the switch manually to allow operation. The only thing that should trigger the safety switch is the door being in the upright and closed position.
Do not use the door to halt the operation of the machine while running. The switch is meant as a safety device, not a control device. The ESTOP button is always the quickest and safest way to halt operation. Using the door to halt operation could lead to damage of the workpiece, the cutterhead, the insert, the motor, or the machine.
Keep the switch clean and clear of debris. To ensure the functionality of the switch, periodically complete a visual inspection for correct placement on the door and for cleanliness.
Do not lean or rest on the door during operation. The door could sag and trigger the switch unintentionally. The door could open and trigger the switch unintentionally. Either case could lead to damage of the workpiece, the cutterhead, the insert, the motor, or the machine as well as personal injury.
Do not rely on the door safety spindle interlock as the only means of safety. The spindle interlock is not the only means of safety on the machine, nor should it be used in place of other standard safety protocols. Always practice safe operation of the machine.

CONTACT

For additional assistance or information regarding Rottler Manufacturing’s S80 Series Door Safety Spindle Interlock or its application, please contact Nick Jenkins or Ryan Thompson via the methods listed below.