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

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

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:

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.

• Ryan Thompson, Lead Applications Engineer, Tel: +1 (206) 707-2458
• Nick Jenkins, Applications Engineer, Tel: +1 (206) 406-1880

Overview

Rottler Manufacturing is constantly improving upon its current machine lineup with new designs, tooling, fixturing, hardware, and software. Occasionally, these updates, such as adding a handwheel or a spindle interlock, require a new, updated software version to be loaded to the computer to work properly. This bulletin stands as an instructional procedure for how to load new software onto any S80 series machine.

Figure 1: S86A Machine

Sections

Software Installation:

The following is a procedure to install the software:

1. Insert the included USB Drive which contains the Software Upgrade into the S80 Series machine. On an S85A/S86A, there is a USB port on the bottom of the control panel.
2. If the Rottler Software is live on the screen, save all data and settings and close the program by pressing EXIT in the top right.
3. You should see the main desktop screen of the computer. On the screen is a file called My Device, as shown in Figure 2. Double tap the icon to open.
   

   My Device on the Desktop Screen of S85A/S86A

4. Once My Device is open, select Hard Disk as shown in Figure 3. The exact layout of the folders and files may look a bit different, but the process and names remain the same.
   

   Figure 3: Hard Disk Folder in My Device

5. Once in the Hard Disk folder, locate the Surfacer_Rottler_v… program file as shown in Figure 4. There may be other files on the USB Drive, ignore them for now.
   

   Figure 4: Surfacer Program File on Hard Disk

6. Copy the file by pressing and holding the icon until the drop-down menu pops up, then dragging your finger down to Copy and releasing.
7. Go back one screen to the My Device folder by clicking on the blue arrow pointing to the left in the upper left-hand corner.
8. Go to the Flash Disk folder, as shown in Figure 5.
   

   Figure 5: Flash Disk Folder in My Device

9. Once in the Flash Disk folder, as shown in Figure 6, press and hold in empty space until the drop-down menu pops up. Drag down to Paste and release to place the updated software version on the machine.
   

   Figure 6: Flash Disk Folder

10. While still in the Flash Disk folder, cut the original version of the software by pressing and holding the icon until the drop-down menu pops up, dragging your finger down to Cut, and releasing.
11. Paste the original version into the Hard Disk folder – the cut function will automatically delete the file from the original location after pasting.
12. Disconnect the USB Drive, which now contains both the original and updated software versions, and store for later reference. This procedure can be repeated any time to swap between versions.
13. Shut down the computer and turn off the breaker at the electrical box.
14. Wait a moment, then turn the machine breaker back on. The new software version should automatically load after reboot.

CONTACT

For additional assistance or information regarding Rottler Manufacturing’s S80 Series Software Update Procedure or its application, please contact Nick Jenkins or Ryan Thompson via the methods listed below.

• Ryan Thompson, Lead Applications Engineer, Tel: +1 (206) 707-2458
• Nick Jenkins, Applications Engineer, Tel: +1 (206) 406-1880

Overview

Rottler Manufacturing has created an exciting option to include a physical control for fine movement for the S80 series surfacer. The Remote Handwheel Kit provides tactile feedback to the operator while performing precise movements with the machine. This device can aid the operator by improving accuracy and reducing setup time during work piece setups.

Figure 1: S85A Machine and Remote Handwheel

Sections

Installation if Retrofitting:

Follow the instructions in the installation addendum provided with the Remote Handwheel Kit. Once the software is installed, power down the machine and restart. The new software should automatically start on boot.

With the software initialized, navigate to the machine settings page by selecting the settings button in the top right corner of the main screen.

Machine Settings Page:

In the Machine Settings page, you can find the option to activate/deactivate the handwheel.

Figure 2: Machine Settings Screen

By pressing the Handwheel/Touch button, you can switch between using the handwheel or the standard increment touch buttons for fine movement control. The button will display whichever control option is currently active. That is, the button will read “Handwheel” if the handwheel is the current fine control or the button will read “Touch Buttons” if the touch buttons are the current fine control.

Figure 3: Handwheel and Touch Buttons control selector buttons

Program Page:

With the handwheel option selected, any program pages should look like Figure 5 below: The Handwheel increment selections are found as gray buttons next to the standard jog sliders.

Figure 5: Program screen

Simply press the button with the increment and axis you desire, and each click of the handwheel will be associated with that distance and direction. When selected, the current increment button will turn RED. At that point the handwheel will be active at the selected increment ratio.

Process for Touching off Cutter, Setting Dial Indicator and Programming with Handwheel:

The handwheel should be used for fine movements and precise adjustment. Rapid movement should always be handled with the slide controls for quicker setup times.

An example step-by-step setup using the handwheel is described below:

1. Fixture and level the head or block as described in the S85A/S86A Operations Manual. Place a cutting insert in the flycutter. Enter the cutting parameters (speeds, feeds, and depths) for the application.
2. Using the horizontal slider control, rapid the column in the -X direction (left) until the flycutter is to the right of the head/block.
3. Using the vertical slider control, rapid the column in the -Z direction (down) until the fly cutter is approximately .250-.500” above the head/block. Note: leave more than enough room to avoid accidentally crashing into the head/block or fixture.
4. Using the handwheel control, select the relevant X-axis handwheel interval amount, and fine tune the X-position of the cutterhead so that the cutting insert is positioned above the workpiece.
5. Select the Z-axis .010” handwheel increment. Using the handwheel one-click at a time, bring the insert down near the block until it is approximately .010-.020” above the workpiece surface.
6. Select the Z-axis .001” handwheel increment. Turn the spindle on by pressing the “Start Spindle” Button. Using the handwheel one-click at a time, bring the insert down until it just contacts the workpiece surface. With the insert in contact, press the “Feed Right” button to move the cutter right and off the workpiece. A small section of the workpiece will be machined.
7. Use the X-axis handwheel once again to position the shroud attached dial indicator plunger over and in contact with the now machined surface. Set the Indicator read out to properly read
   “0” when in contact with this machined surface.
8. With the indicator over the workpiece press “Set Zero” for the Horizontal Program Position
9. Press “Set Zero” for the Vertical Program Position
10. Move the machine up around .500” for clearance above the workpiece using either the vertical slider or the Z-Axis Handwheel increments.
11. Using the horizontal slider control, jog to the left-end of the workpiece to where the cutting insert completely clears the workpiece left end. Press the “Set” button next to the Cut Length /Depth Horizontal readout to set the length of the workpiece.
12. Pressing and Holding “Cycle Start” will move the cutter back into the start cutting position, pressing once more will begin the auto cycle.

CONTACT

For additional information regarding the new Honing Measurement software on Rottler hones, please contact Ryan Thompson or Nick Jenkins via the emails listed below.

• Ryan Thompson, Lead Applications Engineer, Tel: +1 (206) 707-2458
• Nick Jenkins, Applications Engineer, Tel: +1 (206) 406-1880