5-Axis Commissioning

If Coolant Pump is on, check for leaks. Set IFM Switch for Coolant Pump:

Set IFM Switch for Hydraulics

1. Load Commissioning Archive.
2. Disable Internal HMI: Connect Bootstick USB to NCU, set Dial Switch to F and reset NCU to access NCU settings.
3. Check Operate for any missing licenses.
4. Use Alarm List and Topology Display tabs to ensure all encoders and motors are connected correctly.

Set System Passwords

Based on user levels:

• Default Base: SUNRISE
• Manufacture: Tarus123
• Service: GMServ12
• Operator: Operator1

1. Change the device name of the I/O via TIA Portal Devices & Networks Screen. Note: Laptop must be physically plugged into I/O.
2. Download Latest PLC Project to the machine.
3. Verify E-stops are working correctly.
4. Check all inputs for any missing signals (e.g., Low Coolant, Hydraulic Level, etc.).
5. Check Slide LEDs: Red = Drives OFF, Green = Drives ON, Blue = Motion.
6. Check Spindle LED Ring: Should NOT be red!

Once you have loaded an archive into Operate, proceed with the following OPC UA setup:

1. Open Operate and add the OPC UA License: Access mymachine opc ua.
2. Go to Setup (Page 2).
3. Navigate to Network > OPC UA > Settings > Change.
4. Set Company Network: Check.
5. Set System Network: Uncheck.
6. Set Additional Network #1 address to: 192.168.214.200 Note: Matches PC IP address.
7. Set TCP Port Number: 4841.
8. Set Message Encryption: Check all boxes (None, 128bit, and 256bit).
9. Check Activate OPC UA.
10. Reboot the machine.

After rebooting and activating OPC UA, configure the Windows Firewall to ensure proper connectivity.

1. Initial Prompt: If you receive a Windows Firewall popup/alert upon reboot, ensure you enable BOTH Private and Public networks.
2. Open Windows Settings and search for Windows Defender Firewall.
3. On the left pane, click Advanced settings.
4. Under "Public Profile is Active", click on Windows Defender Firewall Properties.
5. Under the "Firewall State" section, find Protected Network Connections and press Customize.
6. Uncheck the Ethernet option corresponding to the machine connections.

Remember to keep switch 8 ON until connected.

1. Make sure the big white switch is down.
2. Check that the I/O unit is properly reacting to the prepared inputs from the remote.
3. Ensure E-stops function correctly and can be cleared using the blue button.

Motor Feedback

1. Ensure X1 and X2 are Active via drive parameter p105.
2. Set Limits on Motor Feedback: Check PLC FC_Axis 1 for MeasSys1 = ON.

Scale Feedback

1. Load K value into 34300[1] (e.g., 192, 332, 368, 384).
2. Go to Encoder 2 Settings and add K value.
3. Set MD34090 = 0.
4. Activate RefPoint Mode and reference X by jogging. Repeat referencing to ensure numbers are counting correctly.
5. Adjust 34320 from -1 to 1, or invert encoder in drive settings.Note: This changes counting direction.

Set Home Offset

1. Move to desired negative limit. Set MD34090 = value of X position.
2. Verify Negative and Positive Limits.

Y Motor Feedback

1. Ensure the hydraulic pump is ON. Verify Pressure/Flow set points are correct on Hydraulic IFM switch.
2. Put starter at 1.6 and flip breaker.
3. Put Y Carrier on crane and Activate Y Drive via p105. Watch hydraulic tank pressure to ensure pumping stops at 1180psi, and cycle pump a couple times.

Set Negative Limit

1. Take down to 4mm from hardstop touching. Note: This creates a physical buffer from a hard stop.
2. Set 34210 to 1.
3. Switch to RefPoint Mode and press Y+ Jog. 34210 will switch to 2 and the axis will be referenced.
4. Ensure positive travel limit p36110 is set properly (e.g. 2400.1 and -0.1).

Y on Scales

1. Add Measuring System 2: Setup > Drives system > Drives > Change. Hit next step until you reach Encoder settings, add Encoder 2 and finish steps.
2. Assign Meas System 2 to Y Axis: Go to Axis assignment > Axis 2/Y. Select Encoder 2 and Measuring system 2.
3. Set Limits on Scales: Set 34210 = 1, put machine into RefPoint Mode and jog positive.

1. Activate Z1 and Z2 motors via p105. Make sure Z is counting in the right direction. If axis is moving the wrong way, alter p32100.
2. Move to 0-limit with 6mm from hard stop and Reference. Set 34210 = 1, put machine into RefPoint Mode and jog positive.

Z Scales

1. Change measuring system to sys 2.
2. Set limit to 0 and verify z travel.

Standard limits: +/- 105.1 for A, +/- 180.1 for C. Move the A/C head by hand to confirm the correct axis is counting and in the right direction.

Motor Feedback

1. Activate motor via drive parameter p105. Move by hand to roughly 0 degrees.
2. Turn drives ON and commutate motor angle via p1990 = 1. Do this 3-4 times to get the pole angle difference number in p1984 close to zero. Note: If the number keeps bouncing around, you may have an encoder or phasing problem.
3. Test A/C soft limits. If axis is moving the wrong way, alter p32100.

A/C Scales

1. Before changing to measuring sys 2, put A/C to zero.
2. Change to measuring sys 2, perform a Reference, then verify movement as well as limits.

1. Activate motor via drive parameter p105.
2. Turn drives ON and commutate motor angle via p1990 = 1. Do this 3-4 times to get the pole angle difference number in p1984 close to zero. Note: If the number keeps bouncing around, you may have an encoder or phasing problem.
3. Crucial: The spindle will need to be commanded to move, either via Jog +/- or by setting a desired speed, before the drive will enable for commutation. Note: Portables do NOT commutate the spindles.
4. Run at 10rpm. Ensure proper count direction (Clockwise from behind, counterclockwise in front).
5. Find tool/tool holder to put in spindle and run up to 10,000 rpm to test full speed.

Navigate to the Optimization screen, select an axis for tuning and click Auto-Servo Tuning.

1. Select Strategy 102, click Copy to Custom, and set the following settings:
   • Kv reduction factor = 0.8
   • Kv Upper Limit = 4
   • Kv Max Method = "PT1 speed filter 2"
   • Disable "Wide Notch Filters" on the Speed Loop.
2. Repeat tuning for all Axes (not including the spindle and slave motors).

Interpolation Path

Once tuning has been completed, select Interp. Path then Edit & Tune. Select axes X, Y, Z, A and C, then click Tune. Note: Always use interpolation strategy 1105.

Circle Test Parameters

After Interpolation, perform circularity tests with XYZ (X+Y, Y+Z, X+Z). Generate the program with the following settings:

After installation, reset X scales. If utilizing Dual Machines on the same rails: Put Machine A at true zero and Machine B roughly 4-6 inches away from it. Get travel on Machine B, minus 4-6 inches from limit to give to Machine A. Travel should be the same across both machines.

Cut Style Parameters

32410 [0] = 0.04
32410 [1] = 0.08
32431 [0] = 16
32431 [1] = 8
32431 [2] = 16 
32431 [3] = 8
32431 [4] = 1
32431 [5] = 1
32432 [0] = 16
32432 [1] = 8
32432 [2] = 16
32432 [3] = 8
32432 [4] = 1
32432 [5] = 1

Ensure MD 14510 = 11. Set Jog Velocity: General SD 41110 = 20,000.

Go Online & Network Setup

1. Choose network address. Set Type of PNG/PC interface = PE/IE.
2. Set PG/PC interface = Realtek PCIe Gbe family controller.
3. Set First gateway = show everything.
4. Select Targeted device = show all.
5. Ensure IP address for your laptop is 169.254.11.# (the last octet must be higher than 10).
6. Download the project to CU_S.

Axis Initialization

1. Lift 1: In Parameter view, verify P10 is 0 ready and set P105 to 1. In Function view → Technology function → Basic positioner → Referencing → Absolute encoder, hit Set.
2. Lift 2: In Parameter view, verify P10 is 0 and set P105 to 1. To reference: ensure R21905 is 0, then change R21902 from 0 → 1 → 0.
3. Rotary: In Parameter view, verify P10 is 0 ready and set P105 to 1. In Function view → Technology function → Basic positioner → Referencing → Absolute encoder, hit Set.

Save & Test

1. Save via the blue floppy disk icon.
2. Go offline, Upload, Go back online, and Release E-stop to Test.

1. Retest motors and logic. Note: If running away, check wires.
2. Deactivate rotary (Hit E-stop, set Parameter 105 = 0).
3. Ensure slave is roughly 2 inches higher than master. Have Mark/Dale connect the motors.
4. Reference both motors (make sure it is E-stopped).
5. "Hit the sticks" to drive both motors up into slots. Note: The guys install rods into the spiral lift—whatever diameter fits the holes in the spirals—this prevents the spiral lift from spinning in place and allows it to actually drive upward.
6. Once slave is touching, deactivate it (Hit E-stop, set P105 = 0).
7. Drive master into the slot.
8. Reactivate slave (Hit E-stop, set P105 = 1).
9. Set limit to 850,000:
   • Hit E-stop.
   • Lift 1: Function view → Technology function → Basic positioner → Referencing → Absolute encoder → Set to 850,000 lu, then hit Set.
   • Lift 2: Parameter 21905 set to 850,000. Change 21902 from 0 → 1 → 0.
10. Take pins out (Move up slowly until they come out).
11. Have Dale level the table.
12. Bring table down slowly until it fits into the slot.
13. E-stop machine and Reset zero:
    • Lift 1: Function view → Technology function → Basic positioner → Referencing → Absolute encoder → Set to 0 lu, then hit Set.
    • Lift 2: Parameter 21905 set to 0. Change 21902 from 0 → 1 → 0.
14. Take fully up to limit, make sure table is 37.500 from base then bring down to fit in pocket.
15. Have Dale measure for shims.
16. Reactivate rotary (Hit E-stop, set Parameter 105 = 1).
17. Set rotary 0 (Hit E-stop. Function view → Technology function → Basic positioner → Referencing → Absolute encoder → Set 0).
18. Go fully up.
19. Test Rotary:
    • 90 degrees
    • 180 degrees (Bring down to make sure it fits in pockets, then take back up)
    • 270 degrees
    • 0 degrees

Note: If cutting quality is bad, look at parameter (r81).

Go to assembly's computer to put in the final measurements.

1. Go online and match the IP address. Note: Same process as Gen 3
2. Open Parameterization.
3. Open Rotate & Optimize (R&O).
4. Navigate to p1990 (in parameterization) and change it to 1. Skip if already set to 1
5. Back in R&O, hit Activate.
6. Hit ON for Measurement.
7. Check p1984 in parameterization. This value should be close to 0. Note: If it is not close to 0, repeat the previous 3 steps until it is
8. Navigate to p971, change it to 1, and hit the Floppy Disk icon to save.
9. Go to R&O and change the Operating Mode to Basic Positioner.
10. Change the two drop-downs in Actual Values to:
    • Current actual value torque generating
    • Torque actual value
11. Change the velocity to the target LU (refer to the test grid below).
12. Check the RPM in parameterization.

    If the RPM is incorrect:

    Navigate to Function View → Mechanical Systems and update:

    • Motor Revolutions: 62992
    • Load Revolutions: 1000
    • LU per Load Rev: 5000

1. Go online (match IP address, either CU320 or old FW). Open parameterization.
2. Open Rotate & Optimize for Leg 1. Slowly raise it in at 10 rpm while watching torque.
3. Back off 6000lu. Put -6000lu in at reference @ hard stop.
4. Set limits to 90170 lu or 90.17mm.
5. In Parameter view, change P971 to 1. If it doesn't revert to 0, manually change it back.
6. Save via blue floppy, go offline, upload, cycle power off/on. Check limits with Tarus NC on their side via Auto Leave.

* Same general procedure as a normal lift table, but there is no rotary component. *

1. Retest motors/logic. Ensure slave is 2 inches higher than master before connecting.
2. Reference both motors (make sure it is E-stopped).
3. "Hit the sticks" to drive both motors up into slots. Note: The guys install rods into the spiral lift—whatever diameter fits the holes in the spirals—this prevents the spiral lift from spinning in place and allows it to actually drive upward.
4. Once slave is touching, deactivate it (P105 = 0). Drive master into slot. Reactivate slave (E-stop).
5. Set Limit to 794,000 (E-stop).
6. Take pins out. Bring table down to fit into the slot. Have Mark check.
7. E-stop machine. Reset zero for Lift 1 and Lift 2.
8. Take up to limit (fully up). Bring down to fit in pocket. Test.