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Roland DG Corp. assumes no responsibility for any direct or indirect loss or damage which may occur through use of this product, regardless of any failure to perform on the part of this product.
Contents Contents ............................1 To Ensure Safe Use ........................4 Pour utiliser en toute sécurité ....................12 Important Notes on Handling and Use ..................21 Chapter 1 Introduction ........................23 1-1 Introduction ........................24 Features ......................................24 Installable Model ..................................24 Organization of the Documentation ...........................24 1-2 Names and Functions .......................
To Ensure Safe Use Improper handling or operation of this machine may result in injury or damage to property. Points which must be observed to prevent such injury or damage are described as follows. Please also read the important safety information in the user's manual for the modeling ma- chine.
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To Ensure Safe Use Incorrect operation may cause injury. WARNING WARNING Be sure to follow the operation procedures Before attempting cleaning, maintenance, described in this documentation. Never or attachment or detachment of optional allow anyone unfamiliar with the usage or items, disconnect the power cord.
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To Ensure Safe Use The cutting waste or workpiece may catch fire or pose a health hazard. WARNING CAUTION Never attempt to cut magnesium or any Wear dust goggles and a mask. Wash other such flammable material. away any cutting waste remaining on the hands.
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Never disconnect the power cord and contact your use if any component is damaged. authorized Roland DG Corp. dealer. Continuing to use the machine may result in Never place any flammable object nearby. fire, electrical shock, or injury. Contact your Never use a combustible aerosol spray authorized Roland DG Corp.
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To Ensure Safe Use Danger exists of components being thrown off or damaged. WARNING WARNING Connect the air hose securely, so that it Never strike or subject the object to im- will not come loose. pact. A pressurized hose that comes loose may whip Components may suffer damage or rupture about uncontrolled, posing a hazard.
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To Ensure Safe Use Important notes about the end (cut edge) of the air hose Failure to observe these cautions may result in air leakage or easy dislodgement of the air hose. Also, when a hose has been detached, cut off the end before reattaching the hose. Ensure that it is not crushed.
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To Ensure Safe Use Warning Labels Warning labels are affixed to make areas of danger immediately clear. The meanings of these labels are as follows. Be sure to heed their warnings. Also, never remove the labels or allow them to become obscured. Caution: Pinching Hazard Contact during operation may cause the hand or fingers to become pinched,...
Pour utiliser en toute sécurité La manipulation ou l'utilisation inadéquates de cet appareil peuvent causer des blessures ou des dommages matériels. Les précautions à prendre pour prévenir les blessures ou les dommages sont décrites ci-dessous. Avis sur les avertissements Utilisé pour avertir l'utilisateur d'un risque de décès ou de blessure grave en cas de ATTENTION mauvaise utilisation de l'appareil.
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Pour utiliser en toute sécurité L’utilisation incorrecte peut causer des blessures ATTENTION ATTENTION S’assurer de suivre les procédures Utiliser uniquement des accessoires d’utilisation décrites dans la documenta- d’origine (accessoires en option, articles tion. Ne jamais permettre à quiconque ne consommables, câble d’alimentation et connaît pas le fonctionnement ou la ma- autres articles semblables), compatibles nutention de l’appareil de le toucher.
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Pour utiliser en toute sécurité Les débris de coupe peuvent s'enflammer ou présenter un risque pour la santé. ATTENTION PRUDENCE Ne jamais tenter de couper du magnésium Porter des lunettes de protection et un ni aucun autre matériau inflammable. masque. Rincer toutes les rognures de Un incendie pourrait se produire pendant la coupe qui pourraient rester collées aux coupe.
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Pour utiliser en toute sécurité Certains éléments peuvent présenter un risque de pince- ment, d'emmêlement, de brûlure ou d'autres dangers. ATTENTION ATTENTION Ne jamais faire fonctionner l'appareil si Attention : outil de coupe. on porte une cravate, un collier, des vête- L'outil de coupe est acéré.
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Continuer à utiliser l'appareil peut causer un incendie, un choc électrique ou des blessures. câble d'alimentation et communiquer avec le Communiquer avec le représentant Roland représentant Roland DG Corp. autorisé. DG Corp. Autorisé. Ne jamais placer d'objet inflammable à...
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Pour utiliser en toute sécurité Il y a risque que des composants soient projetés ou endommagés. ATTENTION ATTENTION Connecter solidement le tuyau à air pour Ne jamais frapper ni soumettre l'objet à éviter qu'il se détache. un impact. Un tuyau sous pression qui se détache peut Les composants pourraient être endomma- fouetter l'air de manière désordonnée et créer gés ou se rompre sous la pression de l'air...
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Pour utiliser en toute sécurité Remarques importantes relativement à l'extrémité (bord coupé) du tuyau à air. Le non-respect de ces consignes de sécurité peut causer une fuite d'air ou le débranchement du tuyau à air. En outre, si le tuyau à air a été débranché, en couper l'extrémité avant de le rebrancher. S'assurer qu'il n'est pas écrasé...
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Pour utiliser en toute sécurité Vignettes d'avertissement Des vignettes d'avertissement sont apposées pour qu'il soit facile de repérer les zones dangere- uses. La signification des vignettes est donnée ci-dessous. Respecter les avertissements. Ne jamais retirer les vignettes et ne pas les laisser s'encrasser. Attention : risque de pincement Un contact pendant le fonctionnement peut coincer la main ou les doigts ce qui...
Important Notes on Handling and Use This machine is a precision device. To ensure the full performance of this machine, be sure to observe the following important points. Failure to observe these may not only result in loss of performance, but may also cause malfunction or breakdown.
1-1 Introduction Features This is an optional unit for adding an automatic tool changer (ATC) to the MODELA Pro II from Roland DG Corp. The bolt-on design allows easy installation. The tool-length offset feature and automatic tool-length measurement feature also make it easy to selectively use tools of different lengths.
1-2 Names and Functions VPanel Installing the ATC unit enables you to perform operations for items that involve the ATC unit. Chapter 1 Introduction...
Chapter 2 Installation 2-1 Before Installing ...................28 Checking the Included Items ................28 Preparing the Compressed-air Source ............... 29 Preparing the Tool Holders ................. 30 Overview of the Installation Procedure ............... 31 Required Setup Operations for the ATC-equipped Models ......... 31 2-2 Step 1: Attach the Control Box ..............32 Attach the Control Box ..................
2-1 Before Installing Checking the Included Items The following items are included with the unit. Make sure they are all present and accounted for. Control box Magazine unit ATC spindle Air cylinder (*1)(*2) (*1) Stripper bolts Base plate Z-origin sensor Spacer (*3) (*5)
2-1 Before Installing Preparing the Compressed-air Source WARNING The pressure of the compressed air must be not more than 1 MPa. Exceeding this may cause rupture or other serious accident. WARNING Ensure no contamination of the supplied compressed air by any water, oils, chemicals, or foreign objects.
2-1 Before Installing Preparing the Tool Holders Provide tool holders that meet the following conditions. Dimensions Taper shank 27 mm (1.06 in.) or less 33 mm (1.3 in.) or less (JBS4002 15T, 7/24 taper) Pull stud 10 mm (0.4 in.) or less (JBS4002 15P [45˚], special) 17 mm (0.67 in.) or more (when gripped)
2-1 Before Installing Overview of the Installation Procedure This is an overview of the installation procedure. For the specific steps required to install this unit, see the following sec- tion. Set Up the Modeling machine Finish installing the modeling machine, installing and setting up the program and other software, and connecting the modeling machine to the computer.
2-2 Step 1: Attach the Control Box Attach the Control Box Procedure Prepare the modeling machine. Perform manual feed to move the table to the front. Use manual feed to move the spindle head to a position about half- way along the X axis and at the lowest location on the Z axis.
2-3 Step 2: Attach the Magazine Unit For a Standard Table The installation method differs slightly depending on the type of table. If the original standard table is attached, then follow the procedure below to install. Procedure Install the base plate. Cap screws (M8 x 20 mm) ...
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2-3 Step 2: Attach the Magazine Unit Fit the tabs on the underside of the magazine unit into the base plate. Tighten the cap screws. Correct tool-change is impossible if the tabs are not engaged properly. Perform positioning carefully. Base plate ...
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2-3 Step 2: Attach the Magazine Unit No Rotary Axis Unit Plastic screws Install the Z-origin sensor. (M4 x 30 mm) For Use in Combination with a Rotary Axis Unit Orient the hole Installation of the Z-origin sensor is in this direction.
2-3 Step 2: Attach the Magazine Unit For a T-slot Table The installation method differs slightly depending on the type of table. If an optionally available T-slot table is attached, then follow the procedure below to install. Procedure From the rear of the modeling ma- chine, pull in the magazine unit.
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2-3 Step 2: Attach the Magazine Unit Fit the tabs on the underside of the magazine unit into locations shown in the figure. Tighten the cap screws. Correct tool-change is impossible if the tabs are not engaged properly. Perform positioning carefully. ...
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2-3 Step 2: Attach the Magazine Unit Slide the T-slot nuts into the grooves. Secure in place with two more cap screws. Gently close the magazine cover. Cap screws (M8 x 16 mm) No Rotary Axis Unit Install the Z-origin sensor.
2-4 Step 3: Attach the Spindle and Cylinder Attach the Spindle and Cylinder Procedure Detach the motor cover. Remove the grommet. Grommet Motor cover Remove the existing spindle and spindle holder. Important Note When Removing the Spindle Holder A thin spacer (shim) may be present be- tween the spindle holder and the Z-axis...
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2-4 Step 3: Attach the Spindle and Cylinder Install the air cylinder. Stripper bolts (d8 x L15 mm) Pass the belt through the ATC spindle. Attach the ATC spindle. Tighten the cap screws in the sequence shown in the figure. For the belt and the cap screws, use the items you removed in step 2.
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2-4 Step 3: Attach the Spindle and Cylinder While turning the pulley to break in the belt, keep the belt at the correct position. Keep centered on the pulley. Keep centered on the pulley. Continue by proceeding with "2-5 Step 4: Connect and Secure the Cables." Chapter 2 Installation...
2-5 Step 4: Connect and Secure the Cables Connect and Secure the Cables Procedure Secure the cabling connected to the magazine in place with retainers. Opening the retainer Remove the screws. Tighten the screw to clamp the cabling. ...
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2-5 Step 4: Connect and Secure the Cables Remove the grommet. Pass the connector for the air cyl- inder through the hole. Connect the connector. Pass the cabling for the air cylinder through both sides. Grommet ...
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2-5 Step 4: Connect and Secure the Cables Attach the cable retainers. Connect the two small air hoses. Secure the hoses in place with the retainers. The joint rotates freely. Labeled Not labeled Secure the cable hose in place with large retaining bands.
2-6 Step 5: Supply Compressed Air Supply Compressed Air WARNING The pressure of the supplied compressed air must be not more than 1 MPa. Exceeding this may cause rupture or other serious accident. WARNING Ensure no contamination of the supplied compressed air by any water, oils, chemicals, or foreign objects.
2-7 Step 6: Adjust the Tool-change Location Adjust the Tool-change Location Procedure Start the modeling machine. Go to the main window in VPanel and make sure the information for the ATC is displayed. Mount a tool holder in stocker No. 1. For information on how to mount this, see the following page.
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2-7 Step 6: Adjust the Tool-change Location Click [OK] to finish adjustment. Shut down the modeling machine. Shut down This completes all installation operations. Times When Readjustment Is Required In either of the following cases, adjust the tool-change location again. When the spindle unit or magazine unit has been reinstalled When the installation environment has changed Chapter 2 Installation...
Chapter 3 Basic Operation 3-1 Starting and Quitting ..................50 How to Start the Machine ................... 50 How to Shut down ....................51 3-2 Mounting the Tool Holders ................52 Mounting Tool Holders in the Magazine ............. 52 About the Stocker Numbers ................54 3-3 Manual Tool-change ..................55 Grasping a Tool Holder by Manual Operation ............
3-1 Starting and Quitting How to Start the Machine When this unit is installed, the procedure for starting the modeling machine changes slightly. Initialization cannot be performed while a tool holder remains gripped by the spindle. This means that if a tool holder remains gripped, it must be released when you begin startup.
3-1 Starting and Quitting Support the tool with your hand to keep it from falling. On the handy panel, press the [CLEAR] key. After the tool holder is released, return to the normal startup procedure. Press the [ENTER] key to perform initialization, then start VPanel.
3-2 Mounting the Tool Holders Mounting Tool Holders in the Magazine The magazine is a "box" for storing the tool holders you use for cutting. Before you start cutting, load it with the needed tool holders. Procedure Close the spindle cover. ...
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3-2 Mounting the Tool Holders Mount the tool holders in the stock- Insert firmly all the way ers. to engage securely. Orient the depression in this direction. Click [Close Magazine Cover]. Check the information displayed in VPanel. The tool holders are displayed in the stockers where they are mounted.
3-2 Mounting the Tool Holders About the Stocker Numbers The stockers are numbered from 1 to 4. The tools Stocker No. 4 used for cutting are all specified by these stocker Stocker No. 3 numbers. This makes it important to decide on Stocker No.
3-3 Manual Tool-change Grasping a Tool Holder by Manual Operation Tool-change is performed automatically according to commands from the computer, but when necessary you can also perform tool-change manually. Note, however, that this operation cannot be performed when the spindle cover is open, during a cutting operating, or while the machine is paused.
4-1 What's the Tool-length Offset? What's the Tool-length Offset? This feature keeps the position of the tool tip from changing during cutting, even when you change among tools of different lengths. This is useful when you want to use multiple tools selectively to cut a single workpiece. Note, however, that this requires measuring the lengths of the respective tools and saving their adjustment (offset) values in advance.
4-2 Automatic Measurement of Tool Length What's Automatic Measurement of Tool Length? This feature automatically measures tool length using the Z-origin sensor and registers its adjustment value. You can perform batch registration for a number of tools at one time. Important ! When performing automatic measurement of tool length, check that no cutting waste and the like is present on the Z-origin sensor and tool.
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4-2 Automatic Measurement of Tool Length Close the spindle cover. In VPanel, click the [Magazine] icon. Click [Measure All]. WARNING: This procedure makes the machine operate. Before you perform this procedure, check to make sure that operation of the machine will not create any hazard or danger.
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4-2 Automatic Measurement of Tool Length To Make the Tool Descend Rapidly When it takes a long time for the tool to make contact with the sensor, turn the hand wheel on the handy panel counterclock- wise. Be careful not to make the tool collide with the sensor. A collision makes accurate detection impossible. If a collision occurs, redo the operation from the beginning.
4-3 Entering Adjustment Values Yourself Entering Adjustment Values When you've measured tool length yourself, follow the procedure below to register the adjustment values. Procedure In VPanel, click the [Length Offset] icon. Enter the adjustment value. Click [OK]. About the Offset Numbers The numbers displayed in the [Length Offset] dialog box are the offset numbers.
4-3 Entering Adjustment Values Yourself Fine-tuning the Results of Automatic Measurement of Tool Length When necessary, you can fine-tune the adjustment values obtained by automatic measurement of tool length. The [Length Offset] dialog box is updated with the results of automatic measurement, so you change the values here.
4-4 Starting Tool-length Offset When Tool-length Offset Starts Tool-length offset is activated in the following cases. In each of these cases, the offsets are applied according to the registered adjustment values. (You can use the [Magazine] dialog box to view and check the adjustment values.) Note, however, that the adjustment values are all zero by default, and unless you change them, no offsets are applied.
Chapter 5 Getting Ready for and Performing Cutting 5-1 Cutting Area ....................66 Workpiece Size and Location Where Secured in Place ........66 Actual Size That Can Be Cut ................67 5-2 Examples of Usage of Tool-length Offset (RML-1 Mode) ......68 Example of Operations up to Starting Cutting ............
5-1 Cutting Area Workpiece Size and Location Where Secured in Place Arrange the workpiece (the material to cut), frames, and the like so that they fit within the determined range. Anything extending beyond may strike moving parts. Be sure to observe this requirement, as failure to do so may result in damage to the workpiece or frame or malfunction of the machine.
5-1 Cutting Area Actual Size That Can Be Cut Creating an object of the size of the full axis travel is not necessarily possible. Because a certain amount of clearance in the X-, Y-, and Z-axis directions is required for no-load feed of the tool, the allowable size of the workpiece is reduced by a cor- responding amount.
5-2 Examples of Usage of Tool-length Offset (RML-1 Mode) Example of Operations up to Starting Cutting This section explains some important points about using an ATC-compatible program to perform cutting with multiple tools. Mount the Tools Decide on the tools to use for draft cutting, finishing, and so on, and mount them in the magazine. Once you've mounted them, it's important not to replace them with others until after you've finished cutting.
5-3 Examples of Usage of Tool-length Offset (NC-code Mode) Example of Operations up to Starting Cutting This section explains some important points about using an NC program to perform cutting with multiple tools. Mount the Tools Decide on the tools to use for draft cutting, finishing, and so on, and mount them in the magazine. Once you've mounted them, it's important not to replace them with others until after you've finished cutting.
5-3 Examples of Usage of Tool-length Offset (NC-code Mode) Example of Setting the Z-axis Origin Procedure Use manual tool-change to grasp any one of the tools. You may grasp any tool whose adjustment value has already been registered. Set the Z-axis origin for the gripped tool.
Chapter 6 Handy Panel 6-1 Features Added to the Handy Panel ............72 Features Added to the Handy Panel ..............72 6-2 Manual Operation of the ATC ..............73 Basic Operation of the ATC ................73...
6-1 Features Added to the Handy Panel Features Added to the Handy Panel Installing this unit adds the following features to the handy panel. Opening and closing the magazine cover Manual tool-change Tool forced release Automatic measurement of tool length ...
6-2 Manual Operation of the ATC Basic Operation of the ATC You can perform basic operation of the ATC using the handy panel. Note, however, that this operation cannot be performed when the spindle cover is open, during a cutting operating, or while the machine is paused. ☞...
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6-2 Manual Operation of the ATC WARNING: This procedure makes the machine operate. Before you perform this procedure, check to make sure that operation of the machine will not create any hazard or danger. Press the [ENTER] key. To go back to the original screen, use the hand wheel to select [Return to main], then press the [ENTER] key. About the Selection Items TOOL 1 through TOOL 4: This grasps the tool holder.
Chapter 7 Appendix 7-1 Daily Care ....................76 Cleaning ......................76 Bleeding Off Air Pressure ................... 76 Cleaning Inside the Magazine Cover ..............77 Care and Maintenance of the Tool Holders and Spindle Nose ......77 Adjusting the Air Pressure .................. 77 Care and Maintenance of the Air Regulator ............
7-1 Daily Care Cleaning WARNING Before attempting cleaning, maintenance, or attachment or detachment of the air hose or any optional items, stop the supply of compressed air and allow the pressure to escape. Allowing the equipment to remain under pressure poses a hazard of flying com- ponents.
7-1 Daily Care Cleaning Inside the Magazine Cover Open the magazine cover and clean away any buildup of cutting waste inside. For information on how to open the magazine cover, refer to the following. ☞ P. 52, "Mounting Tool Holders in the Magazine" Care and Maintenance of the Tool Holders and Spindle Nose Before use, clean away any cutting waste and excess grease.
7-1 Daily Care Care and Maintenance of the Air Regulator WARNING Before removing the bowl, be sure to bleed off the air pressure. Failure to do so may cause danger of rupture or thrown-off parts. WARNING Clean the bowl using a neutral detergent. Never use gasoline, alcohol, thinner, or any other solvent.
7-2 Inspection and Maintenance Checking the Total Working Time This machine automatically keeps track of time in operation. Use this as a general guide for determining when to perform maintenance. The time for which the spindle has rotated is taken to be the working time. In VPanel, click the [Setup] icon.
7-3 What to Do If... Important Notes on Performing Continuous Tool-change operations fail. Cutting for a Prolonged Period Are the tool holders mounted securely? When a Tool Holder Fails to Come Loose When mounting tool holders in stockers, fit them in firmly, as Performing continuous cutting for a prolonged period with a far as they will go.
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7-3 What to Do If... Abnormal ATC air pressure. Paused... Take tool The air pressure has dropped (during cutting). Adjust the air An attempt was made to set the Z-axis origin using the tool pressure, then click [Clear Error]. After recovery, canceling the sensor while no tool was grasped.
7-4 NC Code Specifications Items Related to the Mechanical Specifica- tions of the Machine This section describes the NC codes that are dependent on the machine's mechanical specifications. ☞ "NC Code Reference Manual" Tool-length offset (G43) G43 is supported only when this unit is installed. The parameter range is as follows.
7-5 Unit Specifications Main Specifications ZAT-540 Number of tools housed Maximum tool length 110 mm (4.3 in.) Maximum tool diameter 10 mm (0.4 in.) Maximum tool weight 350 g (0.77 lb.) Tool-holder format Taper shank: JBS4002 15T 7/24 taper Pull stud: JBS4002 15P (45˚), special...
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