Rocketronics ELS 4 Basic User manual

ELS 4 BaSic
ENGLISH
Operating instructions
This manual describes the commissioning and use of
the cycle controller ELS 4 BASIC.
TRANSLATION OF THE ORIGINAL
OPERATING INSTRUCTIONS

The distribution and reproduction of this document, its use and communication of its con-
tents is strictly prohibited. not permitted, unless expressly conceded. Contraventions obligate
to Compensation. All rights in the event of patent grant or utility model registration. reserved.
All product designations mentioned in this manual are trademarks of respective companies.
Subject to technical changes without notice.
All safety regulations, in particular the CE directives, have been observed during pro-
duction. The product was subjected to an extensive nal inspection at the factory.

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CONTENTS
Disclaimer................................................................................................................................ 4
Addressee of the documentation ............................................................................................. 4
Safety instructions .................................................................................................................. 4
Licence conditions for software of the electronic leadscrew control system ............................ 5
Notes .......................................................................................................................................... 6
Scope of delivery and accessories ..................................................................................... 10
Basic requirements ............................................................................................................... 11
Encoder.................................................................................................................................. 12
Axle Drives............................................................................................................................. 14
Selection of right motor ......................................................................................................... 16
Maximum feed speed............................................................................................................. 17
Motor-Drivers ........................................................................................................................ 19
Emergency-STOP ................................................................................................................... 20
Controlelements .................................................................................................................... 22
Front Side .............................................................................................................................. 22
Key functions......................................................................................................................... 23
Display-ElementS ................................................................................................................... 24
LIGHT EMITTING DIODED (LED) .............................................................................................. 24
Micro-SD-Card-Slot ................................................................................................................. 25
Programkey /Settings reset.................................................................................................... 25
Inputs and outputs ................................................................................................................ 26
Screwterminal data ............................................................................................................... 27
Power supply ......................................................................................................................... 27
Extension connector .............................................................................................................. 27
Grounding.............................................................................................................................. 27
Connection of encoder........................................................................................................... 28
Connection motordriver ........................................................................................................ 30
Digital Inputs ......................................................................................................................... 32
Emergency Stop ..................................................................................................................... 33
Digital Outputs ...................................................................................................................... 35
Grounding, cable and shielding .............................................................................................. 37
System connection diagram................................................................................................... 38
SETUP........................................................................................................................................ 39
SETUP GeneraL....................................................................................................................... 40
SETUP ENCODER..................................................................................................................... 40
SETUP Z-Motor ....................................................................................................................... 41
SETUP X-Motor ....................................................................................................................... 42
SETUP DATA ........................................................................................................................... 43
SETUP INPUTS ........................................................................................................................ 44
SETUP Outputs....................................................................................................................... 45
SETUP INFORMATION............................................................................................................. 45
FACTORY SETTINGS................................................................................................................. 45
commissioning ....................................................................................................................... 46
Preparations.......................................................................................................................... 46
Checklist before commissioning............................................................................................. 47
Implementation of the commissioning .................................................................................. 48

Basic functionality................................................................................................................. 52
Selection of cutting passes..................................................................................................... 54
Possible cycles ........................................................................................................................ 55
GEARBOX LEFT ...................................................................................................................... 56
GEARBOX RIGHT .................................................................................................................. 56
TURNING................................................................................................................................ 58
BORING.................................................................................................................................. 62
FACING .................................................................................................................................. 64
PARTING ................................................................................................................................ 66
UNDERCUT ............................................................................................................................. 67
MAKING THREADS .................................................................................................................. 69
EXTERNAL CONE..................................................................................................................... 78
INTERNAL CONE..................................................................................................................... 80
Radius turning in general....................................................................................................... 82
E-RADIUS ) EXTERNAL RADIUS KONVEX................................................................................ 83
E-RADIUS ( EXTERNAL RADIUS CONCAV ............................................................................... 85
I-RADIUS ) INTERNAL RADIUS CONVEX................................................................................. 87
I-RADIUS ( INTERN RADIUS CONCAV .................................................................................... 89
GROOVE ................................................................................................................................. 91
GRINDING .............................................................................................................................. 96
ANGLE.................................................................................................................................... 97
tips for use............................................................................................................................... 98
Approach positions exactly: ................................................................................................... 98
Set the zero point on the workpiece surface: ......................................................................... 98
Drive from waiting position to 0............................................................................................. 98
Precise external turning made easy ....................................................................................... 98
Special dimensions by changing the settings.......................................................................... 99
Moving the X axis manually in gear mode .............................................................................. 99
Softwareupdate ................................................................................................................... 100
Appendix 1 Denition of cone ratio ................................................................................ 101
Appendix 2: Wall mounting ............................................................................................... 102
Appendix 3: Technical data .............................................................................................. 103
Disposal.................................................................................................................................. 104
Contact us: ............................................................................................................................ 104
3

DANGER
means death or serious injury,
if the appropriate precautions are not taken.
WARNING
This warning means that death or serious injury will result if the appropriate
precautions are not taken.
CAUTION
with warning triangle means that a slight bodily injury may occur if the
appropriate precautions are not taken
CAUTION
without a warning triangle means that damage to property may occur if
the appropriate precautions are not taken.
ATTENTION
means that an undesirable result or condition may occur if the relevant
instructions are not followed.
4
DISCLAIMER
We have checked the contents of this publication for conformity with the hardware and soft-
ware described. Nevertheless, deviations cannot be excluded, so that we do not assume any
liability for the complete conformity. However, the information in this publication is checked
regularly and necessary corrections are included in the following editions.
ADDRESSEE OF THE DOCUMENTATION
This documentation is intended for machine tool users and installation personnel. The bro-
chure describes in detail the information required by the user for the installation and operation
of the ELS controls.
SAFETY INSTRUCTIONS
This manual contains instructions that you must follow for your personal safety and to avoid
damage to property. The instructions for your personal safety are highlighted by a warning tri-
angle, instructions for sole material damage are without a warning triangle. Depending on the
hazard level, the warning notices are displayed in descending order as follows:

LICENCE CONDITIONS FOR SOFTWARE OF THE ELECTRONIC LEADSCREW
CONTROL SYSTEM
In the following the company Rocketronics.de, owner Louis Schreyer is referred to as „LICENSER“ of the software.
I. Rights of Use
1. The LICENSER grants to the Customer a royalty-free, perpetual and non-exclusive right to use (license) the SOFT-
WARE contained in this archive (hereinafter referred to as „SOFTWARE“).
2. The license entitles the customer to use the SOFTWARE individually within the scope of normal use. This includes
the installation of the SOFTWARE and the making of a backup copy, the loading of the SOFTWARE into the licensor‘s
control devices provided for this purpose and its expiry. The license does not extend to other types of use. In par-
ticular, the customer may not make any changes and translations or further copies of the SOFTWARE, even partial or
temporary, of any kind and by any means. The printout of the program code also represents an inadmissible dupli-
cation. Changes for which the LICENSER cannot be refused approval in good faith (§ 39 para. 2 UrhG) are admissible.
3 The use of the SOFTWARE on hardware not manufactured by the LICENSER is prohibited.
4. The LICENSER is the owner of all industrial property rights and copyrights to the SOFTWARE and the associated
user documentation. References to copyrights or other industrial property rights which are located on or in the
SOFTWARE may not be changed, removed or otherwise made unrecognizable.
5. The customer may not reverse engineer, decompile or disassemble the SOFTWARE. Otherwise §§ 69d, 69e UrhG
remain unaected.
II. warranty
1. The LICENSER warrants - in accordance with the provisions of §§ 434  BGB - that the SOFTWARE complies with
the specications listed by Rocketronics in the associated program documentation and that it has been created
with due care and expertise. Nevertheless, according to the current state of the art, the complete exclusion of
software errors is not possible.
2. The LICENSER shall correct any errors in the SOFTWARE which signicantly impair the intended use. At the dis-
cretion of the LICENSER, the correction of the defect shall be eected, depending on the signicance of the defect,
by the delivery of an improved version of the SOFTWARE or by instructions for the elimination or avoidance of the
eects of the defect. The Customer shall be obliged to take over a new SOFTWARE version oered to him by the
Licensor in the course of error correction, unless this leads to unacceptable adjustment and conversion problems
for him.
4. The customer has the right to demand a reduction of the license fee or to withdraw from the contract free of
charge. In the event of withdrawal, the customer shall return the hardware with the SOFTWARE contained to the
LICENSER.
5. In any case of negligent breach of contract by the Licensor, the liability shall be limited to the amount of the net
purchase price for the associated hardware.
The warranty period shall be 24 months from delivery of the SOFTWARE.
5

6
NOTES
Notes on installation
WARNING
The ELS controls are simple cycle controls that allow fully automatic cycle machining with
a conventional lathe. For this purpose, drives must be mounted on the axes of the ma-
chine and a rotary encoder for position feedback must be mounted on the main spindle.
Equipped with these components, the machine can then be controlled in 2 axes. The ELS control
generatescontrolsignalsforthedrivemotorsfromtheencodersignals.Thesearestrictlycoupledto
themovementofthemainspindlebytherotaryencoder,thuscreatinganelectronicallycontrollable
gear. This means that many operations can be carried out automatically and speed-dependently.
In addition, the user can freely select the feed rate on the ELS where gear changes or change
gears previously had to be made.
Possible application
The ELS control system allows various applications to be carried out automatically that were
only possible manually before installation. With the ELS, the user can cut threads in all pitches,
even tapered- or multi-threads. It is possible to turn radii and cones, inside and outside, radii
in concave or convex with cutting radius compensation. Longitudinal and face cutting inside
and outside are possible as well as parting and undercuts. It indicates positions and allows the
exact approaching of positions.
The ELS turns a manual machine into an automatic machine with much higher benets and
allows more precise machining.
The ELS control can only be used as a device if it is connected to a machine which has drive
motors and spindle encoders. Only in combination with these parts an automatic machine is
created. It must therefore be ensured by the user or installer that the entire machine complies
with the legal guidelines after completion of the installation.
It is essential that the control is integrated into the emergency stop
function of the machine. This function must be designed in such a way
that, after the emergency stop condition has been removed, it must be
enabled by the user before the machine is ready for operation again. It
must not be possible to restart the machine independently.

Intended use
The ELS controller is used to control stepper or servo motors (or similar drives) for operation
on a lathe. Any other use is considered improper.
Supplied accessories such as power supply units, output stages, sensors or motors must only
be used for their intended purpose.
Disclaimer
Rocketronics produces components that are used on a wide variety of lathes. The selection and
application of Rocketronics products is the responsibility of the system designer or end user.
Rocketronics assumes no responsibility for the integration of the products into the end system.
Under no circumstances may a Rocketronics product be integrated into a product or design as
a safety controller. All products containing a component part manufactured by Rocketronics
must include appropriate warnings and instructions for safe use and operation when handed
over to the end user. All warnings provided by Rocketronics must be passed directly to the end
user.
The user of this control must ensure that all necessary safety precautions have been taken and
that they have been checked for correct operation to ensure safe operation of the machine.
When a lathe is modied, a potentially dangerous device is modied. The automation of move-
ments can cause damage to the machine, but also serious injuries to the operating personnel.
WARNING
If incorrect entries are made, the machine equipped with this control
may make unexpected movements which can be fatal for the operating
personnel. It is therefore the responsibility of the system designer or
end user to ensure that the settings are correct and have been checked.
7

Qualied personnel
Qualied personnel must be able to correctly interpret and implement the safety instructions
and warnings. They must also be familiar with the safety concepts of automation technology
and have received appropriate training. Non-qualied interventions in the devices or failure
to observe the warning notices in this documentation or the warning notices displayed by the
device may result in damage to property or personal injury.
EU directives on product safety
The following EU directives have been observed:
2011/65EU RoHS
2014/30/EU Electromagnetic compatibility (EMC)
DIN EN 61010-1 Safety requirements for electrical equipment for measurement, control,
and laboratory use - Part 1: General requirements
DIN EN 61326-1 Electrical equipment for measurement, control, and laboratory use - EMC
requirements
Other applicable regulations
In addition to this technical manual, the following regulations must be observed:
• Accident prevention regulations
• Local occupational safety regulations
Safety regulations
●The ELS should only be used by authorised specialist personnel and in compliance with
accident prevention regulations and the regulations of the electrical industry.
●Unqualied persons must not put the control unit into operation.
●The control unit is designed for operating temperatures of +5 to +40 °C and storage
temperatures of -10 to +50 °C. The control unit must not be operated by unqualied persons.
It must be protected from high humidity, vibrations and explosive gases.
●Before opening the device, it must be disconnected from the power supply.
●Connection and installation work may only be carried out when the device is de-energized.
Assembly and use of equipment must be carried out in accordance with the standards of
the Declaration of Conformity.
●When connecting motors to motor drivers, the correct polarity must be observed.
Furthermore, the correct motor current must always be set on the driver. In order for the
speed of the motor to be correctly controlled, the steps/revolution must also be set on the
driver. This setting must also be adopted in the settings of the ELS.
●The respective conguration of the controller may only be operated with the motor types
congured for it. Other or further uses do not correspond to the intended purpose.
●Currents and voltages: The ELS works with a low voltage of 12V, which can be provided by a
power supply unit. Therefore, no special safety precautions are required on the output side.
The ELS is built in accordance with the recognised safety regulations and complies with the
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