Roland MODELA Pro ZCL-650A User manual

USER'S MANUAL
Rotary Axis Unit for MDX-650/650A
ZCL-650A
ZCL-650
Thank you very much for purchasing the product.
• To ensure correct and safe usage with a full understanding of this product's performance,
please be sure to read through this manual completely and store it in a safe location.
• Unauthorized copying or transferral, in whole or in part, of this manual is prohibited.
• The contents of this operation manual and the specifications of this product are subject to
change without notice.
• The operation manual and the product have been prepared and tested as much as possible.
If you find any misprint or error, please inform us.
• 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.
• Roland DG Corp. assumes no responsibility for any direct or indirect loss or damage
which may occur with respect to any article made using this product.

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Company names and product names are trademarks or registered trademarks of their respective holders.
Copyright © 2001 Roland DG Corporation http://www.rolanddg.com/
Table of Contents
To Ensure Safe Use............................... 2
Part 1
Features ............................................. 4
Part 2
Setting Up .......................................... 5
2-1. Included Items ..................................................5
2-2. Names of Parts..................................................6
2-3. Installing the Rotary Axis Unit.........................7
Part 3
Using the Operation Panel ............... 9
3-1. Rotating the AAxis
Using the Operation Panel................... 9
3-2. Setting the A-axis Origin Point.......................10
3-3. Setting the Y- and Z-axis Origin Point
at the A-axis Center of Rotation ........10
Y-axis Center Alignment .................................. 10
Z-axis Center Alignment ..................................12
3-4. Added Display Menus .................................... 13
Menu Flowchart ...............................................13
Descriptions of the Menus ...............................14
Part 4
Loading Material.............................. 15
4-1. The Cutting Area ............................................ 15
Maximum Cutting Area
(When ZS-650T Is Installed).....15
Important Points About the CuttingArea .........15
4-2. Loading Material ............................................16
Part 5
Offset Adjustment for the
Y-axis and Z-axis Origin Points .... 17
5-1. When Offset Adjustment Is Required.............17
Inaccuracy in the Z-axis Direction ................... 17
Differences in Height at the Seam Between
the Front and Back Surfaces...... 17
5-2. How to Adjust the Center-Z Offset................. 18
5-3. How to Adjust the Center-Y Offset ................20
Part 6
Cutting Using MODELA Player
ver. 3............................................... 22
6-1. Settings For the Rotary Axis Unit ..................23
6-2. The Tool Movement Range
for MODELA Player ver. 3 ............... 24
6-3. Getting Ready for Cutting .............................. 25
Method of Object Support................................25
Cutting Parameters ........................................... 26
Workpiece Shape and Size ...............................26
Maximum Cutting Depth
of the Cutting Surfaces .............. 26
Check of Required Tool Length
and Check for Interference ........26
6-4.Actual Four-surface Cutting ........................... 27
Effects of Errors in CuttingAccuracy
on Finished Result .....................27
A Cutting Method Taking Error in Accuracy
into Account...............................28
A Method for Reducing Errors
in Cutting Accuracy ................... 29
6-5. Operation of MODELA Player ver. 3............. 30
Step 1. Setting the Origin Point........................30
Step 2. Setting the Cutting Parameters.............30
Step 3. Use the [Settings for Multiple-surface
Cutting] Wizard ......................... 32
Part 7
Appendix.......................................... 34
7-1. Maintenance ................................................... 34
Cleaning the Unit ............................................. 34
Cleaning After Use ...........................................34
Service Life of the Reduction Gear..................34
7-2. What to Do If... ...............................................34
7-3. Specifications..................................................35
Specifications ...................................................35
Attachment Base Dimensional Drawing ..........35

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Used for instructions intended to alert the user to the risk of death or severe
injury should the unit be used improperly.
About and Notices
Used for instructions intended to alert the user to the risk of injury or material
damage should the unit be used improperly.
* Material damage refers to damage or other adverse effects caused with
respect to the home and all its furnishings, as well to domestic animals or
pets.
About the Symbols
The symbol alerts the user to important instructions or warnings. The specific meaning of
the symbol is determined by the design contained within the triangle. The symbol at left means
"danger of electrocution."
The symbol alerts the user to items that must never be carried out (are forbidden). The
specific thing that must not be done is indicated by the design contained within the circle. The
symbol at left means the unit must never be disassembled.
The symbol alerts the user to things that must be carried out. The specific thing that must
be done is indicated by the design contained within the circle. The symbol at left means the
power-cord plug must be unplugged from the outlet.
Do not disassemble, repair, or
modify.
Doing so may lead to fire or abnormal
operation resulting in injury.
Do not use while in an abnormal
state (i.e., emitting smoke, burning
odor, unusual noise, or the like).
Doing so may result in fire or
electrical shock.
Immediately switch off the power, unplug
the power cord from the electrical outlet,
and contact your authorized Roland DG
Corp. dealer or service center.
Fasten the spindle, tool, and material
securely in place.
Otherwise they may come loose during
cutting, resulting in injury.
Do not insert the fingers between the
rotary axis unit and the material.
The fingers may be pinched, resulting in
injury.
Do not wear gloves, a necktie or
wide-sleeved clothing.
They may become caught in the tool,
resulting in injury.
Set the cutting area so that the tool
does not contact the rotary axis unit
or the like.
Pieces of the tool or workpiece may fly off,
resulting in injury.
To Ensure Safe Use

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: Indicates information to prevent machine breakdown or malfunction and ensure correct use.
: Indicates a handy tip or advice regarding use.
In addition to the and symbols, the symbols shown below are also used.
NOTICE
Do not allow liquids, metal objects or
flammables inside the machine.
Such materials can cause fire.

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Part 1 1Features
This is a rotary axis unit exclusively for the MDX-650A/650. By adding an axis of rotation (Aaxis) to the three X,Y, and Z axes, it makes
it simple to achieve multiple-surface cutting. Until now, double-sided cutting required precise positioning of the front and back surfaces,
but using the this unit lets you carry out troublesome operations such as changing the front and back surfaces with ease.
When the rotary axis unit is installed, you can carry out simultaneous three-axis control for the X, Y, and Z axes or the X, Z, andA axes.
(The A and Y axes do not operate simultaneously. Simultaneous four-axis operation of the X, Y, Z, and A axes is not possible.) You can
easily switch between the A and Y axes using commands or the operation panel.
The Aaxis has a positioning range of 0 to 1,080 degrees (three full turns). It cannot be rotated continuously, like a lathe.
The rotary axis unit is suited to cutting resins such as chemical wood and modeling wax. It is not suitable for cutting metal.

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Part 2 2 Setting Up
2-1. Included Items
Hexagonal wrenches
6 mm:1 3 mm:1
Rotary axis unit
Cable clamp
Screws: 4
(for securing the cable clamp and
for the slider retainer)
Cap screws: 4
(for securing the rotary axis unit)
Y-center detection pin
(diameter 6 mm)
Slider retainerSpacers: 4
Washers: 4
(for securing the rotary axis unit)

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2-2. Names of Parts
Part 2 Setting Up
Tab
Tab
Slider
Slider
Attachment base
Attachment base
Set screws
Workpiece retainer
attachment
Clamp marks
Rotation-axis center
sensor
Cable clamp Cable
Workpiece
mounting surface
Drive side
Support side

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2-3. Installing the Rotary Axis Unit
NOTICE Before installing, be sure to switch off the main unit and unplug the power cord.Attempting to connect or discon-
nect cables while the power is on may result in breakdown.
1Turn on the power to the main unit. Press the [ ] key to
move the T-slot table all the way to the front.
2Turn off the main unit and unplug the power cord.
3Use the hexagonal wrench included with the main unit to
remove the six cap screws shown in the figure, then detach
the T-slot table.
4Use two screws to attach the slider retainer to the side and
temporarily secure the slider in place.
5Clean away any build-up grime on the tabs and the sliders.
Place the rotary axis unit on the slider and secure in place
using the four cap screws and washers while firmly press-
ing the tab against the slider. If insufficient pressure is
applied or the installation is not straight, cutting accuracy
cannot be assured.
Part 2 Setting Up
T-slot table
Slider
Slider
Slider retainer
Screws
Tab
Slider
Slider
Cap screw
Tab
Hexagonal wrench
Washer

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6Detach the slider retainer you attached earlier.
7Use two screws to attach the cable clamp and secure the
cable in place. Position the cable clamp so that it is be-
tween the white clamp marks.
8If you're using the optional safety cover, remove the plate
on the left side of the safety cover.
9Firmly insert the cable of the rotary axis unit into the
"EXT.3" connector on the main unit. Use a screwdriver to
tighten the connector screws. The machine will not operate
if this cable becomes disconnected or loose. Tighten
securely.
10 Store the center of rotation (Y axis) of the rotary axis unit
in memory. For information about how to do this, refer to
"3-3. Setting the Y- and Z-axis Origin Point at the A-
axis Center of Rotation" and see "Y-axis Center
Alignment."
Part 2 Setting Up
(Safety cover)
Plate
Cable
Cable clamp
Clamp mark
Screw
EXT.3 connector

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Part 3 3 Using the Operation Panel
When you install the rotary axis unit, the following keys operations and display menus are added. This section describes the added
functions. For information about the basic operation of the operation panel, refer to the manuals of the main unit.
3-1. Rotating the A Axis Using the Operation Panel
1Hold down the [JOG] key for 0.5 seconds or longer. The
display changes to show the coordinates of the A axis.
When the power is switched on, the [ ] and [ ] keys on
the operation panel are assigned to Y-axis operation, and
the display also shows the Y-axis coordinates. Holding
down the [JOG] key for 0.5 seconds or longer switches
from the Y axis to the A axis.
2Use the [ ] key to rotate in the positive direction (toward
the front) and the [ ] key to rotate in the negative direc-
tion (toward the back). Also, when you press the [JOG]
key to line up the [*] with [A], you can also use the dial to
perform these operations.
3Holding down the [JOG] key again for 0.5 seconds or
longer changes from the A axis to the Y axis.
X 0 *Y 0
Z 0 --------
X 0 *A 0
Z 0 --------
Hold down for 0.5
seconds or longer
Negative direction
Positive direction
X 0 *Y 0
Z 0 --------
X 0 *A 0
Z 0 --------
Hold down for 0.5
seconds or longer

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3-2. Setting the A-axis Origin Point
The rotary axis unit has a coordinate range of three rotations from the origin point for machine coordinates. You can set the origin point
for workpiece coordinates within this coordinate range.
1Change the display to coordinate view.
2Rotate the A axis to the angle where you want to set the origin point. (See "3-1. Rotating the A Axis Using the Operation
Panel.")
3Press the [XY/A] key.
4Press the [ENTER] key. The screen flashes once and returns to the coordinate view. The A-axis origin point has now been set.
The origin point is stored in memory until even after the power is turned off.
3-3. Setting the Y- and Z-axis Origin Point at the A-axis Center of Rotation
Aligning the Y- and Z-axis origin point for workpiece coordinates with the A-axis center of rotation makes it easy to determine coordi-
nates at times such as when performing multiple-surface cutting. The rotary axis unit offers as feature that makes it simple to perform this
setting. If you're using MODELA Player, be sure to carry out these operations.
NOTICE Be sure to put back the sensor cover after use. Attempting cutting while the cover is left detached may result in
cuttings building up on the sensor or getting inside the sensor, which may cause breakdown.
Y-axis Center Alignment
Be sure to carry out this operation at least once after installation. Also, do it after replacing the spindle unit.
1Remove the sensor cover.
Part 3 Using the Operation Panel
Rotation-axis
center sensor

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2Install the included Y-center detection pin on the spindle
unit with an amount of extension of about 20 mm (about 1
in.).
3Move the tip of the Y-center detection pin to a position
about 2 to 3 mm (about 1/8 in.) above the rotation-axis
center sensor.
4Press the [EXIT] key to display the main menu.
5Turn the dial to line up the arrow with [ROTARY CON-
TROL], then press the [ENTER] key.
6Turn the dial to line up the arrow with [Y CENTER
MODE], then press the [ENTER] key.
7Aconfirmation prompt appears. If everything is ready, press
the [ENTER] key. The center of rotation of the A axis is
detected automatically, and theY-axis origin point is set at
that point.
The bell beeps when detection ends.
8Put back the sensor cover.
NOTICE Be sure to use the includedY-center detection pin to perform this operation. Using an end mill or the like may make
accurate detection of the origin point impossible.
If Y-axis center alignment of greater accuracy is required, use the [CENTER-Y OFFSET] function. This makes it possible to correct for
sensor error. For detailed information, see "Part 5 OffsetAdjustment for the Y-axis and Z-axis Origin Points."
This Y-axis center position is stored in memory, and does not disappear even if you set the X- and Y-axis origin point at a different
position.You can restore theY-axis origin point to the center location at any time by executing [RESETYPOS]. For detailed information,
see "3-4. Added Display Menus."
12>4 Y CENTER MODE
5 CENTER-Y OFFSET
>12 ROTARY CONTROL
Part 3 Using the Operation Panel

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12>2 Z CENTER MODE
3 RESET Y POS
>12 ROTARY CONTROL
Z-axis Center Alignment
Be sure to carry out this operation every time you change the tool.
1Remove the sensor cover.
2Install the tool to use for actual cutting on the spindle.
3Move the tip of the tool to a position about 2 to 3 mm
(about 1/8 in.) above the rotation-axis center sensor.
4Press the [EXIT] key to display the main menu.
5Turn the dial to line up the arrow with [ROTARY CON-
TROL], then press the [ENTER] key.
6Turn the dial to line up the arrow with [Z CENTER
MODE], then press the [ENTER] key.
7Press the [-Z] key to lower the tool until it touches the
rotation-axis center sensor.As soon as the tool touches the
sensor, operation stops and the tool rises. The center of
rotation of theAaxis is detected automatically, and the Z-
axis origin point is set at that point.
The bell beeps when detection ends.
8Put back the sensor cover.
Part 3 Using the Operation Panel
Rotation-axis
center sensor

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3-4. Added Display Menus
This section describes the MDX-650A/650’s menus that are added when the rotary axis unit is installed.
Menu Flowchart
(Both RML-1 and NC-Code)
0 to 360 degrees
(In step of 15 degrees)
>12 ROTARY CONTROL 12>1 ROTATE
2 Z CENTER MODE
3 RESET Y POS
4 Y CENTER MODE
5 CENTER-Y OFFSET
6 CENTER-Z OFFSET
7 ROTARY USE TIME
8 To Main MENU
12-1 ROTATE
0deg
[EXIT]
12>2 Z CENTER MODE
Please Cursor Move
12>3 RESET Y POS
Are You Sure?[ENTER]
12>4 Y CENTER MODE
Are You Sure?[ENTER]
-1000 to 1000 µ m
(In step of 10 µ m)
-1000 to 1000
µ m
(In step of 10
µ m)
12-5 CENTER-Y OFFSET
< 0 µm>
12-6 CENTER-Z OFFSET
< 0 µm>
12-7 ROTARY USE TIME
0 hours
12-8 To Main MENU
[ENTER]
[EXIT]
[ENTER]
Main Menu
Part 3 Using the Operation Panel

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Descriptions of the Menus
Part 3 Using the Operation Panel
12-1 ROTATE
12-2 Z CENTER MODE
12-3 RESET Y POS
12-4 Y CENTER MODE
12-5 CENTER-Y OFFSET
12-6 CENTER-Z OFFSET
12-7 ROTARYUSE TIME
Stored in memory : No
Setting range : 0 to 360 degrees
Steps : 15
This references the user origin point (workpiece origin point) and rotates the A axis by the
selected angle.
This uses the rotation-axis center sensor to set the Z-axis origin point at a location where the
tool tip coincides with the height of the A-axis center.
This resets the Y-axis origin point at the location set previously with [Y CENTER MODE].
Even after the Y-axis origin point has been set at another location, you can reset it to the A-
axis center by running this item.
Running this item when [YCENTER MODE] has never been run once sets the Y-axis origin
point at the center of the maximum cutting range.
This uses the rotational-center sensor to set the Y-axis origin point at a location where the
tool center coincides with the A-axis center.
Running this item initializes the [CENTER-Y OFFSET] value to zero.
Stored in memory :Yes
Factory default : 0
Setting range : -1,000 to 1,000 µm
Steps : 10
This corrects coordinate misalignment of the Y-axis origin point that [Y CENTER MODE]
sets. Entering a positive value applies correction toward the back, and entering a negative
value applies correction toward the front.
Running [Y CENTER MODE] initializes this value to zero.
Stored in memory :Yes
Factory default : 0
Setting range : -1,000 to 1,000 µm
Steps : 10
This corrects coordinate misalignment of the Z-axis origin point that [Z CENTER MODE]
sets. Entering a positive value applies correction upward, and entering a negative value ap-
plies correction downward.
This displays the total usage time of the rotary axis unit. The value cannot be reset to zero. It
keeps count of spindle rotation time when the rotary axis unit is connected.

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Part 4 4 Loading Material
4-1. The CuttingArea
Maximum Cutting Area (When ZS-650T Is Installed)
Important Points About the Cutting Area
The range that can actually be cut is limited by the following factors, which make it narrower than the range described above.
• Amount of tool extension
• Interference between the rotary axis unit or workpiece retainer attachment and the tool or spindle unit
• Interference between the loaded workpiece and the tool or spindle unit
Special care is needed when you attach square material as the workpiece, because the corners may easily strike the tool when rotating the
A axis.
155
(19)
(174)
103
123
(93)
8
8
Max. 410
Max. 385
Unit: mm

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4-2. Loading Material
1Use the included hexagonal wrench (6 mm) to loosen the
support-side retaining screws, then move the support side
to match the size of the workpiece.
2Securely tighten the support-side retaining screws.
3Use the included hexagonal wrench (3 mm) to loosen the
set screws for the workpiece retainer attachment on the
drive and support sides, then insert the workpiece.
If the workpiece is flat, press the flat surface of the
workpiece against the workpiece brace surface of the
workpiece retainer attachment.
4Tighten the set screws securely, using even force.
If the workpiece is thin and the set screws do not reach,
insert the included spacer or the like and secure in place.
Take care not to apply excessive force when securing the workpiece in place. Doing so may cause the workpiece to warp or deform during
cutting. When you are using a soft workpiece made of foamed material or the like, precision may be affected by slipping of the workpiece
during cutting or twisting during rotation.
When you are using the included workpiece retainer attachment, we recommend using a workpiece with a flat bottom surface.
Part 4 Loading Material
Spacer
Set screw

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Part 5 5 Offset Adjustment for the Y-axis
and Z-axis Origin Points
5-1. When Offset Adjustment Is Required
The Y-axis and Z-axis origin points are generally set at the center of rotation for the A-axis. The rotary axis unit is provided with a
rotation-axis center sensor for setting these origin points. Slight errors may occur in the origin-point settings made with this, but it's
possible to correct them by adjusting the offset.
Misalignment of the position of the origin point may affect cutting as follows.
Inaccuracy in the Z-axis Direction
There is an error in the thickness of the object when cutting the front or back surface. This is due to misalignment of the Z-axis origin
point. Make correction as described in "5-2. How to Adjust the Center-Z Offset."
Differences in Height at the Seam Between the Front and Back Surfaces
There is an error in the depth of the object. This results in differences the upper and lower height at the seam when you perform two-
surface cutting for the front and back surfaces. This is due to misalignment of theY-axis origin point. Make correction as described in "5-
3. How to Adjust the Center-Y Offset."
The specified height
is not obtained.
Difference

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Part 5 Offset Adjustment for the Y-axis and Z-axis Origin Points
X 0 Y 0
Z 0 *8000 RPM
(RML-1)
(NC-CODE)
X 0 Y 0
Z 0 *S80 OFS
X 4520 Y -3125
*Z -80 ---------
5-2. How to Adjust the Center-Z Offset
To adjust the offset, you perform actual cutting of material and evaluate the amount of misalignment.
There are no special rules about the particular cutting you should use. This section explains a simple method that lets you perform cutting
without using any software. We recommend using modeling wax or chemical wood as the workpiece with this method.
1Install a square end mill about 6 mm in diameter, then run [Z CEN-
TER MODE]. For more information, see "3-3. Setting theY- and
Z- axis Origin Point at the A-axis Center of Rotation."
2Load a box-shaped workpiece, then set theA-axis origin point at a
place where the surface is level. Hold down the [JOG] key for 0.5
seconds or longer to return the [ ] and [ ] keys toY-axis opera-
tion.
For more information, refer to "3-1. Rotating the A Axis Using
theOperation Panel" and "3-2.Setting theA-axisOrigin Point."
3Hold down the [SPINDLE] key for 0.5 seconds or longer to rotate
the spindle. Press the [JOG] key to line up the [*] with the spindle
speed, then use the dial to make the setting for about 8,000 to
10,000 rpm.
4Move the tool to the edge of the workpiece. Use the [-Z] key and
the dial to gradually lower the tool and cut in by about 0.2 to 0.5
mm. Make a note of the Z-axis coordinate value that appears on
the display at this time. (Label this "coordinate a.")
5Use the [ ], [ ], [ ], and [ ] keys to move the tool, then cut
the workpiece. Cut a sufficient range to allow use of Vernier cali-
pers or the like.