This document provides instructions for setting up and operating a Roland MDX-540 4-axis CNC mill. It describes how to set up the machine coordinates, secure a workpiece for 4-axis milling, change endmills, set the Z-origin, and post NC code to begin milling. The setup process involves defining the A, Y, X and Z coordinate systems, calibrating the Z-origin sensor, and ensuring the material matches the 3D model. Safety steps are outlined and virtual panel navigation is illustrated with screenshots.

1. The City University of New York
Architectural Technology Dept.
Roland MDX-540
Basic 4-Axis Set-Up:
Machine and Stock Set Up
written by Cody Pfleging and Brian Ringley
Workpiece
.025 Min.
0.25 Min.
4.00Max.
14.60 Max.
4.00Max.
6.00 Max.
Axis
of Rotation

2. 2
This material is based upon work supported by the National Science Foundation
under Grant Numbers 1141234.
Any opinions, findings, and conclusions or recommendations expressed in this
material are those of the author(s) and do not necessarily reflect the views of the
National Science Foundation.

3. 3
Turning on the Roland
MDX-540 CNC Mill
Check to see if the chuck tightening knob is
positioned at the top. If it is not, rotate the chuck
until the knob is at the top using VPanel (Virtual
Panel). DO NOT MOVE IT MANUALLY.
Make sure the emergency stop button is in its
upright position.
Turn on the connected PC and log in.
Turn on the power switch located on the right side
of the front panel (Fig. 4); the machine will begin to
initialize.
Run the V-Panel application from the connected PC.
(Note: the V-Panel shortcut is located on the on the
windows taskbar.)
On the Virtual Panel prompt click OK. (Fig. 1)
On the Command set Selection prompt select NC-
Code and click Set (Fig. 2).
Press the green ENTER button on the Roland front
panel; the dialogue box will disappear and the
V-Panel application will initialize (Fig. 4).
The Virtual Panel is now ready to set the Roland’s A,
Y, X, and Z origins and receive programming.
Fig. 1 - Initial Prompt Dialogue Fig. 2 - Second Prompt Dialogue
Fig. 3 - Command-Set Dialogue Fig. 4 - Roland Front Panel Roland- 4 Axis

4. 4
Virtual Panel
Select coordinate system:
- G54 (FIg. 5).
Move spindle to a safe position:
- Move Tool (Fig 5)
- G54 (Fig. 6)
- Z-Axis to maximum height (Fig. 6)
- A-Axis to 0 degrees (Fig. 6)
Fig. 5 - Virtual Panel “VPanel”
Fig. 6 - Tool Movement Dialogue Roland- 4 Axis

5. 5
Roland- 4 Axis
Matching Physical Material
to Digital Model
Measure your physical material:
Once you have your toolpaths defined it is important
that you check that your 3D model stock in Rhino has
exactly the same dimensions as your actual material
stock. If there are any inconstancies it would result in
a poor final model. Use a ruler or calipers to get the
exact dimensions of your stock.
The biggest stock piece the Roland MDX-540 4 axis
mill can accommodate is 14.6”x”6”x4” anything larger
in any of the dimensions will have to be cut down to
size prior to milling.
If your stock is smaller than that of you 3D model then
you would have to adjust your model so that it fits
inside your stock.
Secure your physical material:
Once you have double checked your dimension you
can now move to placing you stock piece into the
rotation axis.
First you must find the axis of rotation for you stock
piece. The axis of rotation is at the center of your
width and height, mark this point down with a marker,
you will need it as we move along.
On the left of the Roland rotary axis unit you will have
a knob that adjusts the work piece chuck. On the right
you will have the Tailstock spindle. Place your stock
pieces as it is in 3D space. Turn the Chuck tightening
knob so that it is firmly secure. Once you have place
your material use the tailstock to bring is flush against
the live center (the center mark). Tighten the retaining
screw to hold the stock in place. Turn the retaining
knob to further secure the stock.
Workpiece
.025 Min.
0.25 Min.
4.00Max.
14.60 Max.
4.00Max.
6.00 Max.
Axis
of Rotation
Tailstock
Retaining Screw
Chuck
Knob
Fig. 7 - Stock in Rotary Setup

6. Roland- 4 Axis
6
Changing the Endmill
Removing and replacing the endmill
Open the spindle cover (Fig. 8).
Use red wrench and silver wrench to loosen the nut
while holding the endmill at its shank to prevent it
from dropping.
Remove the endmill and unscrew the collet/nut unit.
Remove the collet from the nut; insert new collet
(one that corresponds to the diameter of the desired
endmill).
Place the endmill into the collet/nut unit until the
shank end of the endmill is flush with the portion of
the collet that sits deepest in the spindle. Then, place
that assembly onto the spindle nose and hand tighten.
Use red wrench and silver wrench to tighten the nut
while holding the endmill at its shank to prevent it
from dropping.
Close the spindle cover.
24 mm Wrench
(red wrench)
Nut Wrench
(silver wrench)
Fig. 8 -Spindle Cover Diagram Fig. 9 - Spindle Components
Fig. 10 - Spindle Tightening Diagram

7. Roland- 4 Axis
7
Fig. 11 - Sensor for Z-origin Diagram
Setting the Origins
Setting A, Y and X origins.
To set the origins in the machine using 4 Axis milling
you must first find the A-axis center (the center of
rotation). This is a process which is done when first
set up the Rotary Axis Unit, so the A axis should have
already been calibrated for you. To recalibrate on
your own refer to ZCL-540 User’s Manual Pg. 43. It is
recommended that students do not change the A-axis
center.
The Y origin has also been set, since it follows the
length of the axis of rotation. It is recommended that
students do not change the Y origin.
The X origin has been also been previously set at the
left-most limit, however this origin can be changed to
accommodate different lengths of material.
NOTE: The Z origin has to be changed and checked
with every tool change. It must align on the same
global XY plane on which the axis of rotation is
located.
Z-Origin Sensor
Y-Origin Sensor
Sensor Cable
Axis of Rotation
(Live Center)

8. Roland- 4 Axis
8
Setting the Z Origin
Prior to following these steps, clean the Z-origin
sensor, the sensor cable and the endmill (Fig. 15).
- Load the tool that you want to use as described on
(Pg. 5).
- VPanel
- Base Point (Fig. 12)
- G54 (Fig. 13)
- Z Origin (Fig. 13)
- Apply
- Make sure the sensor cable is connected to the
Z-origin sensor (Pg. 6, Fig. 11), click OK (Fig. 14).
NOTE: Before you perform this procedure, check and
make sure there are no obstructions that will create
any hazard of danger. And that the sensor cable is
connected on both sides.
Fig. 12 - V-Panel Menu- Base Point
Fig. 13 - Set Base Point Window
Fig. 14 - Sensor Prompt Fig. 15 - Cleaning Diagram

9. Roland- 4 Axis
9
Fig. 16 - Clear Previous Job Icon Fig. 17 - Browse Icon
Fig. 18 - Select NC File
Fig. 19 - Output File
Posting NC Code to Mill
Safety Checklist:
- Verify that origins and selected coordinate system
are correct (Pg. 4).
- Verify that correct endmill is installed correctly.
- Verify that USB cable connects the Roland to the PC.
- Verify that your desired NC code file is in the “MILL”
folder located on the PC’s desktop.
- Put on protective goggles.
Begin Milling:
- V-Panel
- Cut
NOTE: When output window appears, use the red
[X] delete button to clear any previously loaded files
in the post list (Fig. 16).
- Browse for and select desired NC file (Fig. 17, 18).
- Output (Fig. 19)
NOTE: Keep your cursor near the Pause button in
case the machine does not behave as anticipated.