473_850 Installation Instructions

452

Transcript of 473_850 Installation Instructions

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GAST
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Contents

Page

1 1.1 1.2 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.6 1.2.7 1.2.8 1.2.9 1.2.10 1.3 1.4

Preconditions and Visual Inspection ................................................... Preconditions ......................................................................................... Visual inspection .................................................................................... Notes and handling modules ................................................................... Earthing ................................................................................................. Position encoders ................................................................................... Cable laying ........................................................................................... Cables ................................................................................................... Shielding ................................................................................................ Interference suppression ............................................................. Operator panel ....................................................................................... Overall condition .................................................................................... Batteries ................................................................................................. Export version ........................................................................................ China export version (Software Version 3 onwards) ............................

2 Installation Checklist ...........................................................................

3 3.1 3.2 a 3.3 3.4 3.5 3.6 3.6.1 3.6.2 3.6.3 3.7

0 4 4.1 4.2 4.3 4.4 4.4.1 4.4.2 4.4.3 4.4.4 4.4.5 4.4.6 4.4.7 4.5

Drive Optimization ............................................................................... Control direction of feed axes . checking and adjustment ......................... Definition of maximum setpoint and tacho-generator compensation .......... Multgain NC MD 260* ............................................................................. Servo gain factor (Kv factor) ........................................................ Acceleration NC MD 276’ ....................................................................... Position monitoring ................................................................................. Exact stop limit coarse and fine (NC MD 204* and 208”) .......................... Clamping tolerance (NC MD 2127 ................................................. Zero-speed monitoring ............................................................... Contour monitoring .................................................................................

Overview of Modules and Standard Jumperings ................................ Overview of modules .............................................................................. Operator panel module locations ............................................................. NC bus structure .................................................................................... PLC connection options .......................................................................... PLC 1 module locations (central controller) ............................................. PLC 2 module locations (external) ........................................................... PLC 1: 130 WB ...................................................................................... PLC 1: 130 WB, PLC 2: 130 WB with SlNUMERlK expansion unit ........... PLC1 150S/U ........................................................................................ PLCl 150S/U, PLC 150SiU ................................................................... PLCl 130WB, PLC2 150S/U ................................................................. Power supply units ................................................................................. 6EW1861-1A . and -2A . power supply unit (power supply unit in central controller) ................................................................................... 6EW18.61-3M power supply unit (power unit in operator panel) ...............

1-1 1-1 1-1 1-1 1-3 1-4 1-4 1-4 1-4 1-4 1-5 1-5 1-5 1-6 1-6

2-1

3-1 3-1 3-3 3-4 3-5 3-7 3-9 3-9 3-9 3-9

3-10

4-1 4-1 4-2 4-3 4-5 4-5 4-8

4-10 4-11 4-12 4-13 4-14 4-15

4-15 4-18

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4.5.3

4.6

4.7 4.8 4.8.1 4.8.2 4.8.3 4.8.4 4.8.5 4.8.6 4.8.7 4.9 4.10 4.1 1 4.12 4.13 4.14 4.15 4.16 4.17 4.18 4.1 9 4.20 4.21 4.22

5 5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.2 5.2.1 5.2.2 5.2.3 5.3

6 6.1 6.1.1 6.1.2 6.1.3 6.1.4 6.13 6.1.6

7 7.1 7.1.1

6ES5955-3LC13 and 6ES5955-3NC12 power supply units (EU power supply units) ......................................................................... 6FX1120-4BA communication CPU (COM CPU) and operator panel CPU (BT CPU) ............................................................................................. 6FX1120-5 NC CPU .............................................................................. Memory modules ................................................................................... 6FX1120-7BA memory module ............................................................... 6FX1128-1BA memory module ............................................................... 6FX1126-7BA memory module ............................................................... 6FX1126-OB . EPROM RAM submodule .... ; ............................................. 6FX1128.48 . EPROM submodule ........................................................... 6FX1126-6BA RAM submodule (SMD) .................................................... 6FX1126-2BA RAM submodule ............................................................... 6FX1126-88 measuring-circuit module .................................................... 6FX1121-48 . measuring-circuit module ................................................... 6FX1121-8BB (-8BA) multiport ............................................................... 6FX1120-3 link module ........................................................................... 6ES5 304-3UA .. and 6ES5 314-3UA .. link modules ................................. 6ES5300-3, 301 -3, 31 0.3, 312-3 link modules ......................................... 6FX1121-2BA00 interface module ........................................................... 6FX1126-1 AA video module ................................................................... 6FX1126-4AA colour display memory module .......................................... Colour monitor ....................................................................................... 6FX1124-6AA inputloutput submodule(l/O submodule) ............................ 6FX1126.5AA .. HANDWHEEL MODULE (MPG) Machine control panel ............................................................................ Adressing of 110 modules .......................................................................

.....................................

Voltage and Functional Tests ............................................................. Voltage test ........................................................................................... Voltage supply ....................................................................................... Limit temperature ................................................................................... Fan monitoring ....................................................................................... Direct voltage + 5V ................................................................................ Direct voltage + 5V external ................................................................... Functional test ....................................................................................... CPU monitoring ..................................................................................... EPROM check ....................................................................................... Brightness adjustment ............................................................................ Drift compensation (from Software Version 03) .......................................

Standard Installation Sequence .......................................................... Standard installation shown as a flowchart .............................................. NC ON (overall reset chart and setting standard NC MD) ........................ NC machine data ................................................................................... PLC machine data ................................................................................. Alarm processing ................................................................................... Axis installation (simplified flowchart) ...................................................... Spindle installation .................................................................................

PLC Description (130 WB) ................................................................... General ................................................................................................. Installation of 130 WB PLC with SINUMERIK 850 ....................................

4-20

4-21 4-23 4-24 4-24 4-25 4-26 4-28 4-29 4-29 4-30 . 4.32 4-34 4-38 4-40 4-43 4-45 4-45 4-46 4-49 4-49 4-50 4-53 4-53 4-54

5-1 5-1 5-1 5-2 5-2 5-3 5-3 5-5 5-5 5-5 5-7 5-8

6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8

7 4 7-1 7- i

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7.1.2 Installation of 150S/U PLC with SINUMERIK 850 ..................................... 7.2 PLC DIAGNOSIS .................................................................................... 7.3 PLC STATUS ......................................................................................... 7.3.1 Operation of the PLC STATUS ............................................................... 7.3.2 PLC STATUS selection .......................................................................... 7.3.3 PLC block overview ................................................................................

8 8.1 8.1.1 8.1.2 8.1.3 8.1.4 8.1.5 8.1.6 8.2

8.2.1 8.2.2 8.3 8.4 8.4.1 8.4.2 8.5 8.6

9 9.1 9.1.1 9.1.2 9.2 9.2.1 9.2.2 9.2.3 9.3 9.3.1 9.3.2 9.3.3 9.3.4 9.3.5 9.3.5.1 9.3.5.2 9.3.5.3 9.3.5.4 9.4 9.4.1 9.4.2 9.4.3 9.4.4 9.5 9.6 9.6.1 9.6.2 9.6.3

Machine Interface ................................................................................ Actual-value input measuring circuit (6FX1 121 .4B .. module) ................... Connector pin assignments ..................................................................... Differential input ..................................................................................... Equivalent circuit diagram with differential input ....................................... Equivalent circuit diagram for actual-value input with integrated EXE ........ Complement with integrated EXE ............................................................ Input signals with integrated EXE ............................................................ Setpoint output measuring circuit (6FX1 121-48 and 6FX1 126.88 . module) ............................................................................ Connector pin assignment ...................................................................... Equivalent circuit diagram of the set speed output (for one axis) .............. Serial interface (V.24 (RS 232C) +20 mA) ............................................... Handwheel interface module (6FX1 126-5AA .. ) ........................................ Connector pin assignments ..................................................................... Equivalent circuit diagram ....................................................................... Short-circuiting connector for actual-value input ....................................... Measuring pulse inputs (sensors) ............................................................

NC Machine Data/PLC Machine Data/NC Setting Data ....................... General .................................................................................................. Control configuration .............................................................................. Notes on configuration ............................................................................ Mode selection ....................................................................................... Installation mode “INITIAL CLEAR” ......................................................... Normal mode (with MD modification) ....................................................... Installation mode .................................................................................... NC machine data ................................................................................... General .................................................................................................. Position control, input and measuring system resolution ........................... Input units .............................................................................................. Other machine data ................................................................................ NC MD description ................................................................................. General values ....................................................................................... Channel-specific values .......................................................................... Axis-specific values/spindle-specific values .............................................. Machine data bits ................................................................................... PLC machine data .................................................................................. General .................................................................................................. PLC machine data bits for basic program ................................................ PLC machine data words for user program .............................................. PLC machine data bits for user program ................................................. Cycle machine data (Cycle MD) .............................................................. NC setting data (SD) .............................................................................. General .................................................................................................. Zero offsets (ZO) ................................................................................... R parameters .........................................................................................

7-1 7-2 7-3 7-3 7-4 7-5

8-1 8-1 8-1 8-2 8-3 8-4 8-5 8-6

8-7 8-7 8-8 8-8

8-10 8-10 8-10

8-12 8-11

9-1 9-1 9-1 9-2 9-5 9-6 9-8 9-9 9-9 9-9

9-10 9-11 9-11 9-11 9-12 9-59 9-64

9-110 9-1 77 9-1 77 9-1 78 9-1 94 9-1 94 9-1 95 9-1 97 9-1 97 9-1 98 9-199

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9.6.4 9.6.5 9.6.6 9.6.7 9.6.8 9.6.9 9.6.10 9.7

Spindle setting data ............................................................................... General NC setting data ......................................................................... Channel-specific NC setting data ............................................................ Axial NC setting data .............................................................................. General NC setting data bits ................................................................... NC setting data bits for serial interfaces .................................................. Axial NC setting data bits ....................................................................... Cycle setting data (Cycle SD) .................................................................

9-200 9-201 9-201 9-201 9-202 9-203 9-206 9-207

10 Machine Operation/Service Data ......................................................... 10-1 10.1 Jog mode 10-1 10.2 Programmed operation ........................................................................... 10-2 10.3 Functional test with NC test tape ............................................................ 10-2 10.4 Axis and spindle service data ................................................................. 10-3 10.4.1 Axis service data .................................................................................... 10-3 10.4.2 Spindle service data ............................................................................... 10-4

..............................................................................................

11 11.1 11.2 11.2.1 11.2.2 11.2.3 11.2.4 11.3 11.3.1 11.3.2

11.3.3

11.3.3.1

11.4 11.4.1 1 1.4.2 11.5 11.5.1 11.5.2 11.6 1.6.1 1.6.2 1.7 1.7.1 1.7.2 1.7.3 1.7.4 1.7.5 1.7.6 1.7.7

1 1.7.8 11.7.9 11.7.10 11.7.11

Description of Operation ..................................................................... Axis movements (available soon) ............................................................ Spindle control ....................................................................................... Corresponding data ................................................................................ S analog (M3. M4. M5) .......................................................................... M19 (oriented spindle stop) .................................................................... Spindle influencing by PLC ..................................................................... Approach to reference point ................................................................... Automatic identification of direction with approach to reference point ...................................................................................... Approach to reference point without automatic identification of direction ............................................................................................ Approach to reference point with automatic identification of direction ............................................................................................ Leadscrew error compensation (SSFK) ................................................... Corresponding data ................................................................................ Functional description ............................................................................ Rotary axis functions .............................................................................. Corresponding data ................................................................................ Functional description ............................................................................ Warm restart .......................................................................................... Corresponding data ................................................................................ Functional description ............................................................................ Axis-specific resolutions (from Software Version 03) ................................ Corresponding data ................................................................................ General remarks on the axis-specific resolutions ..................................... Input, display and position control resolution ........................................... Block diagram of the resolutions ............................................................. Resolution codes ................................................................................... Permissable combinations ...................................................................... The influence of resolution on speed ...................................................... Maximum speed for thread cutting .......................................................... Maximum traverse range ........................................................................ Influence on the display .......................................................................... Influence on the modesifunction .............................................................

Corresponding MD .................................................................................

11-1 11-1 11-1 11-1 11-1 11-2

11-10 11-12 11-12

11-12

11-12

11-15 11-16 11-16 11-17 1 1-25 11-25 11-25 1 1-27 1 1-27 1 1-27 11-31 11-31 11-31 1 1-32 11-33 11-34 1 1-35 1 1-37 11 -39 11 -40 11 -43 11-43

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11.8 11.8.1 1 1.8.2 11.8.3 1 1.8.4 11.8.5 11.8.6 i 1 . 8.7

11.8.8 11.8.8.1 11 A8.2 11.8.8.3

12 12.1 12.2 12.3 12.4 12.5 12.5.1 12.5.2 12.5.3 12.5.4 12.5.5 12.5.6 12.5.7 12.5.8

Coordinate transformation ....................................................................... Corresponding data ................................................................................ Function description of coordinate transformation .................................... The trarisformation data set .................................................................... Transformation parameters ..................................................................... Machine data for fictitious axes ............................................................... NC PLC interface signals ........................................................................ Explanation of the programming and operation of coordinate transformation ....................................................................... Examples of coordinate transformation .................................................... Example of 2D coordinate transformation ................................................ Example of 3D coordinate transformation ................................................

Example of the coordinate transformation TRANSMIT ..............................

Alarms .................................................................................................. List of alarms ......................................................................................... Alarm numbers and groups/clearing of alarms ......................................... Priority of the alarms .............................................................................. Alarm display ......................................................................................... Alarm description ................................................................................... Alarm list POWER ON (1 - 15) ................................................................ Alarm list V.24 (RS 232 C) ..................................................................... Alarm list POWER ON (40 . 81) .............................................................. Alarm list RESET ................................................................................... Alarm list RESET/general ........................................................................ Alarm list RESETlspindle-specific ............................................................ Alarm list ERASE ................................................................................... Alarm list RESET/axis-specific ................................................................

1 1-45 11-45 11-45 1 1-47 11-49 11-51 11-52

11-53 1 1-55 11-55 1 1-56 1 1-57

12-1 12-1 12-1 12-3 12-3 12-6 12-6 12-9

12-13 12-18 12-25 12-36 12-37 12-51

13 Notes of Fault Procedure ..................................................................... 13-1 13.1 General .................................................................................................. 13-1 13.2 Faults in operator panel area ................................................................... 13-2 13.3 Table of faults ........................................................................................ 13-3 13.4 Module exchange ................................................................................... 13-5

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