Setup Beckhoff Control
9-888-43-0040
4.3.0
SEMINAR
9-888-43-0040
Setup Power- Control
Seminar facilitator:
8.3
Date:
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Setup Beckhoff Control
9-888-43-0040
4.3.0
seminar:
430040 Setup Power Control
Contents:
Suppose:
setup Power Control
Participation only for service engineers of authorized
sales partners
Language german or english
PC-Handling: (Windows / Explorer)
European computer driving licence ECDL Part 1+2
This description is only intended for the use of trained
specialists in control
and automation engineering who are familiar with the
applicable national standards.
The responsible staff must ensure that the application
or use of the products described satisfy all the requirements for safety, including all the relevant laws,
regulations, guidelines and standards
1.
2.
3.
Target group:
Safety requirements:
Note:
Trough information which are received within the framework of seminars, technical Weeke documents on site to the machine or the plant are not annulled. This does not concern current alterations.
Behaviour during the education and breaks:
•
Walk into the production field and into the demonstrating centre is only permitted if you are
accompanied by an employee from Weeke.
•
Do never leave during the stay in the production field the yellow marked transport paths seeing
that security measures such as light barriers, safety mats and safety fences are missing for
manufacturing reasons during the running-in of the machines.
Danger for life!
•
Avoid unnecessary stays outside of the training room.
•
Smoking in the training rooms is prohibited.
•
Please do not stay on the WEEKE company grounds if you are not accompanied by an
WEEKE employee.
•
The opening of machine sheeting or the operation of a machine is only permitted under supervision of WEEKE employees.
•
During the training on machines and aggregates, suitable protective outfit must be worn.
Please switch off mobile phones!
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Setup Beckhoff Control
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4.3.0
Contents:
1
Hardware description
1.1
1.2
1.3
1.4
1.5
System configuration ......................................................................................... 6
Description of the system................................................................................... 6
PCI Fieldbus Card.............................................................................................. 7
Bus coupler....................................................................................................... 8
Input / output terminals....................................................................................... 9
2
Drivetop
11
3
Set Referenz distance and home switch offset
11
3.1
3.2
Reset control....................................................................................................14
Adjust not interpolating C-axis ...........................................................................15
4
Set software limits
17
5
Offset working fields PZV_EDIT
22
6
Subprogram toolchanger P1
26
7
Offset of tools
28
8
Backup
31
8.1
8.2
8.3
8.4
8.5
9
Preparation for backup ......................................................................................31
Start Norten Ghost............................................................................................33
Backup............................................................................................................33
Restore............................................................................................................35
Ghost Utilities ..................................................................................................36
Diagnosis
9.1
9.2
9.3
9.4
8.3
6
37
Error bus coupler ..............................................................................................37
Error codes ......................................................................................................38
Error field bus card............................................................................................40
Errors SERCOS - Ring......................................................................................43
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Setup Beckhoff Control
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½ &
8. 00
Hardware descripcion
8. 30
9. 00
Reference point
9. 30
10. 00
Q
10. 30
Offset working fields
11. 00
11. 30
Offset tools
12. 00
KQ
12. 30
Software limits
13.00
13. 30
14. 00
14. 30
Q
Subprogram toolchanger
15. 00
8.3
15. 30
practical operation
16. 00
»
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4.3.0
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Setup Beckhoff Control
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1
Hardware description
1.1
System configuration
1.2
4.3.0
system
Windows XP embedded English
PC
1 GHz Pentium 4
RAM
265 MB
Hard disk
> 20 GB
Description of the system
SERCOS (Serial Real Time Communication
System) is an open, fast bus system, that is
international norm for numeric controlled machines since 1995 (IEC 61491) . High realtime orders and the jam-resistant transfer to
fiver optical transmitters technology are essential features of this bus system. The bus
consists of a master and several slaves. The
servo boosters or the SERCOS gateway BK
7500 / BK 7520 represent the slaves in the
case of SERCOS.
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Setup Beckhoff Control
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1.3
4.3.0
PCI Fieldbus Card
In place of a separate CNC control, a field bus
card 1.1 is installed in the computer of the
machine.
This card is incorporated into the TwinCAT
software and allows optimum access to the
SERCOS interface
Field bus card and Bus Coupler are connected via optical wave wires.
T :\\9888\\430040\\x0002tb.tif
1.1
Position Nr.
Meaning
1.2
Output
1.3
Input
1.4
Diagnostic LED
Reference:
In case of replacement of the field bus board,
install this in the same slot of the computer
again.
T :\\9888\\430040\\x0003tb.tif
1.2
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1.3
1.4
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4.3.0
Bus coupler
The Bus Coupler BK7520 connect the SERCOS bus system with the electronic terminal
blocks, which can be extended in modular
fashion. One unit consists of one Bus Coupler, any number from 1 to 64 terminals and
one end terminal.
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1.5
4.3.0
Input / output terminals
Input / output terminals 2.1 are located in the
electrical cabinet or the machines frame
T :\\9888\\430040\\x0004b.tif
2.1
Legend of the modules
e. g.
IX.2.36.4
1.sign ⇒ I = Input / Q = Output
2.sign w = analog input/output
x = digital input/output
1.sign ⇒ 2 bus coupler
2.sign ⇒ 36 potential
3.sign ⇒ 4. input/output auf I/O-modul
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notes
8.3
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2
4.3.0
Drivetop
The program Drivetop is for the communication between computer and axis controllers.
Start Drivetop
Select folder Weeke BHC from Desktop and
start program Drivetop 3.1 .
T :\\9888\\430040\\x0007so.tif
3
3.1
Set Referenz distance and home
switch offset
Select CNC axis
Start Drivetop and select the CNC axis, witch
has to be adjusted.
T :\\9888\\430040\\e0005so.tif
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Set Refernce distance and home switch offset
Select menu drive functions and select homing/set absolute measurement for the motor
encoder.
T :\\9888\\430040\\e0001.tif
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Afterwards all important parameters of the
selected drive are shown and home switch
offset 4.1 or reference distance 4.2 can be
changed.
T :\\9888\\430040\\e0003.tif
4.1
4.2
Note:
if numbers can not be separated through a
point from the decimal places, then use a
comma !
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3.1
4.3.0
Reset control
After changing the reference point, the control
must be once reseted once, to start a new
reference point run.
Activate the twinjet symbol 5.1 by pressing
the right mouse bottom.
T :\\9888\\430040\\x0008so.tif
5.1
By activating system and restart, the control
is rested.
Note:
Before restart close all running programs.
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3.2
4.3.0
Adjust not interpolating C-axis
After opening the TwinCAT Systemmanagers, load with 4.4 destination system
and change the operation mode of the SERCOS ring from PHA 4 on PHA 2 by activating
command button 4.5.
T :\\9888\\430040\\KEB.jpg
4.4
8.3
4.5
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•
4.3.0
press in total the press buttons X.1 and
X.2 until the following display appears:
.....
•
•
•
•
•
•
•
•
•
•
•
CP ON appears
activate FUNC
activate parameter CP1 Actual position
display
FUNC shows the actual position of c axis.
note down the worth !
C - set axis mechanically to 0° with
probe, so that the index bolt is at the
right.
Adjustment only inPHA 4 mode possible !
CP 1 changes
Enter the difference between old value
and new value in the parameter CP 10
reference impulse offset.
announced value will increase ⇒ increase
parameter CP10 for the differenz
announced value will reduce ⇒ reduce
Parameter CP10 for the differenz
After changing press ENTER button
X1
X2
T :\\9888\\430040\\x0003tb.tif
reference:
Always press buttons X.1 and X.2 until the
following display appears
.
Never press one of the other press buttons,
because the default setting of sercos interface is changed!
.....
Default setting of sercos interface
Preset parameters of the SERCOS - interface:
display
PHA=
b=
c=
A=
P=
S=
8.3
meaning
display only the current SERCOS stage
baut rate
SERCON- test mode attitude
SERCOS-slaveadress
output power fiber-optic transmitter
setup mode
9-888-43-0040 ENU12.doc
value
only display
2
0
4
3
2
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4.3.0
Set software limits
The software limits are adjusted with the system manager.
T :\\9888\\430040\\x0014so.tif
After opening the TwinCAT system manager
load with 5.2 destination system
5.2
T:\\9888\\430040\\x0015so.tif
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Select the axes, that has to be adjusted in
the folder:
CNC-Configuration\CNC-Task GEO\Achsen,
with the program notpad.
T :\\9888\\430040\\x0016so.tif
T :\\9888\\430040\\x0017so.tif
8.3
6.1
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Activate Notepad
Change software limit of axis
Kenngr.swe_pos ⇒ positiv software limit 6.2
Kenngr.swe_neg ⇒ negativ software limit 6.1
6.1
6.2
Close notepad after occurred change and
store file.
Make assignment
It makes assignment between process maps.
check configuraion
It checks the current configuration
Activating the configuration
It secures and activates the current configuration.
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Setup Beckhoff Control
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Restart
After saving and activation of the configuration, a restart is required by the control.
Close TwinCAT System Manager
Before closing of the TwinCAT system manger, store the changes in the following path:
D:\TwinCAT\Daten\M_0_250_XXXXXX_S00_V00.tsm
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notes
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5
4.3.0
Offset working fields PZV_EDIT
PZV_EDIT makes it possible to graphically
make changes to the station offset data for
the individual machine stops saved in the file
pzv.lis
When PZV_EDIT is started the files
Weeke32.ini, ipc32.ini, pzv.lis are read in
sequence.
During this process, the folder for ipc32.ini
and pzv.lis is read from Weeke32.ini, which is
in the Windows system folder.
The machine configuration is read from the file
ipc32.ini and the current station offset data
from the file pzv.lis.
1
2
Depending on the machine configuration, one
or more tabs 1 for the selection of the various
stop types are displayed.
On each tab the machine stations relevant for
the type of stop are displayed in the form of
station graphics 2.
A dialog box is opened by double-clicking a
station graphic:
3
4
5
6
For the selected station, the current X, Y and
Z offset dimensions for the stop type on the
related tab are displayed 3.
To change the offset dimension, a new offset
dimension 4 or a correction 5 can be entered.
As an alternative, offset dimensions can be
increased or decreased by a set amount (default 0.01mm) by clicking an arrow button 6.
7
8
9
Using the buttons the (modified) station offset
data can be applied 7 or reset to the values
read by PZV_EDIT at the start 8.
The dialog box is closed by clicking button 9.
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Using button 1 the station offset data for all
stations can be reset to the values read by
PZV_EDIT at the start.
The (modified) station offset data are saved in
the file pzv.lis by clicking button 2 and the
data then transferred to the controller.
This means that these (modified) station offset data will then be used in MCC. This enables the modified station offset data to be
checked.
1
2
3
4
Attention:
To apply the changes to the station offset
data such that the changes are permanent,
after the changes have been saved using
button 2 and then checked, the data must be
applied in the current project using button 3.
Otherwise the changes will be lost when the
machine is switched off.
You can quit PZV_EDIT by clicking button 4!
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4.3.0
Register board for console and table base
data
In this register board, the consoles and the
table are announced in the form of console
graphics 1 and a table picture 2.
A dialogue window is opened by double click
onto a console picture:
3
4
2
1
8
9
5
The current data of console 4 are announced
and can be processed by changing the values
in individual input fields 3.
Other consoles can be changed by button 4
Mittels der Icons 5
By means of command button 6, the console
data are written into the table.ini.
This is only possible if user level service is
activated.
The data of console 4 currently can be reset
by activating command button 7 onto the
values read in by PZV_EDIT while start.
6
7
All console data can be reset by activating
command button 8 onto the values read in by
PZV_EDIT while start.
The dialogue window is closed by activating
command button 9.
A dialogue window is opened by double click
onto the table picture:
The current table base data are announced
and can be processed by changing the values
in individual input fields 3.
By means of command button 4, the table
base data are written to the table.ini.
This is only possible if user level service user
is activated.
The table base data can be reset by activating command button 5 onto the values read in
by PZV_EDIT while start.
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4
5
6
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4.3.0
The dialogue window is closed by activating
command button 6.
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6
4.3.0
Subprogram toolchanger P1
In file P1 all positions for the toolchanger are
saved.
Reference:
Change of the file P1 is only possible in the
user level service user.
.
Changing P1
In MCC activating button 9.1 and from menu
9.2 and select function 9.3.
Afterwards it opens itself with a text editor
and the file P1 can be modified.
9.1
9.2
8.3
9.3
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Program P1
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7
4.3.0
Offset of tools
The Offsets of tools can be changed in the
tool data base WZ_DBE.
Activate in menu View the function set up 9.1
and at aggregate 9.2 the offset in X-, Y-and Zdirection can be changed for the selected
tool.
9.1
8.3
9.2
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4.3.0
For the following tools it is possible to the
offsets:
8.3
tool NR.
meaning
T 02
Tool changing spindle Nr.2
T 40
Grooving saw in X-direction
T 41
Grooving saw in Y-direction
T 80
vertical drilling spindles
T 82
horizontal driller in X+ direction
T 83
horizontal driller in X- direction
T 84
horizontal driller in Y+ direction
T 85
horizontal driller in Y- direction
T 98
Centre position tool changing spindle Nr.2
T 99
Centre position tool changing spindle Nr.1
T 120
laser
T 121
Doweling aggregate
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4.3.0
notes
8.3
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8
4.3.0
Backup
The backup is carried out by the programm
Norton Ghost.
8.1
Preparation for backup
Before the bachup is started, first carry out an
optimization of the hard disks, so that the
amounts of data to be saved are as small as
possible.
.
Clean hard disk
Start from Programms\Accessores\System
Tools the program disk cleanup
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Disk Defragmenter
Start from Programms\Accessores\System
Tools the program disk defragmenter.
Reference:
Close all applications before optimization of
hard disks.
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Setup Beckhoff Control
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8.2
4.3.0
Start Norten Ghost
Start Norten Ghost 11.1 from the folder
Weeke BHC on the desktop.
8.3
Backup
11.1
Select Backup 11.2
11.2
Select data source 11.3 and destination 11.4
11.3
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During start of backup 11.5, the computer is
shut down and restarted in DOS mode again.
11.5
The process of the backup is announced in a
window.
According to successful backup the computer
is shut down again and then starts again with
the operating system.
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8.4
4.3.0
Restore
With the function Restore 12.1, available
backups can be restored again on the computer.
Select backup ( *.gho ) 12.3 and destination
12.4 .
12.2
12.3
The process of restore is announced in a
window.
According to successful restore the computer
is shut down again and then starts again with
the operating system.
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Setup Beckhoff Control
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8.5
4.3.0
Ghost Utilities
The Norten Ghost utilities 13.1 allow the
preparation of boat floppy disks with the
Ghost boat Wizard 13.2
With the Ghost Explorer 13.3 it is possible to
copy single files from the backup back to the
orignal folder.
13.1 13.2
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9
Diagnosis
9.1
Error bus coupler
4.3.0
After switching on, the bus coupler immediately checks the connected configuration.
Error-free start-up is signalled by extinction of
the red LED “I/O ERR“ 7.1. If the “I/O ERR”
LED 7.2 blinks, an error in the area of the
terminals is indicated. The error code can be
determined from the frequency and
number of blinks. This permits rapid rectification of the error.
T :\\9888\\430040\\x0013tb.tif
Code of flashes
7.1
Rapid flashing
Start of the error code
First slow sequence
error code
second slow sequence
Location of error
7.2
Location of errors with error code 4
The number of flashes corresponds to the
position of the last bus terminal before the
error, not counting passive bus terminals
such as power input terminals ( KL 9100 ).
The bus coupler will carry on flashing the error
code even when you have cleared the fault
and its operating mode will remain at "Stop”.
The only way to restart the bus coupler is by
switching the power supply off and on again.
Note:
The bus coupler will carry on flashing the error
code even when you have cleared the fault
and its operating mode will remain at "Stop”.
The only way to restart the bus coupler is by
switching the power supply off and on again.
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9.2
4.3.0
Error codes
Error
codes
Error code
argument
describtion
remedy
EMC problems
Check power supply for overvoltage
or undervoltage peaks
0
1
EEPROM checksum error
Connect fewer terminals;
too manyentries in the table for the
programmed configuration
0
n (n>0)
Programmed configuration
continuous
blinking
1 puls
2 pulse
3 pulse
4 pulse
0
0
n
Inline code buffer overflow
Incorrect table entry
Check programmed configuration
for
correctness
Terminal bus command error No terminal connected
attach terminals
Terminal bus data error
Break behind terminal n
One of the terminals is defective
Check whether the n+1 terminal is
correctly connected
replace if necessary.
Check whether the end terminal
9010 is connected.
5 pulse
n
Terminal bus error with
register communication with
terminal n
5 pulse
n
6 pulse
0
1
2
n
bus error in the case of
register communication
with wedge n
no ident of the master date
telegram
no indent of the drive
coupler do not support for
wedge
7 pulse
8.3
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Replace terminal n
replace wedge n
Weeke Service Hotline
Weeke Service Hotline
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4.3.0
notes
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9.3
4.3.0
Error field bus card
Diagnosis LED 8.1 of the field bus card lights
up, if data transfer is disturbed on the fiberoptic transmitter.
8.1
T :\\9888\\430040\\x0003tb.tif
The FC750x decrees the state of the card
automatically via different diagnosis variables
ActualPhase
the current stage the sercos ring.
RequestedPhase
The stage requested currently (e.g. from the
plc) is announced. The card and/or the driver
attempts to activate just this stage.
.
SystemState
System state gives more precise information
via the current stage:
0xE001 = Phase 0
0xE002 = Phase 1
0xE003 = Phase 2
0xE004 = Phase 3
0xE005 = Phase 4
0xE008 = Break
0xE011 = Phase switch 0 -> 1
0xE012 = Phase switch 1 -> 2
0xE013 = Phase switch 2 -> 3
0xE014 = Phase switch 3 -> 4
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SystemError
announces the current error:
0x0000 = No error
0x8005 = Drive addresses are incorrect
0x8006 = HS-timeout (service channel)
0x8007 = Double AT-failure
0x8009 = LWL-bus is interrupted
0xD002 = Break
0xD003 = Switch from 2->3 failure (S-0-0127)
0xD004 = Switch from 3->4 failure (S-0-0128)
0xF001 = Configuration error (actual/nominal
channel)
0xF002 = Error in the time slot calculation
0xF003 = Incorrect phase setting by the NC
0xF004 = Internal error
0xF005 = Error lifecounter
0xF008 = Double MDT-failure
0xF009 = Double MST-failure
0xF00A = Sync-In signal failure
Diagnose
FC750x 17
TimingError1
A counter that is incremented, if the NC too
soon accesses the actual values ('over-test
timing"it must be dialed).
TimingError2
A counter that is incremented, if the NC provides with too late new required values ('check
for timing"it must be dialed).
RDistErrorCnt
A counter which counts received telegrams in
a destroyed manner (cf., RDIST in the Refe
rence manual of the SERCON816).
Cause can be a wrong baud rate.
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FibBrErrorCnt
A counter which counts received telegrams in
a destroyed manner (cf., FIBBR in the Reference manual of the SERCON816)
RRerrErrorCnt
Acounter which counts lost ones or belongs
received telegrams to the wrong date (cf.,
RERR in the Reference manual of the SERCON816)).
MstLateErrorCnt
A counter which counts MSTs received too
late (cf., MSTLATE in the Reference manual
of the SERCON816).
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9.4
4.3.0
Errors SERCOS - Ring
Errors SERCOS Interface Indramat
The LED 9.1 distortion display H 20 does
normally not light up.
Iuminescence that LED at the following SERCOS boards, so the error is to search on the
SERCOS board before this .
Transmission rate and transmission power
can be appeared with the button 9.2.
T :\\9888\\430040\\sercos.jpg
9.1
9.2
Following errors lights up the distortion display:
Error
wrong adjusted transmission rate
wrong adjusted transmission power
Defective fiber-optic transmitter
8.3
cause / relief
transmission rate with counter S 20.1
adjust transmission power transmission power
with counters S 20,2 and S 20,3
Test fiber-optic transmitter for harm or bad combination.
Replacement of the fiber-optic transmitter.
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Setup Beckhoff Control
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4.3.0
Change of the fiber-optic transmitter
In order to localize mistake of controllers
and/or fiber-optic transmitter change fiberoptic transmitter 10.1 among one another or
remove controllers from the SERCOS - ring.
Deactivate controllers or I/O modules
10.1
Select in the TwinCat system manager controller or I/O module 10.2 and turn on control
box 10.3, in order to deactivate the selected
component.
10.2 10.3
8.3
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Setup Beckhoff Control
9-888-43-0040
4.3.0
Activating the configuration
Activate new configuration and carry out new
start of control.
Reference:
After deactivation of a component, the machine is no more ready for operation, you can
only find out whether the SERCOS ring is
closed again.
8.3
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Setup Beckhoff Control
9-888-43-0040
8.3
4.3.0
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