Description of Functions 11/2003 Edition

Transcription

1 Description of Functions 11/2003 Edition SINUMERIK 840D/840Di/810D ShopMill

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3 Hardware 1 Supplementary Conditions 2 Reserved Functions 3 SINUMERIK 840D/840Di/810D ShopMill Description of Functions Installation and Start-Up 4 PLC Program 5 Signal Description 6 Maschine Data 7 Tool Management 8 Additional Functions 9 Customer-Specific Operator Interface 10 Miscellaneous 11 Valid for Control Software version SINUMERIK 840D powerline 6 SINUMERIK 840DE powerline 6 SINUMERIK 840Di 2 SINUMERIK 840DiE (export version) 2 SINUMERIK 810D powerline 6 SINUMERIK 810DE powerline 6 Abbreviations References Index A B C Edition

4 SINUMERIK Documentation Printing history Brief details of this edition and previous editions are listed below. The status of each edition is shown by the code in the Remarks columns. Status code in the Remarks column: A..... New documentation. B..... Unrevised reprint with new Order No. C..... Revised edition with new status. If factual changes have been made on the page since the last edition, this is indicated by a new edition coding in the header on that page. Edition Order No. Remarks FC AD80-0BP0 A FC AD80-0BP1 C FC AD80-0BP0 C FC AD80-0BP1 C FC AD80-0BP0 C FC AD80-0BP1 C 6FC AD80-0BP2 C This book is part of the documentation on CD-ROM (DOCONCD) Edition Order No. Remarks FC CA00-0BG0 C Trademarks SIMATIC, SIMATIC HMI, SIMATIC NET, SIROTEC, SINUMERIK and SIMODRIVE are trademarks of Siemens. Other product names used in this documentation may be trademarks which, if used by third parties, could infringe the rights of their owners. Further information is available on the Internet under: This publication was produced with Interleaf V7. The reproduction, transmission or use of this document or its contents is not permitted without express written authority. Offenders will be liable for damages. All rights, including riths created by patent grant or registration of a utility model or design, are reserved. Siemens AG, All rights reserved Other functions not described in this documentation might be executable in the control. This does not, however, represent an obligation to supply such functions with a new control or when servicing. We have checked that the contents of this publication agree with the hardware and software described here. Nevertheless, differences might exist and therefore we cannot guarantee that they are completely identical. The information given in this publication is reviewed at regular intervals and any corrections that might be necessary are made in the subsequent printings. Suggestions for improvement are welcome at all times. Subject to changes without prior notice. Order No. 6FC AD80-0BP2 Printed in Germany Siemens Aktiengesellschaft

5 Preface Structure of documentation The SINUMERIK documentation is divided into 3 different levels: General Documentation User Documentation Manufacturer/Service Documentation Target group This document is intended for the manufacturers of vertical machining centers or universal milling machines incorporating SINUMERIK 840D/840Di/810D. Objective The Installation and Start-up Guide provides you with all the relevant information required to configure, install and start-up ShopMill. Note This Description of Functions is valid for ShopMill SW 6.3. Hotline If you have any questions about the control, please contact the hotline: A&D Technical Support Phone: +49 (0) Fax: +49 (0) adsupport@siemens.com Please send any questions about the documentation (suggestions for improvement, corrections) to the following fax number or address: Fax: +49 (0) Fax form: See reply form at the end of the manual motioncontrol.docu@erlf.siemens.de Internet address SINUMERIK 840D powerline From SINUMERIK 840D powerline and SINUMERIK 840DE powerline will be available with improved performance. For a list of available powerline modules, please refer to the following Hardware Description: References: /PHD/, Configuring Manual SINUMERIK 840D SINUMERIK 810D powerline From SINUMERIK 810D powerline and SINUMERIK 810DE powerline will be available with improved performance. For a list of available powerline modules, please refer to the following Hardware Description: References: /PHC/, Configuring Manual SINUMERIK 810D v

6 Preface Standard scope This document provides information about the control system design and the interfaces of the individual components. It also describes the start-up and installation procedure for ShopMill with SINUMERIK 840D/840Di/810D. For detailed information about individual functions, function assignment and performance data of individual components, please refer to the appropriate document for the subject concerned (e.g. manuals, function description etc.). User-oriented activities such as the creation of parts programs and control operating procedures are described in details in separate documents. Further descriptions of tasks to be performed by the machine tool manufacturer are also available for the standard SINUMERIK 840D/840Di/810D. We may refer to them in this manual if appropriate. Searching aids In addition to the table of contents, we have provided the following information in the appendix for your assistance: 1. Index of abbreviations 2. List of references 3. Index For a complete list and description of the ShopMill alarms, please refer to References: /BAS/, ShopMill Operator s Guide The SINUMERIK 840D/840Di/810D alarms are also listed in References: /DA/, Diagnostics Guide For further useful information on start-up and troubleshooting, please refer to References: /FB/, D1, Diagnostics Tools Notes The following symbols with special significance are used in the documentation: Note This symbol appears in this document to draw your attention to information relevant to the subject in hand. Warning notes The following warning notes with varying degrees of severity are used in the documentation:! Danger Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury or in substantial property damage. vi

7 Preface! Warning Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury or in substantial property damage.! Caution Used with the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury or in property damage. Caution Used without safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage. Notice Used without the safety alert symbol indicates a potential situation which, if not avoided, may result in an undesirable result or state. Unit In this manual, the units of the parameters are always indicated as metric values. The following table shows the corresponding units in inch. Metric mm mm/tooth mm/min mm/rev m/min Inch in in/tooth in/min in/rev ft/min vii

8 Preface Notes viii

9 Contents 1 Hardware Supplementary Conditions Reserved Functions Installation and Start-Up Preconditions for software start-up Initial start-up sequence Sequence Installing ShopMill on PCU Installing ShopMill on PCU NC start-up PLC start-up Adapt display machine data Acceptance report Series start-up Upgrade PLC Program Structure of the PLC program Overview of blocks ShopMill PLC program ShopMill interface DB Standard interface signals for/from ShopMill OB 1 and OB Machine control panel Diagnostics function for start-up purposes Signal Description HMI interface DB Overview of ShopMill interface DB Signals to ShopMill (input signals) Signals from ShopMill (output signals) Diagnostics buffer signals Description of ShopMill interface DB Signals to ShopMill (input signals) Signals from ShopMill (output signals) Description of diagnostics buffer signals ix

10 Contents 7 Machine Data NC machine data for ShopMill Display machine data for ShopMill Overview of display machine data Description of display machine data Tool Management Overview of functions Start-up sequence Start-up in the NC Input of the NC machine data Description of NC machine data Creating and loading the configuration file Start-up in the PLC Example for FC 100 and FB Signal description Display machine data Tool change cycle Manual tools Activating the spindle, coolant, and tool-specific functions Modifying texts for tool-specific functions PCU PCU Configuring the operator interface Procedure Creating a configuration file Defining texts Import tool data Additional Functions Measuring cycles Brief description Probe connection Functional check Probe start-up Machine data for measuring cycles Display machine data measuring cycles Network link General description Linking Windows network drives to ShopMill (PCU 20) Linking Windows network drives to ShopMill (PCU 50) Cylinder surface transformation Function Example of how to set an axis configuration Swivel heads and tables x

11 Contents 9.5 Multiple clamping Measuring cycle support in the G code editor Customer-Specific Operator Interface Configuring the customer booting display PCU PCU Configuring the user screen form Transferring cycles to the machining plan Linking cycles into the machining plan Linking measuring cycles ShopMill Open (PCU 50) Basic menu bar User status display (PCU 50) OP hotkeys, PLC keys Miscellaneous Access protection via password and keyswitch General Password Keyswitch settings Machine data for protection levels ISO dialects Spindle control Automatically generated programs Version display Mold making Startup Data storage, data transfer A Abbreviations A-205 B References B-209 C Index C-223 xi

12 Contents Notes xii

13 Hardware 1 System structure The hardware structure of ShopMill corresponds to the SINUMERIK 810D/840D/840Di standard. References: /PHC/, SINUMERIK 810D, Configuring Manual /IAC/, SINUMERIK 810D, Installation & Start-up Guide /PHD/, SINUMERIK 840D, Configuring Manual NCU /IAD/, SINUMERIK 840D/SIMODRIVE 611D, Installation & Start-up Guide /HBI/, SINUMERIK 840Di, Manual Table 1-1 Basic components Basic components Order number Remarks CCU3 (810D) 6FC5410 0AY03 0AA1 NCU571.4 (840D) 6FC5357 0BB12 0AE0 NCU572.4 (840D) 6FC5357 0BB23 0AE0 NCU573.4 (840D) 6FC5357 0BB34 0AE0 Table 1-2 Operator components Operator components Order number Remarks OP010 operator panel 6FC5203-0AF00-0AA0 OP010C operator panel 6FC5203-0AF01-0AA0 OP010S operator panel 6FC5203-0AF04-0AA0 OP012 operator panel 6FC5203 0AF02 0AA0 OP015 operator panel 6FC5203-0AF03-0AA0 PCU 20 with system software 6FC5210 0DF00 0AA1 166 MHz, 32 MB PCU 20 with system software 6FC5210 0DF00 1AA1 233 MHz, 32 MB PCU 50 6FC5210 0DF21 2AA0 566 MHz, 256 MB, Windows XP PCU 50 6FC5210 0DF22 2AA0 1.2 GHz, 256 MB, Windows XP 19 machine control panel 6FC5203-0AD10-0AA0 Standard/U.S. layout Key cap for 19 machine control panel 6FC5148 0AA13 0AA0 6FC5148 0AA14 0AA0 90, gray 16, transparent with stickers Full OP032S CNC keyboard 6FC5203-0AC00-1AA0 Standard/U.S. layout Machine control panel OP032S 6FC5203-0AD10-1AA0 Standard/U.S. layout 1-13

14 1 Hardware Table 1-2 Operator components Key cap for OP032S full CNC keyboard and OP032S machine control panel Mini handheld unit 6FC5248-0AA02-0AA0 6FX2007-1AD00 Standard/U.S. layout 1-14

15 Supplementary Conditions 2 Observe the following conditions when using ShopMill: ShopMill is only executed in channel 1, mode group 1. The standard MPI bus addresses must not be changed for the PCU 20, PCU 50, NC, and PLC. Up to 5 axes plus a spindle are displayed on the ShopMill operator interface. The machine axes are assigned to fixed numbers (1=X, 2=Y, 3=Z). The spindle can be assigned to axis numbers 4, 5, or 6. ShopMill is executed only with tool management. The change position must always be spindle 1 (see configuration file). The loading point can be 1 or 2 (see MD 9673 $MM_CMM_TOOL_LOAD_STATION). In ShopMill Classic, the position of the ShopMill softkey (switch from the CNC-ISO user interface to ShopMill) must not change, i.e. in the REGIE.INI file this function must always be assigned Task6. In ShopMill Open, you must not change the positions of the following softkeys on the basic menu bar, i.e. a certain task must always be assigned to these functions in the REGIE.INI file. Task 0 (horizontal softkey 1): Machine operating area Task 1 (horizontal softkey 2): Program manager operating area Task 2 (horizontal softkey 3): Program operating area Task 4 (horizontal softkey 5): Tools/zero offsets operating area You can use only one operator panel with ShopMill. Handheld programming unit (HHU) in addition to ShopMill on PCU 50 on request only. The HMI and Windows screen savers must not be used at the same time. References: /IAM/, IM2 Installation and Start-up of HMI Embedded IM4 Installation and Start-up of HMI Advanced 2-15

16 2 Supplementary Conditions Notes 2-16

17 Reserved Functions 3 The following functions are utilized by ShopMill and must not be assigned for other purposes. Extended M functions M functions with extended address: M[value]=100 M[value]=101 M100 and M101 are defaults and must be changed where required. 1st extended M address: DB82.DBB12 ext_m_cmd_1, default=100 Display MD 9684 CMM_M_CODE_TOOL_BITS_1, default=100 2nd extended M address: DB82.DBB13 ext_m_cmd_2, default=101 Display MD 9685 CMM_M_CODE_TOOL_BITS_2, default=101 PROG_EVENT The system cycle PROG_EVENT.SPF is used by the standard cycles and by ShopMill. If you want to use cycle PROG_EVENT.SPF for user functions, too, you must implement these user functions in cycle CYCPE_US.SPF. Place cycle CYCPE_US.SPF in the user cycles or manufacturer cycles directory. 3-17

18 3 Reserved Functions Notes 3-18

19 Installation and Start-Up Preconditions for software start-up Data communication For data communication, you require: Hardware Programming device, e.g. a PG 740 or a PC with MPI module Cable for RS-232 PG/PC-NC (Order No.: 6FX AA01-0BF0) Cable for MPI bus (Order No.: 6ES BF00-0AA0) PCMCIA card This PCMCIA card can be used for the NCU/CCU or for the PCU 20. The PCMCIA card is referred to by the following terms for easier distinction in the start-up sections: For the NCU/CCU NC card For the PCU PC card Software SIMATIC Step7, SW 4 and later (see SIMATIC catalog for order number) PCIN (Order No. see Catalog NC Z) SINUCOPY-FFS for PC card or NC card ShopMill software package The ShopMill software package to be installed comprises the following: ShopMill for PCU 20 ShopMill for PCU 50 Toolbox PLC Toolbox The floppy disks are available on the ShopMill CD-ROM. The files must be copied to the hard disk of a PC/PG. The procedure for further installation of the software on PCU and NC/PC is described in the following sections on installation and start-up. The ShopMill CD-ROM also includes the NC standard software releases for SINUMERIK 810D/840D. These can be loaded onto a PCMCIA card using SI- NUCOPY-FFS. Note The exact contents of the ShopMill CD-ROM can be found in file siemensd.txt (German) or siemense.txt (English). You can find a compatibility list in file compat.xls. 4-19

20 4 Installation and Start-Up 4.1 Preconditions for software start-up ShopMill for PCU 20 The system diskettes contain the system software in five languages (German, English, French, Italian, and Spanish). Note When installing the system diskettes please follow the instructions in file Sys_read.txt on the system diskette. The application software allows you to modify the parameters of the PCU 20 applications and thus to: Set the foreground and background languages Change user texts Change display machine data and Change the MPI parameters (NETNAMES.INI) Add to PLC alarm texts Note When installing the application diskettes please follow the instructions in file App_read.txt on the application diskette. ShopMill for PCU 50 The system diskettes contain the system software in five languages (German, English, French, Italian, and Spanish). Note When installing the system diskettes please follow the instructions in file Sys_read.txt on the system diskette. Toolbox The Toolbox contains the following ShopMill data: ShopMill machine data blocks Cycles, definitions (macros, GUD), and examples Configuration files for the tool management function PLC Toolbox The PLC Toolbox contains: ShopMill PLC program for 8x0D SINUMERIK add-on for Step 7 NCVar selector Besides the ShopMill PLC blocks, the ShopMill PLC program also contains the blocks of the PLC basic program. Installation is supported by menu guidance and an install shield. 4-20

21 4 Installation and Start-Up 4.1 Preconditions for software start-up Note Please read the information in file siemensd.wri (German) or siemense.wri (English) in the PLC Toolbox. 4-21

22 4 Installation and Start-Up 4.2 Initial start-up sequence 4.2 Initial start-up sequence Sequence Before you begin with start-up please read the supplementary conditions and restrictions. Please proceed as follows to install and start up the NC: 1. Installation ShopMill on PCU 2. NC start-up 3. PLC start-up 4. Adapt display machine data 5. Install additional functions (optional) 6. Customize the user interface (optional) 7. Test using the acceptance report You can perform tool management start-up either together with NC and PLC start-up or afterward. If tool management has already been installed on the machine, you only have to adapt the display machine data for tool management (see Section 8.2 Start-up sequence ). 4-22

23 4 Installation and Start-Up 4.2 Initial start-up sequence Installing ShopMill on PCU 20 When you install ShopMill on the PCU 20 the HMI Embedded software is automatically installed with it, that means, you do not have to install the HMI Embedded software on the PCU 20 separately. ShopMill is installed on the PCU 20 by means of PC card. Note ShopMill uses the alarm texts and PLC messages of the CNC ISO operator interface. For detailed information, please refer to the following publication: References: /IAM/, Installation & Start-up Guide HMI 840D/840Di/810D Installation via the PC card Installing the system disks on PC/PG 1. Call program sys_inst from system disk Select option <1> Install System disk on hard disk. 3. Specify the drive on which you wish to install the system disks. 4. Specify the directory in which you wish to install the system disks. sys_inst suggests \hmi_0_2.sys. You can change this if necessary. 5. sys_inst may require you to insert the 2nd system disk. 6. Exit the program with <ESC>. Installing the application disks on a PC/PG 1. Call program app_inst from application disk Specify the drive on which you wish to install the application disks. 3. Specify the directory in which you wish to install the application disks. app_inst suggests \hmi_0_2.app. You can change this if necessary. 4. app_inst may require you to insert the 2nd application disk. 5. Exit the program with <ESC>. Fig. 4-1 Installing on a PC/PG 4-23

24 4 Installation and Start-Up 4.2 Initial start-up sequence Installing the application disks on PC card 1. Switch to the directory instutil of the application software, e.g. \pcu20.app\instutil (the directory specified during installation of the application disks on the PC/PG). 2. Call app_inst. 3. You may change the configuration as required (e.g. user texts, PLC texts, alarms, select languages, select blocks for installation, etc.). 4. Return to the main menu by pressing Esc. 5. Select option <1> Install all modules on hardware. 6. Select option <2> Create Flash Memory Card image. 7. Specify the source directory in which file sys_inst is stored. 8. Specify the target directory to which you wish to copy the system/application image file. File PCU20.ABB is created. 9. Insert the PC card into the PCMCIA slot of the PC/PG. 10. Transfer the created image file to the PC card using SINU- COPY-FFS. Fig. 4-2 Creating a PC card Note You do not need to copy the system software to the PC card separately as it is automatically copied over with the application software. 4-24

25 4 Installation and Start-Up 4.2 Initial start-up sequence Loading the PC card into the PCU Switch off the control. 2. Insert a PC card with new PCU SW release. 3. Switch on the control. 4. Press key 6 when the message PCU 20 Boot Software appears on the screen while the PCU 20 is booting. 5. Select option <0> Update from PC Card. 6. When data comparison has been completed, the message: Remove PC card appears. 7. On removal of the PC card, the control boots and starts up automatically. Fig. 4-3 Loading the PC card into the PCU

26 4 Installation and Start-Up 4.2 Initial start-up sequence Installing ShopMill on PCU 50 The HMI Advanced software must be installed on the PCU 50 before you install ShopMill. When you install ShopMill on the PCU 50, you can choose the ShopMill variant you wish to use, i.e. ShopMill Classic or ShopMill Open. ShopMill Classic is the software package previously marketed under the name ShopMill. For information about ShopMill Open, please refer to Section 10.3 ShopMill Open. Note ShopMill uses the alarm texts and PLC messages of the CNC ISO operator interface. For detailed information, please refer to the following publication: References: /IAM/, Installation & Start-up Guide HMI 840D/840Di/810D You can install ShopMill on the PCU 50 in one of three different ways: Installation via parallel interface (FAT 32) Installation via floppy disk drive Installation via a network link Installation via parallel interface (FAT 32) Preconditions: 1. The interlnk.exe application must be installed on the PC/PG. 2. The following line must be present in the config.sys file of the PC/PG: device = [path]\interlnk.exe /auto ([path] = path of interlnk.exe file, e.g. c:\programs) 3. Connect PCU 50 to parallel interface of the PC/PG. Activate the PCU 50: 4. Switch on the control and when the message Sinumerik appears as the PCU 50 is booting, press the Cursor down key and then Enter. 5. Select option <8> Start PC Link. 6. Enter the password. 7. Intersvr opens. 1 Fig. 4-4 Installation via parallel interface (FAT 32) 4-26

27 4 Installation and Start-Up 4.2 Initial start-up sequence 1 Installing the software: 8. Restart the PC/PG. 9. Copy the contents of the system disk on the Windows interface of the PC/PG to d:\install on the PCU 50. Do not copy over the disk directories themselves. Note: Once the PC/PG has rebooted, the PCU 50 displays the drive on the PC/PG that corresponds to drive D on the PCU 50, (e.g. D: equals F:, i.e. the files must be copied to drive F). 10. Close Intersvr on the PCU 50 with Alt+F Installation is menu-driven. 12. Select the ShopMill variant. Fig. 4-5 Installation via parallel interface (FAT 32) Installation via floppy disk drive 1. Switch on the control and when the message Sinumerik appears as the PCU50 is booting, press the Cursor down key and then Enter. 2. Select Option <1> Install/Update SINUMERIK System. 3. Enter the password. 4. Select option <1> Install from Floppy Disk. 5. Insert the first disk and follow the menu. Note: You must copy the files to drive F. 6. Select the ShopMill variant. 7. After installing the software, power down the PCU 50 with Exit and then reboot it again. Fig. 4-6 Installation via floppy disk drive 4-27

28 4 Installation and Start-Up 4.2 Initial start-up sequence Installation via network link The software is first transferred from the PC/PG to D:\Install on the PCU 50 and then automatically installed when the PCU 50 next boots. In the example given below, the PC/PG has computer number r3344 and the software to be installed is stored in directory SHOPMILL\SM_INST. Preconditions: PC/PG with Windows NT4 or Windows95/98 Set protocol NETBEUI on the PC/PG Start > Settings > Control Panel > Network > Configuration tab > Add : NETBEUI Determine the computer name of the PC/PG: Start > Settings > Control Panel > Network > Identification tab > Computer Name : e.g. r3344 Share the directory on the PC/PG in which the software to be installed is stored: PC/PG with Windows NT4: Assign a share name (e.g. SHOPMILL) Enter share authorization (e.g. User1 [local user] or anyone with read access) PC/PG with Windows 95/98 Enter a share name (e.g. SHOPMILL) Enter access authorization Assign password if necessary Select share level on a PC/PG with 95/98: Start > Settings > Control Panel > Network > Access Control tab > Select Share Level Connect the PC/PG and PCU 50 using an Ethernet cable of type Converted Twisted Pair Activate the PCU 50: 1. Switch on the control and when the message Sinumerik appears as the PCU 50 is booting, press the Cursor down key and then Enter. 2. Select Option <1> Install/Update SINUMERIK System. 3. Enter the password. 4. Select option <3> Install from Network Drive. 5. Select option <1> Connect to Network Drive. 1 Fig. 4-7 Installation via a network link 4-28

29 4 Installation and Start-Up 4.2 Initial start-up sequence 1 Make connection to the PC/PG: 6. Enter a user name and password with which the software can be fetched from the shared directory on the PC/PG (remember password can be confirmed). PC/PG with Windows NT4: User name and password of a local user of the PC/PG. PC/PG with Windows 95/98: Optional user name, password identical to password specified for shared directory (if applicable). 7. Enter drive letter under which the PC/PG is displayed on the PCU 50. E.g.: H 8. Enter the computer name of the PC/PG and directory name (share name) of the PC/PG to be accessed. E.g.: \\r3344\shopmill 9. The following message appears on the PCU 50: Connected Network Drive (last): H: (\\r3344\shopmill) Install Directory: F:\Install Note: F:\Install is a default setting and can be changed. 10. Select option <4> Change Install Directory. 11. Enter drive letter under which the PC/PG is displayed on the PCU 50 and a subdirectory if applicable. E.g.: H:\SM_INST Start transmission and software installation: 12. Select option <5> Install from H:\SM_INST. 13. Software transfer from the PC/PG to D:\INSTALL on the PCU 50 commences. After the software has been transferred, the PCU 50 is automatically restarted and the transferred software is installed under menu guidance. 14. Select the ShopMill variant. Fig. 4-8 Installation via a network link 4-29

30 4 Installation and Start-Up 4.2 Initial start-up sequence If you want to display all connected drives, proceed as follows: 1. Switch on the control and when the message Sinumerik appears as the PCU 50 is booting, press the Cursor down key and then Enter. 2. Select Option <1> Install/Update SINUMERIK System. 3. Enter the password. 4. Select option <3> Install from Network Drive. 5. Select option <2> Show connected Network Drives. Fig. 4-9 Show connected drives If you want to disconnect from all network drives again, proceed as follows: 1. Switch on the control and when the message Sinumerik appears as the PCU 50 is booting, press the Cursor down key and then Enter. 2. Select Option <1> Install/Update SINUMERIK System. 3. Enter the password. 4. Select option <3> Install from Network Drive. 5. Select option <3> Disconnect from all Network Drives. Fig Disconnect from network drives Language The ShopMill software package includes five languages (German, English, French, Italian and Spanish). The foreground language is always German. To select the background language, press the softkeys MMC and Languages in succession in the Start-up operating area on the CNC ISO operator interface and mark the desired language. Use the Change Language softkey to toggle between the foreground and background language in the Start-up area of the CNC ISO operator interface. 4-30

31 4 Installation and Start-Up 4.2 Initial start-up sequence NC start-up SINUMERIK 840D/810D Start-up of the NC includes the following items: Install axes and spindles Load ShopMill machine data, definitions and cycles Set up tool management You only have to set up the axes and spindles if you have not yet done so on the machine. Please observe the supplementary conditions when setting up the axes and spindles (see Chapter 2 Supplementary Conditions ). In the same way, you only have to set up tool management in the NC if none yet exists. NC start-up is different for the SINUMERIK 840D/810D and SINUMERIK 840Di. yes Is the software version installed on the NC? no Preconditions: NC card with 8 MB memory and required NCK software release Insert the NC card Load the software to RAM Start-up switch=1 (reset NCK) Start-up switch=0 (NCK reset) Enter password for the machine manufacturer If the axes and spindles have not yet been set up: Adapt standard MDs to the axes and spindles of the machine. Transfer MD from directory tools\md\... MVAR3A1S.8X0 (3 axes/1 spindle) MVAR4A1S.8X0 (4 axes/1 spindle) 1 Fig Start-up NC SINUMERIK 840D/810D 4-31

32 4 Installation and Start-Up 4.2 Initial start-up sequence 1 NCK reset If the axes and spindles have not yet been set up: Adapt standard MDs to the axes and spindles of the machine. Transfer MD from directory tools\md\... MVAR3A1S.8X0 (3 axes/1 spindle) MVAR4A1S.8X0 (4 axes/1 spindle) Transfer ShopMill MD from directory tools\md\cmm.8x0 (see Section 7.1 NC machine data for ShopMill ) Set axis machine data $MA_SPIND_AC- TIVE_AFTER_RESET 35040=2 manually for the spindle Note: If you want to install additional ShopMill definitions and cycles you must increase the size of the memory. NCK reset Machine Test configuration without drives Configure axes and start up drives Set the speed ranges for the spindles. For example, for 4 axes/ 1 spindle transfer SIM.8x0 from directory tools\md NCK reset 2 Fig Start-up NC SINUMERIK 840D/810D 4-32

33 4 Installation and Start-Up 4.2 Initial start-up sequence 2 PCU 20 PCU 50 Load definitions from directory: tools\cycles\define Import definitions SM_DEF.ARC from PCU 50 archive Activate files SMAC.DEF and GUDx.DEF (x = 5, 6, 7) with the Activate softkey Transfer cycles from directory: tools\cycles Load files SMAC_xx.DEF (xx = sc, sm) and GUD7_xx.DEF (xx = sc, js, sm) with the Load softkey Activate files SMAC.DEF and GUDx.DEF (x = 5, 6, 7) with the Activate softkey Import cycles SM_CYC.ARC from PCU 50 archive Load the these cycles with Load softkey. Note: The cycles are located in directories Standard Cycles and Manufacturer Cycles. NCK reset If tool management has not yet been installed: Create and load the configuration file for the tool management (see Subsection Creating and loading the configuration file ). For example, transfer data from directory tools\sd\... TM_WO_GR.8x0 (configuration without dual gripper) TM_W_GR.8x0 (configuration with dual gripper) Fig Start-up NC SINUMERIK 840D/810D 4-33

34 4 Installation and Start-Up 4.2 Initial start-up sequence SINUMERIK 840Di In NC start-up in the SINUMERIK 840Di, the cycles are not stored in the SRAM as in the SINUMERIK 840D/810D but in the DRAM. For this, you require the software option Cycle storage separate from CNC user memory with order number 6FC AF00 0AA0. Enter password for the machine manufacturer If the axes and spindles have not yet been set up: Adapt standard MDs to the axes and spindles of the machine. Example: In one of the two files stated in directory tools\md\..., comment out MD $MN_DRIVE_LOGIC_NR_[0] to $MN_DRIVE_LOGIC_NR_[14] (i.e. put ; in front of the line) and transfer the required file. MVAR3A1S.8X0 (3 axes/1 spindle) MVAR4A1S.8X0 (4 axes/1 spindle) NCK reset If the axes and spindles have not yet been set up: Adapt standard MDs to the axes and spindles of the machine. Example: In one of the two files stated in directory tools\md\..., comment out MD $MN_DRIVE_LOGIC_NR_[0] to $MN_DRIVE_LOGIC_NR_[14] (i.e. put ; in front of the line) and transfer the required file. MVAR3A1S.8X0 (3 axes/1 spindle) MVAR4A1S.8X0 (4 axes/1 spindle) 1 Fig Start-up NC SINUMERIK 840Di 4-34

35 4 Installation and Start-Up 4.2 Initial start-up sequence 1 In file tools\md\cmm.8x0, comment out MD $ON_USER_MEM_BUFFERED (i.e. put ; in front of the line) and transfer the ShopMill MD (see Section 7.1 NC machine data for ShopMill ) Set axis machine data $MA_SPIND_AC- TIVE_AFTER_RESET 35040=2 manually for the spindle Note: If you want to install additional ShopMill definitions and cycles you must increase the size of the memory. NCK reset Machine Test configuration without drives Configure axes and start up drives Setting the speed ranges for the spindles. For example, for 4 axes/ 1 spindle transfer SIM.8x0 from directory tools\md NCK reset Set the following MDs to store the cycles in the DRAM: $MN_DRAM_FILESYSTEM_MASK, bit 0 or bit 0 and $MN_MM_FLASH_FILE_SYSTEM_SIZE= $MN_MM_DRAM_FILE_MEM_SIZE = Fig Start-up NC SINUMERIK 840Di 4-35

36 4 Installation and Start-Up 4.2 Initial start-up sequence 2 PCU 20 PCU 50 Load definitions from directory: tools\cycles\define Import definitions SM_DEF.ARC from PCU 50 archive Activate files SMAC.DEF and GUDx.DEF (x = 5, 6, 7) with the Activate softkey Transfer cycles from directory: Tools\cycles Load files SMAC_xx.DEF (xx = sc, sm) and GUD7_xx.DEF (xx = sc, js, sm) with the Load softkey Activate files SMAC.DEF and GUDx.DEF (x = 5, 6, 7) with the Activate softkey Import cycles SM_CYC.ARC from PCU 50 archive Load the these cycles with Load softkey. Note: The cycles are located in directories Standard Cycles and Manufacturer Cycles. NCK reset If tool management has not yet been installed: Create and load the configuration file for the tool management (see Subsection Creating and loading the configuration file ). For example, transfer data from directory tools\sd\... TM_WO_GR.8x0 (configuration without dual gripper) TM_W_GR.8x0 (configuration with dual gripper) Fig Start-up NC SINUMERIK 840Di 4-36

37 4 Installation and Start-Up 4.2 Initial start-up sequence PLC start-up To start up the PLC you must first create and then load a PLC user project. A more detailed description of the PLC blocks is given in Chapter 5 PLC Program. Note Before commencing with start-up, set the parameter mnemonic to German in the SIMATIC manager under menu Options Customize Language. Proceed as follows to start up the PLC: Preconditions: ShopMill machine data are loaded Reset memory on the PLC Memory capacity after reset 96 KB Install the ShopMill library on the PG/PC: Start install shield with setup.exe. Installation is menu-guided. Note: The catalog name of the library is SMxxyyzz (xxyyzz = version number) Copy all program blocks and source files from the ShopMill library into the PLC user project (see Section 5.2 Overview of blocks ). If tool management has not yet been installed: Implement FC8 call and generate PLC data (DB4) (see Section 8.4 Start-up in the PLC ). For example, compile a source file: TM_WO_GR.AWL (data transfer without dual gripper) TM_W_GR.AWL (data transfer with dual gripper) 1 Fig PLC start-up 4-37

38 4 Installation and Start-Up 4.2 Initial start-up sequence 1 Supply ShopMill interface DB82 in PLC user program Part 1 (see Section 5.4 ShopMill interface DB82 ). For example, compile a source file: FC90_OP32S.AWL FC90_MSTT19.AWL Note: The generated blocks are stored in the user area and must be adapted to match the machine. Call ShopMill PLC program in OB1 and OB100 (see Section 5.6 OB1 and OB100 ). For example, compile a source file: GPOB810D.AWL (SINUMERIK 810D) GPOB840D.AWL (SINUMERIK 840D/840Di) Load PLC user project into PLC Fig PLC start-up Adapt display machine data Once you have completed installation of ShopMill on the PCU and start-up of the NC and the PLC you must adapt the display machine data. The display machine data are to be found in Section 7.2 Display machine data for ShopMill Acceptance report You can use the acceptance report to conduct a test of the installed ShopMill functions after completion of ShopMill start-up. You will find the acceptance report on the ShopMill CD-ROM. 4-38

39 4 Installation and Start-Up 4.4 Upgrade 4.3 Series start-up Series start-up is used to install software on several machines. When upgrading several machines, a standard software installation is carried out on the 1st machine (see Section 4.2 Initial start-up ) and then an NC and a PLC archive are set up which are then read onto the other machines. When creating or restoring these series start-up archives, you can choose between four different storage media: PG The start-up archives are saved on a programming device connected via the RS-232 interface. Please refer to the details for series start-up in the following publication: References: /IAD/, Installation and Start-Up Guide SINUMERIK 840D /IAC/, Installation and Start-Up Guide SINUMERIK 810D /HBI/, Manual SINUMERIK 840Di NC card The free memory (approx. 2 MB) on the NC card (PCMCIA card) can be used to save the start-up archive it contains. Hard disk (PCU 50 only) The start-up archives are saved to hard disk. Diskette (PCU 50 only) The start-up archives are saved to diskette. The exact operating sequence is specified in the following publication: References: /BEM/, Operator s Guide HMI Embedded or /BAD/, Operator s Guide HMI Advanced Note When you create an archive, you can save the NC and PLC separately or together. When reading in the archive files, the NC archive must be read in first, followed by an NCK reset and, if necessary, a PLC initial clear. Then the PLC archive is read in. Note that all the data of the NC or PLC are deleted and replaced with those in the archive. 4.4 Upgrade You will find information about upgrading ShopMill in file update_x.txt. 4-39

40 4 Installation and Start-Up 4.4 Upgrade Notes 4-40

41 PLC Program Structure of the PLC program In OBs 1, 40, and 100 the ShopMill-PLC program, the tool management, and the PLC basic program (FB 1, FC 2,...) must be called up as shown in Fig ÇÇÇÇÇ ÎÎÎ ÇÇÇÇÇ ÇÇÇÇÇ ÇÇÇÇÇ ÇÇÇÇÇ ÇÇÇÇÇ ÎÎÎÎ ÇÇÇÇÇ ÇÇÇÇÇ ÇÇÇÇÇ ÇÇÇÇÇ ÇÇÇÇÇ ÇÇÇÇÇ ÇÇÇÇÇ ÇÇÇÇÇ ÇÇÇÇÇ ÇÇÇÇÇ ÇÇÇÇÇ ÇÇÇÇÇ ÇÇÇÇÇ ÇÇÇÇÇ ÇÇÇÇÇ ÇÇÇÇÇ ÇÇÇÇÇ ÇÇÇÇÇ ÇÇÇÇÇ ÇÇÇÇÇ Call FC 19/24 Parameter assignment for the ShopMill interface DB 82 (FC 90) Fig. 5-1 Structure of the PLC program 5-41

42 5 PLC Program 5.2 Overview of blocks 5.2 Overview of blocks The blocks used by ShopMill are listed below. These blocks must not be changed and must be used. A precise description of the blocks is given in the following sections. Table 5-1 ShopMill blocks Block FC 30 FC FC 34 FC 35 FB 20 DB 81 DB 82 DB ShopMill PLC program Block called in OB 1. ShopMill PLC program Blocks only loaded. Comment Diagnostics for monitoring the standard interface signals that are written by the ShopMill PLC program. Block can be called in OB 1 for diagnostic purposes. ShopMill PLC program Block only loaded. HiGraphErrEmitterFB block for errors and timeout. Block is only loaded. HMI interface ShopMill interface Data blocks for ShopMill PLC program ShopMill also includes several source files for blocks as examples. You can adapt and compile these source files. As an alternative, you can also use your own blocks. Table 5-2 Example sources Source Block Comment GPOB810D.AWL GPOB840D.AWL FC90_MSTT19.AWL FC90_OP032S.AWL TM_W_GR.AWL TM_WO_GR.AWL OB 1, OB 40, OB 100 FC 90 FC 100, FB 110, DB 110 Example blocks for the OB Example block for supplying ShopMill interface DB 82 Block can be called with OB 1. Example module for configuration of the tool management. Block is called in OB 100. Example module for data transfer of the tool management. Block is called in OB 1. Instance data block for FB 110 A precise description of the example blocks is given in the following sections. The example blocks for tool management are described in Chapter 9 Tool Management. 5-42

43 5 PLC Program 5.3 ShopMill PLC program 5.3 ShopMill PLC program The ShopMill-PLC program includes the following blocks: FC The function blocks FC control the machine control panel functionality in DB 82 and the HMI functionality in DB 81. You must not change the numbers of function blocks FC This means you must change the blocks already assigned these numbers by the PLC user program. ShopMill is much more than just an operator interface consisting of screen forms and images. It also offers a complete operator system providing the user with the necessary functions for each control state. For example, the ShopMill operation mode Manual is not identical to the NCK operating mode JOG. For example, to execute the functions Zero point Workpiece, Measure tool, Positioning, etc. in Manual, ShopMill automatically switches at NC Start to NC operating mode Automatic and back again to JOG mode at the end of the function or at NC Stop. This makes the manual functions independent of the control operating modes of the NC from the operator s point of view. This functionality, which is continued in the ShopMill Automatic mode, is implemented in the PCU (ShopMill user interface) and in the PLC (ShopMill PLC program FC 30). FB 20 The FB 20 function block collects output alarms from the ShopMill blocks FC and display them. Function block FB 20 is only loaded. It must be available in the automation system (AS) during operation. A block call is not required. DB Data blocks DB 81 and DB 82 form the HMI or ShopMill interface. Data blocks supply values to the ShopMill-PLC program. The numbers of data blocks DB must not be changed. This means that the blocks with these numbers already allocated by the PLC user program must be changed. 5-43

44 5 PLC Program 5.4 ShopMill interface DB ShopMill interface DB 82 The ShopMill PLC program also requires an interface to the PLC program in addition to the internal interface to the user interface or to the NC interface. This is provided in the ShopMill interface DB 82. The machine control panel s signals (ShopMill operating modes Reset, Start, Stop, Spindle clockwise/counterclockwise/off, etc.) must be input into this interface by PLC user program part 1. The ShopMill PLC program then carries out the relevant actions and returns the current status to DB 82. This can then be assessed by PLC user program part 2. Please refer to Chapter 6 Signal Description for a detailed description of all the signals of ShopMill interface DB 82. Overview for active ShopMill PLC The figure below shows the connections for the active ShopMill PLC program. MCP MPI bus Base signals Outputs Inputs HMI interface DB 81 Inputs IB Outputs QB PLC user program Data transfer Inputs (keys, switches) Outputs (indicators, etc.) ShopMill PLC program FC 30 DB 82 Active ShopMill interface Standard interface signals DB 10 DB 11 DB 21 NC Mode group Channel Fig. 5-2 ShopMill operation 5-44

45 5 PLC Program 5.4 ShopMill interface DB 82 A list of the standard interface signals that are affected by ShopMill PLC program FC 30 is given in Section 5.5 Standard interface signals for/from Shop- Mill. Note When the ShopMill user interface is active, the ShopMill PLC program is also activated. This is displayed by the output signal DB 82 DBX36.0 cmm_plc_activ =1. The ShopMill interface DB 82 must be assigned parameters by the PLC user program. Data transfer of the base signals from IB0...7/QB0...7 is set via the DB 82 DBB0 signal transfer_base_sig. The default interface signals allocated by the ShopMill PLC program must not be overwritten by the user. 5-45

46 5 PLC Program 5.5 Standard interface signals for/from ShopMill 5.5 Standard interface signals for/from ShopMill Here is a list of the standard interface signals that are influenced by the Shop- Mill-PLC program FC 30 (DB 11 and DB 21) or the ShopMill user interface (DB 19). Table 5-3 Standard interface signals for/from ShopMill DBB0 DBB1 Byte DB 11 Bit0 Bit1 Bit2 Bit0 Bit1 Bit2 DB 19 Designation Signals to mode group (PLC >NCK) AUTOMATIC mode MDA mode JOG mode See /FB1/, Description of Functions, Basic Machine, K1 Machine function TEACH IN Machine function REPOS Machine function REF See /FB1/, Description of Functions Basic Machine, K1 Signals from operator panel (HMI >PLC) DBX18 Bit0 Update tool data See Section 6.1 HMI interface DB19 DBX20 Bit6 Simulation active See Section 6.1 HMI interface DB19 DB 21 Signals to NCK channel (PLC >NCK) DBB0 Bit3 Activate DRF See /FB1/, Description of Functions, Expansion Functions, H1 DBB0 Bit5 Activate M01 See /FB1/, Description of Functions, Basic Machine, K1 DBB0 Bit6 Activate dry run feedrate See /FB1/, Description of Functions, Basic Machine, V1 DBB1 Bit7 Activate program testing See /FB1/, Description of Functions, Basic Machine, K1 DBB2 Bit0 Skip block See /FB1/, Description of Functions, Basic Machine, K1 DBB6 Bit2 Delete distance to go See /FB1/, Description of Functions, Basic Machine, A2 DBB7 DBB30 Bit1 Bit3 Bit7 DB3X (X = 4 to 6) Bit0 Bit1 Bit2 DB3X (X = 4 to 6) DBW86 Cycle Start Cycle Stop Reset See /FB1/, Description of Functions, Basic Machine, K1 Signals to spindle (PLC >NCK) Spindle Stop Spindle Start CW rotation Spindle Start CCW rotation Signals from spindle (NCK >PLC) M function for spindle See /FB1/, Description of Functions, Basic Machine, S1 5-46