commissioning manual828d_ih_0909_en

1、PrefaceSINUMERIKSINUMERIK 828DTurning and MillingCommissioning ManualValid for:NCU system software Version 2.6 HMI sl Version 2.609/20096FC5397-3DP20-0BA0List of abbreviationsBReferencesASeries start-up10Tool management9Easy Extend8Service Planner7Configuring cycles6Setting NCK machine data5Commissi

2、oning the drive4Commissioning the PLC3Settings on the HMI2Scope of delivery and requirements1Legal information Warning notice systemThis manual contains notices you have to observe in order to ensure your personal safety, as well as to preventdamage to property. The notices referring to your persona

3、l safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger.If more than one degree of danger is present, the warning notice representing the highest deg

4、ree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage.Qualified PersonnelThe product/system described in this documentation may be operated only by personnel qualified for the specific task in accordance wi

5、th the relevant documentation for the specific task, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems.Proper u

6、se of Siemens productsNote the following:TrademarksAll names identified by are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.Disclaimer of LiabilityWe hav

7、e reviewed the contents of this publication to ensure consistency with the hardware and softwaredescribed. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included

8、in subsequent editions.Siemens AG Industry Sector Postfach 48 4890026 NRNBERG GERMANYOrder number: 6FC5397-3DP20-0BA0 10/2009Copyright Siemens AG 2009. Technical data subject to changeWARNINGSiemens products may only be used for the applications described in the catalog and in the relevant technical

9、 documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems

10、. The permissible ambient conditions must be adhered to. The information in the relevant documentation must be observed.NOTICEindicates that an unintended result or situation can occur if the corresponding information is not taken into account.CAUTIONwithout a safety alert symbol, indicates that pro

11、perty damage can result if proper precautions are not taken.CAUTIONwith a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.WARNINGindicates that death or severe personal injury may result if proper precautions are not taken.DANGERindicates that

12、 death or severe personal injury will result if proper precautions are not taken.PrefaceSINUMERIK documentationThe SINUMERIK documentation is organized in three parts:General documentation User documentationManufacturer/servicedocumentationInformation on the following topics is available at http:/ww

13、/motioncontrol/docu:Ordering documentation:Here you can find an up-to-date overview of publications. Downloading documentation:Links to more information for downloading files from Service & Support. Researching documentation onlineInformation on DOConCD and direct access to the publicat

14、ions in DOConWEB.Compiling individual documentation on the basis of Siemens contents with the My Documentation Manager (MDM), refer to /mdmMy Documentation Manager provides you with a range of features for generating your own machine documentation.Training and FAQsInformation on

15、 our range of training courses and FAQs (frequently asked questions) is available via the page navigation.Target groupThis documentation is intended for commissioning personnel.The plant or system is readily assembled and wired. For the following steps, e.g. configuring the individual components, th

16、e Commissioning Manual contains all necessary information or at least references.BenefitsThe intended target group can use the Commissioning Manual to test and commission the system or the plant correctly and safely.Utilization phase: Setup and commissioning phaseTurning and MillingCommissioning Man

17、ual, 09/2009, 6FC5397-3DP20-0BA03PrefaceStandard versionThis documentation only describes the functionality of the standard version. Extensions or changes made by the machine manufacturer are documented by the machine manufacturer.Other functions not described in this documentation might be executab

18、le in the control. However, no claim can be made regarding the availability of these functions when the equipment is first supplied or in the event of servicing.Further, for the sake of simplicity, this documentation does not contain all detailed information about all types of the product and cannot

19、 cover every conceivable case of installation, operation or maintenance.Structure of the documentation:Additional references:Turning and Milling Commissioning Manual, 09/2009, 6FC5397-3DP20-0BA04SubjectManualRCS CommanderOnline helpProgramming Tool PLC828Online helpEasy ScreenSINUMERIK 840D sl Progr

20、amming Manual Easy Screen in: Commissioning Manual Base Software and HMI slEasy MessageSINUMERIK 828D/840D sl Operating Manual HMI sl Turning SINUMERIK 828D/840D sl Operating Manual HMI sl MillingePS Network ServicesePS Network Services Function Manual and online helpTarget groupManualUser SINUMERIK

21、 828D/840D sl Operating Manual HMI sl Turning SINUMERIK 828D/840D sl Operating Manual HMI sl Milling SINUMERIK 828D/840D sl Programming Manual Fundamentals SINUMERIK 828D/840D sl Programming Manual Job Planning SINUMERIK 840D sl Programming Manual Measuring Cycles SINUMERIK 802D sl/828D/840D sl Prog

22、ramming Manual, ISO Dialects TurningProgramming Manual, ISO Dialects Milling SINUMERIK 828D Diagnostics ManualManufacturer SINUMERIK 828D Manual PPU SINUMERIK 828D Commissioning Manual Turning and Milling SINUMERIK 828D Service Manual Hardware and Software SINUMERIK 828D Parameter Manual SINUMERIK 8

23、28D/840D sl Function Manual Basic Functions SINUMERIK 828D/840D sl Function Manual Extended Functions SINUMERIK 840D sl Function Manual Tool Management SINUMERIK 802D sl/828D/840D sl Function Manual ISO Dialects SIMATIC NET System Manual GPRS/GSM Modem SINAUT MD720-3 SIMATIC NET Operating Instructio

24、ns Quad-Band GSM Antenna SINAUT 794-4MRPrefaceQuestions about this documentationIf you have any queries (suggestions, corrections) in relation to this documentation, please send a fax or e-mail to the following address:A fax form is available at the end of this document.SINUMERIK Internet addresshtt

25、p://sinumerikTechnical SupportIf you have any technical questions, please contact our hotline:Turning and MillingCommissioning Manual, 09/2009, 6FC5397-3DP20-0BA05Asia/PacificPhone+86 1064 757575Fax+86 1064 747474E-mailmailto:AmericasPhone+1 423 262 2

26、522Fax+1 423 262 2200E-mailmailto:Europe/AfricaPhone+49 180 5050 222Fax+49 180 5050 2230.14 /min from the German fixed-line network; cell phone charges may vary.Internet/automation/support-requestFax+49 9131 98 2176E-mailmailto:docu.motioncontrolsiemens

27、.comSubjectManualNetworkingSINUMERIK 840D sl ManualOperator Components and NetworkingSAFETY (safe standstill)SINAMICS S120/SINUMERIK 840D sl Manual Machine ConfigurationPrefaceNoteNational telephone numbers for technical support are provided under the following Internet address:

28、/automation/partnerEC Declaration of ConformityThe EC Declaration of Conformity for the EMC Directive can be found on the Internet at:under the Product Order No. 15257461, or at the relevant branch office of I DT MC Division of Siemens AG.CompactFlash cards for us

29、ersThe SINUMERIK CNC supports the file systems FAT16 and FAT32 for CompactFlash cards. You may need to format the memory card if you want to use a memory card from another device or if you want to ensure the compatibility of the memory card with the SINUMERIK. However, formatting the memory card wil

30、l permanently delete all data on it.Do not remove the memory card while it is being accessed. This can lead to damage of the memory card and the SINUMERIK as well as the data on the memory card.If you cannot use a memory card with the SINUMERIK, it is probably because the memory card is not formatte

31、d for the control system (e.g. Ext3 Linux file system), the memory card file system is faulty or it is the wrong type of memory card.Insert the memory card carefully with the correct orientation into the memory card slot (take note of arrows, etc.). This way you avoid mechanical damage to the memory

32、 card or the device.Only use memory cards that have been approved by Siemens for use with SINUMERIK. Even though the SINUMERIK keeps to the general industry standards for memory cards, it is possible that memory cards from some manufacturers will not function perfectly in this device or are not comp

33、letely compatible with it (you can obtain information on compatibility from the memory card manufacturer or supplier).The CompactFlash card from SanDisk CompactFlash 5000 Industrial Grade has been approved for SINUMERIK (Order Number 6FC5313-5AG00-0AA0).Turning and Milling Commissioning Manual, 09/2

34、009, 6FC5397-3DP20-0BA06Table ofcontentsPreface3Scope of delivery and requirements13..31.5.4System overview13Toolbox CD and other available tools14This is the general sequence for commissioning15Starting up the control16Communication with the control19How to communicate w

35、ith the control using the Programming Tool.19Example: How to communicate with the control using the NCU Connection Wizard23How to communicate with the control using the RCS Commander25Communicating with the control via X130282Settings on the HMI3...42.6.5

36、..42.7.5Access levels31How to set and change the password33Available system languages34How to set the date and time35Checking and entering licenses36How to enter a license key37How to determine the license requirement38Configuring user alarms40Structure of user PLC alarms40H

37、ow to create user PLC alarms42Configuring the alarm log43How to configure the log44Configuring user alarms with colors46How to configure colors for user alarms47Creating OEM-specific online help50Structure and syntax of the configuration file50Structure and syntax of the help book52Description of th

38、e syntax for the online help53Example: How to create an OEM-specific help57Example: How to create an online help for user PLC alarms603Commissioning the PLC633.1Activating I/O modules644Commissioning the drive6.34.1.4Configuring the drive67Example of a drive configuration67Example:

39、How to configure the drive69Example: How to configure the infeed76Example: How to configure the external encoder78Turning and MillingCommissioning Manual, 09/2009, 6FC5397-3DP20-0BA07Table of contents...44.2.5Example: How to assign the axes83Example: Setting machine

40、 data for an axis/spindle88Parameters for the axis/spindle test run89Terminal assignments91Terminal assignment on X12291Terminal assignment on X13292Terminal assignment on X122 for a Numeric Control Extension93Example: Circuitry for a CU with line contactor.94Connecting the probes975Setting NCK mach

41、ine data1015.15.2Classification of machine data101Processing part programs from external CNC systems1046Configuring cycles10.............11S

42、ettings for activating cycles105How to adapt the manufacturer cycles109Standard cycle PROG_EVENT.SPF110Setting the simulation and simultaneous recording (option)111Drilling113Technology cycles for drilling113ShopTurn: Drilling centered115Milling116Technology cycles for milling116Cylinder surface tra

43、nsformation (TRACYL)117Example: Axis configuration for milling machines118ShopMill: Setting up cycles for milling121Turning124Technology cycles for turning124Example: Residual material machining127Example: Axis configuration for lathes129Cylinder surface transformation (TRACYL)130End face machining

44、(TRANSMIT)133Inclined axis (TRAANG)136ShopTurn: Setting up cycles for turning139ShopTurn: Counterspindle146ShopTurn: Cylinder surface transformation (TRACYL)150ShopTurn: End face machining (TRANSMIT)151ShopTurn: Inclined axis (TRAANG)152Swivel153Technology cycles for swiveling153Setting the workpiec

45、e, tool and rotary table reference156ShopMill: Swivel plane and swivel tool159CYCLE800 checklist for the identification of the machine kinematics160Commissioning of the kinematic chain (swivel data record)161Example of the commissioning of swivel head 1167Example of the commissioning of swivel head

46、2168Example of the commissioning of a cardanic table170Example of the commissioning of a swivel head/rotary table172Example of the commissioning of a swivel table174Manufacturer cycle CUST_800.SPF176Turning and Milling Commissioning Manual, 09/2009, 6FC5397-3DP20-0BA08Tableofcontents

47、......12High Speed Settings (Advanced Surface)182Configuring the High Speed Settings function (CYCLE832)182How to adapt the High Speed Settings function (CYCLE832)184Measuring cycles and measurement functions186General settings for measuring186M

48、anufacturer cycle CUST_MEACYC.SPF189Measuring in the JOG mode189JOG: Measure workpiece during milling191JOG: Measure tool during milling.193JOG: Measure tool during turning197Measuring in the AUTOMATIC mode198AUTO: General settings for the workpiece measurement200AUTO: Measure workpiece during milli

49、ng202AUTO: Measure workpiece during turning204AUTO: Measure tool during milling205AUTO: Measure tool during turning (CYCLE982)2137Service Planner2PLC user program217Interfaces in the PLC user program218Functions on the HMI2238Easy Extend23....

50、........238.5.24Overview of functions231Configuration in the PLC user program233Display on the user interface235Creating language-dependent texts236Description of the script language237Special characters and operato

51、rs238Structure of the XML script239CONTROL_RESET241DATA241DATA_ACCESS241DATA_LIST242DRIVE_VERSION243FILE244FUNCTION245FUNCTION_BODY246INCLUDE248LET248MSGBOX250OP251OPTION_MD252PASSWORD253PLC_INTERFACE253POWER_OFF254PRINT254WAITING255?up256XML identifiers for the dialog256BOX258CONTROL258Turning and

52、MillingCommissioning Manual, 09/2009, 6FC5397-3DP20-0BA09Table of contents8.5.258.5.268.5.278.5.288.5.298.5.308.5.318.5.328.5.3.......3IMG260PROPERTY261REQUEST262SOFTKEY_OK, SOFTKEY_CANCEL262TEXT263UPDATE_CON

53、TROLS263Addressing the parameters264Addressing the drive objects266XML identifiers for statements.268String functions271string.cmp271string.icmp272string.left273string.right273string.middle274string.length275string.replace275string.remove276string.delete277string.insert277string.find278string.revers

54、efind279string.trimleft280string.trimright280Trigonometric functions282Examples.284Example with control elements284Example with parameters to support the commissioning285User example for a power unit2889Tool management29......9.6Fundamentals291Structure of the tool management292Components of the tool management293Loading and unloading tools manually296PLC - NCK user interface297Relocating, unloading, loading tool, positioning magazine298Tool change304Transfer-step and acknowledgment-step tables311Machine d