SIEMENS SIMATIC SS IP 266 Positioning Module ManualSIMATIC S5 IP 266 Positioning Module Manual EWA 4NES 812 6169-02 Edition 03 for 6ES5 266-5AA21STEP and SIMATIC are registered trademarks of Siemens AG. Copyright Siemens AG 1991 Subject to change without prior notice. 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 rights created by patent grant or registration of a utility model or design, are reserved. EWA 4NEB 812 6057-02aPreface Introduction System Overview Technical Description of the IP 266 Installation Guidelines Fundamentals of Positioning Machine Data, Modes and Traversing Programs Fundamentals of COM 266 Communication Between the CPU and the IP 266 Start-Up STEP 5 Programming Troubleshooting Appendix Keyword Index EWA 4NEB 812 6057-024EWA 4NEB 812 6057-02aIP 266 Preface Preface The IP 266 is a powerful intelligent I/O "positioning" module that was developed specially for installation in the S5-100U programmable controller. The IP 266 makes it possible to operate servomotors via power electronics equipment. The IP 266 can be used in conjunction with the following CPUs: e@ CPU 100 (6ES5 100-8MA02 only) @ CPU 102 (without restriction) @ CPU 103 (without restriction) The IP 266 provides numerous functions for both open-loop and closed-loop positioning. These functions are described in detail in the section entitled Modes. The IP 266 provides modes for positioning @ coordinate shift and @ correction (compensation) All modes can be used both separately and as a consequence of individual functions in machining programs. The complex open-loop and closed-loop procedures which a standard programmable controller must perform in order to carry out a positioning task require a great deal of processor time. The IP 266 can considerably reduce the amount of processor time needed because it takes over the entire positioning process. Your contro! program can thus execute in parallel with the positioning procedure. Sequences of motions involving several axes are made possible by the use of additional IP 266 modules. Sequencing control can be implemented via the IP 266s digital inputs and outputs. Because this module can be installed only in an S5-100U programmable controller, it has been assumed that the reader is well acquainted with the $5-100U product manual. The fundamentals of STEP 5 programming are not a topic of discussion in this manual. EWA 4NEB 812 6057-02a VvEWA 4NEB 812 6057-02aIP 266 Introduction Introduction The information presented below is aimed at simplifying use of the manual. Contents The contents of the manual can be subdivided into topical categories: @ Hardware description Section 1 ("System Overview") and Section 2 ("Technical Description") provide information on the components of the positioning system and their integration in the S5-100U System. In addition to explanatory texts on connecting peripherals such as - screen-based programmers - encoders and - power electronics equipment you will also find detailed information on the connector pin assignments for the various interfaces and the locations of these interfaces on the IP 266 module. @ Installation guidelines All information relevant to system installation can be found in Section 3 ("Installation Guidelines"). This includes: - safety guidelines - shielding - switch installation - module installation and removal procedures @ Fundamentals of positioning Section 4 provides information on positioning options within the SIMATIC system, the principles of positioning and the IP 266s position control facilities. This section also defines terms such as setpoint, actual value and following error and the interrelation of acceleration, speed and path. @ Machine data, modes and traversing programs The data which the IP 266 needs in order to carry out the positioning process is discussed in detail in Section 5. This section also provides information on all modes, how they work, and the parameters they require. EWA 4NEB 812 6057-02a vitIntroduction IP 266 vill Fundamentals of COM 266 This section provides information on how to - make a back-up copy of the COM 266 floppy - install COM 266 and - use COM 266. It also includes a full description of all COM 266 screen forms. Communication between the CPU and the IP 266 Defined addressing message frames are used for data interchange over the bus interface. You must know how to use these message frames when you want to control the IP 266 via a STEP 5 program (see Section 7). Examples are presented in Section 9 ("STEP 5 Programming") to show you how to link and process these message frames in STEP 5 programs. Start-up This section describes the procedures for installing and starting the IP 266. The information presented in this section is based on that presented in Sections 5 and 6. STEP 5 programming (Section 9) This section uses examples to show you how to use the message frames discussed in Section 7. Troubleshooting This section tells you what to do when problems arise. It also provides a list of errors and information on how they can be rectified. EWA 4NEB 812 6057-02aIP 266 Introduction Training courses Siemens offers an extensive range of training courses for the SIMATIC STEP 5 system. For details, please contact your local Siemens branch office. . Reference literature This manual deals primarily with the IP 266 positioning module. Other components of the SIMATIC S5 system are mentioned only briefly. Detailed information on these components can be found in the following literature: Programming Primer for the SIMATIC S5-100U Practical exercises on the PG 615 programmer Siemens AG, Berlin and Munich, 1988 Contents: - Configuration and installation of the $5-100U - Introduction to programming on the PG 615 programmer Order No.: ISBN 3-8009-1500-6 Programmable Controllers Volume 1: Logic and Sequence Control Systems; from the Control Task to the Control Program Gunter Wellenreuther, Dieter Zastrow Braunschweig 1987 Contents: - Operating principles of a programmable controller - Theory of control technology using the STEP 5 programming language for the SIMATIC S5 programmable controllers Order No.: ISBN 3-528-04464-0 EWA 4NEB 812 6057-02a ixIntroduction IP 266 Conventions This system manual is organized in menu form to make it easier for you to find information. This means the following: Each chapter is marked with printed tabs. At the front of the system manual is an overview page that lists the title of each chapter. Following this page, you will find a table of contents. At the beginning of each chapter is a table of contents for that chapter. Each chapter has three level headings that are numbered. The fourth level heading is not numbered but appears in boldface type. Pages, figures, and tables are numbered separately for each chapter. On the back of the table of contents for each chapter you will find a list of the figures and tables that appear in that chapter. This system manual employs the following specific structu ring devices: Specific terms have characteristic abbreviations (e. g., programmer is PG). Footnotes are marked with a raised number (e. g.,"1") ora raised asterisk (" * ). You will find the corresponding explanations in the lower margin of the page or under a figure or table if the footnote appears in one of these. Lists are designated with bullets (e as in this particular listing) or with hyphens (-). Cross references are indicated as follows: (see section 7.3.2). There are no references to specific page numbers. Dimensions in drawings are indicated in millimeters and inches. Value ranges are indicated as follows: 17 to 21 or 17-21. Especially important information appears in framed boxes such as the following: uN Warning You will find definitions for the terms Warning, Danger, Caution, and Note in the Safety- Related Guidelines for the User at the end of the introduction. EWA 4NEB 812 6057-02aIP 266 introduction Safety-Related Guidelines for the User This document provides the information required for the intended use of the particular product. The documentation is written for technically qualified personnel. Qualified personnel as referred to in the safety guidelines in this document as weil as on the product itself are defined as follows. e@ System planning and design engineers who are familiar with the safety concepts of automation equipment. e@ Operating personnel who have been trained to work with automation equipment and are conversant with the contents of the document in as far as it is connected with the actual operation of the plant. e Commissioning and service personnel who are trained to repair such automation equipment and who are authorized to energize, de-energize, clear, ground, and tag circuits, equipment, and systems in accordance with established safety practice. Danger Notices The notices and guidelines that follow are intended to ensure personal safety, as well as protect the products and connected equipment against damage. The safety notices and warnings for protection against loss of life (the users or service personnel) or for protection against damage to property are highlighted in this document by the terms and pictograms defined here. The terms used in this document and marked on the equipment itself have the following significance. Danger Warning indicates that death, severe personal injury or indicates that death, severe personal injury or substantial property damage will result if proper substantial property damage can result if proper precautions are not taken. precautions are not taken. Caution Note indicates that minor personal injury or property contains important information about the product, its damage can result if proper precautions are not operation or a part of the document to which special taken. attention is drawn. Proper Usage Warning @ The equipment/system or the system components may only be used for the applications described in the catalog or the technical description, and only in combination with the equipment, components, and devices of other manufacturers as far as this is recommended or permitted by Siemens. @ The product will function correctly and safely only if it is transported, stored, set up, and installed as intended, and operated and maintained with care. EWA 4NEB 812 6057-02a xiEWA 4NEB 812 6057-02a1.2 Axis TyP@S 6... e eee eee eee eee e cece n ee teeeeeetreestteeteeerereees Tm 3 1.3 Installing the IP 266 in a SIMATICS5 System ...... eee cere cece eeeee T= 5 1.4 Operator Servicing Options (PLC and PG) and Their Priorities ......... 1- 6 EWA 4NEB 812 6057-02aPositioning with Three Axes ..............0.0000- Linear Axis with Range Limit Switches (not to scale) The IP 266 in aSIMATIC $5 System .............02. Principle of Job Order Processing ................. AXIS TYPES 2... cece c cece cee cent eecusecuseceaes EWA 4NEB 812 6057-02aIP 266 System Overview 1 System Overview The IP 266 intelligent 1/O module adds yet another powerful positioning unit to the already wide range of $5-100U programmable controller modules. The IP 266 can position drives with exceptional accuracy. Once the programmable controller's CPU has started a job, it is no longer loaded by the IP 266. The positioning process now executes in parallel with your STEP 5 program. The IP 266 counts the pulses generated by the incremental encoder. The count is then used to determine the current position. Limit switches are connected to the modules digital inputs. The IP 266 is equipped with the following: Serial bus interface to the 100U programmable controller Digital inputs and outputs Analog output for driving the power section over the standard + 10 V interface Status indicators for various operating states Interface for connecting an incremental position encoder to determine the current position Programmer port for connection of ascreen-based programmer The following example illustrates a number of typical applications for positioning modules. Particular emphasis is placed on the distinctions between the two types of axes (linear axis and rotary axis). EWA 4NEB 812 6057-02a 1-1System. Overview IP 266 1.1 Application In an assembly line, a gripper takes a workpiece from a conveyor belt and forwards it to an automatic assembling machine. The part is then returned to the conveyor belt. Figure 1-1 shows the schematic arrangement. Included in the illustration are three axes which are positioned e. g. via three IP 266 modules. A linear axis can be used for raising and lowering the workpiece as well as for cross-machining from the conveyor belt to the assembling machine. The movement can be restricted to within defined limits. The conveyor belt can be initialized as continuous belt (rotary axis). i | | Flea = lau Fig. 1-1. Positioning with Three Axes 1-2 EWA 4NEB 812 6057-02aIP 266 System Overview 1.2 Axis Types You can operate either @ rotary axes or e linear axes on the IP 266. Initialization and operator servicing are dependent on the axis type. Any differences are pointed out in the relevant chapters and sections. This chapter contains a description of the individual types of axis. Continuous belt can be initialized in [mm], [inch] can be initialized in [deg], [mm], [inch] EWA 4NEB 812 6057-02a 1-3System Overview IP 266 The linear axis A linear axis is an axis with a limited traversing range. The traversing range is restricted via @ programmable software limit switches (Sa/Sp) e@ hardware limit switches (Ha/H_) @ emergency limit switches (Na/N_g) Start of End of machine machine Na Ha Sa Se He Neg Traversing range Na/N_: Emergency start/end (power section) Ha/H_: Hardware limit switch start/end Sa/S_e: Software limit switch start/end Deceleration distance g, Clearance distance X Fig. 1-2. Linear Axis with Range Limit Switches (not to scale) The software limit switches do not go into force until the reference point has been determined (see Section 5.3.5). The distance between the software limit switches and the hardware limit switches must be such that the drive can be decelerated at the specified deceleration rate before it reaches the hardware limit switches. In addition to deceleration distance Spr, you must also maintain a clearance distance (X) between the end of the deceleration distance and the next limit switch. The same applies to the distance between the hardware limit switches and the emergency limit switches. /\ Caution Incorrect initialization of the limit switches may result in mechanical damage. Always make sure that you observe the clearance distance (X). The emergency limit switches, which are routed directly to the power section, must also take the deceleration distance into account. J Caution If you initialize a linear axis unintentionally as a rotary axis, there are no software limit switches. The drive can be stopped only over hardware limit switches. 1-4 EWA 4NEB 812 6057-02aIP 266 System Overview The rotary axis A rotary axis is an axis with an unlimited positioning range. This may be e. g. e arotary table or @ acontinuous belt When a rotary axis is used, the start and the end of the positioning range are physically the same point on the axis. The only effect the start of traversing range and end of traversing range parameters have is that of switching the actual value displays. Example A traversing range of 0 mm to 400 mm was specified in the machine data for a continuous conveyor belt. The value 0 mm and the value 400 mm both have the same physical location on the belt. When the value 400 mm is reached, the display switches to 0 mm. 100 0 Start of traversing range End of traversing range 3 The hardware limit switches are evaluated in the same way as for a linear axis, and provide extra protection when the positioning range is to be restricted to values less than one revolution. 1.3 installing the IP 266 in a SIMATIC S5 System Data bus OV Data \ as ( PLC interface i 1 1 1 1 i 1 I 1 1 Setpoint 43 Command Co ! Position I . assign- . Power interpreter 9 controller 1 i 1 1 I I 1 1 1 1 1 ment DAC section Programmer port Figure 1-3. The IP 266 in a SIMATIC S5 System EWA 4NEB 812 6057-02a 1-5System Overview IP 266 The IP 266 can be plugged into a bus module slot for analog modules (slot 0 to 7). In addition to the wiring backplane, the IP 266 is also equipped with interfaces for connecting @ aprogrammer (PG 635, 675, 685, 730, 750) @ power electronics equipment with speed controller over the analog output @ 8digital inputs/outputs for limit switches, reference point switches, ... e@ anincremental position encoder (rotary or linear) 1.4 Operator Servicing Options (PLC and PG) and Their Priorities The IP 266 can be controlled viaa programmer (PG) or via the programmable controller's CPU. If job requests are issued to the IP 266 over both interfaces in the same firmware cycle, the request issued via the programmer has priority but the next PLC job request is serviced in the subsequent cycle. If this request differs from the PG request and the latter is still being serviced, the IP 266 aborts the job and flags an error. PLC Job order PG processing Stat fo PLC . - Programmer interface interface Figure 1-4. Principle of Job Order Processing The IP 266 accepts two types of positioning requests: e Single job orders (or requests) are forwarded to the IP 266 over the programmer port or the PLC interface. Single job orders are all modes with the exception of mode 8 (AUTO) and mode 9 (AUTO single block). e Machining programs, i. e. a continuous sequence of single job orders, dwells, corrections and switching operations. The machining programs must be in the IP 266's memory. A machining program is started over an operator interface by specifying the operating mode and the program number. Programmer port The IP 266 can be serviced via a programmer connected over the programmer port. To do this, you must use the COM 266 software package, which provides menus and screen forms for initializing the IP 266. Screen forms are also used to specify the modes and display current actual values. PLC interface Input and output blocks are used for IP 266 control via the programmable controller's CPU and for forwarding return info from the IP 266 to the CPU. These blocks must be initialized in a STEP 5 Program. Positions, mode numbers and the like can be entered using, for example, numerical setters. The values are forwarded in the process input and output images. 1-6 EWA 4NEB 812 6057-02a2.5.3 External Stop (Pin6) ..: 2.5.5 Function Signal FUM (Pin 2.5.6 Position Reached (Pin 9) 2.5.8 Examples ..........66. 2.6 Fault LED ............. 2.7 IP 266 Monitors ........ 2.7.1 Encoder Monitor ...... 2.7.2 Position Control Monitor 2.8 Technical Specifications 2.5.1 Hardware Limit Switches (Pins 3/5) 2.5.2 Reference Point Switch (PIN 4) 2... 0... cece ee eee tee ee teen enees 2.1 IP 266 Hardware Configuration ...... ccc cece sence ence cect ecceees 2.2 Interface to the Programmer ....... cect cece eee n cette tereeteeeeee 2.3 Interface to the Incremental Position Encoder ......... ccc cece eens 2.4 Interface to the Motor Power Section ..........cccee ee eeeeeen ences 2.5 Interface for Digital Inputs and Outputs .......... 0. cece eee e eee eee 2.5.4 External Start Enable (Pin 7) ........ cc cece cece teeter eee en eeneee B) ccc cece cece eee c eee e eee enn tenes 2.5.7 Switching Function M99 (Pin 10) 1... ccc cece tec eee e eens 10 10 10 11 12 12 15 15 17 18 18 19 20 EWA 4NEB 812 6057-02aIP 266 Block Diagram with Interfaces ................0c000-0--. Module Overview Diagram ............0.0.0ceceee Programmer Interface Location and Pin Assignments Position Encoder Interface Location and Pin Assignments Connection Diagram for the Encoder Connecting Cable ... Analog Output Interface Location and Pin Assignments ... Terminal Block ......... cece ccceeeecccceceeuce . eee ee ewe Switch Connections on the Terminal Block .............. Position Reached" Signal as a Function of Zero-Speed monitoring Encoder Sigiials oi c.eiiuscsccieccsvsesbceeccccceecas wees Effect of External Start" on Single Job Orders and Automatic Programs ............ Switching Conditions for the "Position Reached" Signal ... oe eee ee eee Encoder Monitor for 5 Vand 24VEncoders ......... eee eee eee ee eee eee eee eee ey eee eens se eee eee eee . 2 2 2 2 rene 2 - 2 2 2 2 Wow On DAW t wee 2- 5 veee 2 11 -. 2- 14 --. 2- 18 EWA 4NEB 812 6057-02aIP 266 Technical Description of the IP 266 2 Technical Description of the IP 266 The IP 266 is used for controlled positioning of a drive. It is utilized primarily in applications involving e auxiliary axes in metal-working machines @ paper and textile machines e handling and loading equipment e feed facilities for transfer and assembly lines 2.1 IP 266 Hardware Configuration The IP 266 makes it possible for you to position a drive. Once a job has been started, no further demands pertaining to that job are placed on the programmable controllers CPU. The positioning process is self-sustained, and thus executes in parallel with your application program. Internal $5 bus Operating $5 bus Eregeaermer system interface po IP266 Micro- processor (80C188) Memory Counter Registers DAC DAC= Digital-analog converter Inputs for an incremen- 5 binary +10V tal position encoder inputs connection for 3 binary power section outputs Figure 2-1. IP 266 Block Diagram with Interfaces Figure 2-1 provides an overview of the most important module components. EWA 4NEB 812 6057-02a 2-1Technical Description of the IP 266 IP 266 Processor + operating system: Programmer interface: $5 bus interface: (to the PLCs CPU) Counter: DAC: Registers: For coordinating all IP 266 tasks For servicing the IP 266 via the COM 266 software e Start-up e@ Input/modification of machine data e@ Test mode: Starting traversing programs Starting single modes/jobs For servicing the IP 266 via a STEP 5 program e@ Starting traversing programs @ Starting single modes (jobs) @ Reading single values from the !P 266 (actual value, distance to go, following error) e@ Acquiring and evaluating status info Input for an incremental position encoder. The counter counts the encoder pulses. Digital-analog converter: Analog output to the motor power section. The DAC converts the digital setpoint into an analog setpoint. Digital inputs and outputs EWA 4NEB 812 6057-02aIP 266 Technical Description of the IP 266 Locations of the interfaces on the IP 266 The IP 266 communicates with the I/Os over three interfaces located on its frontplate. Elements on the IP 266 front plate Fault LED Red LED Analog output 9-pin D SUB Incremental 15-pin D SUB position encoder CAUTION! Possibility of 8 Programmer 15-pin D SUB confusion port Screw terminal For securing the module POSITIONING CONT. [Eee MODULIP 266 E 6ES5 266-8MA11 Figure 2-2. Module Overview Diagram Note: Be sure not to confuse the interface for the incremental position encoder with the programmer port. When you connect these I/Os, remember that the programmer port is the rightmost of the two 15-pin D SUB connectors. in addition to the two 15-pin D SUB interfaces, the digital inputs and outputs must be connected to the modules terminal block. EWA 4NEB 812 6057-02a 2-3Technical Description of the IP 266 IP 266 2.2 Interface to the Programmer You can connect a programmer to the IP 266 via the programmer port. The programmer port's connector pin assignments are compatible with those of the CPU modules programmer port. Use a standard interface cable, which is preset for 9600 bits/s, to connect a programmer. Pin Description 1 Shield 2 RxD_N 3 - 4 - 5 - 6 TxD_P 7 TxD_N 8 Shield 9 RxD_P 10 to 15 - POSITIONING CONT. MODULIP 266 GES5 266-8MA11 Figure 2-3. Programmer Interface Location and Pin Assignments Caution Like the encoder interface, the programmer port is a 15-pin interface, and it is therefore possible to confuse the one with the other. The programmer port is the one at the right. If you use the wrong interface, the module executes a RESET. EWA 4NEB 812 6057-02aIP 266 Technical Description of the IP 266 2.3 Interface to the Incremental Position Encoder The IP 266 requires two signals in quadrature (signals A and B), i. e. displayed by 90 deg. with respect to each other, for position decoding and for ascertaining the direction of travel. These signals, as well as a reference signal (R), must be provided by the incremental position encoder. Table 2.-1. Encoder Signals ae |] as so 1 . erent eucnae a : ; A\ 4 J J - | Q GB Ter er a 5 A gO Oy I You can connect either encoders with 5 V signals or encoders with 24 V signals. The 5 V encoders must also provide the inverted signals A\, B\ and R\. The 15-pin D SUB socket on the module's frontplate contains all supply and signal lines for both types of encoder. EWA 4NEB 812 6057-02a 2-5Technical Description of the IP 266 IP 266 ed) oo000 x amoontam 77 0000 } 2] ii 6) Pin | Abbr. | Description 5V | 24V 1 5V_ | Encoder voltage e 2 5V_ | Encoder voltage e 3 Mint | Ground (5 V) e 4 Mint | Ground (5 V) e 5 Mext | Ground (24 V) e 6 A\_ | Inverted A signal e POSITIONING CONT. 7 A_ | Asignal e eres ase ane 24 V Encoder voltage ; e signa 2}ala1 316] 10 B\ | Inverted B signal e 11 R Reference signal (zero mark) e 12 R\_ | Inverted reference signal e 13 A* | Asignal (24V) e 14 B* | Bsignal (24V) e 15 R* | Reference signal (zero mark) e Figure 2-4. Position Encoder Interface Location and Pin Assignments The choice between 5 V or 24 V encoder is made in the machine data when you initialize the IP 266. In addition to incremental position encoders made by Siemens, you may also use non-Siemens encoders which conform to the following specifications: @ Method of measurement: Incremental e Supply voltage: 5 Vor24V @ Output signals: - Symmetricalencoders Asignal (5 V signals) B signal R reference signal A\ signal B\ signal R\ signal - Asymmetrical encoders A* signal (switching to P poten- tial only) B* signal 24 V encoders R* reference signal @ Max. operating frequency - 5Vencoder 500 kHz for 30 m cable - 24V encoder 100 kHz for 25 mcable 2-6 EWA 4NEB 812 6057-02aIP 266 Technical Description of the IP 266 We would recommend the following cable for connecting the IP 266 when using a Siemens encoder (6FC 9 320) for 5 V signals: Order No.: 6ES5 705-7... 1 The three dots in the Order No. stand for the three-digit length code. You will find a list of length codes in Catalog ST 52.1. Connecting cable for Siemens 6 FB 9 320 position encoders 5 ry Al \ bk ff) = 5 | Dt oA \ bri Ca 6 tt XY : 6 pie wild : +: Bi \ or ae a 10 : X i _ Yt 11 pa \ eo (3 12 C i: RI \ gr bog - ri XN :; oS! 64 >i ov re : pe 4 3 i+ 11 C it ov bk ::05 > 4 rt rq 10 +5V bh f 305 3 +5V ye i tgs 4 495 | 42 Shield on Shieldon \ J shell shell SS ee Cable 4x 2x 0.38 + 4x0.5sq.mm 6 FC 9 343-0AF 15-pin D Sub plug connector 12-pin circular . . socket connector Wiring post side Wiring post side metal-plated shell SIEMENS with screwed connection 6FC9341-1HC 6FC9341-1FD Figure 2-5. Connection Diagram for the Encoder Connecting Cable EWA ANEB 812 6057-02a 2-7Technical Description of the IP 266 IP 266 2.4 interface to the Motor Power Section The IP 266 can output an analog setpoint speed of +10 V over the 9-pin D SUB socket connector (ANALOG OUT), This voltage is used to control your motor power section. ANALOG OUT Description Ncetp Voltage for setpoint speed M Analog ground POSITIONING CONT. MODULIP 266 GESS 266-8MA11 1}2]3]a[ sf] Figure 2-6. Analog Output Interface Location and Pin Assignments Siemens provides a prefabricated cable for connecting the analog output to the power section. Order No.: Connecting cable 6ES5 705-8 ... 1 The three dots in the Order No. stand for the three-digit length code. You will find a list of length codes in Catalog ST 52.1. The connecting cable is equipped with a 9-pin D SUB plug connector and has an open end for connection of the motor power section. uN Caution The connection information provided by the power equipment manufacturer and the general installation guidelines for SIMATIC components must be carefully observed to ensure fault-free operation. You may connect only power equipment with differential inputs fort10 V, and the analog ground may not be connected to the external ground. 2-8 EWA 4NEB 812 6057-02aIP 266 Technical Description of the IP 266 2.5 Interface for Digital Inputs and Outputs The IP 266 is equipped with five digital inputs and three digital outputs which can be accessed over the bus modules terminal block. L+ (24V) 1 2 |l- External ground 3 | Hardware limit switch (start) 4 | Reference point switch e 5 | Hardware limit switch (end) e 6 | External STOP e 7 | External START enable e 8 | FUM (function signal - controller 6 enable) 9 | Position reached 10 | Switching function M99 o Enable for other modules Figure 2-7. Terminal Block A Caution Always connect reference potential L- (pin 2 on the terminal block) with the programmable controller's chassis ground to ensure fault-free module operation. The polarity of the hardware limit switches and the External STOP" can be specified in the machine data. When you set the machine data parameters, you can choose between "pos" (positive) polarity for NO contacts and neg (negative) polarity for NC contacts. EWA 4NEB 812 6057-02a 2-9Technical Description of the IP 266 IP 266 2.5.1 Hardware Limit Switches (Pins 3/5) I i i i iu ittid i 1ypuddidd u iL DBODSE Beeld 1 3 5 7 9g oe hs Cr 4 DSEQ@ cee =2 4 & 8 10 Ee Table Na Ha Sa Ref Se He Neg Na/Ne: Emergency limit switch start/end (power section) Ha/H_e: Hardware limit switch start/end Sa/Se: Software limit switch start/end Ref: Reference point switch Figure 2-8. Switch Connections on the Terminal Block The hardware limit switches restrict the traversing range of the drive system to defined limits, and must be connected to terminal block pins 3 and 5. 2.5.2. Reference Point Switch (Pin 4) The drive system is synchronized by reference point approach. The reference point switch must be connected to pin 4 on the terminal block (see Figure 2-8) and must lie between the two hardware limit switches. You must make sure that there is enough room between the reference point switch and the hardware switches for the drive to decelerate for reference point approach without reaching a hardware limit switch. 2.5.3 External Stop (Pin 6) Machining can be stopped via the "External Stop" input. Travel is then stopped at the maximum specified deceleration rate and the IP 266 signals an "External stop". This signal also aborts the machining program (see Section 5.4). In Automatic mode, a dwell can also be cancelled. /\ Caution An External stop" in the "Follow-up" and Controlled jog" control modes restarts the position controller. The polarity of the "External Stop" can be specified in the machine data. 2-10 EWA 4NEB 812 6057-02aIP 266 Technical Description of the IP 266 2.5.4 External Start Enable (Pin 7) External Start Enable" allows you to make the start of a positioning operation dependent on an external event, such as a signal from another IP 266 (for instance switching function M99, position reached). A positioning operation cannot be started on the IP 266 unless this signal is present. The signal also makes it possible to disable processing of a machining block or dwell. The machining program can be resumed at the point of interruption by activating the signal. Note: The "External Start Enable" signal does not interrupt a positioning operation or dwell that is currently in progress. Blocks belonging to G10 (see Section 5.4) are treated as two separate blocks. The polarity of the "External Start Enable" signal is not programmable. The input must be wired as NO contact. Table 2-2. Effect of "External Start" on Single Job Orders and Automatic Programs eer rm 7 o ee rN reeeeenes ee caine Son000 Se = a via Single job order The positioning order is interpreted but not Motor waiting for External Start serviced. Enable The positioning order is executed only when the External Start Enable" signal is present. Automatic mode Program is executed up to the first positioning Motor waiting for External Start order or first dwell. Enable The order is interpreted and executed when the External Start Enable signal is present. Subsequent orders can be disabled by cancelling | Motor waiting for External Start this signal. Enable No other requests are permitted while the IP 266 is waiting for an "External Start Enable" signal. An attempt to issue another request is flagged with "Illegal! request". The Stop command resets the "Motor Waiting for External Start Enable" signal and the job is aborted. EWA 4NEB 812 6057-02a 2-11Technical Description of the IP 266 IP 266 2.5.5 Function Signal FUM (Pin 8) The IP 266 outputs the FUM signal when it is ready for operation and has valid machine data at its disposal. Z\ Caution For reasons of safety, you may enable your power section only when the IP 266 has output the FUM signal. To do this, you must interlock the power section's Enable input with the FUM signal. If the power section has no Enable input, you must establish the interlock in some other way. The FUM signal is removed immediately when invalid machine data is transferred to the IP 266. The FUM signal is reactivated when the error has been rectified and correct data forwarded to the IP. 2.5.6 Position Reached (Pin 9) The "Position Reached" signal indicates error-free completion of a positioning operation with absolute or relative target specifications. The signal is generated twice: e Asstatus bit in the input block (see Section 7) e Assignal on terminal block PIN 9 The following conditions must be fulfilled in order for this signal to be generated: e@ The setpoint position must have reached the specified target coordinate (t;). e@ The actual position must lie within the tolerance limits for zero-speed monitoring (t2). 2-12 EWA 4NEB 812 6057-02aIP 266 Technical Description of the IP 266 s A Vv t ty a: Setpoint characteristic t;: Setpoint reached b: Actual characteristic tp: Actual value within zero-speed monitoring tolerance range Sst: Zero-speed monitoring Figure 2-9. "Position Reached" Signal as a Function of Zero-Speed Monitoring The axis status changes from "machining" to finished at the same moment the "Position Reached" signal is generated. Note: During execution of a machining program, the "Position Reached" signal is output after each block, the axis status signal "finished" only on termination of the machining program. EWA 4NEB 812 6057-02a 2-13Technical Description of the IP 266 IP 266 Table 2-3 shows the conditions under which the "Position Reached" signal is set. Absolute and relative target specifications: @ Position setpoint must have reached the target coordinate and @ Actual position lies within the tolerance range of zero-speed monitoring (beginning at time t, in Figure 2-9) e Premature termination of a job with absolute or relative target specification @ = Aresidual distance remains until a new machining operation is started. A subsequent machining request with the distance to go shown positions the drive to the original target position In machining programs, the termination of machining operations or dwells is indicated by the "Position Reached signal. @ During execution of a machining program @ when a dwell is aborted e @ whena traversing movement is aborted e In "1/2 jog following a Stop command e "Controlled jog" when the actual position no longer changes in a sampling interval e Exceptions A large non-compensated drift or a large load may result in the setpoint reaching the target position while the actual value remains outside zero-speed monitoring. If the maximum following error is not exceeded in the process, the IP 266 sets and starts a 5s watchdog timer. When no movement toward the target is detected within this time period, the IP 266 terminates the operation with "Target position not reached". The "Position Reached" signal is not generated. 2-14 EWA 4NEB 812 6057-02aIP 266 Technical Description of the IP 266 2.5.7. Switching Function M99 (Pin 10) So-called M functions can be programmed in a machining program (see Section 5.4). These functions are returned to the PLC in the form of numerical values. One of these functions (M99) is also applied to an output; this signal can be used to execute program-controlled switching operations (for example, enabling another module). 2.5.8 Examples The following examples describe how to use the digital inputs and outputs for external start enable @ external stop position reached e switching function Example 1 This example examines the performance characteristics of the IP 266 when the "External Start Enable" signal is setto "0" prior to execution of each block. A machining program containing machining operations, dwells, corrections and M functions is delayed prior to the start of each block by removal of the "External Start Enable" signal and then aborted with an "External Stop signal. 1 Traverse/rapid NO5 GOO XO MOS Job is not executed 2 Traverse with G10 N10 G10 X50 F100 M10 Job is not executed 3 Traverse with G10 N20 G10 X200 F350 M20 Job is not executed 4 Traverse N30 X250 F400 MOO Job is not executed 5 Dwell N40 G04 F50 M40 Job is not executed 6 Traverse N50 X300 F300 M99 Job is not executed 7 Dwell N60 G04 F50 M60 Job is not executed 8 Correction/offset N70 G54 Job is executed 9 Traverse N80 G04 F50 M80 Job is not executed 10 Traverse N90 X-2000 F2000 M90 Job is not executed 11 Dwell N100 G04 F50 M99 Job is not executed 12 End of program N110 M02 Job is executed EWA 4NEB 812 6057-02a 2-15Technical Description of the IP 266 IP 266 Example 2 The machining program described in example 1 is started, but the "External Start Enable" signal is removed only at certain points. The timing diagram below shows the chronological sequence effected by the "External Start Enable" and External Stop" signals. Start 1 t i t ' t 1 ' ' ae Z Y 3 GY . i ' 1 1 1 ay t bo Y 1 Y to Yj i 1 gf! t ' ' ' 1 i ' i 1 External : . =Y Y > | Y : : > "TA 1g 1 Bg ite} fi fel | TYi i i pcan || (if: *9:: - rs tate @ oG oG vis "Position Yj Z oY : Sgrel =ai Z At tt fr so 1 1 GR + 3 Por nas 1 Y (iY : hor a fying | Ly |: Yj i Poe ite tY.Q4ow. agin YY oo |: > 1 3 1 BA: 3 peo: 3 Traversing ao Mood ad 4 oo % 3 = QQ 22 2 2 ge 4288 8 Yyy The next job is delayed via the External Start Enable signal The "External Start Enable" signal starts the first block of the machining program. Ashort pulse of the "Position Reached" signal appears between blocks that are not interconnected by a "flying change. Switching function M99 is active in the sixth block. The block has executed. Since the "External Start Enable" signal disables execution of blocks containing machining operations or dwells, program execution is interrupted. The External Start Enable" signal does not interrupt offsets or corrections. The "External Stop" signal initiates maximum-rate deceleration, The drive is at a standstill. The machining program is terminated and the "Machining program executing" signal is removed. O OO OO 2-16 EWA 4NEB 812 6057-02aIP 266 Technical Description of the IP 266 Example 3 Three jobs are started in succession. Job 1: Absolute target position Job 2: Relative target position Job 3: Relative target position 2.6 Start of job 1 Job Start of job 2 Start of job 3 External Start External : : Stop : Position Reached signal Executing Axis finished | t Job executing; * axis outside tolerance limits of zero-speed Fault LED The module is equipped with a red fault LED which is located at the right of the analog output. This LED flags faults of special IP 266 functions. Wirebreak or short-circuit on (5 V) incremental position encoder No 24 V voltage supply Polarity reversal of 24 V voltage supply Power section off Error in IP 266 restart routine Open circuit between IP 266 and power section Blocked drive Incorrect position control (track A/A\ and B/B\ reversed) e@ Inthe IP 266 restart routine EWA 4NEB 812 6057-02a 2-17Technical Description of the IP 266 IP 266 2.7 IP 266 Monitors The IP 266 is equipped with a number of monitors for monitoring its I/Os. Some of these monitors are implemented at the hardware level, others at the software level. 2.7.1 Encoder Monitor The IP 266 supports hardware and/or software monitors, depending on the type of encoder used. The table below lists all available options: Software The "Error in position control loop signal is output when the IP 266 fails to detect pulses in ten consecutive IP cycles (10 x 3.75 ms). Hardware Symmetrical encoders are also monitored for wirebreaks and short- circuits, thus enabling a faster response (even prior to the conclusion of ten consecutive IP cycles). A wirebreak or short-circuit is also flagged via the Error in position control loop signal. Note: Software monitoring is possible only in the closed-loop control (automatic) modes. In the event of an "Error in the position control loop, the IP 266 aborts the job currently in Progress, using the specified maximum deceleration rate to do so. It then resets the existing reference point, if any, and starts the open-loop control "Follow-up" mode. The controller enable signal remains activated. You can now modify and store machine data on the IP 266. "Follow-up" mode is terminated as soon as the machine data has been stored, and the IP is once again in closed-loop control mode. 2-18 EWA 4NEB 812 6057-02aIP 266 Technical Description of the IP 266 2.7.2. Position Control Monitor On the first automatic machining movement following IP 266 power-up, the module checks the position control direction. If signals A and B are reversed, the encoder changes the actual value in the opposite direction to that specified by the setpoint. The IP attempts to match the actual value to the setpoint over a period of ten IP cycles. During this time, the analog voltage increases at a very rapid rate. If the two values are still progressing in opposite directions after ten cycles, the current mode is revoked, the "Follow-up" mode started, the controller enable (FUM) signal removed, and "Wrong position control direction" output. Error recovery Rectify the error by interchanging the signal lines. eee cass et rans rene sees To change the counting direction, reverse A/A\ and B/B\. | To change the counting direction, reverse A* and B*. Proceed as follows: > Switch off the 24 V power supply for the IP 266. > Remove the encoder cable from the module. > Reverse the signal lines as shown in the table above. Reconnect the encoder and switch on the 24 V supply. => The module once again checks the position control direction, switching off its position control monitor when the check produces a correct result. When the "Follow-up" mode is exited, the position control monitor is reenabled and is not disabled again until the new check produces a correct result. A Caution Whenever you replace an encoder, always remember to switch off the module's 24 V power supply. Only then can the modules position control monitor detect an incorrect position control direction. EWA 4NEB 812 6057-02a 2-19Technical Description of the IP 266 IP 266 2.8 Technical Specifications The general technical specifications include standards and test specifications which the IP 266 meets and fulfills and which were used during testing of the IP266. UL/CSA Approbations The following approbations have been granted for the IP 266: UL-Recognition Mark Underwriters Laboratories (UL) to UL standard 508, Report 116536 CSA Certification Mark Canadian standard Association (CSA) to C22.2 standard No. 142, Report LR 48323 CE-Marking Our products meet the requirements of EU directive 89/336/EEC " Electromagnetic Compatibility" and the harmonized European standards (EN) listed therein: @ 89/336/EEC Electromagnetic Compatibility" (EMC Directive) @ 73/23/EEC Electrical Equipment Designed for Use between Certain Voltage Limits" (Low- Voltage Directive) ce In accordance with the above-mentioned EU directive, Article 10, the EU declarations of conformity are held at the disposal of the competent authorities at the address below: Siemens Aktiengeselischaft Bereich Automatisierungstechnik AUTE 14 Postfach 1963 D-92209 Amberg Federal Republic of Germany Area of Application SIMATIC products have been designed for use in the industrial area. With individual approval, SIMATIC products can also be used in the domestic environment (household, business and trade area, small plants). You must acquire the individual approval from the respective national authority or testing board. Industry EN 50081-2 : 1993 EN 50082-2 : 1995 Domestic Individual approval EN 50082-1 : 1992 Observing the Installation Guidelines S5 modules meet the requirements if you observe the installation guidelines described in the manuals when installing and operating the equipment ( Section 3). 2-20 EWA 4NEB 812 6057-02aIP 266 Technical Description of the IP 266 Power loss Microprocessor Process clock frequency Position controller sampling time Memory EPROM RAM EEPROM Analog output Output signal range Accuracy Digital signal representation Short-circuit protection Reference potential of the analog output signal Cable length Current carrying capacity Pulse input Position decoding Traversing range Input voltages for the tracks Differential inputs Asymmetrical inputs Supply voltage for the encoder (short-circuit-proof, no overload) Input frequency and cable length Symmetrical encoder (5 V) Asymmetrical encoders (24 V) 4.5 Wtyp. iAPx80C188 16 MHz (quartz frequency) 3.75 ms 64 Kbytes 32 Kbytes (not battery backed) 8 Kbytes +10V +0.8% at +10V 13 bits plus sign Yes Analog ground of the power section 32 m shielded 10mA Incremental +32767.999 mm/0.1linch/deg ov 24V 5 V/350 mA 24V/350 mA Max. 500 kHz for a 30 m shielded cable Max. 100 kHz for a 25 m shielded cable Max. 25 kHz fora 100 m shielded cable Input signals 2 pulse trains in quadrature, 1 zero pulse Input currents 5V to RS 422 24V 7.3 mA typ. EWA 4NEB 812 6057-02a 2-21Technical Description of the IP 266 IP 266 Digital inputs Input voltage range Galvanic isolation O signal 1 signal Permissible quiescent current for 0 signal Typ. input current at 24 V Digital outputs Output voltage range Galvanic isolation Max. output current for "1" signal Short-circuit protection Length of shielded cable Supply voltage Logic voltage generated from ext. 24V with switched-mode power supply Power input from 24 V without outputs and 24 V encoder +30V No -30Vto+5V 13 Vto 30V 1.5mA 7.3MA 20 Vto 30V no 100 mA Short-circuit-proof output Max. 100 m 4.7Vt0o5.5V 180 mA typ. 2-22 EWA 4NEB 812 6057-02aIP 266 Technical Description of the IP 266 Notes for the Machine Manufacturer The SIMATIC programmable controller system is not a machine as defined in the EU Machinery Directive. There is therefore no declaration of conformity for SIMATIC with regard to the EU Machinery Directive 89/392/EEC. The EU Machinery Directive 89/392/EEC regulates requirements relating to machinery. A machine is defined here as an assembly of linked parts or components (see also EN 292-1, Paragraph 3.1). SIMATC is part of the electrical equipment of a machine and must therefore be included by the machine manufacturer in the declaration of conformity procedure. The EN 60204-1 standard (Safety of Machinery, Electrical Equipment of Machines, Part 1, Specification for General Requirements ) applies for the electrical equipment of machinery. The table below is designed to help you with the declaration of conformity and to show which criteria apply to SIMATIC according to EN 60204-1 (as at June 1993). Paragraph 4 General requirements Requirements are met in the devices are mounted/installed in accordance with the installation guidelines. Please observe the explanations in "Notes on CE Marking of SIMATIC $5". Paragraph 11.2 | Digital input/output interfaces Requirements are met. Paragraph 12.3 | Programmable equipment Requirements are met if the devices for protection of memory contents against change by unauthorized persons are installed in locked cabinets. Paragraph 20.4 | Voltage tests Requirements are met. EWA 4NEB 812 6057-02a 2-23EWA 4NEB 812 6057-02a3.1 Notes on System Configuration and Installation ....... 3.2 Wiring Arrangement, Shielding and Measures against Electromagnetic Interference ........ecc cece eee eneenee . 3.2.1 Routing of Cables Within and Outside Cabinets .. 3.2.2. Routing of Cables Outside Cabinets ............ 3.2:3 Equipotential Bonding .............cece ee eees ttle dials Sve Slemueraw wee . 3.2.4 Shielding of Cables and Lines .............. eee ase We ew eek es oa 3.2.5 Special Measures for Interference-Free Operation .......... Stata 3.3 Peculiarities of IP 266 Installation ..........0.0005 wpe emesare-eae meant a 3.3.1 Safety 2... cc cece e cece eee sib Wea ta ae eed ate Ace coiee cee ew ee eee reese 3.3.2 Cable Connections onthe IP 266 .............445 pete eee cece eeeee 3.3.3 Module Installation/Removal ..................065 aitiacdon ate ee eraterateras 3.3.4 Replacingthe Position Encoder ....... a sieeve gee eae eaters See tines Www www www Ww Ww aoumhbWwnhy oowon~ EWA 4NEB 812 6057-02aSee ee ee 3-1, Rules for Laying of Line Combinations eee nee eee ee 3-1. Routing of Equipotential Bonding Conductor and Signal Line 3-2. Examples of Securing Shielded Lines with Cable Clamps ... 3-3. Wiring Coils ........... Ww Ww Ww Ww ' SOAS EWA 4NEB 812 6057-02aIP 266 Installation Guidelines 3 Installation Guidelines 3.1 Notes on System Configuration and Installation Since the module is normally used as a component part of a larger system or plant, these notes are aimed at the hazard-free integration of the product in its environment. The following are notes to be observed for the installation and startup of the product: Warning Strictly follow the safety and accident prevention rules that apply in each particular case. @ In the case of equipment with a permanent power connection not provided with an isolating switch and/or fuses which disconnect all poles, a suitable isolating switch or fuses must be provided in the building wiring system (distribution board). Furthermore, the equipment must be connected to a protective ground (PE) conductor. @ Inthe case of equipment operated on the system voltage, make sure that the rated voltage range set coincides with the local system voltage before taking the equipment into operation. @ In the case of equipment operating on 24 V DC, make sure that the proper electrical isolation is provided between the mains supply and the 24 V supply. Use only power supply units to DIN VDE 0551 / EN 60742 und DIN VDE 0160. e Fluctuations or deviations of the power supply voltage from the rated value should not exceed the tolerances specified in the technical specifications, otherwise function failures or dangerous conditions can occur in the electronic modules/equipment. e Suitable measures must be taken to make sure that programs that are interrupted by a voltage dip or power supply failure resume proper operation when the power supply is restored. Care must be taken to ensure that dangerous operating conditions do not occur even momentarily. If necessary, the equipment must be forced into the "emergency off state. e Emergency tripping devices in accordance with EN 60204/IEC 204 (VDE 0113) must be effective in all operating modes of the automation equipment. Resetting the emergency off device must not result in uncontrolled or undefined restart of the equipment. @ Connecting cables and signal cables must be installed in such a way that inductive and capacitive interference has no adverse effects on the automation functions. e@ Automation equipment and operator controls must be installed in such a way that they are adequately protected against unintentional operation. @ To prevent wire breaks on the signal side leading to undefined states in the automation equipment, the relevant hardware and software precautions must be taken in the case of I/O connections. EWA 4NEB 812 6057-02a 3-1Installation Guidelines IP 266 3.2 Wiring Arrangement, Shielding and Measures against Electromagnetic Interference This section covers the routing of bus, signal and supply lines. The purpose of cable routing is to suppress crosstalk between cables laid in parallel. 3.2.1 Routing of Cables Within and Outside Cabinets For electromagnetically compatible routing of cables and lines, it is advisable to subdivide the lines into the following line groups and lay the groups separately. GroupA: Shielded bus and data lines (for programmer, OP, printer, SINEC L1, Profibus, Industrial Ethernet etc.) Shielded analog lines Unshielded lines for DC voltage <= 60 V Unshielded lines for AC voltage = 25 V Coaxial lines for monitores GroupB: Unshielded lines for DC voltage >60 V and=400 V Unshielded lines for AC voltage >25 V and=400 V GroupC: Unshielded lines for DC and AC voltage > 400 V From the combination of individual groups in the following table, you can read off the conditions for laying the line groups. Table 3-1 Rules for Laying of Line Combinations GroupA @ Group B @ @ Group C @ @ Legend for the table: @ Lines can be laid in common bundles or cable ducts. @ Lines must be laid in separate bundles or cable ducts (without minimum clearance). Lines within cabinets must be laid in separate bundles or cable ducts; outside the cabinets but within buildings, they must be laid over separate cable routes with a clearance of at least 10 cm (3.93 in.). 3-2 EWA 4NEB 812 6057-02aIP 266 tnstallation Guidelines 3.2.2 Routing of Cables Outside Cabinets Outside buildings, lay the lines on metal cable trays if possible. Provide the joints between cable trays with an electrical connection and ground the cable trays. When laying lines outside buildings, you must observe the valid lightning protection and grounding measures. The following applies in general: Lightning Protection Where cables and lines for SIMATIC $5 controllers are to be laid outside buildings, you must apply measures for internal and external lightning protection. Outside the buildings, lay your lines either @ in metal conduits grounded at both ends, e in concreted cable ducts with continuously connected reinforcement. Protect the signal lines from overvoltages by means of varistors or e inert gas-filled surge diverters. Fit these protective devices at the cable entry into the building. Note Lightning protection measures always require an individual assessment of the entire installation. For clarification, please consult your local Siemens Office or a company specializing in lightning protection, such as Messrs. Dehn und Shne in Neumarkt both Germany. Equipotential Bonding Ensure adequate equipotential bonding between the connected equipment. EWA 4NEB 812 6057-02a 3-3Installation Guidelines IP 266 3.2.3. Equipotential Bonding Between separate sections of an installation, potential differences can develop if @ programmable controllers and I/O devices are connected via non-floating links, or e cable shields are connected at both ends and are grounded at different parts of the system. Different AC supplies, for example, can cause potential differences. These differences must be reduced by installing equipotential bonding conductors to ensure functioning of the electronic components. The following points must be observed for equipotential bonding: e@ The lower the impedance of the equipotential bonding conductor, the greater is the effectiveness of equipotential bonding. @ Where shielded signal lines are laid between the relevant sections of the system and connected at both ends to the ground/protective conductor, the impedance of the additional equipotential bonding conductor must not exceed 10 % of the shield impedance. @ The cross-section of the equipotential bonding conductor must be rated for the maximum circulating current. The following cross-sections of copper have proved to be satisfactory in practice: - 16 mm for equipotential bonding conductors of up to 200 m (656 ft.) in length - 25 mm? for equipotential bonding conductors of more than 200 m (656 ft.) in length. @ Use copper or zinc-plated steel for equipotential bonding conductors. They must be given a large-area connection to the ground/protective conductor and protect it from corrosion. e@ The equipotential bonding conductor should be iaid so that the smallest possible areas are enclosed between the equipotential bonding conductor and signal lines (see Figure 3-1). Signal line eS SS ees s Equipotential bonding conductor Figure 3-1. Routing of Equipotential Bonding Conductor and Signal Line 3-4 EWA 4NEB 812 6057-02aIP 266 Installation Guidelines 3.2.4 Shielding of Cables and Lines Shielding is a method of attenuating magnetic, electrical or electromagnetic interference fields. Interference currents on cable shields are passed to ground via the shield bar which is electrically connected to the housing. A low-impedance connection to the protective conductor is particularly important so that these interference currents themselves do not become an interference source. Where possible, only use lines with a braided shield. The coverage density of the shield should be more than 80 %. Avoid lines with a foil shield because the foil can be very easily damaged by tensile strain and compression during fitting; this results in reduced effectiveness of the shield. As a rule, line shields should always be connected at both ends. This is the only way to achieve a good degree of interference suppression in the higher frequency region. Only in exceptional cases should the shield be connected at one end only, as this only achieves attenuation of the low frequencies. Single-ended shield connection may be more advantageous when: @ anequipotential bonding conductor cannot be laid; @ analog signals (of a few mV or pA) are to be transmitted; e foil (static) shields are used. With data lines for serial communication, always use metal or metallized connectors. Secure the shield of the data line to the connector case. Do not connect the shield to PIN 1 of the connector. For stationary operation, it is advisable to fully strip the insulation from the shielded cable and connect it to the shield/protective conductor bar. Note In the event of potential differences between ground points, a circulating current may flow through the shield connected at both ends. In this case, install an additional equipotential bonding conductor. EWA 4NEB 812 6057-02a 3-5Installation Guidelines IP 266 Please observe the following points when connecting the shield: @ Use metal cable clamps for securing the braided shield. The clamps must enclose the shield over a large area and provide a good contact (see Figure 3-2). @ Connect the shield to a shield bar immediately after the cable entry into the cabinet. Route the shield as far as the module but do not connect it there again. Figure 3-2. Examples of Securing Shielded Lines with Cable Clamps 3.2.5 Special Measures for Interference-Free Operation Arc Suppression Elements For Inductive Circuits Normally, inductive circuits (e.g. contactor or relay coils) energized by SIMATIC $5 do not require to be provided with external arc suppressing elements since the necessary suppressing elements are already integrated on the modules. It only becomes necessary to provide arc supressing elements for inductive circuits in the following cases: e If SIMATIC S5 output circuits can be switched off by additionaly inserted contactors (e.g. relay contactors for EMERGENCY OFF). In such a case, the integral suppressing elements on the modules become ineffective. @ If the inductive circuits are not energized by SIMATICS5. You can use free-wheeling diodes, varistors or RC elements for wiring inductive circuits. Wiring coils activated by direct current Wiring coils activated by alternating current with diode with Zener diode with varistor with RC element + + | | it Figure 3-3. Wiring Coils 3-6 EWA 4NEB 812 6057-02aIP 266 Installation Guidelines 3.3 Peculiarities of IP 266 Installation 3.3.1 Safety It is absolutely essential to the overall safety concept that the switching elements discussed in the following be installed and matched to your system. @ EMERGENCY STOP switch for shutting down the entire system. e@ Hardware limit switches for restricting the traversing range. These switches initiate a preprogrammed deceleration procedure, and can be connected as NC or NO contacts to the IP 266s digital inputs. e@ EMERGENCY limit switches for a direct shutdown of the power section. These switches are not reached until the hardware switches have been overrun. J Caution The failsafe switches for the power section must be designed as NC contacts (e.g. failsafe shutdown in the event of a wirebreak). Start of End of Na Ha Sa Se He Ne EMERGENCY, STOP Y 0) EMERGENCY STOP Traversing range Test mode function "STOP" Programmer t 1 | ! I 1 i | | | ! 1 Power section |_. snte {| Gi) Nae Emergency limit switch start/end Hap Hardware limit switch start/end Sare Software limit switch start/end Figure 3-4. Linear Axis with Range Limit Switches EWA 4NEB 812 6057-02a 3-7Installation Guidelines IP 266 3.3.2 Cable Connections on the IP 266 A Caution All connections on the IP 266 (inputs, outputs and the 24 V power supply) require shielded cables to ensure noise immunity. 3.3.3 Module Installation/Removail e@ Installation Before installing an I/O module, you must set the bus modules coding element to the module type. Setting the coding element: uN Caution Before installing a new bus module or adjusting the coding element, always remember to switch off the programmable controller. A code digit is imprinted on the frontplate of every I/O module. A white coding pin, which functions as "key", is located on the back of the every module. How this "key" is set depends on the module, and the setting cannot be changed. The bus module is equipped with a counterpart to this key for each slot, a white, rotary coding element which serves as "lock". Using a screwdriver, set the "lock" on the bus module in accordance with the module identifier, The IP 266 can be addressed in the same manner as an analog module in slots 0 to 7. To install the IP, you need a free bus module slot in this range. > Switch on the 24 V power supply for the IP 266. > Hinge the module onto the top of the bus module. > Swing the IP module down toward the bus module. > Press down firmly and screw the IP into place. e@ Removing the IP 266 > Switch off the 24 V power supply for the IP 266! > Set the PLC to STOP! > Switch off the power section! > Disconnect - the cable to the power section from the IP 266s analog output - the programmer cable from the programmer port - the incremental decoder cable from the encoder interface! Loosen the fixing screw on the module! Remove the module from the programmable controller! vw 3-8 EWA 4NEB 812 6057-02aIP 266 Installation Guidelines Note: When the module is disconnected from the supply voltage and removed from the PLC, all data in its RAM is lost. Any data that is to be retained must be saved before disconnecting the module. 3.3.4 Replacing the Position Encoder The steps you must take to remove the encoder for repair or replacement are listed below, and must be carefully observed. Proceed as follows to remove the encoder: > > Switch off the 24 V power supply for the module. Disconnect the encoder cable from the module. Repair the encoder or insert a new one. Connect the encoder and switch on the modules 24 V power supply. The position control monitor is activated when an automatic mode that outputs an analog setpoint greater than 5 V is invoked. The encoder pulses are compared to the setpoint over a period of ten IP cycles. Once the IP 266 has ascertained that the counting direction for setpoint and actual value are in conformance, the monitor is deactivated. LL Caution The modules 24 V power supply must always be switched off before removing the encoder for repair or replacement, as only then can the monitor detect position control errors. Once an encoder has been replaced or repaired and reinstalled, the new position of the zero mark makes reproduction of an old reference point, if any, impossible. EWA 4NEB 812 6057-02a 3-9EWA 4NEB 812 6057-02a4.1 Positioning Methods .........-.+++8> wal eC ea ca Ma SNS ; 4.2 Components of a Position Control System ............00 ee 4.3 = do | 4.3.1 Positioning ..... cece rete eee nee e ene n een e ee eeeeanes 4.3.2. Setpoint, Actual Value and Following Error ............085 4.3.3 Relationships Between ay, Vig ANd Sq. eee eee eee eee eens 4.4 IP 266 Modes ........... cece centre tee e nen eteeeeneeeee bh a hASH - auuu EWA 4NEB 812 6057-02aPositioning Methods .......... Open-Loop Positioning ................ Schematic Diagram for Closed-Loop Positioning Components of a Position Control System ... Principles of Positioning ............0eeceeee seeeee Characteristic of the Following Error During a Positioning Operation . Relationships Between avty, vit) and s(t) (Characteristic of a Positioning Operation) ........... ccc ccccecececceccucseuceccceccee EWA 4NEB 812 6057-02aIP 266 Fundamentals of Positioning 4 Fundamentals of Positioning Positioning means bringing a load to a certain position within a specific period of time, making allowance for force and torque. Various methods are used to perform this task. 4.1 Positioning Methods A drive can be positioned in one of two ways: @ under open-loop control @ under closed-loop control The figure below shows the options available in conjunction with S5-100U programmable controllers. __ ae as Closed-loop control Open-loop control DC drives Tiree phase ae Fixed-speed drives Stepping motors IP266 positioning 385 B high-speed IP 267 positioning module counter module Figure 4-1. Positioning Methods A setpoint generator is required for programmable positioning operations, regardless of whether positioning is in an open or closed loop. The setpoint generator's output variable depends on a number of parameters: e the difference between the current position of the axis and the target position @ speed e acceleration/deceleration EWA 4NEB 812 6057-02a 4-1Fundamentals of Positioning IP 266 Open-loop positioning When positioning under open-loop control, the setpoint generator provides a time-dependent speed or speed setpoint V,.,,(t). This is the voltage used to drive the power section. Drive movement is governed by this voltage. The setpoint generator outputs the setpoint voltage until the drive has reached the target position. During positioning, the setpoint generator is not informed of the current position. There is thus no guarantee that the drives final position is identical to the required target position. Target position Speed Vact(t) Acceleration ! Setpoint generator Measuring transducer M: Motor T: Tachogenerator Vr: Tacho voltage Figure 4-2. Open-Loop Positioning 4-2 EWA 4NEB 812 6057-02aIP 266 Fundamentals of Positioning Closed-loop positioning When positioning under closed-loop control, the drives current actual position is compared with the setpoint position computed by the setpoint generator. The difference between these two values is fed to the position controller, which supplies a voltage setpoint. This setpoint is proportional to the positioning speed. During positioning, deviations are picked up and fed continually to the position controller, thus enabling precise positioning. Following a positioning operation, the final position is maintained. The position controller is able to detect disturbances and compensates any positional! deviations. <_ |IP266 -<_ Poweer section (control) motor and pu Ise generator > Sact(t) Vv Y~ Position i Speed C- : > J 3) Actuator M controller : controller A : + Power section Setpoint generator Target position Speed Acceleration Figure 4-3. Schematic Diagram for Closed-Loop Positioning EWA 4NEB 812 6057-02a 4-3Fundamentals of Positioning IP 266 4.2 Components of a Position Control System The IP 266s position controller enables precise positioning of the drive. The following components are required for a position control system: Pewsey TT Mains | poten nnn o enn 1 p Power; PUT Teen 7 ; Generalcontrol |; Pome t tate " \ t----4 | Safetydevice [--74 facilities 17-1 Operator console | be. 4 i i bene 4 I I I 4: t IP 266 position Speed controller i P i with static | controller i converter ' t 4 Controller initialization 1 1 Movement ' =] i py . Power section Mechanical Position measuring 0 COM 266 transmission system elements Figure 4-4. Components of a Position Control System @ Power section The power section is driven via the IP 266s analog output, and comprises rotational speed controller and static converter. e Motor The power section drives the motor in accordance with the directives from the IP 266. @ Mechanical transmission elements In addition to the axis, the mechanical transmission elements include gears and coupling systems. @ Position measuring system The position measuring system measures movement. An incremental position encoder supplies the IP 266 with pulses. The number of pulses is proportional to the path travelled. e I/O The term "I/O" is used collectively for all other auxiliary facilities. The most important of these are - the limit switches used to limit the traversing range - the programmer used in conjunction with the COM 266 software to service the IP 266. 4-4 EWA 4NEB 812 6057-02aIP 266 Fundamentals of Positioning 4.3 Terms 4.3.1 Positioning Positioning means bringing a load to a defined position within a specific period of time, making allowance for force and torque. I F ____- | ! | uv i< ax _> PositionA Position B Ax = Distance to be travelled F = Driving force Figure 4-5. Principles of Positioning 4.3.2. Setpoint, Actual Value and Following Error Execution of a positioning operation requires specification of e the target coordinate e@ acceleration and deceleration rates @ positioning velocities. Based on this data, the IP 266 computes a theoretical speed characteristic. An ideal drive system would directly follow this characteristic. The IP 266 provides a voltage value at its analog output which is proportional to the theoretical speed characteristic. This value is referred to as the setpoint, and is computed by the IP 266s setpoint generator. Driven by the power section, the drive travels a specific path. !n accordance with the distance traversed, the position encoder generates a number of pulses which are evaluated by the IP 266's input section. The actual position of the drive is computed from the pulse count and the value for the encoder resolution. This value is called the actual value. The difference between the setpoint S,,.(t) and the actual value S,q(t) is referred to as the following error As: AS = Scotplt) - Sacelt) EWA 4NEB 812 6057-02a 4-5Fundamentals of Positioning IP 266 Figure 4-6 shows the characteristic of the following error during a positioning operation. Sy A a = Setpoint characteristic b = Actual characteristic Figure 4-6. Characteristic of the Following Error During a Positioning Operation 4.3.3 Relationships Between ay), vq) and Sq In order to position to a defined target, the drive must be moved at a specific speed. The iP 266 computes the acceleration and deceleration rates from the machine data. The result is the basic characteristic of a positioning operation. A a) 0 > Vit) S(t) Accele- Constant speed Decele- ration ration Figure 4-7. Relationships Between ait), vi) and s(t) (Characteristic of a Positioning Operation) 4-6 EWA 4NEB 812 6057-02aIP 266 Fundamentals of Positioning The slope of the speed ramp is a measure of the acceleration rate. It is specified in the unit [m/s2], and is generally obtained from the following equation: Vv a= t The IP 266 takes into consideration only a constant acceleration or deceleration rate for each direction. This results in a linear equation for speed Vy). v=aet The unit for speed is [m/s]. The drives path is then computed from the speed curve. In the sections with constant acceleration or deceleration, the path traversed has a parabolic time characteristic In the sections with constant speed, the path is computed as follows: s=vet 4.4 IP 266 Modes In order to compute the setpoint variables S,p(t) and Vyer,(t) correctly, the IP 266 requires data which provides a complete description of the drive system. This data is stored in the modules RAM, and is referred to as machine data. A mode may be @ asequence of motions @ acoordinate shift e@ amachining program call A machining program can be stored on the IP 266 to enable automatic execution of a sequence of motions or special functions (such as dwell or zero offset). EWA 4NEB 812 6057-02a 4-7EWA 4NEB 812 6057-02a5.1 Machine Data .......... 5.1.1 Hardware Description ... 5.1.3 Traversing Range ....... 5.1.4 Speeds ......ceeseeeees 5.1.5 Acceleration Rates ...... 5.1.6 ControllerParameters .. 5.1.7 Correction Parameters .. 5.1.8 Miscellaneous Parameters 5.2 Modes and How to Invoke 5.3 IP 266 Modes ........... 5.3.1 Jog 1(Mode1) ......... 5.3.2 Jog2(Mode2) ......... 5.3.4 Follow-Up Mode (Mode 4) 5.3.27. Synchronize IP (Mode 99) 5.4.4 Syntax Diagram of a Block 5.3.15 Enable Tool Offset (TO) (Mode 15) 5.3.16 Disable Tool Offset (TO) (Mode 16) .........se cece eee cece eee eneee 5.3.17. Acknowledge Error (Mode 17) .......... cece cece enn eee eeneeeees 5.3.18 Enable Drift Compensation (Mode 18) ..........ccce eee eee e en enenee 5.3.19 Disable Drift Compensation (Mode 19) ..........c cece cece cece e eens 5.3.20 Transferring Machine Data (Mode 20) .......--...-.eeee eee e eee eees Cee ee ee ee ee ee ee) 5.1.2 Position Decoding and Resolution ..........cc cece eee eee e eee eeee Pe ee ee ee ee eee eee eee ee Pe ee ee ee THEM: ieevesesctcw sms nnewiawreseneaenans eee eee eee eee eee he eee eee ee he eee eee 5.3.3 Jog under Open-Loop Control (Mode 3) 0... ..eeeeee eee ereeereeee eee eee eee ee 5.3.5 Set/Approach Reference Point (Mode 5) .......... ese cece eee eeeees 5.3.6 Increment Mode Absolute (Mode 6) ............ ccc ece cece ence ees 5.3.7 Increment Mode Relative (Mode 7) ..........-.cseeeeeee eee eeeeees 5.3.8 Automatic Mode (Mode 8) .......- eee e eee cece cence scene eneeeees 5.3.9 Automatic Single Block (Mode 9) ...........:-ceee ence eee rene eeees 5.3.10 Enable Teach-In(Mode 10) ..........ccc eee e eee ne tence ee eeereeeeee 5.3.11 Disable Teach-In (Mode 11) ........ ccc cece ese e eee e eee eeeeeeeeee 5.3.12 Absolute Zero Offset (ZO) (Mode 12) 2... .. ccc cece ener ee eee eee eees 5.3.13 Relative Zero Offset (ZO) (Mode 13) .........cc cece cence eee eens 5.3.14 Delete Zero Offset (ZO) (Mode 14)... 22... cece cece cece e cette eens eee eee ee ee ee ee 5.3.21 EEPROM (Mode 26) .......cccceee cece cece e cence eee ee eee eneeneens 5.3.22 Unrestricted Speed Specification (Mode 31) .......-----ee-eeeeeeees 5.3.23 Reading Out the Unrestricted Speed Specification (Mode 32) ........ 5.3.24 Disabling the Monitors (Mode 33) .........ceeee eee ene eweneeennees 5.3.25 Enabling the Monitors (Mode 34) 2.2.22... . cece eee ence wenn eee nenes 5.3.26 Information Modes (Mode 71, Mode 72, Mode 73) ...........--2000. eee ee eee eee ee 5.4 Elements of the Traversing Program ..........eeceeeeeeeeeeeeeeneee 5.4.1 Program Header ......... 2c cece cece cece eee ete e tent eee eee eenes 5.4.2 THAVETSING BIOS oicieiie ccesiecn cain scersewinewe esses wee mnmeeiens 5.4.3 Last Block .sccses ts cee tewaaees cee eee wane en cee wereedeeienmewn we Pee ee 17 19 19 22 22 23 24 32 34 36 37 38 41 41 44 45 46 49 49 50 52 52 56 57 59 60 61 62 63 63 64 65 80 81 EWA 4NEB 812 6057-02a5-3. 5-10. 5-11. 5-12. 5-14. 5-15. 5-16. 5-17. 5-18. 5-19. 5-20. 5-21. 5-22. 5-23. 5-24. 5-25. 5-26. 5-27. 5-28. 5-29. 5-30. 5-31. 5-32. 5-33. Encoder Signal Evaluation Linear Axis with Range Limit Switches (not to scale) Rotary Axis, Programmable in mm/inch/deg ..........0..0cceceeeee 5 - Acceleration and Deceleration of the Drive System in Both Directions ...... Maximum Deceleration Rate on Abort of a Traversing Movement ............. Control Response of the Position Controller in Dependence onthe Kv Factor ........... cc cc ceccecececesuceeecece 5- 11 Following Error in Dependence on Setpoint and Actual Value... ... cl cece cece nce c census ecucuccuceuvucecees 5 - 11 Using a Zero Offset 2.0... cece cece cence ceneceececencunves. 5 - 13 Backlash Outside the Control Loop (compensatible) ................. 5 - 15 Format of an Operator Command .............ccccececccccucucccee 5 - 19 Initiating a Mode ....... 0... cece ccc c eee caeccneceecucencencens 5 - 20 Controlling the Traversing Speed via the Override Factor ........ ccc ccc ccc n ce cueceesuetececcucecuveucucs 5 - 21 Drive Starting Positions for a Reference Point APProach .... cece cece cece cece cena vee eecereecucusvsnenacnece 5 - 25 Principle of the Reference Point Approach in ExampleA ............. 5 - 26 Reference Point Approach inExampleB ..........ccccccecccccecee. 5 - 27 Reference Point Approach inExample C ........ ccc cccccecuccccceee 5 - 28 Reference Point Approach inExampleD ............cccccceecceeeee 5 - 29 Deceleration at Different Deceleration Rates ................2-.-... 5 - 30 Reproducibility of the Reference Point for Reference Point Coordinate 0 ........ 0... ccc cec ccc cccecuceccecccee 5 - 31 Absolute Target Specification in Mode6 ............ecccceceececcee 5 - 32 Relative Target Specification ......... cc... ccccseccecceeccuccuuccs 5 - 35 The Use of Speeds in Mode 10 ....... 0... cece cece ccceccucecccccen 5 - 39 Zero Offset in Mode 12 ........... ccc cccscaccncaccncucucececccecus 5 - 43 Zero Offset fora Rotary Axis .......... cc cc cececcecucucusecucccecee 5 - 43 Relative Zero Offset with Different Values ............ccecccee0-e.. 5 - 45 Voltage - Speed Characteristic with Drift Compensation ......... cece cece cece cece seccessavetaceeucucecucs 5 - 51 Erroneous Following Error Characteristic in Conjunction with Drift Compensation ............cccecececcecccee. 5 - 51 Format of the Program Header ......... 0. ccc cececececececccecuce. 5 - 64 Traversing of a Rotary Axis with Backlash .. 2.0.00... ccc cececeuceee 5 - 71 Overview of Tool Offsets 22.0.0... cc cece cece ceccuceveucucuccccecs 5 - 74 Using Zero Offsets ..... 0... cee cece ccc cencceenecenteenceucenccee 5 - 75 Overview of Zero Offsets ........ 0. ccc ccc ceccecceccucucucucceceu. 5 - 77 Syntax Diagram of aBlock ..........c cece cee ceeccececucuueucececs 5 - 81 wm ' SAO EWA 4NEB 812 6057-02a5-1. IP 266 Machine Data ...........ccccccceeceee reece een eeneeeaenees 5 - 5-2. Speeds for Jog Mode ......-. eee e eee e cree eee e eect ersten eeeeeenes 5 - 5-3. Coordinate Shift as Consequence of a Zero Offset ..........002 eee eee 5 - 5-4. Positioning Modes with and without Position Control .............-- 5 - 5-5. Overview of Available Modes .............ccce cence cece eeeeeneeeee 5 - 5-6. Prerequisites for the Reference Point Approach (Examples Ato D) .......ccccccceccescersceeceecssenseeeeeenssaese 5 - 5-7. Drive Performance in Absolute Increment Mode ...........0eeeeeeee 5 - 5-8. Permissible Functions in Absolute Increment Mode" ..........+++++ 5 - 5-9. Determining the Direction of Travel in Relative Increment MOde 20... 006s ean accccewecccneesenneesreceecnsennesees 5 - 5-10. | Using the Forward Function in Mode 7 .......-. cece reece eee eees 5 - 5-11. Interruption Points in a Traversing Program in Mode9 ........+-+-++ 5 - 5-12. TargetSpecification in Mode 10 ........-..6 22sec eee eee eee eeeee 5 - 5-13. Generating a New Traversing Program in Mode 10 ....-..-..-+--+-+: 5 - 5-14. IP 266 Zero Offset Options .........cc cece cece eee cece ene e eee eaeeee 5 - 5-15. Coordinate Changes Produced by a Zero Offset ...........-eeeeeeeee 5 - 5-16. Coordinate Changes Produced by a Tool Offset ..........--.eeeeeees 5 - 5-17. Data for Calibrating the Power Section ......... cece eee seen eee eeee 5 - 5-18. | Machine Data with Parameters Entered inBytes4to7 .......---.+.. 5 - 5-19. Machine Data with Parameters Entered inByte2 .......-...5.eeeuee 5 - 5-20. Functionsina Traversing Block .........2cceee eee e cece nee e eee e eens 5 - 5-21. Permissible G Functions .......ccceceeeeeee erence etree eee eeneenaes 5 - 5-22. Tool Offset .......: cece ccc cece eee e cette teense neers eee eeeeeneee 5 - 5-23. Effectof Function G53 2... ccc ccc c cece cere reer eee eee e tent eeeeneee 5 - 5-24. Preselecting Dimensions ...........sccceeeeenecereeenceeteneeeees 5 - 5-25. Using the F Function in Traversing Blocks ......-.---2eeeeeeeeeeeees 5 - EWA 4NEB 812 6057-02aEWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs 5 Machine Data, Modes and Traversing Programs The IP 266 can execute positioning operations only when it has correct machine data at its disposal. You cannot start a positioning operation until you have provided the IP with this data. The machine data and all permissible parameters are discussed in detail in Section 5.1. In Section 6, you will find information on how to enter these values and transfer them to the IP 266. 5.1 Machine Data The machine data describes the properties of e thedrive system, e@ the position encoder, @ andthe position controller. The IP 266 needs machine data in order to compute the correct speed and path. Errored data can therefore result in an unpredictable or incorrect system response. You can also enter machine data values for coordinate shifts and corrections which are needed, for instance, if tool dimensions change. Table 5-1 shows you which items of machine data you need for different tasks. The table also provides cross-references to the sections describing these data items. EWA 4NEB 812 6057-02a 5-1Machine Data, Modes and Traversing Programs IP 266 Table 5-1. IP 266 Machine Data Module Section 5.1.6 Zero-speed monitoring Hardware 1to99 description Axis type linear, rotary Section 5.1.1 Pos. decoding Unit of measure mm, in, deg and resolution | Encoder type 5V,24V Travel per encoder revolution 0.001 to 400.000 | [mm;0.1 in;deg] Section 5.1.2 | Pulses per encoder revolution 1 to 65 000 [pul] Machining Software limit switch-start (linear axis) + 32 767.999 [mm;0.1 in;deg] range Software limit switch-end (linear axis) + 32 767.999 [mm;0.1 in;deg]} Start of traversing range (rotary axis) + 32 767.999 [mm;0.1 in;deg]} End of traversing range (rotary axis) + 32 767.999 [mm;0.1 in;deg] Section 5.1.3 | Reference point + 32 767.999 [mm;0.1 in;deg] Speeds Maximum speed 1 to 65 000 Forward speed for JOG 1 1 to 65 000 es mn Reverse speed for JOG 1 1 to 65 000 Forward speed for JOG 2 1 to 65 000 [Ate 0.1 a Reverse speed for JOG 2 1 to 65 000 min Incremental speed 1 to 65 000 deg Reference point approach speed 1 1 to 65 000 [se | Section 5.1.4 | Reference point approach speed 2 1 to 65 000 Acceleration Maximum deceleration rate 10 to 9 999 0.1 in Deceleration Forward acceleration 10 to 9 999 [== m [ae A] Forward deceleration 10 to 9 999 Reverse acceleration 10 to 9 999 [= r | Section 5.1.5 | Reverse deceleration 10 to 9 999 . Controller Servo gain (kv) factor 0.1 to 99.9 [1/s] parameters Maximum following error 0.001 to 99.999 | [mm;0.1 in;deg] Monitoring of the following error on, off 0.001 to 64.999 [mm;0.1 in;deg]} Correction Zero offset 1 + 32 767.999 [mm;0.1 in;deg]} parameters Zero offset 2 + 32 767.999 [mm;0.1 in;deg] Zero offset 3 + 32 767.999 [mm;0.1 in;deg] Zero offset 4 + 32 767.999 [mm;0.1 in;deg] Tool length compensation + 32 767.999 [mm;0.1 in;deg] Section 5.1.7 | Backlash compensation 0.000 to 64.999 | [mm;0.1 in;deg} Miscellaneous Reference point direction forw, rev parameters PLC BCD-coded yes, no Polarity of the hardware limit switches Pos, neg Section 5.1.8 | IP stop on CPU stop yes, no 5-2 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs 5.1.1 Hardware Description Module To distinguish between the IP 266 modules in a PLC, you can assign each IP a number between 1 and 99. Axis type This machine data item is used to specify either a rotary or a linear axis. A linear axis has a restricted traversing range, which must be limited via hardware limit switches. Start. point = End point There is no limit to the traversing range of a rotary axis. On each revolution, the axis goes from the starting point to the end point. The values assigned for these points specify the traversing range of the axis. Both points are at the same physical position. One complete revolution of the axis does nothing more than change the actual value indication from the start value to the end value of the traversing range. 5.1.2 Position Decoding and Resolution Unit of measure You may use one of the following units of measure on the IP 266 for all positional specifications: e@ Metricsystem with 0.001 mm as base unit e@ Inch with 0.001 inches as base unit e Degree with 0.001 degrees as base unit A base unit is the smallest unit that may be entered as the unit of measure. The specified unit of measure also applies to @ speeds e acceleration rates and @ encoder resolution if you have chosen [deg] as the unit of measure, the speed is specified in [deg/min]. Encoder type You may connect the following types of encoder to the IP 266: e@ Encoders with symmetrical 5 V output signals e Encoders with asymmetrical 24 V output signals The encoder type is specified in the machine datas Encoder type" parameter. In order to ensure precise measuring of the drive's current position, you must use an encoder whose resolution meets with your specific requirements. Two items of data are needed to compute the resolution: e@ Travel per encoder revolution and e Pulses per encoder revolution Travel per encoder revolution The "travel per encoder revolution" depends on your drive system, and should take accurately into account all transmission elements, such as couplings and gears, which are located between the motor and the incremental encoder. EWA 4NEB 812 6057-02a 5-3Machine Data, Modes and Traversing Programs IP 266 Pulses per encoder revolution The "pulses per encoder revolution" can be found in the data sheet for your encoder. Resolution The IP 266 distinguishes between two resolution types: e@ External resolution is calculated from the actual technical specifications of the connected components. The IP 266 processes an external resolution of 0.4 to 400.0. @ internal resolution is calculated from the external resolution on the basis of the internally used quadruple evaluation over factor 0.25. Travel per encoder revolution [pm] [9.0001 inch] [0.001 deg] Resolution IP/p5u1] [0.0001 inch/ py] [0.001 deg/puil Use the following formula to compute the : Travel per encoder revolution resolution: A= Pulses per encoder revolution When dimensioning your system, you must therefore ensure that the internal resolution never falls below the value 0.1. This means that a minimum external resolution of 0.4 is dictated by the external hardware. Comparison of the resolution types Internal resolution External resolution Path/revelution O1< < 100 o4< Path/revolution A09 Pulses/revolution Pulses/revolution Special characteristics of the rotary axis: To enable reproducibility of the reference point when using a rotary axis, the ratio between the full machining range and the distance travelled by the drive during one encoder revolution must be an integer number. Example: Traversing range: 0 to 360 During one encoder revolution, the rotary table revolves 20. The ratio of these two values must be an integer number. Rotary table @ Gear __e Encoder - 360 =1 Motor @ 20 5-4 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs Example 1: An incremental encoder generates 1000 pulses 5 mm per revolution. During this time, the reference |A= point on the axis travels a distance of 5 mm. 1000 pul The resolution is thus: A= 5 pm/pul Example 2: in your drive system, you are using an encoder that generates 1000 pulses per revolution. You are using a rotary axis, and have initialized it in [deg]. During one encoder revolution, the drive moves 10 degrees. Based on these values, the encoder resolution computes to the following: 10 deg 1000 pul A= 0.01 deg/pul A= A= 10:0.001 deg/pul Example 3: The table below lists a number of examples of permissible and impermissible parameter values: Imm [pm] a 5000 0.200 | [P/pu)) e 200deg | [0.001 deg] 1000 200 | [9-001 deg/,,.)] 40deg _| [0.001 deg] 500 so | [0-001 deg/,,4] e 10 in [0.0001 in] 1800 55.56 | [9-0001 in/,,.] 100 in {0.0001 in] 2000 500 | [0.0001 in/.,)] EWA ANEB 812 6057-02a 5-5Machine Data, Modes and Traversing Programs IP 266 Encoder direction of rotation The direction in which the encoder revolves is ascertained from the encoders two signals, which are displaced from each other by 90 deg. SP; bY PLP LT LE LL Le Le peepee epee hp Pb bed abbey aie Pe >! a Signal A leading _ 54, _ Signal B leading _> t 90 The direction changes at this point Figure 5-1. Encoder Signal Evaluation 5.1.3. Traversing Range Software limit switches (linear axis only) The software limit switches are used to define the traversing range of your drive. In a fully configured drive system, the software limit switches define the internal boundaries of the traversing range. Start of End of machine Tae machine Traversing range N,/N_: Emergency limit switches start/end Deceleration distance S g, (power section) Clearance distance X Ha/He: Hardware limit switches start/end Sa/S_e: Software limit switches start/end Figure 5-2. Linear Axis with Range Limit Switches (not to scale) Note: The software limit switches are active only when a valid reference point is set. Target specifications outside the traversing range are not processed. The drive is decelerated at the software limit switches. Different values may be specified in the machine data for forward and reverse deceleration. 5-6 EWA 4NEB 812 6057-024IP 266 Machine Data, Modes and Traversing Programs Start/end of traversing range (rotary axis only) Start/end of traversing 4 p ran e (mm suet >) 100mm 110mm O 10mm Figure 5-3. Rotary Axis, Programmable in mm/inch/deg in the case of a rotary axis, the values define the limits of the display range. The start and the end of the traversing range are at the same physical location. At the range limits, the display changes e fromthe start value to the end value or e fromthe end value to the start value depending on the direction of rotation. Absolute target specifications must lie within this range, while relative specifications may exceed it. The hardware limit switches remain in force as additional protection for the drive system. Reference coordinate The reference point is used to calibrate the axis. its location can be specified via the "Set/Approach to reference point" mode (see Section 5.3.5). The "reference coordinate" machine data parameter is used to assign a value to this position. The value must lie within the maximum range limits. When you define the reference point coordinate, you also define the following coordinates: e coordinate basic origin e software limit switches You can make absolute target specifications only in a system with a defined reference point. EWA 4NEB 812 6057-02a 5-7Machine Data, Modes and Traversing Programs IP 266 5.1.4 Speeds The speeds specified in the machine data define the true speeds of the drive system, and depend on e@ the motor rotational speed e@ the number of encoder pulses per revolution e@ the travel per encoder revolution The absolute values for all speeds must be less than or equal to the maximum speed. Input values must be in the range from 1 to 65,000. Depending on the parameter assignments, the IP expects values in [mm/min], [deg/min] or [0.1 inch/min]. Maximum speed Under IP 266 control, the drive reaches the maximum speed with a setpoint of +10V. /\ Caution The maximum speed must be computed from the technical specifications for the complete drive system (motor, axis, encoder, and so on). Jogging speed For jog mode, you must define four speeds in the machine data. Table 5-2. Speeds for Jog Mode oe Forward Jog 1 Jog 2 Reverse Jog 1 Jog 2 These four parameters define the speeds for modes Jog 1 and Jog 2. The specifications for Jog 2 also apply for "Controlled jog", i. e. jogging under open-loop control. Incremental speed The incremental speed is used as the positioning speed in e@ incremental feed mode absolute @ incremental feed mode relative When a traversing program is generated in TEACH-IN mode, this speed is taken over into the new program. 5-8 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs Reference point approach speed The IP 266 takes recourse to two speeds in order to determine the reference point. To enable a purposeful reference point approach, you should specify two different speeds. Section 5.3.5 explains how these speeds are used. A Caution Reference point approach speed 1 must be greater than reference point approach speed 2. 5.1.5 Acceleration Rates In order to reach the speed initialized for the specified mode, the drive must accelerate. The following five values may be entered in the machine data: e@ Maximum deceleration rate Forward acceleration rate Forward deceleration rate Reverse acceleration rate Reverse deceleration rate The absolute maximum deceleration rate must be greater than or equal to all other acceleration or deceleration rates. This deceleration rate is used to stop travel @ whenthe drive has reached a hardware limit switch or @ whenan external Stop command was issued. The values must be in the range from 10 to 9 999. The entry must be in [mm/s2], [deg/s2] or [0.1 inch/s2]. Example 1: This example illustrates the use of the various acceleration and deceleration rates in normal operation. @ Forward acceleration @ Reverse acceleration @ Constant speed forward Constant speed in reverse @ Reverse deceleration Reverse deceleration Figure 5-4. Acceleration and Deceleration of the Drive System in Both Directions EWA 4NEB 812 6057-02a 5-9Machine Data, Modes and Traversing Programs IP 266 Example 2: When the drive reaches a hardware limit switch, it decelerates at the maximum deceleration rate. This is also the case when an external Stop command is issued. - Hardware limit switch or external Stop Viev @ Forward acceleration @ Constant speed forward @ Maximum deceleration Figure 5-5. Maximum Deceleration Rate on Abort of a Traversing Movement 5.1.6 Controller Parameters Kv (servo gain) factor The IP 266 uses a proportional-action controller (P controller) for position control. The only parameter a P controller needs is the servo gain factor Kv. The unit for the Kv factor is [1/s]; the value range is from 0.1 to 99.9 [1/s]. The higher the Kv factor, the better the control loops dynamic response. Z\ Caution An excessively high Kv factor results in e oscillation, @ instability and @ animpermissibly high machine load 5-10 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs The maximum Kv factor depends on e thedrives design or dynamic response and e@ the quality of the machine. VA Jn Vsetp eV Setpoint characteristic Kv factor too high system oscillates Kv factor adequate optimum controller initialization Kv factor too low controller too slow; setpoint is reached very slowly ance Figure 5-6. Control Response of the Position Controller in Dependence on the Kv Factor For best results, start with a very low initial value (1 to 2 1/,) as the basis for subsequent optimization. Maximum following error The difference between the actual position and the setpoint position is called the following error. A field is provided in the machine data for specification of the maximum following error, which must be in the range from 0.001 to 99.999. If the following error exceeds the specified value, the IP 266 aborts the positioning operation and displays "Maximum following error exceeded" on the programmer. The position controller remains active. The axis does not come to a stop until the following error has been brought back into range. Setpoint characteristic Actual characteristic a b As: Following error tp: Start of positioning t;. The following error has reached its maximum range limit 2 t>: Following error is brought t back into range 1 fom aeote ND ! | bo | t = Figure 5-7. Following Error in Dependence on Setpoint and Actual Value EWA 4NEB 812 6057-02a 5-117Machine Data, Modes and Traversing Programs IP 266 The following error changes in direct proportion to the traversing speed in accordance with the following equation: v As = ky [mm] If the actual value stops changing during a positioning operation, for instance because @ the encoder failed or e@ the power section was switched off, the following error continually increases. AS = Sset - Sact The driving voltage for the power section increases in proportion to the increase in the following error. If the voltage exceeds 5 V, the current operation is aborted with "Position control loop interrupted". The IP 266 automatically switches to follow-up mode, a mode in which the position controller is disabled. Following error monitoring You can choose between "ENABLE" and "DISABLE". If you choose "DISABLE", the following error is no longer monitored and may therefore exceed the maximum value of 99.999. Zero-speed monitoring The IP 266s "Zero-speed monitoring" function also monitors the following error (difference between actual value and setpoint). In contrast to following error monitoring, zero-speed monitoring is effective only when the drive is at a standstill. Because the following error is expected to be very small when the drive is at zero speed, the value range is more closely restricted, being only from 0.001 to 64.999. When this function has been activated, the error message "Zero-speed monitor responded" is displayed on the programmer. Aside from this error message, there is no further reaction of any kind. Note: The tolerance limit for zero-speed monitoring may not exceed the maximum following error. 5-12 EWA 4NEB 812 6057-028IP 266 Machine Data, Modes and Traversing Programs 5.1.7 Correction Parameters Too! wear necessitates adjustments to the plant or the program. These adjustments can be made via various correction parameters. The use of zero offsets makes it possible to invoke a subroutine in the traversing program for performing similar or identical positioning operations. Example: Using a zero offset (ZO) 0 10 20 40 | | 7 @-@ Jy 2a| 20 = <i 50 | I 1 T I I I -@-1-+ f A. yo | { 50 2nd ZO 20 A v 90 1 3rd ZO I | 1 Figure 5-8. Using a Zero Offset Zero offset (ZO) A zero offset makes it possible to match the coordinate basic origin to different conditions. You must enter four values ("0" is also allowed) in the machine data for zero offsets 1 to 4. These values need not be identical. Entries not within the traversing range are reported with an error message. Also note that e thesoftware limit switches e the reference point and e theactual value are recomputed when a zero offset is used. When you enter the data, remember that all coordinates must be within the permissible range (refer to the following example). The zero offset values are available only to the programmable ZOs in traversing programs (see Section 5.4). If you want to specify another zero offset, you must use modes 12 and 15. EWA 4NEB 812 6057-02a 5-13Machine Data, Modes and Traversing Programs IP 266 Example: Table 5.3 contains absolute position values. The "Before" column shows the positions that were current prior to a ZO. A relative zero offset of - 400 mm renders the actual value, the software limit switches and the reference point more positive by 400. As you can see in Table 5-3, this measure puts the software end limit switch out of range. Tool offset (TO) The tool offset is a coordinate shift, and is used to compensate for tool wear. The maximum value for a tool offset depends on the axis used. The value specified in the machine data can be called up from a traversing program only via G functions for positive or negative tool offsets (see Section 5.4). Value range: + 32767.999 mm The sum of the coordinate values for e@ software limit switches and e tool offset must be in the range + 32767.999 mm. Note: Invocation of a tool offset does not result ina traversing movement. Use mode 15 if you want to implement a tool offset other than the one defined in the machine data. Following a tool offset, the coordinate system is displaced by the value of that tool offset, i. e. the values become more positive by the value of the tool offset. You will find two detailed examples showing the use of tool offsets in the part of Section 5.3.15 that describes the tool offset mode. Backlash compensation Play in the drive system is referred to as backlash. On each reversal of the direction of movement, the backlash causes the motor to rotate without changing the position of the axis. Backlash outside the position control loop can be compensated. When the direction of movement is reversed, the IP 266 makes allowance for the backlash. 5-14 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs * Backlash ZIT TLV // L:O:O:@ Displayed actual value increases ) Reversal of direction tn ' Actual value display remains constant y, : " 7 although the encoder is generating LILLLL) : TLL (m) (T) CY pulses => axis passes through the back- es lash Backlash =! a [1] After traversing the path = backlash p value, the actual value display shows the ZLZLZL/ PTDL T REM OED) actual value to be on the decrease 1 1 >. Axis movement around the backlash M: Motor T: Tachogenerator PL : Incremental encoder Figure 5-9. Backlash Outside the Control Loop (compensatible) Conditions for correct operation: e Positive mechanical coupling between drive and slide - when adistance > backlash value is traversed. @ Reference point has been approached - when the distance to zero mark recognition is > backlash value. e Following a drive movement within the permissible play of the backlash (follow-up mode), the conditions for correct operation are no longer fulfilled. A positive mechanical coupling must be reestablished between the drive and the slide. @ Overswing can also resuit in loss of positive mechanical coupling. This is possible when the overswing movement caused the distance traversed to be less than the backlash. Overswing can be avoided by reducing the Kv factor. EWA 4NEB 812 6057-02a 5-15Machine Data, Modes and Traversing Programs IP 266 5.1.8 Miscellaneous Parameters Direction of the reference point approach To enable exact reproducibility, the reference point must always be approached from the same direction. The direction is selected by specifying "forw" for forward or "rev" for reverse. Note: Specification of the direction is crucial to the reproducibility of the reference point (see Section 5.3.5). PLC BCD-coded You must enter "yes" in this field when you want to enter the positioning specification data in BCD format. Entries in BCD code must be in the range 9 999.999 mm. Actual value, distance to go and following error, when monitored, are also output in BCD code. Polarity of the hardware limit switches The hardware switches and the IP 266 "External Stop" may be designed as NO or NC contacts. You must enter the identifier for NO or NC in the machine data. Enter pos to identify the switches as NO contact. Enter "neg" to identify the switches as NC contacts. IP STOP if CPU STOP If you enter "YES", the operation in Progress when the CPU stops is aborted. 5-16 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs 5.2 Modes and How to Invoke Them The IP 266 provides a large variety of options for positioning, coordinate shifting and positional corrections. These options are grouped under the term "modes". The available modes can be divided into the two basic categories @ open-loop positioning and e closed-loop positioning Table 5-4 lists the modes belonging to each of these two categories. Table 5-4. Positioning Modes with and without Position Control Output ofaconstant | Setpointoutput = 0V | Approach toa Command- Bring coordinate speed setpoint + drift voltage specific target initiated for- system to a defined position; traversing | ward/reverse state a specific distance travel Controlled jog Follow-up mode Increment mode Jog 1 Approach to reference absolute point Increment mode Jog 2 relative Automatic mode eee ft UROL block mode In addition to the modes listed above, a number of information modes are also available. These include modes 71 to 73, which provide information on the status and position of the drive. EWA 4NEB 812 6057-02a 5-17Machine Data, Modes and Traversing Programs IP 266 The table below provides an overview of all IP 266 modes and a section reference for each. You can call up these modes @ fromthe PLC's CPU via a STEP 5 program or e fromthe programmer via the COM 266 software An appropriate indication is given in the descriptions of those modes, which cannot be invoked on the programmer. Table 5-5. Overview of Available Modes 1 | Jog1 5.3.1 16 | Disable tool offset 5.3.16 2 | Jog2 5.3.2 17 | Acknowledge error 5.3.17 3 | Controlled jog 5.3.3 18 | Enable drift compensation | 5.3.18 4 | Follow-up 5.3.4 19 | Disable drift compensation | > 5.3.19 5 | Set/approach to ref. point | > 5.3.5 20 | Transferring machine data | > 5.3.20 6 | Increment mode absolute | > 5.3.6 26 | EEPROM<>!P 266 5.3.21 7 | Increment mode relative 5.3.7 31 | Unrestricted speed 5.3.22 specification 8 | Automatic mode 5.3.8 _ 32 | Reading out the 5.3.23 9 | Automatic single block > 5.3.9 unrestricted speed 10 | Enable teach-in mode 5.3.10 specification 11 | Disable teach-in mode 5.3.11 33 | Disabling the monitors > 5.3.24 12 | Zero offset absolute 5.3.12 34 | Enabling the monitors > 5.3.25 13 | Zero offset relative = 5.3.13 71 | Read actual position > 5.3.26 14 | Delete zero offset >5.3.14 72 | Read following error 5.3.26 15 | Enable tool offset 5.3.15 73 | Read distance to go 5.3.26 99 | Synchronize IP 5.3.27 5-18 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs 5.3 IP 266 Modes A mode is invoked on the IP 266 by entering an operator command. An operator command comprises three elements: the mode, the parameters, and the keystroke representing the function. When you select a mode, you choose a function. After entering the required parameters, you start the mode by choosing the function. Figure 5-10 shows the elements comprising an operator command. In the following sections, each mode description is preceded by a diagrammatic line showing the available options for the operator command for that mode. Operator command Mode Parameters | Function Y Example: Jog 1 Override 1 to 200% Forw/Rev/Stop/Exec Mode Parameters Function Figure 5-10. Format of an Operator Command 5.3.1 Jog 1 (Mode 1) Jog 1 Override 1 to 200% Forward/Reverse/Stop/Exec -- Mode Parameters Function The drive can be positioned at a constant speed. The IP 266 uses jog speed 1 from the machine data for this purpose. Please remember that you must specify two speeds in the machine data for this mode, i. e. forward jog speeds 1 and reverse jog speeds 1. Forward speeds and reverse speeds need not be identical. After selecting the mode, start the positioning operation by entering the function "Forward" or "Reverse". in COM 266, the functions are actually keystrokes. Each function is allocated to a specific function key, and a function is "entered" by pressing the function key to which it is assigned. EWA 4NEB 812 6057-02a 5-19Machine Data, Modes and Traversing Programs IP 266 Figure 5-11 illustrates a positioning operation in the "Jog 1" mode. "Forward" starts the positioning operation. "Stop" initiates a defined deceleration procedure. The "Reverse" function is executed as soon as the drive reaches zero speed, as it was issued while deceleration was still in progress. A direct change from Forward to Reverse is permitted. Forward A Cc] = : as : t Reverse A: A | eo bi t stop | 7] ii t | : eV Figure 5-11. Initiating a Mode The drive moves at 100% of the specified speed, "Stop" initiates a defined deceleration procedure. You can vary the speed with the Override factor. The IP 266 permits entry of an Override factor of from 1% to 200% of the specified speed. Note: Theoretically, an excessively high Override factor could result in the drive exceeding the maximum speed. In this case, the IP 266 Positions at maximum speed and flags the discrepancy on the monitor's error line. If you want to change the speed during travel, simply forward the appropriate Override factor to the IP 266. Change the Override factor in the COM screen form or in the output frame (PLC > IP 266). > Press "Exec". => The drive accelerates or decelerates ata steady state to reach the new positioning speed. The IP 266 takes the - acceleration rate or - deceleration rate from the machine data. 5-20 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs Vv 100 % i : 200% : 50% Override factor V | | j | sy Execkey t Figure 5-12. Controlling the Traversing Speed via the Override Factor Override factor A change in the override factor during an acceleration or deceleration phase is rejected. The job is aborted with the fault message F82 (Inadmissible order). Execution of the current job, however, is not affected. Astop during an acceleration or deceleration phase, however, is executed immediately. Vv Velocity characteristic, with stop job Overrideisrejected Velocity characteristic, without stop job EWA 4NEB 812 6057-028 5-21Machine Data, Modes and Traversing Programs IP 266 5.3.2. Jog 2 (Mode 2) Jog 2 Override 1 to 200% Forward/Reverse/Stop/Exec Parameters Function Mode J In essence, the "Jog 2" mode is identical to the "Jog 1" mode. The machine data contains two speed values for this mode: @ Jog 2 forward speed e Jog 2 reverse speed The jog speeds for jog mode 1 and jog mode 2 need not be identical. 5.3.3 Jog under Open-Loop Control (Mode 3) Jog under Op.- Override 1 to 200% Forward/Reverse/Stop/Exec Loop Contol Mode Parameters Function In this mode, axis travel is under open-loop control. Computation of the setpoint position is disabled when this mode is started with @ "Forward" or e@ "Reverse" The setpoint position is now matched to the actual position. The result is a following error of zero. The setpoint position is matched at the speed defined in the machine data for Jog 2 mode. This value can be varied from 1 to 200% via the Override factor. The speed computed from the encoder signals is displayed on the programmer. If you invoked mode 73 before starting Jog 2 mode, the distance to go is displayed. Note: The IP 266 needs correct data for the drive system (encoder, axis) to attain the speed displayed. Incorrect machine data will result in incorrect computation of the actual value. If the power section is correctly calibrated, the speed displayed and the actual speed are identical. The functions e@ "Forward" e "Reverse" and @ "Exec" are the same in mode 1. "Stop" decelerates the drive at the specified deceleration rate until it has reached zero speed. When the axis has reached zero speed, the position control loop is once again closed and the axis is positioned under closed-loop control. 5-22 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs 5.3.4 Follow-Up Mode (Mode 4) Follow-up Mode Start/Stop Function Like mode 3, mode 4 is a controlled mode. Invoke mode 4 with "Start". The IP 266 executes the following operations: => - Computing of the position setpoint is disabled - The position setpoint is corrected to the actual position - Actual-value acquisition remains enabled. The speed controller is thus driven with a setpoint of 0 V + drift compensation. Adrift compensation value is taken into account only when mode 18 was previously started. You can adjust the position of the axis either @ manually after switching off the power supply for the power section or @ via an external speed setpoint. The coordinate system is not affected. The speed controller can be reenabled at any time. Note: lf your drive system is not free from backlash, care must be taken that the drive be adjusted by at least the value of the backlash, regardless of whether the adjustment is made manually or via an external speed setpoint, as only then can it be guaranteed that a positive mechanical coupling will be maintained after the adjustment has been made. "Stop" terminates the mode. The axis returns to the closed-loop state. Mode 4 is also enabled on a response from the IP 266s encoder monitor. In this case, a setpoint of 0 V is output. When you have rectified the error, stop mode 4. The controller is reenabled, as is the position contro! monitor. EWA 4NEB 812 6057-02a 5-23Machine Data, Modes and Traversing Programs IP 266 5.3.5 Set/Approach Reference Point (Mode 5) Reference point | Set/Approach Start/Stop_| Mode we Parameters Function This mode is used to synchronize the IP 266s pulse counter with the drive system. Synchronization of drive and pulse counter is necessary e to enable an approach to an absolute target position @ to enable evaluation of the software limit switches @ to invoke modes 6, 8,9 and 10 and @ because the reference point is lost following power-up When this mode is invoked, the IP 266 assigns the coordinate value specified under "reference coordinate" in the machine data to the axis position. Note: Zero offsets and tool offsets that were in force before the reference point was assigned are not affected. The IP 266 provides two options for establishing a reference point: e@ Approach reference point e@ Setreference point Approach reference point When you configured the drive, you installed a reference point switch. The reference point switch must lie in the positioning range between the two hardware limit switches. This switch is required for the "Approach reference point" mode. Note: Hardware limit switches cannot be used as reference point switch. Figure 5-13 illustrates the use of the various switches and their layout ina drive system. 5-24 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs From the instant at which a switch is actuated until the instant at which it is passed, the drive moves a specific distance. This distance, or path, is represented as the spatial extent of the switches. This extent is absolutely necessary for the correct functioning of the system. The drive must be so designed that it can be decelerated from the maximum speed without passing the switch. Forward (actual value increases) fal el 6 << Range of the linear axis Nave: Emergency limit switches start/end A: Possible drive Have: Hardware limit switches start/end B: positions prior toa Save: Software limit switches start/end Cc: reference point Ref: Reference point switch D: approach Figure 5-13. Drive Starting Positions for a Reference Point Approach Before approaching a reference point, you must make a distinction between four different situations. The criteria for making this distinction are @ the position of the drive prior to the reference point approach (position A, B, C or D) e@ thedirection from which the reference point is approached The four examples below describe a reference point approach in dependence on the starting position of the drive. The prerequisites listed in Table 5-6 apply to all four examples. Table 5-6. Prerequisites for the Reference Point Approach (Examples A to D) TT = see ake 2 Direction of reference point approach Reverse Reference point approach speed 1 2000 mm/min Reference point approach speed 2 200 mm/min Reference point coordinate 0.000 mm EWA 4NEB 812 6057-02a 5-25Machine Data, Modes and Traversing Programs IP 266 Example A: The drive is in front of the reference point switch. Start the reference point approach with "Start". The drive then executes the following movements in succession: 1. 2. 3. First, the axis accelerates in a forward direction, the IP 266 accelerating it at the specified acceleration rate. The drive thus accelerates toward the reference point switch. When reference point speed 1 has been reached, the drive continues at a constant speed. The movement is decelerated when - the drive has reached the reference point switch and - this switch is once again opened. When the drive has come to rest, the IP 266 changes the direction of the reference point approach (to reverse). The drive again accelerates until it reaches reference speed 1. When the edge of the signal from the reference point switch goes to 1, the IP 266 decelerates the drive to reference speed 2. An edge change from 1 to 0 in the signal from the reference point switch sets an internal Enable signal. When this signal is set, the IP 266 waits (while the drive is moving at reference speed 2) for the next zero mark pulse from the encoder. This signal is present only once during each encoder revolution. A change of the zero mark signal from 0 to 1 sets the reference point. The reference point coordinate specified in the machine data is assigned to this position. At the same time, the IP 266 decelerates the drive until it reaches zero speed. The actual value is detected and displayed. When the drive is at zero speed, the actual value is lower (i. e. more negative) than the reference point coordinate. ey View i I I I i I 1 | I 1 : i Start : 1 : I I I i I I I 1 ! I I Enceders zero mark T] T] [] > R: Reference point Ha/He: Hardware limit switches start/end Position of the drive: Vir Reference speed 1 A: Prior to the reference point approach V2: Reference speed 2 B: After the reference point approach Figure 5-14. Principle of the Reference Point Approach in Example A 5-26 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs Example B: The drive is positioned to the reference point switch \v : R 8 y Iv. Encoders zero mark i \: V2 / s v R: Reference point Figure 5-15. Reference Point Approach in Example B This represents a special feature of the "Approach reference point" mode. Start the reference point approach with "Start". The drive then executes the following movements: 1. The IP 266 accelerates the drive immediately in the specified direction until it reaches reference speed 2. 2. A change from 1 to 0 in the signal from the reference point switch sets an internal Enable signal. When this signal is set, the IP 266 waits for the next zero mark pulse from the encoder. A change of the zero mark signal from 0 to 1 sets the reference point. The reference point coordinate specified in the machine data is assigned to this position. At the same time, the IP 266 decelerates the drive to zero speed. The actual value is acquired and displayed. When the drive is at zero speed, the actual value is lower (i. e. more negative) than the reference point coordinate. EWA 4NEB 812 6057-02a 5-27Machine Data, Modes and Traversing Programs IP 266 Example C: The drive is behind the reference point switch. V rev Encoders zero mark | | R: Reference point Figure 5-16. Reference Point Approach in Example C Start the reference point approach with "Start". The drive then executes the following movements: 1. 2. 3. First, the IP 266 accelerates the axis in a forward direction at the specified acceleration rate. The drive is thus accelerated toward the hardware end limit switch. When it has reached reference speed 1, the drive moves at constant speed, When the limit switch is reached, the IP 266 decelerates the drive at the specified deceleration rate. . When the drive reaches zero speed, the IP 266 switches it into reverse, again accelerating it until it reaches reference speed 1. . When the edge of the signal from the reference point switch goes from 0 to 1, the IP 266 decelerates the drive to reference speed 2. - An edge change from 1 to 0 in the signal from the reference point switch sets an internal Enable signal. When this signal is set (the drive is moving at reference speed 2), the IP 266 waits for the next zero mark pulse from the encoder. A change from 0 to 1 in the zero mark signal sets the reference point. The reference point coordinate specified in the machine data is assigned to this position. At the same time, the IP 266 decelerates the drive to zero speed. The actual value is acquired and displayed. When the drive is at zero speed, the actual value is lower (i. e. more negative) than the reference point coordinate. 5-28 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs Example D: The drive is positioned to the hardware end limit switch. vy V rev Encoders zero mark [ | v R: Reference point Figure 5-17. Reference Point Approach in Example D Start the reference point approach with "Start". The drive then executes the following movements: 1. The IP 266 accelerates the axis in a reverse direction at the specified acceleration rate. The drive is thus moved toward the reference point switch. 2. When it has reached reference speed 1, the drive moves at a constant speed. 3. When the edge of the signal from the reference point switch goes from 0 to 1, the IP 266 decelerates the drive to reference speed 2. 4. An edge change from 1 to 0 in the signal from the reference point switch sets an internal Enable signal. When this signal is set (the drive is moving at reference speed 2), the IP 266 waits for the next zero mark pulse from the encoder. A change in the zero mark signal from 0 to 1 sets the reference point. The reference point coordinate specified in the machine data is assigned to this position. At the same time, the IP 266 decelerates the drive to zero speed. The actual value is acquired and displayed. When the drive is at zero speed, the actual value is lower (i. e. more negative) than the reference point coordinate. EWA 4NEB 812 6057-02a 5-29Machine Data, Modes and Traversing Programs IP 266 Actual-value display following a reference point approach The reference point is set when the position encoders zero mark signal goes from 0 to 1. At the same time, the drive is decelerated. The drive moves a distance of X away from the reference point, the value of X depending on the specified deceleration rate and on reference speed 2. The distance X varies in dependence on the specified deceleration rates. If the drive is to come to rest exactly at the reference point, it must be set to this Position with the "Increment mode absolute" following termination of the reference point approach. VA V2 81,42, 43: Deceleration values V2: Reference point approach speed 2 _ let x P--->-- > i Encoders zero mark Figure 5-18. Deceleration at Different Deceleration Rates Reproducibility of a reference point In order to be able to use the traversing programs without any modifications even after an IP 266 power failure, it must be possible to reproduce the coordinate zero point exactly. This can be done when you make the next reference point approach from the same direction. A change in the direction of reference point approach shifts the coordinate zero point. You can thus define two different zero points. The distance between them depends on the "width" of the reference point switch (see Figure 5-19). Note: If you replace an encoder, the old reference point cannot be reproduced because of a change in the position of the zero mark. 5-30 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs Forward SS Reference point switch Encoders zero mark a A ED Location of the co- ordinate zero point A fem Ptr | 1 tottbkebeppd : when the reference : 3~direction is reverse -2 -1 1 2 5 9 i Location of the co- ordinate zero point | | when the reference ct tt [ TT direction is forward 5 Bay A Figure 5-19. Reproducibility of the Reference Point for Reference Point Coordinate 0 Set reference point Mode 5 allows you to set a reference point without moving the axis. To do so, select the "Set" function in mode 5. By invoking this function, you can set the reference point at an arbitrary axis position. The value specified in the machine data is then assigned to this position. Tool offsets and zero offsets that existed before this mode was started will still be taken into account. Note: A reference point set with the "Set reference point" function is not reproducible. Only when there is positive mechanical coupling can this function be used in drive systems that are not backlash-free. The backlash is lost when the reference point is set. In this case, you must establish a positive mechanical coupling by traversing a distance greater than the value of the backlash. EWA 4NEB 812 6057-02a 5-31Machine Data, Modes and Traversing Programs IP 266 9.3.6 Increment Mode Absolute (Mode 6) Linear axis Override 1 to 200% Increment mode absolute Absolute target Start/Stop/Exec position L_____. Parameters _ Mode Function This mode allows you to specify a target position in absolute coordinates. The target position is approached at incremental speed, without regard to the starting position of the drive. You can vary the incremental speed between 1 and 200% by specifying an Override factor. ==> A< J. j i j } | } = q i T t ' 1 tT t pao t t ; 0 -10 0 10 20 30 40 50 60 70 80 90. 100 dee t l ' Coordinate zero point Figure 5-20. Absolute Target Specification in Mode 6 Before you can use this mode, e@ the reference point must be set and @ the absolute target position specified must lie within the positioning range of the software limit switches. Example for Figure 5-20 You start mode 6 with the following parameters: e@ Override 100% e@ Absolute target coordinate: 30 mm Table 5-7. Drive Performance in Absolute Increment Mode Se as ee : cs ee : : Starting point A must be locatedin front | The drive moves forward to the specified target In the example, 50 of defined absolute target position B Position at 100% incremental speed. mm forward Starting point C must be located behind The drive moves in reverse to the specified target In the example, 40 defined absolute target position B position at 100% incremental speed. mm in reverse 5-32 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs Rotary axis Override 1 to 200% Increment mode absolute | Absolute target position Parameters Start/Stop/Forward/Reverse /Exec Mode Function The IP 266 responds differently to "Start" when the axis is rotary rather than linear. It computes the shortest possible path to the target position, and positions the axis accordingly. If the distance is the same in both directions, the forward direction (clockwise) has priority. Backlash is not taken into account. If the axis is already at the target position, no movement is made, i. e. only the displacement of the object to be positioned is taken into account, not that of the motor. The "FORWARD" and "REVERSE" functions can also be invoked in this mode. The table below lists the permissible functions in absolute increment mode for both rotary and linear axes. ers START Approach to target over the shortest possible path | Approach to absolute target position STOP Exit mode FORWARD Approach to target in forward direction (clockwise). If the axis is already at the target position, the entire range is traversed once. REVERSE Approach to target in reverse direction (counter- clockwise). If the axis is already at the target position, the entire range is traversed once. EXEC Change the speed via the Override factor when the axis is "traversing". EWA 4NEB 812 6057-02a 5-33Machine Data, Modes and Traversing Programs IP 266 5.3.7. Increment Mode Relative (Mode 7) Override 1 to 200% Distance Parameters Increment mode relative Forward/Reverse/Stop/Exec Mode Function This mode differs from mode 6 primarily as regards specification of the target position; in this mode, you specify the target coordinate in relation to the cu rrent position of the drive. As in mode 6, the incremental speed can be varied by specifying an Override factor. Prerequisites when a reference point has been set: The resulting target coordinate must lie between the two software limit switches. When you use this mode without having set a reference point, the target position may lie anywhere within the range of the two hardware limit switches. The positioning direction depends on e the first function selected in this mode and e@ thesign of the position specification Table 5-9 shows how the direction of travel is determined. Table 5-9. Determining the Direction of Travel in Relative Increment Mod cara : eS : se ranean saa ee ea 2 oa e a se 5 ee = a Positive Forward Forward Negative Forward Reverse Positive Reverse Reverse Negative Reverse Forward 5-34 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs Example: Relative increment mode is to be invoked at starting positions A (-10 mm) and B (60 mm). Forward 5 ! I | | | | J I J 1 T 1 q 1 qT q 1 q -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 1 1 1 I ! l ' 1 Reference point Reference point Figure 5-21. Relative Target Specification > Youstart mode 7 with the parameters - Override 100%, - Distance: +30mm and the "Forward" or Reverse function. = Based on the starting positions in Figure 5-21, the table below shows the resulting values: Table 5-10. Using the Forward Function in Mode 7 ee pane a se Ac -10 mm +30mm +20mm B>D +60 mm +30mm +90 mm EWA 4NEB 812 6057-02a 5-35Machine Data, Modes and Traversing Programs IP 266 5.3.8 Automatic Mode (Mode 8) Automatic mode Program number Start/Stop Mode Parameters Function A traversing program (TP) is started in automatic mode. Before you can start a traversing program, you must write it and store it on the IP 266 (see Section 5-4). The program may contain @ positioning operations @ coordinate shifts @ corrections and @ dwells. The IP 266 executes all programmed operations in succession. You run the program by invoking the Start function. Program execution always begins with the first block in the program. The Stop function aborts the program. Any zero offsets invoked during program execution are retained, i. e. they are not reset. Zero offsets are reset only when the program executes in its entirety. In automatic mode, enabled tool offsets are retained after the program terminates or is aborted. If a traversing program processes a rotary axis, it is preset for traversing to the target position over the shortest possible path. Because the IP 266 itself computes the shortest path, and thus the direction of travel, you must be aware of the possible results of a flying change; if you have programmed a flying change, you must know in advance whether such a change is permissible or whether it will result in an error. Note: A machining program that was aborted with Stop cannot be resumed at the point of interruption. The remaining distance to go is retained until the next positioning operation. Interruption of the traversing program via the "External Start Enable" signal is possible. If a positioning operation or dwell is currently in progress, it is completed prior to interruption of the program. When the signal is enabled, i. e. when the signal level is "1", the traversing program is resumed at the point of interruption. 5-36 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs 5.3.9 Automatic Single Block (Mode 9) Automatic single block Program number Start/Stop/Exec Mode 1 Parameters Function Traversing programs written for mode 8 can be used without modification in mode 9. Before starting the mode, enter the number of the traversing program you want to execute. Start the mode by selecting the "Start" function. The IP 266 interrupts program execution prior to every positioning operation or dwell. Start the next job with "Exec". As in mode 8, an "External Start Enable signal can interrupt the traversing program. if a positioning operation or dwell is in progress, it is completed prior to the interruption. The IP then awaits the "Exec" command. When you have pressed "Exec", absence of the * External Start Enable" signal is flagged with an error message. When the signal is enabled, i. e. becomes "4" the traversing program is resumed at the point of interruption. "Exec" is not permitted at this point, and would abort the traversing program. Interruption points in a traversing program in single block mode Table 5-11 lists the points at which a program is interrupted. ie : = = oe = rbencrehae Blocks containing a flying change N10 G10 X1000 F100 M10 Blocks are treated as a single block. No (G10 function) N20 X2000 F500 interruption takes place. Blocks containing a flying change N10 G10 X 1000 F100 M00 Blocks are executed separately. The (G10 function) and a programmed | N20 X2000 F500 program is interrupted stop (MOO function) immediately preceding the X2000 function. Blocks containing N10 X100 F1000 M10 The program is not aborted until changes, N20 G56 X200 F1000 M11 function G56 has executed, i. e. just corrections or prior to the new positioning offsets operation. Blocks containing a programmed stop (function M00) A programmed stop (M00) is suppressed in mode 9. Exception: The block containing the M00 function also contains the G10 function. EWA 4NEB 812 6057-02a 5-37Machine Data, Modes and Traversing Programs IP 266 5.3.10 Enable Teach-In (Mode 10) Enable teach-in | Program number Start Mode Parameters eee Function This mode is used to create a new traversing program for @ automatic mode @ automatic single block mode Prerequisites to the use of this mode: @ The new traversing program must be assigned a number that has not already been assigned to another program. @ The IP 266s RAM must contain valid machine data. e The reference point must be set. @ There must be enough room in the IP 266s RAM for the new program. Enter a program number that is not yet on the module. A traversing program with this number is then generated on the IP 266. Each block in the new program has the same structu re, and comprises three elements: @ Block number @ Target position @ Speed Block number The blocks are numbered (see Section 5.4) in ascending order, beginning with N01. The third block thus has the number N03. Target position You can approach a target position in various modes. A new block is not written until you press Exec while the drive is at zero speed. Table 5-12. Target Specification in Mode 10 by approaching it in The modes can be started by selecting one of the following mode 1 functions: mode 2 Forward Reverse Start by entering the coordinate in Exec if you want to iin the override mode 6 : mode 7 5-38 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs Speed You can specify a new target position in modes 1, 2/3, 6 and 7. This allows positioning to take place at the speeds specified in the machine data. You can vary these speeds via an Override factor, thus enabling extremely exact positioning. Incremental speed 100% is always entered for each traversing program block generated in teach- in mode. The figure below illustrates the use of the various speeds. Positioning to a speci- fic target using various modes Speed specified in the machine data Selection of the actual 3 speeds via the Over- 50% 200% ride factor 1000 m/_ 2500 / 4 but at no more than V imax Following transfer to the block Entry in the traversing incremental speed 100% : 2500/,,,, program Figure 5-22. The Use of Speeds in Mode 10 Exception: An error occurs in the position control loop in "Teach-in" mode. In this case, the IP 266 starts mode 4on its own initiative. You must then carry out the following steps: e Terminate mode 4 by selecting the "Stop" function e Terminate the Teach-in" mode with mode 11 EWA 4NEB 812 6057-02a 5-39Machine Data, Modes and Traversing Programs IP 266 Example: Generating a new traversing program in "Teach-in" mode: The table below lists the actions you must take. Start at the top of the table and work down. The entries in the "Axis status" column indicate the state of the axis after the relevant key has been pressed. Table 5-13. Generating a Ne ere IT - w Traversing Program in Mode 10 panne : Pree ; Program 7 is generated on the Stopped Arbitrary Prog. no. 7 module Mode 1 Forward Move axis forward at 20% of jog Travers- Variable in Override 20% speed 1 ; ing accordance with movement Mode 1 Exec Change the speed to 50% of jog Travers- Variable Override 50% speed 1 ing Mode 1 Stop Decelerate Travers- Variable ing E.g. Zero speed Stopped 1258.250 mm ae . Ue ea rela a eae ee eet PTE Mode 1 Exec Store as block =| Stopped 1258.250 mm 3 NO1 X1258.250 F2500 Mode 6 Start Move to absolute target position Travers- Variable Abs. target pos. wee a- 29 4 3000 mm Decelerate at position 3000 mm Stopped 3000 mm Mode6 Exec Store as block 2 Stopped 3000 mm NO2 X3000 F2500 Ss si 5-40 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs 5.3.11 Disable Teach-in (Mode 11) Disable teach-in Mode Start Function This mode disables teach-in (mode 10). Prerequisites: Mandatory: Mode 10 was started. Recommended: The creation of positioning blocks in mode 10. End block Nnn M02 is entered in the machining program. nn is the block number. The value of Nnn depends on the current length of the traversing program. 5.3.12 Absolute Zero Offset (ZO) (Mode 12) Absolute zero offset Absolute coordinate Start Mode Parameters IL. + Function AZO is used to assign new coordinates to a drive system. A ZO transforms all coordinates for e thereference point and e thesoftware limit switches and checks them for validity. No reference point need be set when this mode is invoked. An "Absolute zero offset" assigns the value of the "Absolute coordinate parameter to the actual value. This value is referred to in the following as ZO, or zero offset. Actvalnew = ZO The zero point is offset by the value ZO - Actvaloig The "Invalid position specification" error message is displayed if the maximum range is exceeded. Note: If mode 12 is restarted, the old ZO is replaced by the new ZO. The IP 266 also provides other options for specifying a zero offset. The available options are listed in Table 5-14. EWA 4NEB 812 6057-02a 5-41Machine Data, Modes and Traversing Programs IP 266 12 Assigns a coordinate value to the current actual position. This coordinate value is displayed on the programmer as the new actual position. 13 Offsets a coordinate value by a specifiable value G54 to G57 | Offset ina traversing program by the values specified in the machine data. These offsets are reset when the traversing program is exited. Once set, a zero offset is retained until @ itis overwritten by a new value @ reset via mode 14 or @ the modules power supply is switched off. Note the following when specifying a zero offset: Negative offset: - Offset = 32767.999 - |Software end limit switch] Positive offset: Offset = 32767.999 - |Software start limit switch| Example: The drive is at the absolute position 50 mm. This position is to be offset in succession by 400 mm, -200 mm and 0 mm. > Select mode 12. > Enter the coordinate value for the new actual position. > Start the mode with the "Start" function. > Repeat the sequence for each zero offset. = The coordinate system must "respond" as shown in Figure 5-23. You can control the response by viewing the actual-value displays. 5-42 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs ZO 400mm { Vv 350 400 ZO -200 mm {| : -250 -200 ~ ZO Omm {| i i > -50 0 s [| = Limit switches (software, hardware, emergency end switch) Figure 5-23. Zero Offset in Mode 12 Rotary axis: When using a rotary axis, you may specify an absolute zero offset value outside the boundaries of the positioning range. Example: A continuous belt has a positioning range of 0 to 200 mm. The current actual position is 150 mm. An absolute zero offset of 300 mm changes the coordinate system => The current actual position is now 300 mm. The positioning range starts at 150 mm and the end of the positioning range is 350 mm. The coordinate system was thus offset by the value ZOaps- Actvalotd From this point on, all absolute target specifications must lie within the new positioning range limits. Absolute ZO 300 mm Act. position 0 mm = PS Act. position 150 mm = PS 150 mm 200 mm = PE 300 mm 350 mm = PE PS = Start of positioning range PE = End of positioning range Figure 5-24. Zero Offset for a Rotary Axis You will find an overview of all zero offsets in those portions of Section 5.4 which deal with G functions G53 to G57. EWA 4NEB 812 6057-02a 5-43Machine Data, Modes and Traversing Programs IP 266 5.3.13 Relative Zero Offset (ZO) (Mode 13) Relative zero offset Value Forward/Reverse Mode Parameters 1 Function In contrast to mode 12, this mode allows you to specify the direction of the offset by selecting the Forward or "Reverse" function. You can also, of course, specify the offset direction by signing the offset value. This mode does not require that a reference point be set. The true direction of a zero offset is determined by e@ thesign of the offset value and e@ theselected function. Each time this mode is started, the zero offset is summated as shown in Figure 5-15. A zero offset can be reset only via mode 14 or by power off". Note: An absolute zero offset overwrites a relative zero offset. Table 5-15. Coordinate Changes Produced by a Zero Offset ian the valu . - - ; ae net dinat sh come . Positive Forward more negative Negative Forward more positive Positive Reverse more positive Negative Reverse more negative The new actual value thus computes to @ = Actvalnew = Actvalgig - ZO when the direction is "Forward" @ = Actvalnew = Actvaloig + ZO when the direction is "Reverse" Example: The drive is at the absolute position + 150 mm. Zero offsets of 300 mm, - 200 mm, - 150 mm and 50 mm are to be carried out in succession. > Select mode 13. > Enter the value for the offset, including the sign. > Start the mode with the "Forward" or "Reverse" function. The function specifies the direction of the offset. Repeat the sequence for each of the zero offsets. => The coordinate system must respond as shown in Figure 5-25. 5-44 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs Note: when you enter the offset value. If you want to start the mode with the "Reverse" function, you must invert the sign Actual value }+}+_+_+_+__ +__+ > -50 0 150 390 ZO 300 forw. ly : }+__+_+_+_+_ +4 > -350 = -300 : -150 0 ZO -200 forw. I : : {t+ +-__+__+_++ > -150 -100 0 50 200 ZO -150 forw. I : : i | j j i J J ! T 1 1 I t I | cael 0 50 200 350 ZO -50 reverse I : : | al l 1 ; 1 1 1 I 1 1 I I 1 1 = -50 0 150 300 $ Figure 5-25. Relative Zero Offset with Different Values 5.3.14 Delete Zero Offset (ZO) (Mode 14) Start Function l Delete zero offset Mode This mode deletes (resets) all zero offsets that were set @ viamode 12, @ via mode 13 and @ via G functions (in prematurely aborted traversing programs). EWA ANEB 812 6057-02a 5-45Machine Data, Modes and Traversing Programs IP 266 3.3.15 Enable Tool Offset (TO) (Mode 15) Enable tool offset Offset Forward/Reverse Mode +. Parameters Function This mode is used to compensate for changes in the tool length caused e. g. by tool wear. Prerequisites for a tool offset: @ Valid machine data on the IP 266 e@ The offset value must lie within the maximum range. This mode does not require a reference point. The direction of the tool offset is determined by e thesign of the offset value and @ the Start function ("Forward" or "Reverse") Table 5-16. Coordinate Changes Produced by a Tool Offset Positive Forward more positive Negative Forward more negative Positive Reverse more negative Negative Reverse more positive Following a tool offset, the position of the new tool tip is always displayed as actual position. The tool offset is taken into account when a target position is specified. The range of the software limit switches is recomputed following a tool offset. Use the following formulas as basis for specification of a tool offset: In a negative direction: - Tool offset = 32767.999 - |Software end limit switch| In a positive direction: Tool offset = 32767.999 - [Software start limit switch] The IP 266 does not execute a tool offset outside the permissible range limits. 5-46 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs Example: Tool offset with mode 15 Adrilling program used to drill a hole 15 mm in depth is to carry out the following steps: Move the drill to the start position Switch on the drill Drill feed 15 mm Return drill to the drilling position Switch off the drill Move the drill to the start position au PWN The longer the drill is used, the more the drill depth decreases. When the drill reaches a length of 40 mm, it can no longer drill a complete hole. The drill tip remains in the workpiece. A tool offset shifts the coordinates. After being set to the starting position (100), the drill can once again drill a complete hole. Actual po- sition on sitios sores TO = -10mm TO and posi- tioning Location of the drill tip onstart Final Z position Location of the drill tip when the final drilling osition as been reached Location of the drill tip when the final - drilling position has been reached Workpiece is no longer com- pletely drilled EWA 4NEB 812 6057-02a 5-47Machine Data, Modes and Traversing Programs IP 266 Example: Tool change and TO When the tool has reached a length at which a tool offset is no longer possible, it must be replaced. The new tool is 10 mm too long. This can be compensated for via a tool offset, thus fulfilling the prerequisites for the automatic drilling sequence. Tool change, TO and Actual po- Positioning | =e sition on start feeteeeeeeseeerenses * TO=10mm ~ Location of the drill tip on start Final position Location of the drill tip when the final drilling position has been reached Example: The traversing range of a linear axis lies between the software limit switches; a reference point has been set. Software start limit switch: -500 mm Software end limit switch: 700 mm Traversing range is from - 500 mm to 700 mm. Following a tool offset of 100 mm in a forward direction, these limits change as follows: Software start limit switch: -400 mm Software end limit switch: 800 mm The new range limits must be taken into account when specifying absolute target positions. You will find an overview of all TO options in Section 5.4.2 under the heading "G Functions". Rotary axis The tool offset value must always be less than the difference between the end of the traversing range and the start of the traversing range. If the value is too high, it is rejected and an error message displayed. A tool offset value that is within the permissible range modifies the actual position by the tool offset value. This does not affect the traversing range, which maintains its original range limits. 5-48 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs Example: Oto 360 0 to 360 Disable tool offset Mode Start Function This mode resets all tool offsets that were set via @ mode i5or eG functions in the traversing programs Mode 16 cancels all tool offsets, i. e. you cannot use this mode to revoke the tool offset that was set via mode 15 while retaining the tool offset that was set via G functions. 5.3.17 Acknowledge Error (Mode 17) Start Function Acknowledge error Mode Parameters == Errors occurring during operation or during IP 266 start-up may have a number of different causes, such as @ operator input error @ external event (such as tripping of a limit switch) @ incomplete installation (e. g. machine data not complete) e@ errors in machine data Mode 17 is used to acknowledge an error. Aside from mode 17, you can acknowledge an error only by starting another mode. You cannot acknowledge an error by invoking an info (i. e. monitoring) mode. EWA 4NEB 812 6057-02a 5-49Machine Data, Modes and Traversing Programs IP 266 5.3.18 Enable Drift Compensation (Mode 18) Start Function Enable drift compensation Mode Prerequisite to correct operation of the IP 266 is a properly calibrated power section (see Table 5-17). Table 5-17. Data for Calibrating the Power Section = +10V rotates in the forward direction at the rated speed -10V rotates in the reverse direction at the rated speed xt0V is at zero speed These conditions must be regarded as ideal conditions, and cannot be attained during operation. Drift may occur even in well-calibrated power sections due to @ tolerances in the power electronics components and @ temperature drift You can use mode 18 to compensate for such a drift. Prerequisites: @ The axis must be at rest (finished status) @ The position control loop must be closed Drift compensation: Select mode 18 > Start mode 18 with the "Start" function. The IP 266 now monitors the following error for approximately 4 seconds. The following error corresponds to the drift in the power electronics. The IP 266 then computes a voltage value Proportional to the following error as setpoint speed. When mode 18 is exited, this constant voltage is continually superimposed on the position controller's setpoint speed. An "External Stop" does not abort this mode. 5-50 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs n J Ps Optimum characteristics -10V 7 y +10V Vv a 1 I n : Speed ls 7 Nrated > Rated speed x Max. attainable with drift Np : Driftspeed at0V Zt compensation V : Output voltage Y Vp : Drift voltage for FN rated O speed Figure 5-26. Voltage - Speed Characteristic with Drift Compensation A Warning Serious errors disable the IP and produce a setpoint of 0 V without drift compensation. Serious errors are: watchdog errors (internal errors) resets The drive moves if there is drift. The graphic shows that it is no longer possible to cover the full speed range. A portion of the high negative speed range can no longer be used. If you were now to execute a positioning operation at a speed within this range, the following error would continually increase. Figure 5-27 illustrates this more clearly. \f the following error exceeds the specified maximum value, the IP 266 aborts the positioning operation currently in progress and outputs an error message. Movement with V max. increase in the following error s Vsetp= V rated Vact t AS : Following error Figure 5-27. Erroneous Following Error Characteristic in Conjunction with Drift Compensation EWA 4NEB 812 6057-02a 5-51Machine Data, Modes and Traversing Programs IP 266 Following modification of the machine data and "Power Off", the drift compensation voltage, if any, is disabled. Mode 18 must be restarted in order to determine the required compensation voltage. 5.3.19 Disable Drift Compensation (Mode 19) Start Function Disable drift compensation Mode Parameters With mode 19, you can disable the drift compensation enabled via mode 18. The compensation voltage is set back to 0 V. /\ Warning If there is drift, there will be movement in your drive system, as the compensation voltage needed to counteract the drift is no longer available. 9.3.20 Transferring Machine Data (Mode 20) Start Function Transferring machine data Mode Parameters This mode enables you to change all 36 values of the machine data of the IP 266. This allows you to change the parameterization of the IP 266 without using COM 266. For this purpose, you can load the parameters from previously prepared data blocks. Note: Machine data can only be transferred when the axis is at zero speed. On transfer of a machine data item, the entire machine data set is re-interpreted and checked for errors. The function signal (FUM) is briefly revoked during this process. After a machine data item has been transferred, any active shifts and compensating values on the module are deleted. The synchronization (reference point) remains in force during transfer of machine data. The machine data items "Travel per encoder revolution (No. 9) and Pulses per encoder revolution (No. 19) are exceptions to this. The machine data is transferred to the RAM of the IP 266, i.e. these values are lost at Power off. On "Power on, the data inthe EEPROM is loaded again. You can, of course, store the new data in the EEPROM with mode 26. 5-52 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs A Caution The machine data is transferred from RAM to EEPROM for backup purposes only. If the machine data for your application constantly varies, it is inconvenient to always save this data direct on the EEPROM since the sum of EEPROM write cycles is limited to 10,000. One machine data item per data cycle can be transferred to the IP 266 over the 8-byte long output frame. The individual bytes have different meanings depending on the data. The output frame has the following basic structure for this mode: Byte 0 Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Lt L____ Mode START Number of the an machine data item TOGGLE The shaded fields indicate the bytes which are transferred dependent on the machine data item Byte 0 - Operating mode Specify the number of the mode in this byte. Enter KF = 20 for mode 20. Byte 1 - The start condition Set the start condition in bit 0 with the value "1" and the TOGGLE function as Execute bit in bit 7 ( Kap. 7.1.2). Byte 3 - Number of the machine data item You can preselect the machine data item to be transferred by specifying a value in KF format in the range 1 to 36. The IP 266 checks during transfer that the parameter values have been specified correctly. If they are outside the permissible range, the IP 266 outputs an error message. The following tables show the number assignments, the data descriptions and the arrangement of the parameters in the individual bytes. Ail unnamed bytes are not significant for the byte in question and can assume any values, i.e. e@ the values for machine data 1 to 27 are entered in bytes 4 to 7, e@ the value for machine data item 28 is entered in bytes 4 to 5 and e thesettings for machine data 29 to 36 are entered in byte 2. EWA 4NEB 812 6057-02a 5-53Machine Data, Modes and Traversing Programs IP 266 Table 5-18. Machine Data with Parameters Entered in Bytes 4to7 Number Description Pe nance Data Byte 4, Byte 5 Byte 6, Byte 7 1 Maximum deceleration 10 to 9999 10 to 9999 0 2 Acceleration forward 3 Deceleration forward 4 Acceleration revers 5 Deceleration revers 6 Places before the Places after the point point 0/1 to9 Seton cscssueessscesesand anes Rintsnccosecescacsh eeeg tO OO | aeeeeoneene _ 7 pe Maximum following error 0.001 to 99.999 0 to 99 0/1 to 999 gL standstill moniter Ty 0.001 1064999 | otocd | oi tosaa sf Distance per encoder revolution 9001 to | otoaoo | ov toss 400.000 10 | Backlashcompensation | oo00 weasea | oaeee To agaeg 11 Zero offset 1 -32767.999 to -32767 to 0 to 999 +32767.999 +32767 12 Zero offset 2 13 Zero offset 3 14 Zero offset 4 15 Places before the Places after the point Tool length offset -32767.999 to 32767 to Oto 999 +32767.999 +32767 16 Reference point coordinate 17 Software lower limit 18 Software upper limit 19 Pulses per encoder revolution 1to 65000 0 to 65 0/1 to 999 20 Maximum speed 21 Jog speed 1 forward 22 Jog speed 1 backward 23 Jog speed 2 forward 24 Jog speed 2 backward 25 Incremental speed 26 Reference speed 1 27 Reference speed 2 28 Module number 1 to99 1 to 99 ennnneenne 5-54 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs with Note: The Module number must contain the number previously transferred to the module COM 266. Table 5-19 shows machine data 29 to 36. The parameter values of this data are entered in byte 2 and contain information for enabling or disabling specific statuses on the module. Table 5-19. Machine Data with Parameters Entered in Byte 2 Number Description Permissible Data Range in Byte 2 29 meas. system 1 = metric, 2 =inch, 3 =degree snsvavene Fo nnn pintawtayae seeeaweee ST 32 | Referencedirection Vonforward,1=backward eeeeneees ania oir pea menemamaaaamms einen a 3a [polarity ofthe HWlimitswitches~~~(| O= positive, 1 = negative a a i wogiepuces capeuanesrsxenerrneaeatsesancesessnenssde . a ; 36 |Foiowingerrormonitoring =SSS*dO = =f Note: if "BCD = yes is set by machine data number 33, this is not significant for modes 20, 31 and 32. All data transferred to the IP 266 must be in binary format. EWA 4NEB 812 6057-02a 5-55Machine Data, Modes and Traversing Programs IP 266 Different limit values when specifying data in bytes 6/7 The values 0 or 0.000 must not be specified for machine data Nos. 6 to 9 and 19 to 27. Division of a machine data item into two data words results in different limits for the inputs in byte 6/7 depending on the value specified. This is represented in the tables, for example, by the entry 0/1. 0 is permissible if bytes 4 and 5 contain a value not equal to 0. Actual value characteristics as affected by specification of the machine data If a reference point has not been set, the actual value coordinates will not change with the transfer of the machine data. The machine data items "Travel per encoder revolution and Pulses per encoder revolution are an exception to this. When this machine data is transferred, the actual value is adapted to the current specification. 3.3.21 EEPROM (Mode 26) EEPROM Direction Start Mode Parameters l Function You can use this mode to transfer data from the IP 266's RAM to EEPROM or from EEPROM to the IPs RAM. Mode 26 always transfers all available data from the source to the destination, i. e. the machine data and all traversing programs. Note: This mode can be invoked only in a STEP 5 program (see Section 7). These functions can also be invoked in the COM 266 "TRANSMIT" (TRANSFER) form (see Section 6.4.2). This mode is started automatically on the IP 266 run-up that follows a Power ON". The IP 266 outputs an error message when the EEPROM contains no valid machine data. The service life of an EEPROM chip is 10,000 write cycles. Example: The IP 266s RAM contains the following data block: @ One machine data record in DB1 @ Several traversing programs in DB1 to DB4 When the mode is started for RAM EEPROM, both the machine data and the traversing programs are transferred. Any data in the EEPROM prior to the transfer is overwritten with the new data. 5-56 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs 5.3.22 Unrestricted Speed Specification (Mode 31) Unrestricted speed specification Mode Start Function Parameters For some applications, the speed variation is not covered by the override factor. For this reason, the new mode 31 enables you to transfer the speed of your choice to the IP 266. This speed is then valid for modes 1, 2, 6 and 7. This newly defined speed is then used in place of the traversing speed entered in the machine data. Note: The speed specification does not overwrite the entry in the machine data. It is still possible to vary this newly defined speed using the override factor. Value range The speed specified must not exceed the value of the maximum speed in the machine data. If you enter a greater value, the IP 266 flags an error. The previously set mode remains in force. Switching the speed to the parameterized machine data If the value 0 is transferred as the new speed, this switches the IP 266 back to the parameterized machine data. Overview of the operating mode To select the functions, you must assign values in the output frame: Byte 0 Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 ee KF =0 to65 KF = 0/1 to. 999 Mode START an TOGGLE ) The shaded fields indicate the unused bytes EWA 4NEB 812 6057-02a 5-57Machine Data, Modes and Traversing Programs IP 266 You must divide the value to be entered into two individual values and enter them in byte 4/5 and byte 6/7: 6 5:00 0 Setting 1 5:0 00 Setting 2 0:50 0 Setting 3 Enter in KF format in Enter in KF format in byte 4/5 byte 6/7 If the value 0 is set, the IP 266 switches back to normal mode. Note: Mode 31 is only signalled back to the CPU until mode 1, 2, 6 or 7 is invoked. It then still remains active but can no longer be signalled by reading out byte 0. However, the following description "Enable control for mode 31 tells you how you can nevertheless establish whether mode 31 has been enabled. Aspeed specified by mode 31 cannot be stored long term. A "Power off deletes a speed set by mode 31. This also has the effect of switching the IP 266 back to normal mode. Mode 26 (Transferring from RAM to EEPROM) does not transfer this speed to the EEPROM of the IP 266. Enable control for mode 31 When enabled, mode 31 remains active even after further invocation of mode 1, 2, 6 or 7. However, only the last invoked mode is flagged in the input frame; i.e. not mode 31. You can read out a newly specified speed (BA 31) with mode 32. If you select this mode and read it out as the value "0", mode 31 is not enabled. 5-58 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs 5.3.23 Reading out the Unrestricted Speed Specification (Mode 32) Start Function Read out the unrestricted speed specification =e__=r Mode Parameters Mode 32 extends the three information modes 71, 72 and 73. You can use mode 32 to read out the new traversing speed set with mode 31. Note: Only the speed entered by you is flagged, not the actual speed. In order to invoke the mode, you need only assign KF = 32 to byte 0 in the output frame and set the START bit and invert the TOGGLE bit in byte 1 of the output frame. No other bytes are significant for selecting the mode. The value set by you is then signalled back to you by the IP 266 over the input frame in bytes 4 to 7. Output Value After Invocation of Mode 32 1 to 65000 0 Mode 31 is enabled. Mode 31 is disabled. The new speed value is active for modes 1, 2,6 | Modes 1, 2, 6 and 7 take the speeds specified in and 7. the machine data Information mode 32 remains active even after mode 31 has been disabled. You must therefore also change the information mode back again to another information mode (71, 72 or 73). EWA 4NEB 812 6057-02a 5-59Machine Data, Modes and Traversing Programs IP 266 5.3.24 Disabling the Monitors (Mode 33) Read following error Start Function Mode Mode 33 allows you to disable the following monitors: @ Software encoder monitor (see Section 2.7.1) and @ Position control monitor (see Section 2.7.2). If the torque from the motor is to be used not only for positioning but also for joining parts - e.g. Pressing in screws - the mode must remain enabled until it is terminated by the program. This can result in pulses not being captured for a period in excess of 10 IP cycles (10*3.75 ms). It is necessary to disable the monitors in such cases in order to avoid the IP 266 aborting the job request with an error message. J Caution The following wirebreaks are not detected in the case of disabled monitors: e@ Wirebreak of 24 V encoders e@ Wirebreak in the setpoint line Note: Hardware monitoring of the 5 V sensors is always active. All monitors are active after a "Power off. The output frame has the following structure for this mode: Byte O Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 TOGGLE The shaded fields indicate the unused bytes 5-60 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs 5.3.25 Enabling the Monitors (Mode 34) Enabling the monirors Mode The following monitors disabled by mode 33 can be re-enabled by mode 34: e@ Software encoder monitor (see Section 2.7.1) and e@ Position control monitor (see Section 2.7.2). The output frame has the following structure for this mode: Byte 0 Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Mode START an TOGGLE J The shaded fields indicate the unused bytes EWA 4NEB 812 6057-02a 5-61Machine Data, Modes and Traversing Programs IP 266 5.3.26 Information Modes (Mode 71, Mode 72, Mode 73) Current information can be called up from the IP 266 independently of modes 1 to 19 and 26. The IP 266 provides the so-called Information (or Monitoring) modes for this Purpose. These modes do not affect other modes, and can be invoked at any time without regard to the status of the axis. Once started, an Information mode is invoked cyclically, and remains in force until another Information mode is started. In contrast to modes 1 to 26, modes 71 to 73 do not return information to the STEP 5 program. Read actual position (mode 71) Start Function Read actual position Mode S Parameters Gos This mode is preset on IP 266 start-up, and displays the value which the IP 266 computed from the current encoder data and the machine data. Read following error (mode 72) Start Function Read following error Mode This mode allows you to read the following error so that you will have this information at your disposal should an abort due to a "Response from following error monitor" be imminent. This, in turn, allows you to react to an increase in the following error prior to the abort and take measures to rectify the problem. Read distance to go (mode 73) Start Function Read distance to go Mode Parameters & Select this mode when you want to initiate additional actions in your STEP 5 program prior to termination of an IP 266 job (e. g. 20 mm before the target position). 5-62 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs 5.3.27 Synchronize IP (Mode 99) Start Function Synchronize IP Mode Parameters This mode must be selected when the IP 266 is put into operation, as it synchronizes communication between the PLC and the IP 266. This mode must be started after every PLC cold (power off/power on) or warm (STOP RUN) restart and after every IP 266 reset. If this mode is not started, it will not be possible to invoke any other mode. As in the case of the Information modes, this mode does not return information to the STEP 5 program. Note: This mode is not needed to work with COM 266. 5.4 Elements of the Traversing Program A traversing program is a cohesive sequence of traversing operations, dwells and corrections. It consists of individual blocks comprising at least one self-contained, purposeful job. The traversing programs are stored in the IP 266s RAM, and can be executed as a whole with mode 8 or block by block with mode 9. A traversing program is divided into three main parts: %33 Test program > Program header (see Section 5.4.1) N1 G25 X300.000 F2000 M10 . N2 G04 F1000 Traversing blocks N3 X200.250 F1000 M30 9 (see Section 5.4.2) N4 GOO X120.000 M40 N5 Mo2 Termination block; end of pro- gram (see Section 5.4.3) A traversing program must comprise at least a program header and a termination block. A traversing program may contain no more than 1023 ASCII characters. The number of traversing programs is limited to 250. The IP 266 provides 7K bytes RAM for traversing programs. EWA 4NEB 812 6057-02a 5-63Machine Data, Modes and Traversing Programs IP 266 5.4.1. Program Header The program header comprises e@ the program identifier @ the program number @ max. 58 characters of arbitrary text @ a<.!> character as header terminator Program identifier | % =Main program L =Subroutine _| Program number = DB no. | Oto 255 Max. 58 characters of arbitrary text a <.1> as header terminator % | 5 Main program in DB5 <JI> ce rc _ hw Subroutine in DB12 <J> Figure 5-28. Format of the Program Header The distinction between main program and subroutine is for documentational purposes only. The IP makes no distinction. Every program can be either a main program ora subroutine. Note: Recursive structures and reciprocal calls are not possible. 5-64 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs 5.4.2 Traversing Blocks Table 5-20 lists all functions permitted in a traversing program. Table 5-20. Functions in a Traversing Block oe pee = ee = ae ee Block no. N Block number Organization Subroutine Function 1 L Calls Function 2 G E. g. type of position specification (absolute/relative) Preparatory Function 3 xX Positioning information Geometry Function 4 F E. g. machining speed, dwell time, loop passes Technology Function 5 M Auxiliary functions (output to the PLC interface for control of machine functions) A block may contain one or more of the functions listed in the table. Each block must begin with a block number. If several functions are to be programmed in one block, they must be programmed in the order shown in the table. Each function may appear only once in a given block and must be followed by at least one <space>. Every block must be terminated with <>. The N function (block number) The first function in a block, the N function, specifies the block number. This block is mandatory, and consists of the letter "N", followed by a number comprising up to three digits in the range 0 to 999. Block numbers may appear in any order, and may be used more than once within a traversing program. The blocks are always processed in the order in which they are written in the traversing program. EWA 4NEB 812 6057-02a 5-65Machine Data, Modes and Traversing Programs IP 266 In the following example, the processing order does not change. The order in which blocks are processed is determined only by the order of those blocks in the program. Example: %9 Sample program 1 %8 Sample program 2 N10 G74 M10 N30 G74 M10 N20 G24 F5 N10G24F5 N30 L36 N20L36 N40 X50 F2000 N60 X50 F2000 N50 G20 N50 G20 N60 M02 N40 Mo2 The two sample programs are identical. The L function Within a block, another program can be called as subroutine. The subroutine call must immediately follow the N function, and comprises the letter "L", followed by the program number of the program to be called. No further functions may follow the L function. The block may only be terminated with <>. Example: N10L123) <> Subroutines may be nested, but the nesting depth of loops and subroutines together may not exceed five. Note: Recursive structures and reciprocal calls are not possible. 5-66 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs The G function The first function to follow an N function may also be a G function. A G function is identified by the letter "G", followed by a two-digit number. A number of G functions are latching functions, i. e. they remain in force when the traversing program is exited. Table 5-21. Permissible G Functions oe er eS 00 Rapid traverse 04 Dwell 10 Flying change 20 End of loop 24 Start of loop 25* Approach targets over the shortest path 26 Approach targets in a clockwise direction (rotary axis only) 27 9 Approach targets in a counter-clockwise direction (rotary axis only) 40 Cancel tool offset 43 Enable positive tool offset 44 Enable negative tool offset 53 Cancel offsets 54 Enable offset 1 55 Enable offset 2 56 Enable offset 3 57 Enable offset 4 70 Size specifications in 0.1 inches 71 9 Size specifications in mm 74 Approach to reference point 90* e Absolute size specifications 91 Incremental size specifications * These functions are preset on |P 266 start-up e G00: Rapid traverse A defined target is approached at maximum speed. The target must be specified as an X function immediately behind the G function. A block containing the G00 function must have the following format: N10 GOO X1000 The drive approaches target position 1000 at maximum speed. An additional speed specification after the X function is not permitted. The maximum speed is taken from the machine data. EWA 4NEB 812 6057-02a 5-67Machine Data, Modes and Traversing Programs IP 266 @ G04: Dwell A block containing G04 effects a dwell. The duration of the dwell can be specified in increments of 100 ms with the F function. Example: N10G04F10 The IP executes a dwell of 10x 100 ms. @ G10: Flying change The block that follows the one containing the G10 function is executed without stopping the axis. This makes it possible to - change the speed during a positioning movement - modify M functions during a continuous positioning Note: By retracting the "External Start Enable" signal, you can also interrupt a block that was linked to the preceding block via G10. Example 1: Changing the speed during a positioning movement V 1000 Program without G10 N10 X50 F1000 M30 500 N20 X100 F500 M131 N30 X150 F1000 M32 N40 MOo2 UJ T T > 50 100 150 s ~E 30 >~<- M31 >< M32 > t ( i The G10 function makes of the interrupted movement a Positioning oper- ation with smooth speed transitions. Vv 1000 Program with G10 N10 G10 X50 F1000 M30 500 N20 G10 X100 F500 M31 N30 X150 F1000 M32 N40 M02 | | T 50 100 150 $ = 30 >< 31 >< 32 ~~ 5-68 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs Example 2: Alternating M functions Vv 1000 Program without G10 N10 X50 F1000 M10 500 N20 X100 F1000 M11 N30 X150 F1000 M12 N40 MO2 i t q t > ' 50 100 150 < Mio M1 eT M12 t 1 | ! Without the M function output, this movement could also be programmed in a block: N10 X150 F1000 A smooth movement of the type programmed in this block can be attained with the G10 function. Vv 1000 Program with G10 500 : ; N10 G10 X50 F1000 M10 N20 G10 X100 F1000 M11 N30 X150 F1000 Mi2 N40 M02 J j a. : T t T > | ! 50 100 150 $ 1 < M10 >< M1 M12 ~~ 1 t ! 1 The "Position reached" signal is not output following a block containing a G10 function. in mode 9 (Automatic Single Block), blocks linked with G10 are treated as one block. When G10 and M00 (programmed stop) are programmed in the same block, MOO has priority. To continue the program, you must press the EXEC key. The G10 function (flying change) is not permitted when the block to follow in a flying change e actsin the opposite direction e@ contains a dwell e@ contains only an M02 @ is too short to reach the required final speed @ contains a change, a tool offset or a zero ofset e contains a traversing path which is shorter than the preceding block's deceleration distance e@ could not be completely interpreted before the block containing the G10 finished executing EWA 4NEB 812 6057-02a 5-69Machine Data, Modes and Traversing Programs IP 266 The traversing program interpreter aborts the program immediately when it detects one of the above errors. Because the interpreter is always three blocks ahead of the block currently executing, however, the program is aborted in the current block rather than in the block that actually caused the error. Example: A traversing program containing eight positioning operations is to be processed. The first seven blocks contain a G10 function, i. e. all blocks are to be executed without stopping in flying change" mode. The eighth block, however, was programmed so that a change of direction would ensue. The interpreter detects this error and aborts the fifth block, the block cu rrently executing. Program: N10 G10 X50 F100 N20 G10 X80 F200 N30 G10 X130 F300 N40 G10 X155 F400 N50 G10 X200 F500 <--- Traversing program aborted N60 G10 X%240 F600 N70 G10 X280 F700 N80 XO F800 <--- Block with error N90 MO2 @ G20: End of loop G24: Start of loop Loops may be nested. Subroutines which themselves contain loops may also be calied in a loop. The nesting depth for loops and subroutine calls together may not exceed five. A continuous loop may be programmed only once, and only at the highest level. A program invoked via an L function may not contain a continuous loop. G20: End of loop G20 identifies the end of a program loop. A block containing G20 may contain no other functions. G24: Start of loop The G24 function identifies the start of a program loop. The number of loop passes must be specified via the F function. Example 1: N20 G24 F5 Aloop with five passes begins on . this line N120 620 The loop ends on this line Example 2: N20 G24 FO When you specify a0 as the parameter for the number of loop Passes, you define the loop as continuous loop. N130 G20 End of the continuous loop. 5-70 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs @ G25: Approach target over the shortest path G26: Approach target in a clockwise direction G27: Approach target in a counter-clockwise direction These functions can be executed for a rotary axis only, and are ignored for a linear axis. G25: Approach target over the shortest path When the program is invoked, it defaults to G25. The IP computes the direction of travel. If the distance is the same in both directions, the target is approached from the preferred direction (clockwise). The IP does not take backlash compensation into account when computing the direction, thus making it possible that the longer path will be taken in a small number of special situations. Figure 5-29 illustrates such a situation. i Beene: Backlash-++ 7 180 180 180 Traversing movement by the Traversing movement by backlash. Actual value is still the backlash and an 0/360 degrees additional 180 degrees Actual value is 180 degrees Figure 5-29. Traversing of a Rotary Axis with Backlash Prerequisites: @ The backlash compensation value was entered in the machine data @ G25 was programmed and the distance is the same in both directions e@ Thedirection of travel in the last operation was counter-clockwise Result: The IP 266 chooses the preferred direction. Due to the programmed backlash, the movement takes longer than it would in the opposite direction. The distance for the motor- driven axis is longer by the backlash compensation value. The function selects the direction of travel only when absolute target positions have been defined. G26: Approach target in a clockwise direction All absolute target positions are approached in a clockwise direction. G27: Approach target in a counter-clockwise direction All absolute target positions are approached in a counter-clockwise direction. G26 and G27 are effective only in conjunction with "Absolute size specifications (G90). EWA 4NEB 812 6057-02a 5-71Machine Data, Modes and Traversing Programs IP 266 @ G40: Disable tool offset G43: Enable positive tool offset G44: Enable negative tool offset A tool offset can be regarded as a coordinate shift, and is required to compensate for changes in the tool length caused by tool wear. An existing traversing program need not be reprogrammed to include a tool offset, but is adapted via a compensating factor. Periodic tool wear (e. g. drill wear) can be measured and corrected using the G functions. The following table shows the effect of a tool offset. Table 5-22. Tool Offset Stee praes TTT ae The offset value for functions G43 and G44 is in the machine data on the IP 266. In contrast to mode 15, offsets via G functions are additive offsets which change the total tool offset value by the value of the programmed offset (see Section 5.3.15). 5-72 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs The following TO limiting values apply for the resulting tool length change: Maximum offset value +32 767.999 mm End of range start of range Software end limit switch + offset < 32 767.999 mm value ~~ Software start limit switch + offset < 32 767.999 mm value If a traversing program containing a G function for a tool offset is terminated without the G40 function, the current additive offset is retained. The additive value can then be reset to zero only together with the external (offset) value in mode 16 (see Section 5.3.16). Entry of a new external offset in mode 15 also resets the additive value to zero. e G40: Disable tool offset The G40 function disables all positive and negative tool offsets in a traversing program. e@ G43: Enable positive tool offset The G43 function enables a positive offset of the length specified in the machine data. e@ G44: Enable negative tool offset The G44 function enables a negative offset of the length specified in the machine data. You are now acquainted with the various options for tool offsets, i. e. the tool offset initiated with mode 15, which can be used as absolute tool offset, and the tool offset initiated via the G functions, which is an additive tool offset. EWA 4NEB 812 6057-02a 5-73Machine Data, Modes and Traversing Programs IP 266 The diagram below shows the interplay between modes 15 and 16 and G functions G40, G43 and G44. | STEP 5 program or COM 266 eee eee ee ee ee ee el r ! 4 I I ! ! ! ! ! | I ! | 7 I ' I ew Add to additive tool offset value Vv Se: Reset additive TO Nee Reset absolute To fh Write absolute 10 Cc Npsteeenenuoenismenas Figure 5-30. Overview of Tool Offsets A Total TO=additive TO + absolute TO G53: Cancel zero offsets G54-G57: Enable offset 1-4 These functions effect a relative shift in the axiss coordinate system. Such a shift may be required when it is necessary to perform identical steps with the same incremental dimensions at different positions (see Example). Example: Using a zero offset Only one zero offset may be invoked at any given time. A zero offset enabled via G54 remains in force only until another G function (G54 - G57) is invoked. 5-74 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs ele listZq_ 20 | | 50 | 10. 1 2nd ZO | 20 90 | - 10 emcees w a N o 8 Figure 5-31. Using Zero Offsets The workpiece is to be drilled at the points indicated. The three drill holes in each group are the same distance apart. The machining sequence for the groups can be programmed in a subroutine. Zero offsets and positioning operations are used to set the start position for the subsequent subroutine-controlled positioning of the drill. Rough structure of the program: 1. 2. 3. 4. 5. 6 ZO forward + 10 mm (e. g. ZO 1) Callsubroutine forthe three drill holes atthe positions 10 mm, 20 mmand 30 mm ZO forward + 50 mm to absolute position 50 mm (e. g. ZO 2) and positioning to the start position Call subroutine for the three drill holes at the positions + 50 mm, 60 mm and 70 mm ZO forward to absolute position + 90 mm (e. g. ZO 3) and positioning to the start position Call subroutine for the three drill holes at the positions 90 mm, 100 mm and 110 mm Four offsets can be entered in the machine data. The sign indicates the direction of the offset. AG function is assigned to each offset. - Zerooffset1 G54 (10 mm) - Zerooffset2 G55 (50 mm) - Zerooffset3 G56 (90 mm) - Zerooffset4 > G57 (150mm) EWA 4NEB 812 6057-02a 5-75Machine Data, Modes and Traversing Programs IP 266 A G-function zero offset is added to both the absolute and relative zero offsets set via modes 12 and 13. The offset value modifies all coordinate values for - software limit switches - reference point - coordinate zero point Enabled zero offsets are automatically reset when the traversing program terminates. Zero offsets set in a subroutine are not reset until the main program is exited. The G53 function resets the zero offsets set in the traversing program and the associated subroutines. Note: When you abort a traversing program, the set zero offsets are retained, and can be reset only via mode 14. @ G53: Cancel offsets This function disables the zero offsets enabled in the traversing program. ZOs enabled in the traversing program ZOs enabled in the traversing programs subroutines Relative ZOs set via mode 13 @ G54 -G57: Enable offset 1-4 A block containing one of these G functions enables a zero offset. Figure 5-32 shows how zero offsets interact and how they can be cancelled. 5-76 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs =<<<---4 woe we eee eee 7 wee ee ee ee we ee ee ee ee eee ee Machine ! data! I Mode invoked in STEP 5 program or via ' COM 266 Traversing program Figure 5-32. Overview of Zero Offsets e@ G70: Dimensions in 0.1 inch G71: Dimensions in mm The IP 266 positioning module always interprets traversing programs in the dimension specified in the machine data. Table 5-24. Preselecting Dimensions G70 G71 [degrees] G70 and G71 ineffective Functions G70 and G71 can be used to change the dependence of dimensions on the specification made in the machine data. EWA 4NEB 812 6057-02a 5-77Machine Data, Modes and Traversing Programs IP 266 Note: G functions cannot be used to implement this options for a rotary axis that was initialized in [deg] in the machine data. @ G70: Dimensions in 0.1 inch When the G70 function is invoked, all subsequent distances are interpreted in units of 0.1 inches and all subsequent speeds in 0.1 inches/min. @ G71: Dimensions in mm When G71 is invoked, all subsequent distances are interpreted in mm and all subsequent speeds in mm/min. @ G74: Approach to reference point This function can be used to approach an existing physical reference point. The position specified by the value of the reference coordinate is not approached; this position may differ from that of the physical reference point due to compensations or offsets. The incremental speed specified in the machine data is used as approach speed. Note: The G74 function does not execute a reference point approach on the same basis as mode 5. The zero offsets and tool offsets currently in force are taken into account in the actual-value display. Example: Following an approach to reference point and subsequent positioning, the drive is at the position - 50. Following a zero offset, the actual position is 50 mm and the reference point position is 100 mm. Function G74 moves the drive to the position 100 mm, which is the physical zero point (not to coordinate 0, which is the reference coordinate specified in the machine data). Position of the drive Reference coordinate set via mode 5 ZO = 50mm WV | | Oo 50 100 | G74 V__-> L Y | Oo 50 100 5-78 EWA 4NEB 812 6057-02aIP 266 Machine Data, Modes and Traversing Programs e G90: Absolute position specifications G91: Relative position specifications These two G functions control the interpretation of all target specifications (X functions). G90: Position specifications are interpreted as absolute values G91: Position specifications are interpreted as relative values These two G functions control the interpretation of all target specifications (X functions). The X function In this function, the character "X" is followed by a target coordinate for the positioning operation. The target coordinate may be specified as either an absolute or relative value (can be selected via G90/G91). The numerical value may comprise up to five integer and three decimal places and a sign. Max. +32767.999 Min. - 32767.999 The decimal point may be omitted if the value has no decimal places, and is then assumed to be located at the last position in the target specification. if BCD format was specified in the machine data, the target coordinate must be in the range from + 9999.999 to - 9999.999. The F function How an F function is interpreted depends on the function which precedes it. Table 5-25. Using the F Function in Traversing Blocks G04 Dwell 1 to 65000 Multiple of 100 ms X function, except for Speed 10 to 65000 mm/min X function following GOO 0.1 inches/min degrees/min G24 Number of loop passes 0 to 65000 0=Continuous loop The F" must be followed by an unsigned integer comprising no more than five digits. EWA 4NEB 812 6057-02a 5-79Machine Data, Modes and Traversing Programs IP 266 The M function M functions are auxiliary functions used to control external events. An M function consists of the letter "M", followed by a number of no more than two digits. The binary value of that number is forwarded to the programmable controller, where it can be evaluated to control other modules or as status info on a positioning operation. With the exception of the function MOO, M functions following switching functions, compensation values or offsets have no effect, and are ignored. The M function that was active before the block was invoked remains in force. The IP 266 interprets the M00, M02 and M99 functions directly. @ M00: Programmed stop M00 interrupts a program for mode 8 or 9. The Program can be resumed by pressing the EXEC key. In a block containing both M00 and G10, M00 has priority. An External stop is not executed while an M function is in progress. @ M02: End of program This function must be programmed in the last block of a main program or subroutine. e@ M99: External switching function This switching function is applied directly to an IP 266 digital output. This output is connected with pin 10 on the terminal block. All other values (i. e. M01 and M03 to M98) are available to the user. An M function is output when execution of a block begins, and remains in force until the next M function is output. If a traversing program begins with blocks in which no M functions have been programmed, M255 is output to the PLC. One byte is available for the display. The value "FF" is displayed if the format is KH, the value "-1" if the format is KF, 5.4.3. Last Block The last function programmed in the last block of a traversing program must be an M function with the parameter 02. The format of the last block is the same as that of all other blocks. In its shortest form, the last block must contain Nnn M02 <I> 5-80 EWA 4NEB 812 6057-02aIP 266 5.4.4 Syntax Diagram of a Block =C 4 > Block number Rapid traverse >{ L } Nene Subroutine call =) 3 Target p>) >_> Dwell time in 100 ms > x Flying change A Target Speed HAP COPED Switching function Vv q G25 }> Shortest path v AAAHARARAAAAAD QSISTHARUEGELS G74 Forward (clockwise) Reverse (counter-clockwise) Cancel tool offset Enable positive tool offset Enable negative tool offset Cancel zero offset Enable offset 4 Enable offset 2 Enable offset 3 Enable offset 4 Dimensions in 0.1 inches Dimensions in mm Absolute dimensions Relative dimensions Vv Approach reference point G20 Vv End of multiple-pass loop Start of multiple-pass loop Vv = KF Number of loop passes Se a Machine Data, Modes and Traversing Programs Figure 5-33. Syntax Diagram of a Block The Figure above shows all permissible combinations of functions within a block. EWAANEB 812 6057-02a 5-81EWA 4NEB 812 6057-02a6.2 The "FUNCTION SELECT" 6.4.1 Entering Machine Data 6.6 COM 266 Test Mode ... 6.6.2 "Mode Select" Mode .. 6.10 COM 266 Error Messages 6.4 "INPUT" Form ........- 6.7 Output ...........-55-- 6.8 Delete ......cccuececen 6.9 Information .........-. 6.1 Preparations for Using COM 266 .......-. 0 eee eee reece eee eee ene 6.1.1 Copying the COM 266 Floppy ........- eee cece cece renee eee eee ene 6.1.2. System Configuration .. 6.1.3 Starting COM 266 ...... Pe ee eee eee ee eee eee eee ee ee ee Menu ...cccc cece cece rere ence ene eeeneeee 6.3 Hierarchical Structure of COM 266.20... eee ce eee ee eee eee ee eens eee eee eee ee eee ee eee eee eee ee ee eee eee 6.4.2 Entering Traversing (Machining) Programs ...-.-.+-.++e+eeeeeeeeees 6.5 Transferring an Existing Machine Data Record ora Traversing (Machining) Program ......-..0eseeeeeeee eer eeeeeeeeeee eee eee eee eee eee eee ee 6.6.1 Actual-Value Display" Mode .......... 02 ec e cece ene e eee e ener n ee eeee ee ee ee ee ee eee eee eee ee eee tee eee eee eee ee Se ee ee Pee ee ee ee wna wo 10 11 14 30 39 43 47 51 53 55 57 EWA 4NEB 812 6057-02a6-1. KOMI Screen Form ose cece cece ceseseutecucuceccccucece 6- 3 6-2. "CONFIGURATION" Form; COM 266 Screen LAYOUE ees cctiaws sees aes 6- 4 6-3. Format of the Header Lines 4... 0.cccccsscesecsecseacbavcdvcccces 6- 4 6-4. Initializing Che IP... .scacsw saw sie svigadaetaveNiis 6445%%S6e0eneecc.., 6- 6 6-5. "FUNCTION SELECT" Menu .........0..ccccccuceccceuccceceuuccuce 6- 9 6-6. Hierarchical Structure of the "FUNCTION SELECT" Menu and Subsequent Screen Forms .......c.cceccecececucccccucee 6- 10 6-7. Structure of the "INPUT" and "OUTPUT" Forms ............0.2-.... 6- 11 6-8. Data Block Selection 2.0.0... ccc cece cece ce ceuccevctuccuccecces 6 - 12 6-9. Machine Data Page 1.02... eee eee c ccc ccc cuncccccuuccceucncce. 6- 14 6-10. Machine Data Page 2. ecusccsseccdaeeecsssincied oedvedevvsscececeucs, 6 - 16 6-11. Machine Data Page.3 sissies sca swiawtieistiouissenivs ov Sesae cues oneenece 6- 18 6-12. Machine Data Page 4.0.2... eee cc cece ceccncceuceuececcccces 6 - 20 6-13. Machine Data Page 5 2.0... eee cece cece cccecccceuuucseuccs 6 - 22 6-14. Machine Data Page 6 2.2... kee cece cece cceccucceuceucess 6 - 24 6-15. Machine Data Page7 ........... cece ccc ceecccunececeuuceccuccce. 6 - 26 6-16. A 6- 28 6-17. Machine Dats PHINtOUt oc ceesscscis aveai eu Nelo eRNEESSESS4R oo. 6 - 30 6-18. Program Type Select Form ........ 00.0 ec ceccceccecccuceccccccccee, 6- 31 6-19. Traversing (Machining) Program Form to DIN with SampleProgram .. 6 - 33 6-20. Traversing (Machining) Program Formin Text Mode ................ 6 - 35 6-21. "TRANSFER" Form 2... 0... cece cece ceceeccucsectencsuceunceccence 6- 39 6-22. Hierarchical Structure of the TEST Form .........cccccccecsecccecee. 6- 43 6-23. "TEST" FOFM 2... cece eee ce cee cenctuccucccunceanecencesunecencee. 6- 44 6-24. Mode Select Font .scscsenswieeeneacvac'sarieie sce oseiboececscecees 6- 47 6-25. Table of Operating Modes for Testing ...........cccecccceeccceuce. 6 - 50 6-26. BIGCK SIGCHI: aiiiisiesie's'sis.0'9.0:8:87SG aiid ane o.e-caemacuseawewweueeecees 6- 52 6-27. "DELETE" FOr 22.2.6... ceeccecececccecceueuccsseeeceeeuucceucces 6- 53 6-28, INFORMATION " Form with Blank Data Area .......-0..cccc0ee00. 6 - 55 6-1. Contents of the Fields in the Header Lines ................00.00000-. 6- 5 6-2. Mode-Dependent Output Fields 2.2.0.0... 0... cece ccc ceucceceee 6 - 46 6-3. Function Keys <F2> to <F6> in Modes 1to19 .................... 6 - 49 6-4. Input Fields for Modes 1to 19 10.0.0... ccc cece ccceccccuueeeccucce, 6- 50 EWA 4NEB 812 6057-02aIP 266 Fundamentals of COM 266 6 Fundamentals of COM 266 The COM 266 software provides user-friendly support for programming the IP 266 and putting it into operation. All functions can be executed by making the appropriate entries in the interactive screen forms. The relevant program sections are invoked via function keys. In order to acquaint you with the COM 266 software and how to use it, Section 6.1 provides information on e@ making a working copy of the COM 266 floppy e configuring asystem e starting COM 266 and making all initial preparations for its use You will then find an overview showing you the hierarchical structure of the COM 266 software. Section 6.2 provides general information on the COM 266 screen forms which precede the "FUNCTION SELECT" form. The subsequent sections describe all available COM functions. 6.1 Preparations for Using COM 266 Before putting COM 266 into operation, you should first copy all the files you need to a floppy. Standard package COM 266 is delivered on a floppy disk in the format required by the $5-DOS operating system. Make sure that $5-DOS has been installed on your programmer. 6.1.1 Copying the COM 266 Floppy Before you start, make a copy of the original COM 266 floppy and store itina safe place. > Start the PCP/M86 operating system > Copy the original COM 266 floppy PCP/M86 provides a utility for formatting and copying floppy disks. To call this utility, e enter DSKMAINT <./> if you are using an older version of PCP/M- e orDISK <.J> if you are using the newest version Please refer to your programmer manual for a detailed description of this utility. EWA 4NEB 812 6057-02a 6-1Fundamentals of COM 266 IP 266 6.1.2 System Configuration 6-2 First of all, you should learn how to install COM 266 on your hard disk. Load the PCP/M86 operating system Insert the COM 266 floppy into drive A You must now copy the contents of the floppy to USER extent 0 on the hard disk. > To doso, enter the following line: PIP) = =B:=A:S5 PDC 13X.CMD <> => This command copies the COM 266 Program to USER extent 0 on your hard disk. In order to make it possible to invoke COM 266 from any USER > Set these file attributes with: SET B:S5 PDC 13X.CMD[RO SYS] <u> => The program is now installed. When you start $5-DOS, COM 266 will now appear in the "PACKAGE SELECT" menu. Preparations for using a programmer that is not equipped with a hard disk unit: First, you must generate an S5-DOS floppy. To do so, copy the following files to a new or blank floppy that has been formatted for PCP/M86: S5WX000H.CMD SSWX100X.CMD S5WX200X.CMD SSWX201X.CMD S5WX202X.CMD S5.CMD S5KXS02X.CMD S5KDS01X.DAT SSKDSO2X.DAT EWA 4NEB 812 6057-02aIP 266 Fundamentals of COM 266 6.1.3 Starting COM 266 You can start the COM 266 program from either the hard disk or the floppy. @ Preparations for a programmer equipped with two floppy disk drives: Activate drive A by entering A: on the command line and pressing <>. Insert the S5-DOS floppy into drive A and the COM 266 floppy into drive B. @ Preparations for a programmer equipped with a hard disk drive: > Activate drive B e@ Starting $5-DOS: Enter the following line: $5 and press <I>. => The KOMI screen form appears briefly during loading eee em ee we ee er a eee Simatic $5 $5-KOMI Serial-No.: XXXX-Yyy-ZZZZZZ All rights reserved Copyright (C) 1989 SIEMENS AG Figure 6-1. KOMI Screen Form This screen form is then replaced by the "PROGRAM SELECT" menu. Using the cursor control keys, select the COM 266 program in the "PROGRAM SELECT" menu. Start program loading by pressing function key <F1>. => "CONFIGURATION", which is the first of the COM 266 screen forms, is displayed on your screen. EWA 4NEB 812 6057-02a 6-3Fundamentals of COM 266 IP 266 The "CONFIGURATION" form Header [copytight (c) SIEMENS AG SIMATIC 5 /couase \ CONFIGURATION ccecc 0000 MMM MMM 2222 666 666 cccccce 000000 MM MMMM MM 222222 66666 66666 ccc 000 000 MM MM MM 22 22 66 66 ccc 000 6000 MM MM 22 66 66 Data ccc ooo 86000 MM MM 22 666666 666666 area ccc 000 86000 MM MM 22 66 66 66 66 cecccc O00000 MM MM 22222 66 66 66 66 cccc 0000 MM MM 222222 66666 66666 Version: V**.+* Serial-No.: 7994-0036-654321 Error line Function key menu \ staat Figure 6-2. "CONFIGURATION" Form; COM 266 Screen Layout Every COM 266 screen form is divided into the four sections shown above. @ Header e Data area e Error line e@ Function key menu Header: The two-line header for each screen form comprises six subfields. Field 3 Field 4 Figure 6-3. Format of the Header Lines 6-4 EWA 4NEB 812 6057-02aIP 266 Fundamentals of COM 266 Each of these fields contains information specific to the screen form in which they appear. This information is listed in Table 6-1. In screen forms that have subordinate screen forms or functions, this field contains the name of the basic, i. e. supraordinate, screen form. In the basic screen form itself, this field is blank 1 (see the Example for fields 1 and 2). 2 Field 2 always shows the name of the on-screen form. 3 Field 3 is blank in all screen forms. 4 In some screen forms, this field contains a device identifier. This identifier depends on the the screen form, and is explained in those screen forms in which it appears. 5 This field always contains the text "SIMATIC $5/COM266". 6 This field is screen form-dependent. In some screen forms, it contains the text "Block:DB...". The field content is explained in those screen forms in which the field is displayed. 1 Exception: Inthe "CONFIGURATION" form, this field contains the copyright entry. Example for fields 1 and 2: in the "INPUT MACHINEDATA" form, "INPUT" is the name of the basic screen form and is displayed in field 1 of the header. MACHINEDATA" identifies the current screen form, and is displayed in spaced type in field 2. Data area: The data area of a screen form provides information on the machine data e thedefaults e theconfiguration parameters e Traversing (machining) programs The data area is subdivided into the following fields: e Fields with fixed texts A fixed text describes the relevant item of data. Input fields are displayed in reverse video. These fields are shown in the manual on a gray background. You may change the contents of these fields. e Output fields An output field provides information on data already entered. In the screen forms, an output field is always preceded by a colon. Data in an output field cannot be changed. EWA 4NEB 812 6057-02a 6-5Fundamentals of COM 266 IP 266 Error line: lf errors occur during program execution, an appropriate error message is displayed on this line. Auxiliary messages and control information are also displayed on the error line. Each error message comprises an error code followed by an error text. The same error code is entered in the error byte in the STEP 5 message block. Function key menu: @ The function key menu shows the functions which can be invoked in a screen form. A function is selected by pressing the function key allocated to it. @ You can exit each screen form by pressing <F8>. In many cases, you must confirm the exit request by pressing <F1>. Note: In the screen forms which follow, you will see data in various input and output fields. This data is only sample data to demonstrate possible field entries. And what now? > Start the COM 266 program by pressing <F1>. => The "PRESETS" form now appears on your screen. The entries in this screen form define the working environment for both the IP 266 and COM 266, PRESETS form { SIMATIC $5/COM266 PRESETS Drive Filename Plant designation Generated by Generated on Mode Module-No. Slot-No. Firmware Date-Time \ sean OFFUNE HELP Figure 6-4, Initializing the IP 6-6 EWA 4NEB 812 6057-02aIP 266 Fundamentals of COM 266 Header: The header contains the following information: @ Thename of the screen form in field 2 : PRESETS e@ Thename of the software package in field 5 : SIMATIC $5/COM 266 Data area: Drive: Specifies the current drive. Filename: The filename specifies the file in which your data blocks are to be stored. You can thus assign different files to different projects or plants. Press <F7> to display files with file extension 266. Plant designation: An entry in this field is mandatory. If the field is blank, the error message "Inadmissible input" is displayed. Enter a short characterizational text in this field. Generated by: An entry in this field is mandatory. Enter your name. If you entered the name of an existing file under "Filename", a name will automatically appear in this field. Generated on: If you entered the name of an existing file, its creation date is displayed in this field. If you are creating a new file, the current date and time is displayed. Mode: Operational status "ONLINE" or "OFFLINE". You can change back and forth between the two with <F2>, but ONLINE will appear only when the programmer is interfaced to the IP. Module-No*: You may enter a number between 0 and 99 to identify a specific positioning module in a programmable controller. If machine data has already been stored on the module, you must enter the same module number in this field as you entered inthe machine data. (You cannot assign different module numbers to the same module). Slot-No: The slot number may theoretically be in the range from 0 to 255, but should be between 0 and 7. This number is for the purpose of documentation only. Firmware: The firmware version is displayed in this output field. Date-Time: The programmer's hardware clock data is displayed in this field. When you change these values, you reset the PG clock. When the programmer is switched off, this setting is lost again. "Type" column: | = input field, O = output field * The contents of these fields can be changed only when the operational status is ONLINE. EWA 4NEB 812 6057-02aFundamentals of COM 266 IP 266 Function key menu: <F1> <F2> <F7> <F8> This key @ takes you to the next screen form and e forwards the initialization data to the module when correct entries have been made in all input fields. This key is used to switch back and forth between "ONLINE" and "OFFLINE" in the "Mode" field. The following values are read out from the module and displayed in the screen form in ONLINE mode: @ Module number e Slot number e@ Firmware version The first time COM 266 is started, the module number and slot number fields are "0". These fields are not displayed in "OFFLINE" mode. This key is used to display a list of available e@ drives or e. filenames. Press this key to return to the "CONFIGURATION" menu. And what now? > Fillin all input fields in the "PRESETS" form. > Press <F1> to display the "FUNCTION SELECT" form. 6-8 EWA 4NEB 812 6057-02aIP 266 Fundamentals of COM 266 6.2 The "FUNCTION SELECT Menu ( SIMATIC 35 /com266 \ FUNCTION SELECT Drive : A Filename : Example Plant designation : Linear axis Generated by : Meier Generated on : 12.06.89 Mode : ONLINE Module-No. : 11 Slot-No. : 002 IP 266 firmware : Z01 Date-Time : 05.10.89-17:35 TRANS- INFOR- Kine UT OUTPUT TEST FER DELETE MATION Figure 6-5. FUNCTION SELECT" Menu The "FUNCTION SELECT" menu relists all data from the "PRESETS" form. All fields in this screen form are output fields; none of the values can be changed. You can invoke a series of functions in this screen form. When you abort a function with <F8> (EXIT), COM returns you to the "FUNCTION SELECT" menu. Function key menu: <Fi> <F2> <F3> <F4> Press this key to branch to the screen forms for entering @ machine data and e traversing (machining) programs. Press this key to display @ machine data and e@ traversing (machining) programs. This key is used to invoke the branch of the program used to test modes 1 to 19, and may be pressed in "ONLINE" mode only. Press this key to invoke the Transfer function. This function is used to transfer e@ machine data or @ traversing (machining) programs from memory to various storage media. EWA 4NEB 812 6057-02a 6-9Fundamentals of COM 266 IP 266 <FS> Press this key to invoke the "Delete" function. This function is used to delete @ machine data and @ traversing (machining) programs from various storage media. <F7> If you want to find out which machine data and traversing (machining) programs are on which storage media, press this key to invoke the "Information" function. <F8> _ This key returns you to the "PRESETS" form. 6.3 Hierarchical Structure of COM 266 The Figure below illustrates the hierarchical structure of COM 266. The diagram shows the names of all screen forms; forms for which there are subordinate screen forms are outlined in bold type. Functions or additional screen forms are invoked via the function keys (see Figure 6-6). INFORMATION FijF2)F3/F4)F5 |} F6 | F7/ Fs Figure 6-6. _ Hierarchical Structure of the "FUNCTION SELECT" Menu and Subsequent Screen Forms And what now? Now you must decide which function you want to select. : If you have just installed the module, start with the "INPUT" function. This function is invoked by pressing function key <F1>. You will find detailed information on the screen forms in this group in the next section. If the machine data and traversing programs have already been stored on the module, you can press <F3> to invoke the "Test" function (see Section 6.6). At this point, however, you should learn how to enter machine data. 6-10 EWA 4NEB 812 6057-02aIP 266 Fundamentals of COM 266 Enter the machine data prompted on your screen. > <F1> takes you from the "FUNCTION SELECT menu to the program branch for entering => The "INPUT" form is displayed. From this form, you can branch to the screen forms for entering machine data and traversing (machining) programs. 6.4 "INPUT" Form The "INPUT" form is a main screen form with a number of subordinate forms. Figure 6-7 shows its hierarchical structure. The "OUTPUT" form has the same hierarchical structure as the "INPUT" form. { INPUT MACHINEDATA INPUT MACHINEDATA a F1 | F2)F3) F4) FS) F6 | F7 | FS : _ \ ied PRINT | MACHINEDATA INPUT MACHINING PROGRAM INPUT MACHINING PROGRAM _ PRINT MACHINING PROGRAM n=1to3 Figure 6-7. Structure of the "INPUT" and "OUTPUT" Forms EWA 4NEB 812 6057-02a 6-17Fundamentals of COM 266 IP 266 In the following, each input form is preceded by a graphic of the path to that form. FUNCTION SELECT V FI [f2 [3] ra |rs| re |e7 |r) i SIMATIC S5/COM2 se \ INPUT DEVICE: BLOCK: DB Data Block Block No. \ woouz PG FD HELP oar) Figure 6-8. Data Block Selection Header: The header shows the following: @ Field 2: INPUT e Field 5: SIMATIC S5 / COM 266 @ Output fields for the target device (field 4) and the data block number (field 6). Both fields are initially blank. Data area: Data Block I Use <F7> to switch back and forth between MACHINEDATA and MACHINING PROGRAM. Block No. | Number of the data block in which you want to store your data. Must be in the range from 0 to 255. Type column: | = input field 6-12 EWA 4NEB 812 6057-02aIP 266 Fundamentals of COM 266 Function key menu: Select the data destination with function keys <F1> to <F3>. <F1> Data destination is the IP 266. Depending on the entry in the "Data Block" field, COM branches to the screen form for entering e@ machine data or e traversing (machining) programs <F2> Datadestination is the programmer's RAM. COM uses the same criterion for the branch as for <F1>. <F3> _ Data destination is the disk drive and file specified in the "PRESETS" form. COM uses the same criterion for the branch as for <F1>. <F7> _ Use the HELP key to set the "Data Block" field to either @ MACHINEDATA or @ MACHINING PROGRAM <FS> <F8> (EXIT) returns you to the "FUNCTION SELECT" menu. And what now? > Position the cursor to the "Data Block" field. Select MACHINEDATA using <F7>. Using the cursor control keys, move the cursor to the "Block No." field. Enter there the number of the data block. Enter "1" in this field. Choose your data destination with <F1>, <F2> or <F3>. <F3>, for instance, selects FD as data destination. Press <F1> to choose the IP 266 as data destination. Note: If you have not installed an IP 266, your data destination must be either a disk drive or the programmer. => The first page of the "INPUT MACHINEDATA" form is displayed on your monitor screen. EWA 4NEB 812 6057-02a 6-13Fundamentals of COM 266 IP 266 6.4.1. Entering Machine Data INPUT MACHINEDATA" form (page 1) FUNCTION SELECT es tez|eadre|es rs] Ls) Fis SIMATIC ss/comaee \ INPUT MACHINEDATA > MACHINEDATA DEVICE: IP 266 BLOCK: DB 1 Module (O...99) Meas. System (mm, in, grd) Axis type NNEXT PREVIOUS PRINT \ ease PAGE MDAT TRANSFER HELP ext J Figure 6-9. Machine Data Page 1 Header: The header contains the following: @ Name of the screen form (fields 1 and 2): INPUT MACHINE DATA @ Name ofthe software package (field 5): SIMATIC $5/COM 266 @ Data destination. You chose the data destination with <F1> inthe "INPUT" menu. The output field shows: DEVICE: IP 266 @ You also specified the number of the data block in the "INPUT" form. The output field contains the string: BLOCK: DB1. The header is the same for all seven pages of the "INPUT MACHINEDATA" form. 6-14 EWA 4NEB 812 6057-02aIP 266 Fundamentals of COM 266 Data area: ee : : ee Module | You must enter a number for the module in this field. This is absolutely mandatory, as a programmable controller may be equipped with more than one IP 266. The number you enter must be in the range from 0 to 99, and must be identical to the one you entered in the "PRESETS" form. Meas.System | Enter the physical unit you want to use. Use <F7> to select mm (millimeters), in (inches) or deg (degrees). The default is mm. Axis type | The IP 266 supports both linear and rotary axes. Use <F7> to choose either LINEAR or ROTARY. "Type" column: | = input field Function key menu: <F1> Press this key to screen the next page of the "INPUT MACHINEDATA" form. This function is possible only when you have filled in all input fields correctly. <F2> Use this key to screen the preceding page of the "INPUT MACHINEDATA" form. This function is possible only when you have filled in all input fields correctly. <F4> __s~Prress this key to start a printout. <F6> Once you have filled in all input fields, you can press this key to store the machine data onthe specified destination device. The data destination is shown in the header. Data stored on the IP 266 is first verified. Errors are flagged on the error line. When an error is detected, the page of the "INPUT MACHINEDATA" form in which the error was made is displayed on the monitor. <F7> _ Use this key to choose the values for Meas.System and Axis type. <F8> After confirming your intention to exit by responding to the relevant prompt with <F1>, this key returns you to the "FUNCTION SELECT" menu. With the exception of <F7>, the function key menu is the same for all seven pages of the "INPUT MACHINEDATA" form. <F7 > is included in the function key menu on pages 1, 3 and 7 only. EWA 4NEB 812 6057-02a 6-15Fundamentals of COM 266 IP 266 And what now? > Enter 11 (the same number entered in the "PRESETS" form) in the Module field. > Set the cursor to the input field for Meas.System and make your selection with <F7>. The default value for this field in [mm]. > Move the cursor to Axis type and select the linear axis with <F7>. The word "LINEAR is displayed in the input field. Press <F1> to screen the second page of the "INPUT MACHINEDATA" form. INPUT MACHINEDATA" form (page 2) FUNCTION SELECT INPUT MACHINEDATA > x f}_> fi jez jes) rales [re [rz] rs) (nov SIMATIC s5/couase \ MACHINEDATA DEVICE: IP266 BLOCK: DB 1 Module: 11 Dimensional unit: mm _ Axis type: LINEAR Maximum deceleration [mm/sec~] (10... 9999) Acceleration fwd. Imm/sec~] (10... 9999) Deceleration fwd. [mm/sec~] (10... 9999) Acceleration rev. [mm/sec~] (10... 9999) Deceleration rev. Imm/sec~} (10... 9999) Reet NEXT PREVIOUS \ ease PAGE MDAT Figure 6-10. Machine Data Page 2 TRANSFER Header: The header is the same as on page 1 of the "INPUT MACHINEDATA" form. 6-16 EWA 4NEB 812 6057-02aIP 266 Fundamentals of COM 266 Data area: These fields are the same as those on page 1 of the screen Module 0 Meas.System O | form. Axis type oO Maximum deceleration | You must enter these data items in the appropriate fields. Remember that "Maximum deceleration" must be the highest Acceleration fwd. | absolute value. Deceleration fwd. | Acceleration rev. 1 Deceleration rev. I Type column: | = input field, O = output field Function key menu: In contrast to the function key menu for page 1, the function key menu for page 2 does not contain <F7>. And what now? > Fillin all input fields on this page. Note: You cannot exit an input field until you have entered a value. Press <F1> to screen page 3 of "INPUT MACHINEDATA". EWA 4NEB 812 6057-02a 6-17Fundamentals of COM 266 IP 266 INPUT MACHINEDATA" form (page 3) FUNCTION SELECT INPUT MACHINEDATA Fi [F2 | F3]F4] FS | F6 | F7 | Fs MACHINEDATA DEVICE: IP 266 SIMATIC ss comaee \ BLOCK: DB 1 Module: 11 Encoder type IP-STOP if CPU-STOP Gain factor Backlash comp. value Standstill monitor Max. following error PREVIOUS PAGE Following error monitoring Dimensional unit: mm [1/sec] [mm] {mm] [mm] PRINT MDAT TRANSFER HELP Axis type: LINEAR (5V/24V) (yes/no) (0.1...99.9) (0.000...64.999) (0.001...64.999) (0.001...64,.999) ext / Header: Figure 6-11. Machine Data Page 3 The header is the same as on page 1 of the "INPUT MACHINEDATA" form. 6-18 EWA 4NEB 812 6057-02aIP 266 Fundamentals of COM 266 Data area: Module Meas.System Refer to the data area for page 2 Axis type Encoder type Enter the type of encoder you are using in this field. You have a choice between two types of encoders: 5V (symmetrical encoders) 24V (asymmetrical encoders) IP-STOP if When an error occurs during execution of the STEP 5 program, it is sometimes CPU-STOP best to stop the IP. You can do so by entering yes in this field or selecting "yes" with <F7>. Active modes are interrupted with STOP. This aborts all active modes except mode 4. Gain factor This factor defines the gain factor for the position controller in the unit 1/sec. The permissible value range for the gain factor is from 0.1 to 99.9, although system limitations or machine data specifications (such as the resolution or the maximum speed) preclude the use of some of these values in the majority of cases. Backlash comp. value This value is added to the travel distance on each traversing (machining) movement that involves a reversal of the direction of travel, thus enabling compensation of backlash outside the control loop (drive backlash). The backlash is compensated only when there is positive mechanical coupling between drive and slide. When a reference point is approached, this may be the case immediately following the approach. Otherwise, you must program the movement yourself. Standstill monitor Maximum difference between the setpoint position and the actual position when the position controller is active. This value must be greater than zero and less than the maximum following error. Max. following error Maximum difference between the setpoint position and the actual position during traversing (machining) under closed-loop control. The maximum following error must be equal to or greater than the tolerance range ofthe standstill (zero-speed) monitor. Following error monitoring You can disable monitoring of the following error by entering off in this field orselecting off" with <F7>. The default is "on". "Type" column: | = input field, O = output field EWA 4NEB 812 6057-02a 6-19Fundamentals of COM 266 IP 266 Function key menu: The function key menu is the same as that on page 1 of "INPUT MACHINEDATA", You can use <F7> to select the appropriate value for the " and "Following error monitoring fields. And what now? > Fill in all fields on this screen only after an entry has been made. > Press <F1> to screen page 4 of "INPUT MAC INPUT MACHINEDATA" form (page 4) FUNCTION SELECT coulis fea ieatentiatertie) 5. _ Encoder type", "IP-STOP if CPU-STOP" Page. An input field for which there is no default can be exited HINEDATA". INPUT MACHINEDATA | Li [F2|F3 [Fa [es [F |F7 | Fe) x fp MACHINEDATA SIMATIC S5/COM2 so DEVICE: IP 266 BLOCK: DB 1 Module: 11 Ref. point coordinate Software lower limit Software upper limit Tool length offset NEXT PREVIOUS PRINT \ race PAGE MOAT Dimensional unit:mm Axis type: LINEAR [mm] (+-32767.999) Imm] (+- 32767.999) [mm] (+-32767,999) [mm] (+-32767.999) od EXIT TRANSFER Figure 6-12. Machine Data Page 4 Header: The header is the same as that on page 1 of "INPUT MACHINEDATA". 6-20 EWA 4NEB 812 6057-022IP 266 Fundamentals of COM 266 Data area for a linear axis: Module Meas.System oO Axis type Refer to the data area on page 2 The reference point coordinate must lie between the lower and upper software limit switches or at the exact position of one of these switches. Ref. point coordinate I This value specifies the lower software limit switch. This value must be lower than that for the upper software limit switch and must also be such that the axis cannot reach the lower hardware limit switch during deceleration. Software lower limit | This value defines the coordinate of the upper software limit switch. This value must be greater than that for the lower software limit switch and must also be such that the axis cannot reach the upper hardware limit switch during deceleration. Software upper limit | This value is used to compensate for tool wear. Each target position ina traversing (machining) program is offset by this value. The tool length offset is added to any previous tool offset, and can be used repeatedly. Tool length offset | "Type" column: | = input field, O = output field Data area for a rotary axis: \f you are using the IP 266 to operate a rotary axis, the two fields for the software limit switches are replaced by fields for e the start of the traversing (machining) range and e the end of the traversing (machining) range Module Meas.System oO Refer to the data area on page 2 Axis type Ref. point coordinate The reference point coordinate must lie within the traversing (machining) range or at exactly the upper or lower limit of that range. Start of traversing (machining) range This value specifies the start of the traversing (machining) range for the rotary axis, and must be lower than the value specifying the end of the traversing (machining) range. End of traversing (machining) range This value specifies the end of the traversing (machining) range for the rotary axis, and must be higher than the value specifying the start of the traversing (machining) range. Tool length offset See the table entitled Data Area for a Linear Axis "Type" column: | = input field, O = output field EWA 4NEB 812 6057-02a 6-21Fundamentals of COM 266 IP 266 Function key menu: The function key menu is identical to that for page 2 of "INPUT MACHINEDATA". And what now? > Fill in all input fields on this page. > Press <F1> to screen page 5 of "INPUT MACHINEDATA". "INPUT MACHINEDATA" form (page 5) a> FUNCTION SELECT 1 Je2]r3 ra es [rs [7 |) [i007 SIMATIC s5/cou266 \ MACHINEDATA DEVICE: FD BLOCK: DB 1 INPUT MACHINEDATA Module: 11 Dimensional unit: mm Axis type: LINEAR Zero offset 1 (+- 32767.999) Zero offset 2 (+-32767.999) Zero offset 3 (+-32767.999) Zero offset 4 (+- 32767.999) NEXT PREVIOUS PRINT \ ease PAGE MDAT TRANSFER EXIT Figure 6-13. Machine Data Page 5 Header: The header is identical to that on Page 1 of "INPUT MACHINEDATA" 6-22 EWA 4NEB 812 6057-02aIP 266 Fundamentals of COM 266 Data area: oo 3 oo oo pene ee = Module Oo You already entered the parameters for these fields on page 1. Meas.System Axis type Zero offset 1to 4 | Each of the four zero offsets is independent of the others, and can also be activated in traversing (machining) programs via G54 to G57. These values are added to the offsets used in modes 12 and 13. lf several ZOs are used in a traversing (machining) program, they are not added; instead, they replace the existing ZOs. For instance, a zero offset set with G54 would be overwritten by a zero offset set with G56. Type" column: | = input field, O = output field Function key menu: The function key menu is identical to that on page 2 of INPUT MACHINEDATA". And what now? Fillin the fields for the zero offsets. Press <F1> to screen page 6 of INPUT MACHINEDATA". EWA 4NEB 812 6057-02a 6-23Fundamentals of COM 266 INPUT MACHINEDATA" form (page 6) FUNCTION SELECT > 1x fi }> INPUT MACHINE DATA SIMATIC S5/COM266 DEVICE: FD BLOCK: DB1 Module: 11 Maximum speed Jog speed 1 fwd Jog speed 1 rev Jog speed 2 fwd Jog speed 2 rev Incremental speed NEXT PREVIOUS \ ence PAGE Dimensional unit: mm [mm/min] ot {mm/min] [mm/min] TRANSFER Axis type: LINEAR (1...65000) (1...65000) (1...65000) (1...65000) (1...65000) (1...65000) IP 266 Header: Figure 6-14. Machine data Page 6 The header is identical to that on Page 1 of "INPUT MACHINEDATA". 6-24 EWA 4NEB 812 6057-02aIP 266 Fundamentals of COM 266 Data area: ae 33 es Module: oO These fields are the same as those in the data area on page 1. Meas.System: Axis type: Maximum speed | This value defines the speed at which the axis is positioned when the power sections applied voltage is 10 V. All subsequent speed specifications must be lower than or equal to the maximum speed. Jog speed 1 fwd: | Speed for forward jogging in "Jog 1" mode. Jog speed j rev: | Speed for reverse jogging in "Jog 1" mode. Jog speed 2 fwd: | Speed for forward jogging in Jog 2" mode. Jog speed 2 rev: I Speed for reverse jogging in "Jog 2" mode. Incremental speed: I Speed for modes 6 and 7. "Type" column: ! = input field, O = output field Function key menu: The function key menu is identical to that on page 2 of the "INPUT MACHINEDATA" form. And what now? Enter all speed values in the appropriate fields. Press <F1> to screen page 7 of "INPUT MACHINEDATA". EWA 4NEB 812 6057-02a 6-25Fundamentals of COM 266 IP 266 INPUT MACHINEDATA" form (page 7) FUNCTION SELECT 1 [F2 | F3 Ja [rs | F6 | 7 | Fs) INPUT MACHINEDATA x /exeur MACHINEDATA SIMATIC S5/COM266 DEVICE: FD BLOCK: DB1 Module: 11 Reference speed 1 Reference speed 2 Reference direction Pulses/revolution Travel/revolution PLC BCD coded Polarity HW limit switch SEAS NEXT PREVIOUS \ pace PAGE Dimensional unit: mm Axis type: LINEAR [mm/min] (1...65000) [mm/min] (1...65000) [fwd/rev] [pulses/rev.] (1...65000) [mm] (0.001...400.000) [yes/no] [pos/neg] PRINT MDAT TRANSFER HELP Figure 6-15. Machine Data Page 7 Header: The header is identical to that on page j of "INPUT MACHINEDATA". 6-26 EWA 4NEB 812 6057-02aIP 266 Fundamentals of COM 266 Data area: Module: oO These fields are the same as those in the data area on page 1. Meas.System: Axis type: Reference speed 1: 1 The drive begins a reference point approach at this speed. Reference speed 1 is the higher of the two speeds for the initial approach to reference point, and must be less than or equal to the maximum speed. Reference speed 2: I The IP 266 requires this speed for an exact approach to the reference point. Reference speed 2 must be less than or equal to the maximum speed and less than or equal to reference speed 1. Reference direction: | Defines the direction for the reference point approach. Use <F7 > to choose between forward and reverse. Pulses/ | Specifies the number of pulses per encoder revolution (this information can be revolution: obtained from the encoders rating plate). Travel/ | The distance traversed per encoder revolution must be entered in this field. The revolution: value must take into account all ratios between encoder and axis. PLC BCD coded: | When you select "yes with <F7>, all coordinates transferred from the PLC are interpreted in BCD code. The value range in BCD format is restricted to +/- 9999999 pm. Polarity HW limit I This field is used to indicate which edge of the limit switch or External Stop" switch: signal is to be evaluated. Type" column: | = input field, O = output field The "travel/pulses" resolution is computed from the values for travel/revolution" and "pulses/revolution Function key menu: With the exception of <F7>, the function key menu is identical to that on page 1 of this screen form. <F7> is used to select predefined texts for the following input fields: e Reference direction @ PLCBCD coded e Polarity HW limit switch EWA 4NEB 812 6057-02a 6-27Fundamentals of COM 266 IP 266 And what now? > Fill in all input fields. = You have now entered all machine data. > Press <F6> to transfer the machine data to its destination. = "Active" appears briefly on the error line. Additional function keys in the "INPUT" menu: > You can output any page of the screen form to your printer by pressing <F4> (Print Screen function). Before attempting to start a printout, be sure that you initialized the printer with $5-DOS. > You can screen through all pages with <F1> or <F2>, and make changes if necessary. You can forward your changes to the data destination while on any page with <F6>. Press <F8> when you want to return to the "FUNCTION SELECT" menu. You must confirm your request to exit with F1. Printing out the machine data The following print menu is displayed when you start a printout by pressing <F4>: fixer SIMATIC 55 /cou26e \ MACHINEDATA DEVICE: FD BLOCK: DB100 Lines per page (40 - 95) : 72 Columns per line (80-132): 96 PRINT LO MDAT ext / Figure 6-16. Print Form Header: The header is taken from the screen form in which you selected the Print function. For example, if you are in the "INPUT MACHINEDATA" form and press <F4>, the header for the printout is taken from that screen form. 6-28 EWA 4NEB 812 6057-02aIP 266 Fundamentals of COM 266 Data area: The entries you make in the upper portion of the data area indicate how you want to end your printout. The information entered in this area is printed out at the end of the machine data or traversing (machining) program listing. DATE: -- -- --+ These items of data cannot be modified in any way, and appear at the same location on all printouts. You can enter arbitrary com- mentary in this gray-backed in- put field; the commentary then appears at this location in the printout. The information on the last line was taken from the The current date is output in the DATE field. You can change the date prior to starting the printout. The page number is output next to the word PAGE. PRESETS form. In the lower portion of the data area you will find two fields for initializing the printer. The fields can be changed only with $5-DOS. "Lines per page (40-95)": The specified number of lines per page is shown in this field. "Columns per line (80-132)": The specified number of columns per line is shown in this field. Function key menu: <F4> Press this key to start the printout. => The following message is displayed on the error line while printing is in progress: FEC Printing ... => When the printer stops, you will see the message: FEE Printed! <F8> This key has two functions. While a printout is being made, you can abort it by pressing this key. When you do so, "Abort printing (Y/N) 2 is displayed on the error line. You must either confirm the abort request by entering Y or revoke it by entering N. If you press this key when the printer has stopped, you immediately exit the Print menu. EWA 4NEB 812 6057-02a 6-29Fundamentals of COM 266 IP 266 A machine data printout has the following layout: Machinedata Source DB no. Module Dimensional unit LINEAR ' FD 1 11 mm Maximum deceleration : 500 [mm/sec~] (10...9999) Acceleration fwd : 200 [mm/sec~] (10...9999) Incremental speed : 1000 [mm/min] (10...9999) Siemens AG Printout Date 16.11.90 Simatic $5 Machinedata Page 1 COM 266 - IP 266 | LINEARAXIS Meier Figure 6-17. Machine Data Printout 6.4.2 Entering Traversing (Machining) Programs The structure of traversing (machining) programs corresponds in all essentials to a subset of the DIN 66 025 standard. The programs comprise a sequence of ASCII characters, and may not exceed 1023 characters in total. COM 266 stores traversing (machining) programs in data blocks. These blocks are distinguished from one another by a data block number. Each data block generated by COM 266 contains precisely one traversing (machining) program. COM 266 enters the data block number in the traversing (machining) program's header as program number. The total number of data blocks may not exceed 250. Data block numbers must be in the range from 0 to 255. Traversing (machining) programs can be written in two modes of representation: @ To DIN 66025 e In Text mode In addition, mode 10 ("TEACH-IN") allows you to generate traversing (machining) programs automatically. Please refer to Section 5.4 for more detailed information on traversing (machining) programs. 6-30 EWA 4NEB 812 6057-02aIP 266 Fundamentals of COM 266 Entering a traversing (machining) program > Press <F1> in the "FUNCTION SELECT" menu to screen the "INPUT" form. You are already acquainted with this screen form from your "experiments" with the "Input Machinedata* function. > Fill in the two input fields as follows: Data block : Traversing (machining) PROGRAM Block-No. : DB2 > Press <F1>, <F2> or <F3> to select the destination for your data (e. g. <F3> for disk drive). = Youare now inthe "INPUT MACHINING PROGRAM" form. INPUT MACHINING PROGRAM" form (ovovr SIMATIC 35/comase \ MACHINING PROGRAM DEVICE: FD Block: DB2 Program type (NPUT INPUT \ow TEXT Figure 6-18. Program Type Select Form HELP ext J Header: The header shows the names of the screen form and the software package. The DEVICE" and the "BLOCK" are taken from your entries in the "INPUT" form. "DEVICE" identifies the data destination. This data is stored in data block DB 2 ("BLOCK: DB2"). EWA 4NEB 812 6057-02a 6-37Fundamentals of COM 266 IP 266 Data area: The input field for "Program type" is subdivided into two sections, the first of which is for entry of the program type. Using <F7>, you can choose between e MAIN for a main program and e SUB for a subroutine In the second part of the input field, you can enter an arbitrary text as commentary. Function key menu: <F1> Press this key when you want to enter traversing (machining) programs to DIN. <F2> Press this key if you want to enter traversing (machining) programs in Text mode. <F7> _Use this key to choose "MAIN" or "SUB" in the first section of the " Program type" field. <F8> Press this key to exit the screen form. And what now? > Select the program type and enter a commentary. > Press <F1> to enter programs to DIN. > Press <F2> to enter programs in Text mode (optional). 6-32 EWA 4NEB 812 6057-02aIP 266 Fundamentals of COM 266 @ Entering programs to DIN The following screen form is displayed when you press <F1> in the "INPUT MACHINING PROGRAM" form: INPUT MACHINING PROGRAM DIN frroor SIMATIC 5s/cou6e \ MACHINING PROGRAM DIN DEVICE: FD BLOCK: DB2 Prog. header: %2 SAMPLE PROGRAM PREVIOUS OIN--> PAGE TEXT INSERT DELETE STORE TRAPRO EXIT / Figure 6-19. Traversing (Machining) Program Form to DIN with Sample Program Header: The header is taken from the Program Selection form. Data area: The program header for the traversing (machining) program is displayed on the first line in the data area. "%2 SAMPLE PROGRAM" identifies a main program stored in DB2. "SAMPLE PROGRAM" was entered in the preceding screen form as commentary. The remaining lines in the data area are for the program itself. Only one block may be entered on each line. Refer to Section 5.4 for more detailed information on the structure of traversing (machining) programs and the blocks of which they are comprised. When you have reached the last line in the data area, the screen is scrolled up one line. EWA 4NEB 812 6057-02a 6-33Fundamentals of COM 266 IP 266 Function key menu: <F1i> <F2> <F3> <F4> <F5> <F6> <F7> <F8> 6-34 If the last page of the traversing (machining) program has not yet been reached, use this key to page down. Use this key to page up. Press this key to change from "DIN" to "TEXT MODE". When you press this key, the cursor must be located in a line containing a complete, correct block. Press this key to insert a blank line above the line containing the cursor. Press this key to delete the line containing the cursor. Press this key to forward a syntactically correct traversing (machining) program to the selected destination device. The data block is assigned the number shown in the header, which is identical to the program number in the first line of the data area. If a traversing (machining) program with this number already exists, you are prompted to indicate whether or not you want to overwrite the old file. If you reply in the affirmative, the old file is overwritten. Press this key to output the traversing (machining) program to printer. Press <F8> to exit the screen form. EWA 4NEB 812 6057-02aIP 266 Fundamentals of COM 266 @ Entering traversing (machining) programs in Text mode The following screen form, in which only one block may be entered, is displayed when you press <F2> in the "INPUT MACHINING PROGRAM "form. FUNCTION SELECT INPUT MACHINING PROGRAM TEXT Keown SIMATIC S5/COM266 > MACHINING PROGRAM T E XT DEVICE: FD BLOCK: DB2 mm Tool offset: off Offset: undef Dimensions: absolute Prog. header %2 SAMPLE PROGRAM Stat. number: Function 1 [L] Function 2 [G} Function 3 [X] Target: Function 4 [F] Feed rate Function 5 [M] PREVIOUS TEXT--> BLOCK DIN (INSERT DELETE STORE Figure 6-20. Traversing (Machining) Program Form in Text Mode Header: The header is taken from the Program Selection form. EWA 4NEB 812 6057-02a 6-35Fundamentals of COM 266 IP 266 Data area: Dice ee ee The current physical unit is displayed in the first ou to all distances and speeds. e"mm" can be selected via G70 @ "0.1 in can be selected via G71 In the course of a traversing (machining) program, the unit can be changed as often as necessary via G70/G71. tput field. This unit is applied Tool offset oO The tool offset status is displayed in this field. e "off" can be selected via G40 e "negative" can beselected via G44 @ "positive" can be selected via G43 The sign of a value is not displayed in this field. Offset oO This field shows the number of the last zero offset. @ "undef" can be selected via G53 e"1on" can be selected via G54 e"2on" can be selected via G55 e"30n" can be selected via G56 e"4on" can be selected via G57 Dimensions The numerical values of the target functions (X functions} can be interpreted as either absolute or incremental values. G70 Absolute G71 Incremental Program header %2 SAMPLE PROGRAM Stat. number I Enter the block number as a numerical value in this field. A block number may (Block number) comprise up to three digits. Block numbers need not be entered in ascending order. The blocks are processed in the order in which they are entered, without regard to the block number. Function 1 [L] I Enter a number in this field when you want to invoke a subroutine. If an entry is made in this field, the text Subroutine no." is displayed. Function 2 [G] l Press <F7> to display the available G functions. An error message is displayed if you enter any G function not in this list. Function 3 [X] l Enter a target position in this field. How this target position is interpreted depends on the entry in the "Dimensions" field. "Type" column: | = input field, O = output field 6-36 EWA 4NEB 812 6057-02aIP 266 Fundamentals of COM 266 Function 4 [F] I The contents of this field depend on the preceding function in the traversing (machining) block. If the preceding ... the following is displayed: function is... Text Value Unit an X function Feed rate: 400 mm/min G04 Dwell time 1000 msec G24 Loop pass: 5 Function 5 [M] | AnM function is output at the beginning of a block. Function Output Text Number Moo Program stop 00 M02 Program end 02 mMs9 99 M01 and O1or MO3 to M98 03 to 98 No further blocks may be appended following an M02 function. Type column: | = input field Function key menu: <F1> Page down through the blocks to the end of the program. <F2> Page up through the blocks to the beginning of the program. <F3> _~Press this key to switch to "DIN" mode. <F4> __ Press this key to insert a new block in front of the block that is currently on screen. <F5> __~Press this key to delete the on-screen block. EWA 4NEB 812 6057-02a 6-37Fundamentals of COM 266 IP 266 <F6> Press this key to forward a syntactically correct traversing (machining) program to the specified destination device. The destination data block is assigned the number shown in the header, which is identical to the program number in the first line of the data area. If a traversing (machining) program with this number already exists, you are prompted to indicate whether or not you want to overwrite the old file. If you reply in the affirmative, the old file is overwritten. <F7> ~~ Use this key to select a G function. <F8> Press this key to exit the screen form without storing the data. And what now? > Enter a traversing (machining) program. Before doing so, select either DIN mode by pressing <F1> or TEXT MODE by pressing <F2>. Forward the traversing (machining) program to the specified destination device (FD, PG, IP 266) with <F6>. > Exitthe screen form with <F8>. You must confirm your intention to exit by pressing <F1>. => The "FUNCTION SELECT" menu is displayed. You have now generated machine data anda traversing (machining) program. @ Ifyou entered your data directly on the IP 266 (target device: IP 266), you can now invoke the "TEST" function. The description of this function begins in Section 6.6. @ If you stored your data on the floppy or programmer, you must first forward it to the IP 266 before continuing. You will find details on how to do so in the next section. 6-38 EWA 4NEB 812 6057-02aIP 266 Fundamentals of COM 266 6.5 Transferring an Existing Machine Data Record or a Traversing (Machining) Program Once you have generated machine data in the programmer or on floppy disk, you can load it into the IP 266 with the "Transfer" function. Press <F4> inthe "FUNCTION SELECT" menu to select the "Transfer" function. This function allows you to transfer machine data or traversing (machining) programs from a source to a destination device. The TRANSMIT" (TRANSFER) form is displayed on the programmer screen. Note: The "Transfer" function can be invoked only when the axis status is stopped (i. e. "finished"). Exception: When an operation is aborted with "Error in position control loop", the machine data can be edited and forwarded to the IP with <F6> with mode 4, even when the axis status is "traversing". "TRANSMIT" (TRANSFER) form f SIMATIC S5/COM2 ) TRANSMIT DEVICE: FD BLOCK: DB Data Block: Macht Source Target Device Block No. Drive Filename ; = Plant code t LINEAR AXIS (*= all DBs) oY Developer : MEIER Generation date : 12.12.89 RAM> EEPROM EEPROM RAM TRANSFER HELP Figure 6-21. "TRANSFER" Form EWA 4NEB 812 6057-02a 6-39Fundamentals of COM 266 IP 266 Some of the fields in the header are initially blank. The current values are not entered in these fields until you have started the "Transfer" function by pressing <F4> inthe "TRANSMIT" (TRANSFER) form. This is taken into account in the following description of the fields in this screen form. Header: @ The header is as follows before you start the "Transfer" function by pressing <F4> in the TRANSMIT" form: The word "TRANSMIT" is shown as the name of the screen form. The name of the software package is the same as in all screen forms. The DEVICE field is blank, as is the field "BLOCK: DB". e@ While the "Transfer" function is executing, the name of the screen form is supplemented by either "MACHINEDATA" or "MACHINING PROGRAM" in field 2 of the header, depending on your entries in the data area of the "TRANSMIT" form. The "DEVICE" field now shows the source device and the "BLOCK" field the number of the data block you want to transfer. Field 2 of the header indicates whether machine data or traversing (machining) programs are being transferred. Data area: Before starting the transfer, you must enter @ thesource and @ the destination. These values are displayed when the transfer function has been started. "Data Block" field: Before starting the Transfer function, select either MACHINEDATA or MACHINING PROGRAMS with <F7>. When the Transfer function is started, your selection is displayed in the header as supplement to the name of the screen form. 6-40 EWA 4NEB 812 6057-02aIP 266 Fundamentals of COM 266 Device: Select one of the following with <F7>: @ Module/IP 266 @ Programmer/PG e Disk drive/FD The next selection is displayed each time you press <F7>. DB No.: Enter the number of the data block you want to transfer. The source data block is displayed as default. You may change this number. Anasterisk (*) in this input field automatically selects all "traversing (machining) program" DBs. "" is also allowed for transferring machine data from FD to FD. The DB no. of the destination device is irrelevant. Drive: If the DEVICE is a floppy disk or hard disk, you will be prompted to specify the drive. Make the appropriate selection with <F7>. The drive identifier is taken from the PRESETS form, and cannot be changed. Filename: if you selected a drive, you must enter the filename in this field. Select a file from the list of files on the relevant drive with <F7>. "Data block missing" is displayed if no file is available. The name specified in the "PRESETS" form is displayed as filename, and cannot be changed. Plant code Developer Generation date The "Plant code", "Developer" and "Generation date fields are updated in accordance with the file selected. EWA 4NEB 812 6057-02a 6-41Fundamentals of COM 266 IP 266 Function key menu: lf the IP is disconnected from the mains power, or if a power failure occurs, the data in its RAM is lost, and must therefore be stored on EEPROMs before the IP is actually put into operation in the plant. This applies to both machine data and traversing (machining) programs. On IP start-up, this data is transferred to IP RAM. The EEPROM has a maximum storage capacity of 8 Kbytes, only 7K of which is available for traversing (machining) programs. The remaining capacity is needed for machine data and housekeeping routines. <F1> Press this key to transfer the data currently on the module to EEPROM. This data may include machine data and/or programs. <F2> _ Before the data stored on EEPROM can be used, it must be transferred to the IPs RAM. The IP 266 normally makes this transfer automatically in its restart routine. If you want to retransfer data from EEPROM to RAM (because the data in RAM has been modified, for instance), you can do so by pressing <F2>. <F4> Press this key to start the transfer you defined in the data area of this screen form. <F7> This key is used as selector key for the following input fields: "Device: " "Drive:" Filename:" <F8> = This key terminates the "TRANSFER" function and returns you to the "FUNCTION SELECT" menu. And what now? Machine data must be available on the IP 266 before you can proceed to the "TEST" form. If no valid machine data is in the IPs RAM, you must forward this data to the IP 266 from the programmer, disk or EEPROM. > Select the source device and the number of the data block containing the machine data. If your source is a disk, enter the drive and the name of the source file. Select the IP 266 as destination. Start the transfer with <F4>. Press <F8> to return to "FUNCTION SELECT. vvvv If you have not yet generated machine data, please do so. You will find details on this procedure in Section 6.4.1. If your machine data is on EEPROM, transfer it to the IPs RAM with <F2>. 6-42 EWA 4NEB 812 6057-02aIP 266 Fundamentals of COM 266 6.6 COM 266 Test Mode COM's Test Mode allows you to test the interplay between the IP 266 and the mechanical elements of the drive in all modes. A Caution if your system has just been installed, please follow the steps below in order. Prerequisites: @ The programmer must be interfaced to the IP 266. @ The programmer must be in "ON LINE" mode. You can change the programmer mode by pressing <F2> in the "PRESETS" form. Start the "Test" function by pressing <F3> in the "FUNCTION SELECT" menu. => The "TEST" form is displayed. Figure 6-22 shows the hierarchical structure of the "TEST" form. There are two "TEST" modes: When the "TEST" function is invoked, COM 266 is in the "Actual-value display" mode. The default operating mode is the "FOLLOW-UP" mode (mode 4). This mode has not been started, however. The output fields in the data area are not yet updated. The second "TEST" mode is "Mode Select". In this mode, you can make changes in the screen forms input fields. FUNCTION SELECT F1 LF2 1 F3 | F4 5 FS | F6 JF? LFS Actual-value display mode Mode Select mode TEST v Mode table | Jr2 [3 [ra] rs [re F7 | F8 a Figure 6-22. Hierarchical Structure of the TEST Form EWA 4NEB 812 6057-02a 6-43Fundamentals of COM 266 IP 266 And now? > Once you have become acquainted with the two "TEST" form modes, you can begin your first test. > The two "TEST" modes are described in detail in Sections 6.6.1 and 6.6.2. 6.6.1 Actual-Value Display" Mode ( SIMATIC S5/COM acs) TEST DEVICE: IP 266 BLOCK: DB Actual value : 12.105 [mm] Following error: . 2 [mm] Distancetogo : . 0 [mm] Aux. function : Mo2 Tool ref, pt. : reset CLC > oon Teach-Mode : off Status > finished Mode FOLLOW-UP Program Distance [mm] Override (1% ... 200%) \ gr.mone Figure 6-23. "TEST" Form In this "TEST" mode, the IP 266 provides the current actual position, following error/speed distance to go and switching functions. i These values are recomputed and redisplayed at regular intervals. Header: Header field 2 shows the name of the on-screen form, which consists only of the word TEST, in spaced type, until you have invoked an operating mode (Figure 6-23). Field 1 is initially blank, and is not filled in until you have started a mode (see Section 6.3.3). Note: COM 266 automatically generates mode 17 (reset errors) when you exit the "TEST" form with <F8>. When "TEST" is reinvoked, "START ERROR RESET" is displayed in field 2 and the name of the "TEST" form in field 1. 6-44 EWA 4NEB 812 6057-02aIP 266 Fundamentals of COM 266 Field 5 shows the name of the software package, i. e. SIMATIC S5/COM 266. IP 266 is displayed in field 4 ("DEVICE"), and the text "BLOCK: DB" in field 6. Data area: Actual value: The current position of the axis is displayed in this field. The basis for the display is the specified dimensional unit. Following error: The difference between the actual position and the setpoint position is displayed inthis field. The upper limiting value is defined in the machine data parameter Max. following error" (see Section 5.1.6). Speed In modes 3 and 4, "Following error" is replaced by "Speed". This field shows the actual speed computed by the IP 266. Distance to go: fe) When a mode is started with absolute or relative target position specification, the IP 266 computes the distance between the target position and the current position of the drive. During traversing, the continually changing value is displayed in this field. Switching function: oO M functions may be programmed in a traversing (machining) program. When mode 8 or 9 is started in a traversing (machining) program, the programmed M functions are displayed in this screen form field. Tool ref. pt.: 3 The word "set" appears in this field when mode 5 has executed. The word "reset" is displayed if there is no reference point. CLC: O This field shows the controller status. "On" is displayed in all modes except 3 and 4. Off" is displayed in modes 3 and 4. Teach-Mode: oO The word on" is displayed in this field when a traversing (machining) program is generated in mode 10. The word "off" appears only when mode 10 is terminated with mode 11. Status: fe) finished: No mode has been started. As soon as the zero-speed monitor is tripped during a traversing movement, the displayed changes from "running" to finished. running: Amode has been started and is still in progress. Mode in actual-value display" mode, these fields are static output fields, and are used Program to display the specified mode and all parameters. Distance Override "Type" column: O = output field EWA 4NEB 812 6057-02a 6-45Fundamentals of COM 266 IP 266 Overview of the output fields in the "TEST" form Table 6-2 provides an overview of TEST" form output fields @ following error @ distance to go and @ aux. function and their use in the various modes. The "following error" is replaced by the "speed" in the open-loop control modes. Table 6-2. entO Fields OTeOlis i oalulalwlin] = 10 =/2)/a4/42/4./a2/5n] 6] oT ein altulastwin] a 6-46 EWA 4NEB 812 6057-02aIP 266 Fundamentals of COM 266 Function key menu: <F1> Press this key to screen the "Mode Select" form. The actual-value display is "frozen" to the current value. The "Mode", "Program", "Distance" and "Override" fields become input fields, and the cursor is set to the start of the "Mode" field. <F2>...<F6> These keys are mode-dependent. Refer to Table 6-3 in Section 6.6.2 for a key- to-mode assignment list. <F8> Press this key to exit the "TEST" form and screen the "FUNCTION SELECT" menu. COM 266 generates mode 17 when you press this key. And what now? The "TEST" forms "Mode Select" subform is described in detail in the next section. 6.6.2 Mode Select" Mode / TEST SIMATIC S5/COM 26s \ JOG_1 STOP DEVICE: IP 266 BLOCK: DB 1 Actual Value : 50.602 {mm} Following error : 0.013 [mm] Distancetogo : 0.000 [mm] Aux. function : Mo2 Tool ref. pt. $ reset CLC >on Teach-InMode_ : off Status : finished Mode : FOLLOW-UP Program Distance [mm] Override (1% ... 200%) ACT. \yatu ES START STOP Figure 6-24. Mode Select Form on Header: The header is identical to that for the "Actual-Value Display mode of this screen form. EWA 4NEB 812 6057-02a 6-47Fundamentals of COM 266 IP 266 Data area: Soon : an : Suess Actual value, distance to go, following error the mode was changed. Aux. function Oo The last M function activated is displayed in this field, or "255" ifnoM functions were invoked (in the PLC: KH format= "FE", KF format= "1"). M02 is output following termination ofa traversing (machining) program. Mode I Enter the number of the required mode in this field. The mode number must be in the range from 1 to 19. The mode identification text is displayed at the right of this number. Press <F7> to screen a list of all modes (1 to 19). The display for mode 5 differs from that of the other modes in that an additional input field is provided at the right of the mode identification text; using <F7>, you can set this field to either "set" or approach. Program | Enter the number of a traversing (machining) program in this field for modes 8, 9 and 10. Distance I An entry must be made in this field for modes which require a distance specification for an absolute or relative positioning operation, a zero offset or a tool offset. Override 1 The speed for a positioning operation can be modified by entering an override factor in this field (for modes 1 to 7). The positioning speed can also be altered during traversing. The override factor must be forwarded to the IP with <F>. "Type" column: | = input field, O = output field EWA 4NEB 812 6057-02aIP 266 Fundamentals of COM 266 Function key menu: The function key menu in this screen form is mode-dependent. Table 6-3 shows the allocation of the five commands "Start", "Stop", "Forward", "Reverse" and "Transfer" to modes 1 to 19. Table 6-3. Function Keys <F2> to <F6> in Modes 1 to 19 Jog 1 Jog 2 Jog open loop Follow-up mode Reference point approach incremental absolute incremental relative 8 Automatic 9 Autom. single statement 10 Teach-Inon 11. Teach-In off 12. Zero offset absolute 13 Zero offset relative 14 Clear zero offset 15 Tool offset 16 Tool offset off 17 Delete error 18 Drift compensation 19 Drift compensation off e x Rotary axis only The current speed can be modified via the override factor when the axis is "traversing (machining)" (axis status running"). 2 Acknowledge an MOO function (programmed stop) 3 Execute next block EWA 4NEB 812 6057-02a 6-49Fundamentals of COM 266 IP 266 Auxiliary screen form for Mode Select Different modes require different entries in the "TEST" forms input fields. Table 6-4 shows the allocation of input fields to modes. Table 6-4. Input Fields for Modes 1 to 19 sheng Sas Bs af: sa Bee ce En st Socio sScue pear : : si i Program @l\ele Distance/Targe ele ele t Override elel/e ele @ = Entry required for this mode Selecting a mode If you do not know the number of the mode you want to select, press <F7> (HELP) to screen a mode list. (rest SIMATIC $5 / coma6d\ INCREMENTAL_ABSOLUTE START DEVICE: IP266 BLOCK: DB Operating modes for testing 1 Jog speed 1 11 Teach-in off 2 Jog speed 2 12 Zero offset absolute 3 Jog openloop 13 Zero offset relative 4 Follow-up mode 14 Clear zero offset 5 Reference point approach 15 Tool offset 6 Incremental absolute 16 Tool offset off 7 Incremental relative 17 Delete error 8 Automatic 18 Drift compensation 9 Autom.single statement 19 Drift compensation off 10 Teach-In on Enter number of operating mode TRANSFER Figure 6-25. Table of Operating Modes for Testing The Help menu lists all modes and their numbers. Header: The header does not change when you screen the Help menu. Data area: The data area comprises a single input field. After viewing the mode list, enter the number of the mode you want in this field. 6-50 EWA 4NEB 812 6057-02aIP 266 Fundamentals of COM 266 Function key menu: <F6> _~Press this key to transfer the mode number you entered in the Help menu to the Mode field inthe "TEST" form. <F8> Press this key to exit the Help menu without transferring the mode number to the "TEST" form. The mode always defaults to 4 when you exit Help with <F8>. And now? > Practice using the TEST forms. Enter various different modes and view the changes in the data area and the function key menu. You have now familiarized yourself with the COM 266 screen forms and menus you need to start with. The remaining screen forms, which are also invoked in the "FUNCTION SELECT" menu, are described in detail in the following subsections. 6.7 Output The "Output" form is invoked by pressing function key <F2> in the FUNCTION SELECT menu. This screen form allows you to display machine data or traversing (machining) programs on the programmer. Press <F1>, <F2> or <F3> to select the data source: <Fi>: IP 266 <F2>: Programmer (PG) <F3>: FD The structure of the "Output" form is the same as that ofthe "INPUT" form shown in Figure 6-7. EWA 4NEB 812 6057-02a 6-57Fundamentals of COM 266 IP 266 "OUTPUT" form / SIMATIC $5/CoM 266 \ OUTPUT DEVICE: BLOCK: DB Data Block : Block No. : PG FD HELP -, Figure 6-26. Block Selection The structure of each "OUTPUT" form is identical to that of the corresponding "INPUT" form; the only difference is the name of the form shown in the header. The data display begins when you have pressed <F1 >, <F2> or <F3>. @ Output machine data The seven screen form pages of machine data are displayed when you entered MACHINEDATA in the Data Block field or selected MACHINEDATA with < F7>. The data on each screen page is identical to that on the corresponding page of the "INPUT MACHINEDATA" form. All fields are input fields, i. e. the data in these fields can be overwritten. You can store and print out your new data. @ Output traversing (machining) program You can display your traversing (machining) program by entering MACHINING PROGRAM in the Data Block field or by selecting MACHINING PROGRAM with <F7>. You can edit the Program and store any changes made. 6-52 EWA 4NEB 812 6057-02aIP 266 Fundamentals of COM 266 6.8 Delete Screen the "DELETE" form by pressing <F5> inthe "FUNCTION SELECT" menu. / SIMATIC S5/COM aes \ DELETE DEVICE: BLOCK: DB Data block : MACHINEDATA Source device : Block-No.: DB (* = all DBs) \ Figure 6-27. DELETE Form Header: Prior to first-time execution of the "DELETE" function: You will see only the word "DELETE" as screen form name. The "DEVICE" field is initially blank, as is the "BLOCK" field. e@ Machinedata" or "Traversing (machining) Program" appears in the header while the "DELETE" function is executing, depending on your entry in the data area of the screen form. The "DEVICE" field now shows the identifier of the device on which data is being deleted, and the "BLOCK" field the number of the data block. The screen form name, which is now complete, indicates what is being deleted (machine data or traversing (machining) programs). e Further delete operations Each time a new Delete operation is started, the header shows the information for the preceding Delete. EWA 4NEB 812 6057-02a 6-53Fundamentals of COM 266 IP 266 Data area: You must specify the following before executing the "DELETE" function: @ The type of data block @ The device on which data is to be deleted e@ The number of the data block to be deleted Data block J Use <F7> to select either "MACHINEDATA" or MACHINING PROGRAM". Source device I This field is used to select the device on which data is to be deleted. Use <F7> for cyclic enabling of the source devices. Block No.: DB I Enter the number of the data block to be deleted in this field or enter "*" to delete all existing DBs. Type column: | = input field Function key menu: <F5> When you have specified the file you want to delete, press this key to start the Delete operation. The output fields in the header are updated. A prompt is displayed on the error line asking you whether you are sure you want to start the Delete operation. If you confirm with <F1>, the word "Deleted" appears to show you that the Delete operation has been successfully completed. Entry of a non-existent file is flagged by an error message. <F7> Use this key in the "Data block" field to choose between "MACHINEDATA" and MACHINING PROGRAM". <F8> Use this key in the "Data block" field to choose between "MACHINEDATA" and MACHINING PROGRAM". 6-54 EWA 4NEB 812 6057-02aIP 266 Fundamentals of COM 266 6.9 information You can invoke this function to screen an overview of all machine data or traversing (machining) programs stored on the IP 266, FD or PG. This function is invoked by pressing <F7> in the "FUNCTION SELECT" menu. => The data area of the "INFORMATION screen form is blank when this function is invoked. Axeoruar10N SIMATIC S5/COM 206) INFORMATION: DEVICE: BLOCK: DB Data block : Name Length Name Length Name Length Name Length eu PG FD PRINT HELP Figure 6-28. "INFORMATION" Form with Blank Data Area Header: The header contains the following information: @ Screen form name: INFORMATION INFORMATION e Name of the software package: SIMATIC $5/COM 266 DEVICE field The contents of this field depend on which key you press to start the function (i. e. <F1>,<F2> or <F3>). Data area: Until you have selected a device, no filenames are displayed in the data area and the cursor is set to the screen forms only input field. Choose between MACHINING PROGRAM and MACHINEDATA. The portion of the screen form beneath the line Name Length Name Length Name Length Name Length is not filled in until the device has been selected. EWA 4NEB 812 6057-02a 6-55Fundamentals of COM 266 IP 266 Example: Press <F7> in the "FUNCTION SELECT" menu to invoke the Information function. > The text MACHINEDATA is displayed in the Data block field. Press <F3> to select a disk drive (FD) as source. => Alldata blocks on the source device that contain machine data are listed in the data area. You specified the disk drive in the "PRESETS" form. Function key menu: <F1> ~The Information function outputs the IP 266s data directory. <F2> ~The Information function outputs the programmer's data directory. <F3> = The Information function outputs the numbers of the data blocks on the disk. <F4>__s This key is added to the function key menu after you have selected a device, and is used to output the data block list to printer. Note: The printer must be on and must also have been initialized with $5-DOS. <F7> Use this key to select the data block type, i.e. MACHINEDATA or MACHINING PROGRAM <F8> Exit and return to the "FUNCTION SELECT" menu. 6-56 EWA 4NEB 812 6057-022IP 266 Fundamentals of COM 266 6.10 COM 266 Error Messages in all COM 266 screen forms, one line is reserved to display error codes and the corresponding error messages. F1 [F2]F3]F4]F5| re [Fz les These messages provide information on incorrect parameters or parameter syntax errors and problems relating to a positioning operation or to the hardware. Once an installation has been correctly initialized, any error messages normally relate directly to positioning operations or to the limits of the traversing (machining) range. These errors are flagged in the TEST" form and on the PLC. An error message can be cleared by starting a new mode in which that error cannot occur or by invoking mode 17. When an error message has occurred and the COM 266 test mode is exited, the error message is cleared on both the programmer and the PLC. Note: When the test mode is exited, COM 266 invokes mode 17. EWA 4NEB 812 6057-02a 6-57EWA 4NEB 812 6057-02a7.1 Output Frame (PLC CPU IP 266) 7.1.4 Byte 0: Mode .......0eeereee ees 7.1.4 Byte 3: Override Factor .......-. 7.2 Input Frame (IP 266 PLCCPU) . 7.2.2 Byte 1: MFunction ........++--- 7.2.3 Byte 2: Status Bits .........+-+-- 7.2.4 Byte3:ErrorFlags ........--+-- 7.2.5. Bytes 4 to 7:Input Values for the Monitoring Functions .........- 7.2.6 Operating the IP 266 in the ET 200 eee eee tee eee eee ee ee pee eee eee eee ee ee ee eee 7.1.2 Byte 1: Commands .......-.eeeeeeee rene ener eect reeset eeeen nese nes 7.1.3. Byte 2: Program Number, Reference Point or EEPROM RAM Parameters .....--- esse ener eet e cree eeeees eee eee eee eee eee eee eee 7.1.5 Bytes 4to 7: Positioning Specifications ......+.++seeeeeeeeer cere eees 7.1.6 Example of aComplete Output Frame .....--- +e sere reer reece eee eee eee ee ee ee 7.2.1 Byte 0: Mode ....... 0. cece eee cence e este eee eeneeesee ste esencanes eee eee wee eee eee eee pee he ee eee meee eee ee eee eee eee ee eee ee eee eee eeee eee ee eee eee eee ee seen eee nee eee eee eee hwh anu u 10 11 13 14 15 EWA 4NEB 812 6057-02a: oe 2 : ee : ES = Example of Data Interchange Between CPU and IP 266 (inslot 3) ... Interpreting a Job Order in Dependence on the TOGGLE Bit ......... Ds cnn UNS baht Module Address Assignments ............0ceccccccuceccccee Addressing of the Output Frame ..........0.--cccceeeeee.. Overview of the Output Frame ......0. 0. cece ccc eec cece. Command Codes ....... 0.0... cece ec ceencccceecccucceece. Position Specifications ........... ccc. ccc ee cece Entering a Small Negative Value SS ip ace oes ain ce ecmielielere! ave aiuwiet way weve cts Addressing of the Input Frame Oe: eogc erg: pia mae ecaaa le aile aca ava alata" Overview ofthe InputFrame ....................-. SNNNNSNNONSU ' WW OOARNN = EWA 4NEB 812 6057-02aIP 266 Communication Between the CPU and the IP 266 7 Communication Between the CPU and the IP 266 The IP 266 can be plugged into slots 0 to 7 of the $5-100U programmable controller. Eight bytes are reserved in both the process input (PII) and process output (PIO) image for each slot. The CPU and the IP 266 use all eight bytes of the Pll and the PIO to interchange data. Please note that the IP 266 requires version 6ES5-100-8MA02, or a newer version, of the CPU 100. in this manual, an interchange of data is referred to as a "frame". From the STEP 5 point of view, there are two types of "frames": Data interchange: PLCCPU->IP266 Output frame Data interchange: IP 266PLC CPU Input frame Table 7-1. Module Address Assignments aot ri addresses The permissible address range is from 64 to 127. The IP 266 is addressed with byte-oriented or word-oriented Load and Transfer statements, as are analog input or analog output modules. , r CPU TQWS88, TQW 90, TQW92 and TQW94 IP LIW88, LIWS0, LIW92 and LIW94 266 A. x Figure 7-1. Example of Data Interchange Between CPU and IP 266 (in slot 3) The IP 266 interchanges data with the programmable controller's CPU over the 100U bus. To make this possible, you must write operator commands to the process output image (PIO). From here, these commands are forwarded to the IP 266 once in each data cycle. A bit in byte 1 of the output frame prevents multiple execution of identical job orders. The data in the output frame is needed to operate the IP 266, providing the IP 266 with information on @ the mode e@ the parameters and e the operations to be carried out. Data fromthe IP 266 is forwarded to the Pll in each firmware cycle (every 3.75 mis). EWA ANEB 812 6057-02a 7-1Communication Between the CPU and the IP 266 IP 266 7.1 Output Frame (PLC CPU- IP 266) The allocation of the bytes in the output frame depends on which slot the IP 266 is plugged into in the PLC. Table 7-2 shows the allocation of the output bytes (QB) to the current slot numbers. Table 7-2. Addre ne ssing of the Output Frame 1 72 73 74 75 76 77 78 79 2 80 81 82 83 84 85 86 87 3 88 89 90 91 92 93 94 95 4 96 97 98 99 100 101 102 103 5 104 105 106 107 108 109 110 111 6 W12 113 114 115 116 117 118 119 7 120 121 122 123 124 125 126 127 Table 7-3. Overview of the Output Fram en Mode codes Bit7 Bit 6 Bit5 Bit4 Bit3 Bit 2 Bit 1 Bit 0 4 KM TOGGLE 0 0 TRANS REV FWD STOP START Byte parameter for various modes KM/KF Override factor KF Binary-coded: KF 16-bit fixed-point number with sign (bit 7 in byte 4) for forwarding the integer digits in the value to the IP 266. BCD: KH byte 4, bits 4 to 7: sign of the BCD number byte 4, bits O to 3 and byte 5, bits Oto 7: 3 BCD digits Binary: KF 16-bit binary number for forwarding the decimal digits to the IP 266. BCD: byte 6, bits 4 to 7: least-significant integer KH byte 6, bits Oto 3 and byte 7, bits Oto 7: three decimal digits in the BCD number 7-2 EWA 4NEB 812 6057-02aIP 266 7.1.1 Byte 0: Mode Byte 0 is used for coding the modes, which you can invoke via a STEP 5 program. Communication Between the CPU and the IP 266 To choose a mode, enter one of the mode numbers listed in the table below in byte 0 in KF format. 1 |JOG1 2 |JOG2 3 | CONTROLLED JOG 4 | FOLLOW-UP MODE 5 | REFERENCE POINT 6 | INCREMENTAL ABSOLUTE 7 | INCREMENTAL RELATIVE 8 | AUTOMATIC 9 | AUTOMATIC SINGLE BLOCK 10 | TEACH-IN ON 11. | TEACH-IN OFF 12 | ZERO OFFSET ABSOLUTE 13 | ZERO OFFSET RELATIVE 14 | CLEAR ZERO OFFSET 15 | TOOL OFFSET ON 33 34 71 72 73 99 ACKNOWLEDGE ERROR DRIFT COMPENSATION ON DRIFT COMPENSATION OFF TRANSFERRING MACHINE DATA RAM < EEPROM UNRESTRICTED SPEED SPECIFICATION READING OUT THE UNRESTRICTED SPEED SPECIFICATION DISABLING THE MONITORS ENABLING THE MONITORS READ ACTUAL POSITION READ FOLLOWING ERROR READ DISTANCE TO GO SYNCHRONIZE IP Note: Mode 99 must be started before issuing the first job order. Modes 71 to 73 are monitoring modes, and can be started in parallel to all other modes. Even while a mode is in progress, you can switch between modes 71 to 73 without affecting the process. EWA 4NEB 812 6057-02aCommunication Between the CPU and the IP 266 IP 266 7.1.2 Byte 1: Commands The commands for executing a mode depend on the mode specified in byte 0. Table 7-4 lists the permissible commands for all modes. Table 7-4. Command Codes START "71 0 0 0 0 6 Oo 1 STOP v1 0 08 680 60 4 0 FORWARD "1 09 08 60 08 +4 @ 4g REVERSE o/1 0 0 0 1 0 0 0 TRANSFER v1 Oo 0 1 OO O oO 0 Note: Only one of the bits 0 to 4 may be set at any given time. An error is flagged if you set more than one of these bits, and the job request is not serviced. Bits 5 and 6 must always be "0". TOGGLE bit Bit 7 has a special function, and is used as Execute bit. A change in the value of this bit informs the IP 266 that a new job request has been issued. In this case, the IP 266 interprets the frame as a new job request. The next job cannot be started until bit 7 once again changes its signal state, thus ensuring that a given job will not be reinterpreted and restarted in every cycle. This bit must be set to "0" in the restart OBs, thus ensuring that the first job will always be started on a change from 0 -> 1. The IP 266 scans this TOGGLE bit in each firmware cycle, and starts a new job where appropriate (see Figure 7-2). IP 266 cycle Bit? Job request is interpreted in this cycle v Cycle trigger; beginning of a new cycle Figure 7-2. Interpreting a Job Order in Dependence on the TOGGLE Bit 7-4 EWA 4NEB 812 6057-02aIP 266 Communication Between the CPU and the IP 266 Example: Give the IP 266 the Start command for the specified mode by coding byte 1 as shown below. Before the command was forwarded to the IP, bit 7 was 0. This issues the Start command "Forward" to the IP 266. The mode is started because the TOGGLE bit (bit 7) changed from 0 to 1. 7.1.3 Byte 2: Program Number, Reference Point or EEPROM <~ RAM Parameters The contents of this byte depend on the specified mode. In modes 5, 8, 9, 10 and 26, byte 2 is used as byte parameter. It is irrelevant in all other modes. Reference point: Re BitO = O : approach | 5 _ BitO = 1 :set X: variable; bit 1 to 7 irrelevant 8 Number of the machining Example: 9 program - KF = +7 10 Program no. 7 26 Direction of data transfer: o}o}lojojo];ojo IP EEPROM <> IP RAM BitO = 0: RAM> EEPROM Example: This bit combination is 1: EEPROM > RAM used to transfer data from the IP 266s EEPROM to IP RAM, i.e. the current RAM contents are overwritten. 7.1.4 Byte 3: Override Factor Byte 3 is the second of the byte parameters, and contains the override factor. A valid value must be entered in this byte for all modes which allow modification of the speed via an override factor. The value must be in the range from 1% to 200%, and should be entered in KF (fixed-point constant) format if possible. The override factor is transferred in byte 1 to the IP 266 with "TRANSFER". EWA 4NEB 812 6057-02a 7-5Communication Between the CPU and the IP 266 IP 266 Example: Assuming you want to operate your drive in mode 1 (JOG 1) with an override factor of 75%. Enter the number in byte 3 in binary (KF format). KF = +75 Set bit 4 in byte 1 to activate the override factor during a traversing movement. 7.1.5 Bytes 4 to 7: Positioning Specifications A number of IP 266 modes require specification of a position. This value may be: @ an absolute target position or coordinate (see modes 6 and 12) or @ arelative position (see modes 7, 13 and 15) Enter this value in bytes 4 to 7 of the output message as follows: able 7-5. Position Specifications Sign and Sign and the integer digits three highest integer digits Decimal First integer digit digits and 3 decimal digits The value can be entered in one of two formats. The value range depends on the format used: Binary: +32767.999 BCD: _+ 9999,.999 Binary-coded positions 15 bits are provided for the integer portion of the number. It is thus possible to represent the number 215- 1, or 32 767. In the case of a negative number, the integer portion is represented as two's complement. The decimal digits are specified as an absolute value. 7-6 EWA 4NEB 812 6057-02aIP 266 Communication Between the CPU and the IP 266 BCD-coded positions The sign is specified in bits 4 to 7 of byte 4. If the number is negative, bit 7, at least, must be "1". Since there are three decimal places, four decades are still available for the integer portion of the number. Integer positions Byte 4 Byte 4 Byte 5 Byte 5 Byte 6 (bits 4 to 7) Decimal positions Byte 6 Byte 6 (bits 0 to 3) Byte 7 Byte 7 Positions in the range 0 to - 0.999 Special rules govern the definition of a binary value between -1 and 0 (e. g. - 0.5). These values have an integer value of - 0, which cannot be represented as twos complement. When you want to specify a position in this range, you must enter the values that make up the position in the following order: 1. Enter integer position "0" as a positive value in bytes 4 and 5. 2. Enter the decimal positions as a negative number in twos complement representation in bytes 6 and 7. Asmall negative number in BCD format is defined in the usual manner. Example 1: The drive is to be moved a distance of - 50.500 mm in "relative increment mode (mode 7). . - 50 . 500 Binary KF . . . . = sign and integer positions = decimal positions BCD KH 8005 0500 = sign and integer positions = 1 integer and 3 decimal positions Integer positions Decimal positions Byte 6 | l 500 Byte 7 t Byte 7 L EWA 4NEB 812 6057-02a 7-7Communication Between the CPU and the IP 266 IP 266 Example 2: The drive is to be moved the very short distance of - 0.500 mm in " relative increment mode" (mode 7). When you enter the value in binary, you must specify the decimal digits as a negative number. Entering a Small Negative Value = 2 ease - Ws ee 0 - 500 Binary KF . . = sign and integer positions = decimal positions BCD KH 8000 0500 = sign and integer positions = 1 integer and 3 decimal positions 7.1.6 Example of a Complete Output Frame The drive is to be moved backward - 35.750 mm in "relative increment mode" (mode 7) at 20% of the incremental speed. BCD is to be used as data format. The data formats recommended in Table 7-3 have been used in the table below for the output frame. Output frame: Mode7 Bit 3: REVERSE command 1 _ 41} 0 0 1 : Bit 7: TOGGLE bit 2 0 _ Not relevant in this mode 4,5 8003 __ Relative distance - 35.750 mm 6,7 5750 The TOGGLE bit (bit 7) must change its value each time a command is issued. If it was 0 for the last command, you must now enter a 1. 7-8 EWA 4NEB 812 6057-02aIP 266 Communication Between the CPU and the IP 266 7.2 Input Frame (IP 266 PLC CPU) The allocation of the bytes in the input frame depends on the slot used for the IP 266 in the programmable controller. Like Table 7-2 for the output frame, Table 7-7 shows the allocation of the input bytes (IB) to the current slot numbers. 1 72 73 74 75 76 77 78 79 2 80 81 82 83 84 85 86 87 3 88 89 90 91 92 93 94 95 4 96 97 98 99 100 101 102 103 5 104 105 106 107 108 109 110 111 6 112 113 114 V5 116 17 118 119 7 120 121 122 123 124 125 126 127 Table 7-8. Overview of the Input Frame Current mode M function KF Bit7 Bit 6 Bit5 Bit 4 Bit 3 Bit 2 Bit 1 Bit oO KM o/1 0/1 o/1 ot o/1 o/1 o/1 or Status bits for axis, controller and machine data Current IP 266 error codes KH Bytes 4 to 7 are used for actual position, distance to go or following error, depending on the specified mode and on the current monitoring command. Binary: KF 16-bit fixed-point number with sign (bit 7 in byte 4) used to forward the integer positions of the value to the IP 266. BCD: KH Byte 4, bits 4 to 7: sign of the BCD number Byte 4, bits Oto 3 and Byte 5, bits Oto 7: 3 BCD digits #] Binary: KF 16-bit binary number used to forward the decimal positions to the IP 266. BCD: KH Byte 6, bits 4 to 7: least-significant integer Position Byte 6, bits 0 to 3 and Byte 7, bits 0 to 7: three decimal positions EWA ANEB 812 6057-02a 7-9Communication Between the CPU and the IP 266 IP 266 7.2.1 Byte 0: Mode The IP 266 acknowledges the mode in byte 0. This value can be read in KF (fixed-point constant) format. Example: The IP 266 returns the mode that is currently in progress or was just executed in byte 0 of the input frame. KF = +2 = The current mode is mode 2 (JOG 2). Note: Neither the current monitoring mode (71, 72 or 73) nor mode 99, which synchronizes the IP 266, is acknowledged. 7.2.2 Byte 1: M Function In modes 8 and 9, the drive is positioned via machining programs. If M functions were written in these programs, their values are entered in byte 1 when the relevant machining block is processed. The value is best read out in KF format. Value range of Mnn: nn is a two-digit number in the range 00 to 99. If no M function is programmed, the IP 266 forwards the three-digit number "255" to the COM program (PLC format KH: "FF"; format KF: "- 1"). Example: The IP 266 returns the following in byte 1: KF = +50 => An M50 function has been written in the machining program. 7-10 EWA 4NEB 812 6057-02aIP 266 Communication Between the CPU and the IP 266 7.2.3 Byte 2: Status Bits v IP 266 is synchronized 1 1 1 Number format: 1 = BCD, 0 = BINARY Axis is in position Controller is on No reference point No valid machine data IP266 is in Teach-In mode Job completed; 0 = Jobin progress BitO =1 The IP is synchronized. This bit is set to "1" if the IP 266 was correctly synchronized with mode 99. = 0 This bit is set to "0" on every IP 266 runup (Ident run). Bit 1: Specified number format Binary or BCD has been entered in the machine data on the IP 266. The IP 266 returns the relevant code in bit 1 so that you will be able to interpret the values for position specifications correctly. =1:BCD = 0: Binary Bit2 =1 The axis is in position. This bit is set when the actual position is within the standstill or zero-speed monitor's tolerance range (see Section 2.5.6). This bit also goes from 0 to 1 when a dwell time has expired. Bit3 = 1 Thecontroller is on. This bit is always set when the position controller is on. = 0 This bit is set to "0" in modes 3 and 4. Bit4 =1 The IP 266is in Teach-In mode. This bit is set when you select mode 10 (Teach-In mode). = 0 This bit is reset to "0" when the Teach-In mode is terminated by invoking mode 11. EWA 4NEB 812 6057-02a 7-11Communication Between the CPU and the IP 266 IP 266 Note: When mode 10 is aborted because of an "error in the position control loop", the IP 266 enters mode 4. When mode 4 is terminated with the Stop command, the Teach-In mode must also be terminated by invoking mode 11. BitS =1 No reference point has been set. Target positions may be specified or a machining Program invoked only when a reference point has been set. An error is flagged if you attempt to execute an operation that requires a reference point. =0 The reference point is set. Bit6 =1 Valid machine data is not available. You can start a mode only when the IP 266 has been correctly initialized, i. e. when valid machine data is available. = 0 Valid machine data is available on the IP 266. Bit7 =1 This bitisset whena job has executed. Inmodes 8 and4Q, it is set only when the relevant mode has terminated. It is not set after single machining operations. = 0 The job is in progress. Example 1: The reference point is set: The IP 266 services a job request in a controlled mode (e. g. mode 6). The status data is returned in BCD format. All input data is valid. The IP 266 returns the following in byte 2: y IP 266 is synchronized BCD-coded data Axis is not in position Controller is on Teach-In off Reference point is set Machine data is OK Job is in progress 7-12 EWA 4NEB 812 6057-02aIP 266 Communication Between the CPU and the IP 266 Example 2: The IP 266 receives a request to position the axis in a controlled mode (mode 1, 2 or 7). All status data is returned in binary. The machine data is correct. There is no reference point. The IP 266 returns the following in byte 2: 4 IP 266 is synchronized BCD-coded data Axis is in position Controller is on Teach-In off No reference point Machine data is OK Job is in progress 7.2.4 Byte 3: Error Flags IP 266 errors are flagged in bits 0 to 7 of byte 3. The error code is right-justified and in binary. Use KH (hexadecimal constant) format to read the error code. You will find a list of error messages in Section 10. The error codes forwarded to the PLC are identical to those output by COM 266. EWA 4NEB 812 6057-02a 7-13Communication Between the CPU and the IP 266 IP 266 7.2.5 Bytes 4to 7: Input Values for the Monitoring Functions In each firmware cycle, the IP 266 returns a monitoring mode-dependent value. If you entered a monitoring function in the output frame for the IP 266, the IP 266 returns a current value in bytes 4to 7 at regular intervals. These values can be read out in either KF or KH format. Integer positions Byte 4 Byte 4 Byte 5 Byte 5 Byte 6 (bits 4 to 7) Decimal positions Byte 6 Byte 6 (bits 0 to 3) Byte 7 Byte 7 Example: The drive is positioned under closed-loop control in "JOG 2" mode (mode 2). Monitoring function mode 72 was also selected in the output frame. => The IP 266 returns the current following error in bytes 4 to 7, e.g. + 5.310 mm Binary in +5 310 KF format = sign and integer digits = decimal digits BCD in oo0o 5310 KH format = sign and 3 integer digits = least-significant integer position and 3 decimal digits 7-14 EWA 4NEB 812 6057-02aIP 266 Communication Between the CPU and the IP 266 7.2.6 Operating the IP 266 in the ET 200 To operate the IP 266 in the ET 200, special rules apply. These rules are explained in the following. Since the $5-100U PLC and the ET 200 have different cycle times, you must ensure that every Job completed bit can be detected and evaluated. This must be guaranteed at the programming stage. For this reason, version 2 of the IP 266, MLFB 6ES5 266-8MA11, contains one further mode which can be used to ensure clear detection of the "Job completed bits. Mode 100 e setsthe FF error signal. All subsequent decisions of the STEP 5 program are linked to this error message. e must be invoked before all modes which terminate the current job and set the Job completed bit autonomously - without external abort or STOP command. @ aborts jobs flagged with Job in progress. In jog mode, direct change from FORW > REV or REV FORW is only possible over the additional STOP command. EWA ANEB 812 6057-02a 7-15Communication Between the CPU and the IP 266 IP 266 The following flowchart outlines the principle of operation with the ET 200. After the CPU STOP - RUN changeover, the IP 266 must be synchronized with mode 99. The synchronization is flagged in byte 2/bit O witha "1". Start BA99 Synch- roniz. IP 266.? Yes Start BA 100 No Mode 100 sets error message "FF. Ifthe message is read out of byte 3/bit 0 to 7, the IP 266 is ready to accept a new job request. Anew mode can be started when error message FF is received. Reminder: Enabling a mode deletes any outstanding error Message (except in the case of information modes). As soon as the error message has been deleted, the job is accepted. The Job completed bit is scanned inthe subsequent wait loop. The bit set enables the next job. Information modes must not be invoked according to this method since they do not reset outstanding error messages when they are invoked. If IP STOP if PLC STOP is entered with YES in the machine data, the IP 266 goes to STOP with the message "PLC failure. However, operation can be continued over COM 266. This means that Startup of the IP 266 is also possible when the PLC is still at STOP. Address codes for I/O modules The address code for input/output modules (095) given in the "ET 200 Distributed I/O System Manual must be replaced by the new value 223. 7-16 EWA 4NEB 812 6057-02a8.1 Configuring the System .......cseeeeee eee e reece et tee eens eeeees 8.1.1 IP 266 Limit Switches .......ccc cece eee eee eee rene ten eceeeeennane 8.1.2 | The Power Section on the IP 266s Analog Output ..........:eeeeeeee 8.1.3 Drive System Mechanics .........eceeeeeee rece ence tee eerereeeseces 8.1.4 The Incremental Position Encoder ........... eee ee nee eee een ees 8.1.5 ProgramMer ......- cece eee cence reenter e ee eeereaenstaeesseeeeenes 8.1.6 Checking the Wiring 2.0... 0... cece ee eee ence eee e een eee en sere rees 8.2 Computing the Machine Data ......- 6. eee eee cere eee eetees 8.3 Initializing the IP 266 2.2... 2.0. e eee eee eee eee reece eee en eenes 8.4 Executing the Start-Up Test ........:ese reece eee e cece eee e rece eeeee EWA 4NEB 812 6057-02aLocation of the Programmer Interface and Connector Pin Assignments i ee ee ee 2 Linear Axis and Range Limit Switches (not to scale) ie Data for Initializing the IP 266 Hardware and the Peripheral Elements eee ee eee eee Se : a ) 8-2. Formulas for Computing the Machine Data ....................--.. 8- 6 EWA 4NEB 812 6057-02aIP 266 Start-Up 8 Start-Up 8.1 Configuring the System Before putting the IP 266 into operation, you must check to make sure that you are using the right interface module and that the peripheral elements have been assigned the correct parameters. These peripheral elements include: @ the emergency limit switches the power section on the IP 266s analog output the hardware limit switches the drive system mechanics the incremental position encoder the programmer. 8.1.1 IP 266 Limit Switches In order to limit the positioning range, you must fit limit switches which ensure that the drive will be moved only within its mechanical limitations. A Warning | The limit switches must be connected and tested before powering up the IP 266 and the power section. As regards the IP 266, you must differentiate between software limit switches, hardware limit switches and emergency limit switches. e Software limit switches You define the locations of the software limit switches in the machine data. These switches are activated when a reference point is set. e Hardware limit switches Hardware limit switches are switches which are connected to the IP 266 via connecting leads. They are connected to the terminals on the terminal block, and are used to limit the path of travel. Check the following carefully: - The hardware start limit switch defines the start of the traversing range, and must be connected to PIN 3 on the terminal block. - The hardware end limit switch defines the end of the traversing range, and must be connected to PIN 5 on the terminal block. Note: You must observe the minimum distances when installing the limit switches, i.e. there must be a sufficient distance for deceleration. The hardware limit switches are properly connected. ok O EWA 4NEB 812 6057-02a 8-1Start-Up IP 266 @ Emergency limit switches The emergency limit switches must be directly connected to the power section. When a hardware limit switch fails, the emergency limit switch must ensure a reliable power section shutdown. > Check the following: The connecting leads for the two emergency limit switches must be run directly to the power section. /\ Caution Connecting the emergency limit switches to the IP 266 is not allowed. The emergency limit switches are properly connected. ok C) 8.1.2 The Power Section on the IP 266s Analog Output The power section must be connected to the IP 266's analog output. > Check the connection between the IP 266 and the power section When you calibrate the power section, make sure that there is sufficient power reserve. The drive must never be operated at the current limit, as the motor speed could not follow the setpoint speed. 8.1.3 Drive System Mechanics All mechanical elements located between the motor and the part of the drive to be positioned are part of the drive system mechanics. There may be play (backlash) in the drive system. AN Caution Backlash can be compensated for only when it is outside the position control loop. Backlash within the position control loop results in oscillations in the control response. To prevent backlash in the position control loop, the incremental position encoder should be connected directly to the motor shaft. Check your drive system for backlash. If you detect backlash outside the position control loop, measure it exactly. => The backlash is [ mm/inches/degrees 8-2 EWA 4NEB 812 6057-02aIP 266 Start-Up 8.1.4 The Incremental Position Encoder Control precision depends on the location of the encoder in the drive system. A sequence of movements can be easily verified when the encoder is mounted directly on the motor axis. Check to make sure that the encoder is correctly installed. You must use an encoder which supplies two pulse trains displaced by 90 deg. with respect to each other and a zero mark signal. You may use a 5 Vora 24 V encoder. in addition to all required signals, the 5 V version must also supply the inverted signal for each signal. Which encoder version are you using? [| Vv if you are using a 5 V encoder, check the following: Does the encoder supply the inverted signals? You must select an encoder resolution that enables evaluation of a sufficient number of pulses per interval even at low speeds. The minimum resolution should be greater than the positioning accuracy. The maximum operating frequency of encoder and module must not be exceeded at Vmax. The maximum operating frequencies for 5 V and 24 V encoders are as follows: e Forsymmetrical 5Vencoders: 500 kHz e For asymmetrical 24 V encoders: 100 kHz (for a max. cable length of 25 m) 24 V encoders: 25 kHz (for a max. cable length of 100 m) EWA 4NEB 812 6057-02a 8-3Start-Up IP 266 8.1.5 Programmer The module is equipped with two 15-pin D subminiature interfaces. The programmer must be connected to the one at the right. Pin Description 1 Shield 2 RxD_N 3 3 4 5 - 6 TxD_P 7 TxD_N 8 Shield 3 RxD_P 10 to 15 ~ POSITIONING MODULE IP 266 SESS 266-8MA11 HRA Figure 8-1. Location of the Programmer Interface and Connector Pin Assignments Z\ Caution The programmer interface and the encoder interface both have 15 pins, and it is possible to confuse the two. Remember that the programmer interface is the one on the right. If you confuse the two, the module executes a Reset. 8-4 EWA 4NEB 812 6057-02aIP 266 8.1.6 Checking the Wiring Check all cabling -Make sure that the control cable and the power cable are sufficiently far apart and without kinks. - Make sure that the cables to and from the controller are shielded over their entire length, and that the cable shields are grounded at both ends. One important point is the laying of the ground wires, as insufficient cross-sections, ground loops or failure to connect the ground may result in malfunctions. Locating and eliminating such problems can be costly and time-consuming. Make sure that the ground wires have sufficient cross-sectional area and are properly laid and connected. > If you are using a 5 V encoder, check to make sure that the inverse signal leads are shielded. Make sure that the leads for the n set and M signals are shielded and twisted. Check the following cables for short-circuits and wirebreaks and make sure that the pin assignments are as described in the section dealing with the hardware (Section 2): - Encoder cable (ENCODER) - Setpoint cable (ANALOG OUT) - Digital cable - FUM signal wired? - 24 V supply - After making sure that all components are off circuit, attach the cables and screw them down. EWA 4NEB 812 6057-022 okC) okC) ok.) okC) okC) okC) okC) okC) okC) okC) okC) okC) Start-UpStart-Up IP 266 8.2 Computing the Machine Data In this section, you will learn to compute the machine data with which you must initialize the IP 266. The machine data is based on the capabilities and mechanics of the drive. In order to compute the machine data, you need information on the hardware. Please take this information from the data sheets describing the drive and/or from the commissioning report. Motor/axis ratio Motor speed at 10 V [1/min] e e e@ = Travel per encoder revolution {mm] e@ = Pulses per encoder revolution [1] e@ Hardware start limit switch [mm] @ Hardware end limit switch * [mm] e Time needed to decelerate from v max. tO Zero speed [s} The following values are computed on the basis of this data: Table 8-2. Formulas for Computing the Machine Data Maximum velocity (speed) The factor G must be taken into account only when it is not Vinax [ min] = Xg * Migy* o part of x,. Maximum deceleration rate b,,a, Take the time from the commissioning report for the power Vmax [ Vege] section you are using. Drax [/,2] = ea t [s] Vmax mm mm = Bmax [ 1,2] t-60 E Maximum following error As Vinax | /60 ] As [mm] = Kv [1/,] Vmax As [mm] = Kv: 60 The following data is computed from the results of these calculations Kv (gain) factor The gain factor depends on the design, dynamics and Kv 1/6] disturbance variables (load variations) affecting your drive. An optimum gain factor cannot be ascertained until the system is actually put into operation. A very low value (1 to 21/s) should be selected for start-up in order to avoid damage. 8-6 EWA 4NEB 812 6057-02aIP 266 Computing a set of machine data: Start-Up Measuring system mm, in, deg. Axis type Linear, rotary Linear The following applies for all deceleration and acceleration rates: jal = [bmaxj |b] = |bmax| The absolute acceleration and/or deceleration rates must be less than the absolute maximum deceleration rate by,. Maximum deceleration 10 to 9999 /,2 1000 m/,2 Acceleration fwd. 10 to 9999 /,2 500 m/,2 Deceleration fwd. 10 to 9999 M/,2 500 m/,2 Acceleration rev. 10 to 9999 M/,2 500 mm/,2 Deceleration rev. 10 to 9999 /,2 500 /,2 Encoder type 5V,24V 5V IP-STOP if CPU-STOP yes, no no Gain factor 0.1 to 99.9 1/, 16.6 1/, Backlash compensation 0.000 to 64.999 mm 0.000 mm Zero-speed monitor 0.001 to 64.999 mm 2.000 mm Max. following error 0.001 to 99.999 mm 15.000 mm Following error monitoring on, off on The following condition applies for the switching elements - software start limit switch Xsq - softwareendlimitswitch Xs_e - reference point coordinate REF: Xua < Xsa < Xpee < Xse < Xue Xya is the hardware start limit switch, X ye the hardware end limit switch. Reference point coordinate + 32767.999 mm 0.000 mm Software start limit switch + 32767.999 mm -400.000 mm Software end limit switch + 32767.999 mm 400.000 mm Tool length offset + 32767.999 mm 0.000 mm For a rotary axis, the two fields for the software limit switches are replaced by the two fields start of traversing range and end of traversing range. The range limits are identical to those for a linear axis. Zero offset 1 + 32767.999 mm 10.000 mm Zero offset 2 + 32767.999 mm 25.000 mm Zero offset 3 + 32767.999 mm 30.000 mm Zero offset 4 + 32767.999 mm 35.000 mm EWA 4NEB 812 6057-02aStart-Up IP 266 All speeds must be lower than Vinax Maximum speed 1 to 65000 mm, 15000 mm, Jog speed 1 fwd. 1 to 65000 mm/,_ 2000 m_,. Jog speed 1 rev. 1 to 65000 m/,_ 2000 m_. Jog speed 2 fwd. 1 to 65000 mm, 4000 mm, Jog speed 2 rev. Tto 65000 mm, 4000 m7, Incremental speed Tto 65000 mm, 12000 mm Reference point approach speed 1 1to 65000 mm, 1000 mm, Reference point approach speed 2 1 to 65000 mm, 500 m/_., Reference direction fwd./rev. fwd. Pulses/revolution 1 to 65000 puises/, 1000 pulses, Distance/revolution 0.001 to 400.000 mm 5.000 mm PLC BCD-coded yes, no no Polarity HW limit switch pos/neg neg 8.3 Initializing the IP 266 Before you can use the IP 266, you must first supply it with valid machine data. You have two options for entering machine data: e@ Defining machine data for a newly installed system @ Loading an existing record from a non-volatile storage medium Entering machine data fora newly installed system Before putting a new system into operation, you must define your machine data for that system. The information presented in Section 8.2 showed you how to compute the required data on the basis of the drive's technical specifications. To enter your machine data, you need a programmer and the COM 266 software package. Start COM 266 as described in Section 6 and Proceed to the "FUNCTION SELECT menu. All COM 266 basic functions are invoked from within this menu. The input of machine data is described in detail in Section 6.4.1. Loading an existing record from a non-volatile storage medium Invoke the TRANSFER function in the "FUNCTION SELECT" menu (see Section 6.5) to load an existing set of machine data. 8-8 EWA 4NEB 812 6057-02aIP 266 Start-Up 8.4 Executing the Start-Up Test The drive must be within the permissible traversing range before the IP 266 can be tested together with the drive. This range is defined by the two hardware limit switches. A Caution All limit switches must be correctly installed before executing the start-up test, i. e. both the hardware limit switches and the emergency limit switches must be connected. Remember that you can actuate the emergency off switch at any time! it has been assumed that your power section has been matched to the drive. The first step > Power up the PLC No CPU program need be available at this point. If you entered "yes" for "IP-STOP if CPU-STOP" in the IP 266 machine data, the CPU must be at RUN. The CPU should not address the IP 266 during the first phase of the start-up procedure. > Switch on the 24 V supply The power section is still off. Connect the programmer to the IP 266 > Start COM 266 (ON-LINE) Keep an eye on the monitor's error line when making your entries. If a problem occurs, it will be flagged on this line. For testing, a set of machine data and a traversing program are stored on EEPROM. Since this data does not necessarily coincide with your hardware, you may find that errors will be reported. Change the machine data as indicated by the error messages. These messages, and the changes they indicate, will apply primarily to the encoder type, the polarity and the encoder resolution. A Caution The IP 266 outputs the enable signal (FUM) directly when it detects data whose logic and signal level are correct. If a positioning operation was triggered, it will be started immediately! Correct the machine data as indicated by the error messages. Generate a traversing program for modes 8 and 9 and transfer it to the IP 266. EWA 4NEB 812 6057-02a 8-9Start-Up IP 266 Testing the axis > Select the COM 266 test mode. Start mode 4 (follow-up mode) => The following is displayed in the screen form's output fields: Axis status: running ok OC CLC: off ok O Switch on the power section = The axis must remain at zero speed and its drift must be barely perceptible. If this is not the case, you must repeat the fine adjustment for 0 volts on the drive. Ww > Stop mode 4 and check the return data. Axis status: finished ok C CLC: on ok C Testing the encoders direction of rotation /\ Caution If the encoder rotates in the wrong direction, there is direct feedback from the position control loop (the CLC is on). As a result, the drive, instead of stopping, traverses at maximum speed. You must therefore make sure that the drive can be immediately stopped via external switches whenever necessary while performing this test. Should the drive begin to oscillate when it is at zero speed, you must reduce the gain (Kv) factor! The IP 266 monitors the position control direction, aborting the current operation with an error message when an error occurs and starting mode 4. When the IP detects the correct sense of rotation, it disables the monitor; the monitor remains disabled until mode 4 is once again started. When mode 4 is terminated, the position contro! direction is again monitored. 8-10 EWA 4NEB 812 6057-02aIP 266 Start-Up Please note: A forward traversing movement always means a movement in the direction of the software end limit switch, whose coordinate position must be higher than that of the software start limit switch. The IP 266 generates a positive output voltage (setpoint speed). The incremental encoder must be connected to the IP in such a way that the resulting direction of rotation causes the IPs counter to function as an up counter. The IPs counter counts up when the A signal is detected before the B signal. The opposite is true in the event of a reverse traversing movement. As regards the direction of rotation of the encoder and the motor, the conventions are the same for linear and rotary axes. A clockwise (or forward) traversing movement always means a positive output voltage (setpoint speed), a cou nter-clockwise (or reverse) traversing movement a negative output voltage. When the axis traverses in a clockwise direction, the IPs counter must count up. A forward movement moves the axis toward the end of the traversing range, which, in the case of a rotary axis, is the same as the start of the traversing range, but which must always be more positive than the latter. Select mode 3 (Controlled jog). > Select alow speed (approx. 1-5 %) via Override. Select the "Forward" function and observe the actual position; this value must increase. if the actual position value decreases, switch off the power section immediately! in this case, you must interchange encoder signals A-A\ and B-B\ (if you are using a 5 V encoder) or A* and B* (if you are using a 24 V encoder) and retest the direction of rotation. Forward travel must result in an increase in the actual position, reverse travel ina decrease. Testing the hardware limit switches Initiate forward traversing in mode 3. Trip and hold the hardware end limit switch. The traversing movement must be aborted with the "HW end limit switch tripped" error message. There must be no further travel when a new "Mode 3 forward" command is issued. ok C) > Initiate reverse travel in mode 3. Release the hardware end limit switch during traversing. > Trip the start limit switch. The traversing movement must be aborted with the error message "HW start limit switch tripped". There must be no further travel when a new "Mode 3 reverse" command is issued. ok C) Start mode 3 Forward" and release the hardware start limit switch during traversing. Traversing movements in both directions are now once again possible. EWA 4NEB 812 6057-02a 8-11Start-Up IP 266 Refer to the following figure when you want to simulate tripping of a limit switch within the traversing range: LALLY oy + Traversing range ey > Traversing ra nge Na/N_: Emergency start/emergency end limit switch (power section) Ha/H_: Hardware start/hardware end limit switch Deceleration distance S 5, Clearance distance X Figure 8-2. Linear Axis with Range Limit Switches (not to scale) @ Move the drive at a controlled jog toward the hardware start limit switch. During traversing, actuate the relevant limit switch briefly, then release it. The drive decelerates at maximum deceleration speed. Travel is now possible only in the direction of the hardware end limit switch. @ Move the drive at a controlled jog toward the hardware end limit switch. During traversing, actuate the relevant limit switch briefly, then release it. The drive decelerates at maximum deceleration speed. Bidirectional travel is now impossible. Should this situation occur, you must hold the relevant hardware limit switch in one of the two directions before starting the "controlled jog". Testing the following error > Travel a considerable distance in mode 1 or 2 ("Jog 1" or" Jog 2"), observe the following error, and stop travel. => The result must be the buildup of a following error which, after some time, remains fairly constant and then goes back to zero following deceleration. At zero speed, the following error can vary by approximately + 3 increments, depending on the drive calibration. If it varies by more than + 3 increments, you must either increase the Kv factor or recalibrate the drive. The following error should assume approximately the following value during traversing: v [mm/min] 60 - kv- [1/s] As [mm] = 8-12 EWA 4NEB 812 6057-02aIP 266 Start-Up Testing the maximum speed Move your drive in mode 3 with an override factor of 100%. => The computed speed is displayed in the test form. If this speed does not coincide with the speed specified in the machine data, you must check and correct your specifications. Computing the reference point Select "Reference point approach mode (mode 5). Initiate the "Start" function. => The drive must execute a traversing routine and return Reference point set". ok C) Possible errors: 1. The drive does not move although "Reference point set" is displayed. You have accidentally executed a "Set reference point. 2. The drive traverses, but does not reduce its speed at the reference point switch and does not find the reference point. The reference point switch is either defective or is an "NC" contact. 3. The drive reduces its speed at the reference point switch, but continues traversing until it reaches the limit switch. "Reference point deleted" is displayed on the monitor. The zero mark of the encoder is not used in the IP 266. You must test the reference point switch signal and the zero mark signal. If the reference point exists, the software limit switches are also effective. > Traverse in both directions in mode 1 or 2 and check to see whether the software limit switches are tripped before the hardware limit switches are reached. If necessary, you must shift the coordinates of the software limit switches so that the drive comes to a standstill before reaching the hardware limit switches. increment mode Once the coordinate system has been established, you can approach absolute target positions. Enter various different target positions in modes 6 and 7 and check to see if the axis reaches these positions. Executing automatic programs Write a short traversing program and transfer it to the module. Test this program in modes 8 and 9. EWA 4NEB 812 6057-02a 8-73Start-Up IP 266 Teach-In > Select mode 10 ("Teach-in on"). > Specify a program number. > Start mode 10. = Return info: Teach-in: on ok OC) > Approach various positions and store them with " Transfer". > Start mode 11 ("Teach-in off"). > Execute the program you generated in "Teach-in" mode. Supplement the program in DIN or Text mode by adding dwells, loops, programmed stop, speed changes and the like. 8-14 EWA 4NEB 812 6057-02aIP 266 Start-Up Familiarize yourself with the following modes e Zero offset absolute (mode 12) ok e Zero offset relative (mode 13) ok e Clear zero offset (mode 14) ok e@ Tool offset (mode 15) ok e@ Tool offset off (mode 16) ok e Acknowledge error (mode 17) ok > Generate an error such as "External STOP". The error is flagged on the programmer ok Start mode 17. => The error is acknowledged. v ok e@ Drift compensation (mode 18) ok OOO O OO0000O e@ Drift compensation off (mode 19) ok Save the optimized machine data and traversing programs on floppy and transfer the contents of the floppy to the modules EEPROM. Controlling the IP 266 via the programmable controller After testing the interplay between the IP 266 and your drive, you must test the positioning application in your STEP 5 program. Refer to the following sections for help: e Section 7, which describes communications between the PLC's CPU and the IP 266 e Section 9, which provides two examples for using the input and output messages. EWA 4NEB 812 6057-02a 8-15EWA 4NEB 812 6057-02a9.1 What to Observe when Programming .......-. wetereuse nie oe Swain 9.1.1 General Information on Program Structure .........eeee eens ieee 9.1.2 Edge Evaluation and Modes .......-.2sseseeeeeeeererrerees seeeee 9.1.3 Programming the TOGGLE Bit ..........-.-06s fi aee a ae minors seeee 9.1.4 ErrorAnalysis ........- Sees eleS eNe Wee Deas iatewarm eines 90 9.1.5 Automatic Synchronization inOB1 .......-.-- pees aia euaeienecers wiatwiee 9.2 Switches, Indicators and Flags in the Sample Programs ......---+-+++ 9.3 Description of Sample Program 1 .......-e eee e eter eee ence eee ees 9.4 Sample Program 1: Overall Structure ........ sibialata erate ae latee beeeeee 9.4.1 Cold $5-100U Restart ......... di CHaeDE Deke nee URE OT eee pace ainies 9.4.2 Cyclic Operation with OB1 .......+--- 3, diet wees iGiWle eiviaie walteews sibs tiarai 9.4.3 FB 26: Control FB forthe IP 266 ..........++-- nea eee stg eieaeka palebias 9.4.4 Selecting Modes Via IB4 .. 2... cece eee e erence cree een e rn rete een ees 9.5 Sample Program 2: Traversing to Two Fixed Target Positions ......... wowouw ow oO wo 10 11 14 25 EWA ANEB 812 6057-02a9-1. Using a Linear Axis EWA 4NEB 812 6057-02aIP 266 STEP 5 Programming 9 STEP 5 Programming 9.1 What to Observe when Programming 9.1.1 General information on Program Structure When programming the IP 266, you must observe a number of special features and exceptions. These are discussed in detail below. Response to starting a mode When you start a mode, you can expect the latest status info at the earliest two cycles later. If you are using a high-speed CPU in conjunction with a short OB 1 cycle time, you may not receive this information until the third or fourth cycle. Cycle n-1 cyclen Cyclen+1 |Cyclen+2 | Cycden+3 Cyclen+4 Mode is Response Earliest started when mode | response to is started in | invocation cyclen-1or | ofa mode earlier, i.e. incyclen status info is not upto date a. f + Process output image is forwarded to IP 266 (readied in cycle n) Process input image is read from the IP 266 (in cycle n-1) A special programming technique should be used to prevent repeated reading of "out of date" information. Two optional techniques are discussed below: e@ Ablank cycle can be programmed in each second OB 1 cycle to ensure that the status info will be read no earlier than cycle n+ 2. However, this alone does not ensure that the current status info will be read. e A preferable technique would be to evaluate the signal edge of the Job terminated/in progress bit. EWA 4NEB 812 6057-02a 9-1STEP 5 Programming IP 266 9.1.2 Edge Evaluation and Modes The preferable technique to ensure a readout of the latest status info is edge evaluation, Sequence: 1. Ajob is started in cycle n. The status info shows "Job terminated". 2. The status info still shows Job terminated" in cycle n+1 because the job had not yet been started when the process input image was read. Note: If this status bit were the only criterion for starting a new job, it would be possible to start another job at this point although the first is still in Progress. The first job would thus be aborted and error F82 (Inadmissible job") flagged. The IP 266 reports "Job in progress" in cycle n+2 at the earliest. It would therefore be preferable to use an edge flag to make sure that this problem cannot occur. No job can be started unless this flag is set, and it is set only when the IP 266 returns "Job in progress", Application in example 2 (see Section 9.5): When a job is started, flag 3.0 is reset. As long as this flag is not set, no job can be started. The flag is not set and a further job initiated until the IP 266 reports Job in progress". A new job can be started when the IP 266 changes the status bit from "Job in progress" to "Job terminated. 9.1.3 Programming the TOGGLE Bit A change in the value of the TOGGLE bit informs the IP 266 that a new job request is waiting to be serviced. The IP 266 then interprets and executes this request. Job n-1 Jobn Job n+1 Jobn+2 Job n+3 Job n+4 To the IP 266 To the IP 266 To the IP 266 with | To the IP 266 with | To the IP 266 with with TOGGLE = | with TOGGLE= | TOGGLE = o" TOGGLE = "1" TOGGLE = "1" qe Ho" Job request is Job request is Job requestis not | Job request is Job request is not serviced serviced serviced serviced serviced In sample program 1, the TOGGLE bit is Programmed in FB 25. 9-2 EWA 4NEB 812 6057-02aIP 266 STEP 5 Programming 9.1.4 Error Analysis Errors should be analyzed to enable the STEP 5 program to respond quickly to an event. It is recommended that errors be analyzed in every cycle. When doing so, however, you should also keep track of the "Job terminated bit so that you will not respond to "old" data. 9.1.5 Automatic Synchronization in OB 1 Mode 99 is the first mode the IP 266 will accept. Only then can one of the modes 1 to 73 be started. Mode 99 should therefore be invoked automatically in OB 1. The TOGGLE bit must always be set to "1" for this mode. Note: No status info is returned for mode 99. If this mode executes without error, bit 0 is set in byte 2 of the input message (Pll). EWA 4NEB 812 6057-02a 9-3STEP 5 Programming IP 266 9.2 Switches, Indicators and Flags in the Sample Programs Maintained-contact/momentary-contact switches All control elements for the program are interfaced over IB 3 and IB 4. Some inputs require only momentary-contact switches, while others require maintained-contact switches. Inputs | 3.0 to 14.7 are listed in the table below. oo ee External start enable (IP pin 7) e NC contact 13.1 START e NO contact 13.2 STOP e NO contact 13.3 FORWARD e NO contact 13.4 REVERSE e NO contact 13.5 TRANSFER e NO contact 13.6 Override 100 % /50 % e 13.7 14.0 Selector switch for mode 5 e NO contact 14.1 Selector switch for mode 2 e NO contact 14.2 Selector switch for mode 6 e NO contact 14.3 Selector switch for mode 8 e NO contact 14.4 Selector switch for mode 9 e NO contact 14.5 Absolute target specification e +360.800 mm / -360.600 mm 14.6 14.7 Continuous operation for mode 7 NO contact (brief example in Section 9.5) 9-4 EWA 4NEB 812 6057-02aIP 266 STEP 5 Programming Indicator elements/outputs oo Q2.0 No external start enable signal (IP pin 7) FB 26 Q2.1 IP not initialized/synchronized OB 1 Q2.2 No reference point FB 26 Q2.3 IP in follow-up mode FB 26 Q2.4 Axis not in position FB 26 Q2.6 Lower drill" FB 20 Q2.7 "Raise drill FB 20 QB5 Error code, hexadecimal (KH) FB 20 Flags, auxiliary flags and edge flags Edge flag (in example 2, Section 9.5) This flag prevents a second job from being started until "Job in progress has been returned (see Section 9.5). F4.0 Auxiliary flag for START These flags prevent repeated forwarding of the same job requests to the IP when a P41 Edge flag for START command remains in force over more F4.2 Auxiliary flag for STOP than one OB 1 cycle (see FB 20). F4.3 Edge flag for STOP F4.4 Auxiliary flag for FORWARD/REVERSE F4.5 Edge flag for FORWARD/REVERSE F4.6 Auxiliary flag for TRANSFER F47 Edge flag for TRANSFER EWA ANEB 812 6057-02a 9-5STEP 5 Programming IP 266 F5.0 Auxiliary initialization flag F6.0 START FB 6 is transferred to byte 1 of the output message (QB 65 in the F6 STOP example). Before FB 6 is transferred to F6.2 FORWARD QB 65, the TOGGLE bit must be pro- grammed in F 6.7. F6.3 REVERSE F6.4 TRANSFER F6.5 F6.6 F 6.7 9-6 EWA 4NEB 812 6057-02aIP 266 STEP 5 Programming 9.3 Description of Sample Program 1 A workpiece is to be machined on an assembly line comprising several assembly bays. The following steps are to be carried out at four positions within the positioning range of the linear axis: Position 0: Position 0 is the home position of the worktable in the linear axiss traversing range. It is at this position that a workpiece is to be placed on the table for machining and at which the workpiece is to be placed back on the table after machining. Positions 1to 3: Holes are to be drilled in the workpiece at these three positions. When the hole has been drilled at the last of these three positions, the drive is to return to position 0. The procedure can be restarted when the workpiece has been removed from the table. A traversing program is used to approach positions 0 to 3. External activities in the STEP 5 program are initiated via M functions. Figure 9-1 shows an installation suitable for this example. / Workpiece * gotit Me ie Worktable fF 7 * * # # Lae 0 1 23 \ actual position 100 | 400 |420 } +40 [mm] SN Figure 9-1. Using a Linear Axis EWA 4NEB 812 6057-02a 9-7STEP 5 Programming IP 266 9.4 Sample Program 1: Overall Structure For better readability, many subfunctions have been programmed in separate FBs. The diagram below illustrates the overall structure: OB 22 Y FB 4/Mode 4 FB 10 For errors in the po- Mode 99 sition control loop OB 1 FB 27 FB 20 Wait loop Read actual values Cyclic operation FB 26 FB 5/Mode 5 Main Traversing program FB 2/Mode 2 FB 6/Mode 6 FB 8/Mode8 FB 9/Mode9 FB 21/START MN FB 23 FORWARD/ REVERSE FB 24/TRANSFER FB 22/STOP FB 25/TOGGLE | EWA 4NEB8 812 6057-02aIP 266 STEP 5 Programming 9.4.1 Cold S$5-100U Restart Before you can work with the IP 266 following a cold $5-100U restart, you must wait for completion of the moedules runup phase. You must program the waiting time in OB 22, which executes after every "Power OFF/Power ON". The programmed waiting time must be at least 3 seconds. ij a sete : a START Call the delay time FB. Call wait loop Ju FB 27 FB 27 NAME DELAY JC =M1 M1 L KT 300.0 sD T 0 Time-out after 3s SCHL AN T 0 Jc =SCHL Reset and enable timer R T 0 A T 0 L KT 001.0 Reset timer and enable with RLO = 0 EWA 4NEB 812 6057-02a 9-9STEP 5 Programming 9.4.2 Cyclic Operation with OB 1 At the beginning of each OB 1 cycle, a check must be made to see whether the IP 266 has been initialized. This check consists of scanning bit 0 in byte 2 of the input message (PII). If the IP 266 has not been synchronized, mode 99 must be invoked in FB 10. If the IP has been synchronized, FB 26 is invoked. All further functions in the sam started from FB 26. START IP synchron- ized? | Set auxiliary flag Call FB 10 IP synchron- ized? Set output (indicator) Reset output (indicator) set AND IP synchon= Call FB 26 for machining Call FB for IP 266 synchronization via mode 99 in ee : dependence on the status bits in the input message. AN I 66.0 s F 5.0 Jc FB 10 NAME M099 Set output if IP not synchronized AN I 66.0 = Q 22d The FB for selecting the mode can be invoked when the IP 266 has been synchronized. A F 5.0 A I 66.0 JC FB 26 NAME AXIS1 BE 9-10 EWA 4NEB 812 6057-02a IP 266 ple program areIP 266 9.4.3. FB 26: Control FB for the IP 266 The following steps are executed in succession in this FB: Read input message (PII) Error analysis Scan external signals Check reference point and set if required Select mode Select function Program TOGGLE bit STEP 5 Programming The relevant calls must be made in this FB to invoke additional modes or change existing modes. The sample program could also be upgraded by programming mode interlocks. One complete FB 26 pass is equivalent to one OB 1 cycle. Call FB 20 Error Wrong position control direction or break in position control loop Controller off? start enable signal Unconditional FB call to read the input frame (Pll) from the IP 266 Jc FB 20 NAME READ Mode 4 is invoked in the event of an error in the position control direction (F B2) or in the position control loop (F B6). oC L KH OOB2 L IB 67 {=F ) oC L KH OOB6 i=F ) Jc FB 4 NAME MO4 The indicator for follow-up mode goes on when the controller is off. AN I 66.3 ol Ol ol ol ol ol Ol = Q 2.3 Set output according JB =STOP to RLO AN I 3.0 = Q 2.0 EWA 4NEB 812 6057-02a 9-17STEP 5 Programming IP 266 Set output to indicate that there is no reference point Reference point missing? A I 66.5 Invoke mode for approaching/setting reference Set outputs point when the relevant input is set. according to RLO A I 4.0 JC FB 5 Mode 5 NAME MO5 selected? Invoke "Jog 2" mode when relevant input is set. Mode 2 A I 4.1 selected? JC FB 2 NAME Mo2 Set indicator for Job terminated" AND "Axis net in position A tf 66.7 AN I 66.2 2.4 il 0 Set output according toRLO 9-12 EWA 4NEB 812 6057-02aIP 266 STEP 5 Programming Mode 6 selected? Modes selected? Mode 2 selected? Unconditional STOP call Invoke mode 6, 8 or 9 when the associated input is set. A I 4.2 MODE 6 gc FB 6 NAME MO6 A I 4.3 MODE 8 Jc FB 8 NAME MO8 A I 4.4 MODE 9 Jc FB 9 NAME MO9 "START" in mode 5, 6, 8 or 9 0 I 4.0 MODE 5 I 4.2 MODE 6 I 4.3 MODE 8 I 4.4 MODE 9 gc FB 21 NAME START "FORWARD/REVERSE" in mode 2 A I 4.1 MODE 2 Jc FB 23 NAME FWDREV TRANSFER in modes 2 and 9 I 4.4 I 4.1 JC FB 24 NAME TRANS Unconditional STOP call STOP JU FB 22 NAME STOP Call the TOGGLE FB if edge flag for START, STOP, FWD/REV or TRANSFER was set. Oo 6F 4.1 START Oo 6F 4.3 STOP Oo 6F 4.5 FWD/REV Oo 6U6F 4.7 TRANSFER gC FB 25 NAME TOGGLE BE EWA 4NEB 812 6057-02a 9-13STEP 5 Programming IP 266 9.4.4 Selecting Modes via IB 4 All modes are selected in FB 26. In almost all cases, the number of the FB is identical to the mode number. e FB 2is for "Jog2" mode @ FB 5 is for approach/set reference point mode @ FBs 6,8 and 9 are for modes 6,8 and9 @ The only exception is mode 99. Since not all CPUs allow FB numbers as high as 99, the FB number for this mode is 10. This mode is also the only mode that is directly invoked in OB 1. All FBs for selecting a mode have the same structure. First, the number of the mode, in binary, is entered in output byte 64 (output byte 64 is byte 0 of the output frame; see Section 7.1). For some modes, the mode parameters are also preset in dependence on specific conditions, and entered in the relevant bytes. FB 10: Synchronize IP 266 FB 10 is always invoked automatically in OB 1 when bit 0 in byte 2 of the input frame is "0" (IB 66). If the IP has not been synchronized, mode 99 must be started with the TOGGLE bit = "1" and the START function. xa a Mode 99 is loaded into re - Se = RS = aise QB 64, START and TOGGLE bit into Enter parameters L KB 99 inthe output T OB 64 frame L XB 129 T QB 65 . 9-14 EWA 4NEB 812 6057-02aIP 266 STEP 5 Programming FB 2: Jog 2 with override specification When the mode number has been entered into QB 64, input 3.6 is scanned. Select an override of 50 % or 100 %, depending on the selector switch setting. This value is entered in QB 67. Select mode START L KB 2 Enter mode T OB 64 number into QB 64 Override set via selector switch: Select 100 % A I 3.6 50% / 100% yes 5 override and enter Jc =M100 into QB 67 L KB 50 50% x QB 67 Select 50 % BEY override and enter M100 L KB 100 100% into QB 67 T QB 67 , BE FB 4: Follow-up mode The only entry made in this FB is the mode number. In the sample program, this mode cannot be selected via switches. It is invoked only to respond to error messages. Mode 4 (follow-up mode) is invoked in the sample program only to respond to a position control loop error or an error in the position control direction. Enter mode number in QB 64 L KB 4 T QB 64 Cae) " EWA 4NEB 812 6057-02a 9-15STEP 5 Programming IP 266 FB 5: Approach/Set reference point When this operating mode has been selected, a "0" in QB 66 sets the "APPROACH" submode. The reference point approach is invoked via the Approach parameter: t meer and L KB 5 MODE 5 number an snlect T QB 64 "APPROACH" L KB 0 0 = approach T QB 66 FB 6: Increment mode absolute In addition to the mode number, this mode requires specification of an override factor and an absolute target position. Simple parameters were chosen for the sample program. Select the parameters as follows via input | 4.5: 14.5 =0 positive direction 14.5 =1 negative direction Enter override factor 30 % in QB 67 and target position | Enter override factor 60 % in QB 67 and target position 360.800 mm in QW 68 and QW 70. 360.600 mm in QW 68 and QW 70. If the positioning specifications are in binary, @ QW 68 contains the integer digits and @ QW 70the decimal digits of the value 9-16 EWA 4NEB 812 6057-02aIP 266 STEP 5 Programming Selecting mode 6 T QB 64 Enter mode Determining the direction in dependence on the switch atinput 4.5 ye A I 4.5 JC =MINU no Loading an override factor of 30% and the integer and Override 30% decimal digits of the value for the positive direction of Target+ 360.800 mm travel: L KB 30 OVERRIDE 30% T QB 67 L KF +360 Override 60 % T QW 68 INTEGER DIGITS Target -360.600 mm L KF +800 T QW 70 DECIMAL DIGITS BEU Loading an override factor of 60% and the integer and decimal digits of the value for the negative direction of travel: MIND L KB 60 OVERRIDE 60% T QB 67 L KF -360 T QW 68 INTEGER DIGITS L KF +600 tr QW 70 DECIMAL DIGITS FB 8/FB 9: Automatic mode/Automatic single block mode in both cases, enter the number of the mode in QB 64 and the number of the traversing program in QB 66. Invoking mode 8 with traversing KB Enter mode numbe QB Enter TP number KB QB EWA 4NEB 812 6057-02a 9-17STEP 5 Programming IP 266 The traversing program for mode 8 and mode 9 As an example, the following traversing program is used to approach three positions; drilling is started at these positions via an M function. Traversing program %5 Subroutine L6 The first step in main program %5 is the approach to start position 0 (100 mm), where, for example, a NO1 GOO X100 MOO NO1 X20 F100 workpiece can be placed on the worktable. The table is NO2 G04 F50 NO2 G04 F100 M30 then to be brought to the starting position for the NO3 G91 NO3 G04 F100 M40 drilling procedure. NO4 280 F200 NO4 M02 Subroutine L6 executes three times. Dwells simulate NO5 G24 F3 the drilling operation, which NO6 L @ is enabled with M30 and NO7 G20 e = disabled with M40. NOS GOO X100 MOO After drilling, the drive is brought back to position O. NOS G04 F50 M99 The M99 function initiates removal of the workpiece N10 MO2 from the table. External start enable switch The "External start enable switch must be wired as an NC contact. The IP 266 will accept no jobs until it receives a "1" signal. In FB 26, this signal is scanned and routed via Q 2.0 to pin 7 on the IP 266s terminal block. Selecting the functions for the different modes via IB 3 Not all functions are allowed in all modes. To preclude errors due to selection of an invalid function, the program in FB 26 checks the function for validity. If the RLO is 1 (valid function), the program branches to the relevant "Command FB". START | FB 21 : 5,6,8,9 STOP FB 22 All modes FWD/REV FB 23 2 TRANSFER FB 24 2,9 The table above lists only the modes programmed in the sample program. Refer to Table 6-3 in Section 6.6.2 for a list of all modes and their functions. 9-18 EWA 4NEB 812 6057-02aIP 266 Every Command FB" includes the following code-evaluation routine: STEP 5 Programming not set? no no Input set AND auxiliary flag Edge flag = 0 Auxiliary flag = 0 Edge flag = 1 Auxiliary flag = 1 Setting auxiliary flags and edge flags Edge flags A I 3.1 AN F = F 1 Auxiliary flags A I 3. = F 4. This routine works with auxiliary flags and edge flags, the output byte only once in the first cycle that follows setting o for this purpose. and ensures that a command is entered in f the input. Edge flag 4.1 is used Oth cycle Switch/key is actuated Frame 1st cycle Input appears in the Pll as being set Auxiliary flag = 1 Edge flag =1 is entered in output byte 2nd to nth cycle Input remains set Auxiliary flag = 1 Edge flag =0 is not entered in output byte EWA 4NEB 812 6057-02a 9-19STEP 5 Programming IP 266 The edge flag for programming the TOGGLE bit is also required (FB 25/FB 26). Job in progress -> abort AN I 66.7 Job in progress? ; BEC no Programming the edge and auxiliary flags Evaluate auxiliary A I 3.1 START KEY and edge flags AN F 4.0 = F 4.1 EDGE FLAG A I 3.1 START KEY F 4.0 Edge flag = 0? no Edge flag not yet set > abort AN F 4.1 BEC Load bito = 1 (QB 65) into FY 6 Load Start command L KB il START COMMAND BE = edge flags for the STOP function casa oo Programming the auxiliary and START Program auxiliary and edge flags A I 3.2 STOP KEY AN F 4.2 = F 4.3 EDGE FLAG Evaluate auxiliary A I 3.2 STOP KEY and edge flags = F 4.2 Edge flag not yet set > abort AN F 4.3 BEC Edge flag = 07 ys no Load Start command Load bit 1 = 1 L KB 2 STOP COMMAND (QB 65) into FY 6 T FY 6 9-20 EWA 4NEB 812 6057-02aIP 266 FB 23 - FORWARD/REVERSE Two inputs are scanned in this FB to gather the information required to program the auxiliary and edge flags. The inputs for FORWARD and REVERSE are ORed. Process auxiliary and edge flags as function of the FORWARD or REVERSE input Reverse? no Load bit 2 = 1 (QB 65) into FY 6 Load bit3 = 1 (QB 65) into FY 6 Programming the edge and auxiliary flags 3 0 i 3 I AN F = F I I = F Edge flag not yet set abort .5 AN F 4 BEC Jump in dependence on the keys for FWD and REV pe Jc =M001 A I 3 JC =M002 BEU Load start command MOO. L KB 4 T FY 6 BEU MoO2 L kB 8 T FY 6 BE bm WwW PF & Ww 4 4 5 3 4 4 Programming the auxiliary and edge flags for the FWD/REV functions 3 4 STEP 5 Programming FORWARD REVERSE FORWARD REVERSE FWD command REV command EWA 4NEB 812 6057-02a 9-21STEP 5 Programming IP 266 FB 24- TRANSFER In the example, the TRANSFER command is allowed only as long as the job is not yet TERMINATED. It is used to forward a speed modification (override) or start a traversing program block in Single Block mode. START command When job terminated abort A tI 66.7 no BEC Evaluate auxiliary and edge flags in Programming the auxiliary and edge flags dependence on the A I 3.5 TRANSFER input AN F 4.6 = F 4.7 EDGE FLAG A I 3.5 TRANSFER <Gice tus => flag = 0? = F 4.6 no Edge flag not yet set > abort AN F 4.7 Load bit 4 = 1 into BEC FY6 L KB 16 TRANSFER COMMAND T FY 6 BE FB 25 - TOGGLE bit The TOGGLE bit must be inverted to enable the IP 266 to recognize a job as being a new job. If the nth job was started with TOGGLE = "1", job n + 1 must be started with TOGGLE = "0". In FB 25, the STEP 5 operations AW and OW were used to invert the TOGGLE bit. 9-22 EWA 4NEB 812 6057-02aIP 266 STEP 5 Programming Programming the TOGGLE bit: inverting the bit from the preceding job START Scanning the TOGGLE bit from the preceding job A Q 65.7 TOGGLE gc =INVT TOGGLE bit was "0"; invert TOGGLE bit in command flag byte FY6 L FY 6 Bit7 issetto "1" in Bit 7 issetto "O" in L KH 0080 TOGGLE BIT "1" FY 6 (preset in FY 6 (preset in ow FB 21 to 24). FB 21 to 24). . op 65 FY 6 is loaded into FY 6 is loaded into QB 65. QB 65. BEU TOGGLE bit was "1"; invert TOGGLE bit in command flag byte FY 6 INVT L FY 6 L KH OO7F TOGGLE BIT "0" Cen) an T QB 65 BE FB 25 is invoked only if a command edge flag was set (in FB 21 to FB 24). FB 20 - Read actual values The IP 266 provides three modes for reading out IP data (see Section 5). The default mode is mode 71, which is used to read the actual position. Since mode 71 is to be used in the example, it need not be explicitly started. In contrast to the other modes, modes 71 to 73 can also be started while the axis is traversing (Running status). The first part of the program in FB 20 displays the errors flagged in IB 67. EWA 4NEB 812 6057-02a 9-23STEP 5 Programming IP 266 Reading of the input frame (Pll) is only outlined. In practice, you would program the response to specific system states to suit your particular requirements. One practice-based application has been Programmed in the function block. Using M functions, you can trigger external activities such as lower drill (M30in the example) raisedrill (M40inthe example) START displaying errors L IB 64 MODE Read input L IB 65 M FUNCTION bytes L IB 66 STATUS L IB 67 ERRORS Display errors T QB 5 DISPLAY Reading the integer and decimal digits Read actual values L Iw 68 INTEGER DIGITS L Iw 70 DECIMAL DIGITS yas Activate the L IB 65 | Lower drill" L KB 30 M30 function 1=F LOWER DRILL = Q 2.6 ==> LOWER DRILL L IB 65 Activate the "Raise L KB 40 M40 drill" function l]F RAISE DRILL = Q 2.7 ==> RAISE DRILL BE 9-24 EWA 4NEB 812 6057-02aIP 266 STEP 5 Programming 9.5 Sample Program 2: Traversing to Two Fixed Target Positions A second sample program is to be written to move the drive from one fixed target position to another in "Relative increment" mode. At each of the two fixed target positions, the direction of travel is to be reversed and a new positioning operation started. e Example Flags Is used as M 3.0 Edge flag Flag bit 3.0 must be set to start a positioning operation. This bit ensures that a mode can be started only when the Job Terminated bit has been set for this operation. To start the first operation, the bit must be set "externally", e.g. via an input. You must scan this input in OB 1. You can take basic functions, such as the wait loop for the IP runup and mode 99 for synchronizing the IP 266, from sample program 1. This means that you can use OB 22, FB 27, OB 1 and FB 10. In OB 1, FB 11 must be invoked in place of FB 26. The description of FB 11 includes only the automatic sequence controlled by this function block. EWA 4NEB 812 6057-02a 9-25STEP 5 Programming IP 266 In FB 11, flag 3.0 is set in dependence on the Job Terminated bit. If this flag is not set, FB 11 is simply exited. If it is set, and if the "Job Terminated" bit is also set in the input byte, FB 11 invokes the function block used to invert the TOGGLE bit. Program the input frame for mode 7, including the mode, the override factor and the distance: JU FB 12 NAME LOAD Check to see whether a new job is allowed and, if so, terminated? invoke FB 13: AN I 66.7 s F 3.0 AN F 3.0 Set F 3.0 ac =END A I 66.7 Jc FB 13 NAME TOGGLE END BE Job terminated? no 9-26 EWA 4NEB 812 6057-02aIP 266 STEP 5 Programming Program output bytes 64 and 67 to 71 END Mode 7 requires the following data: These specifications define a distance of 50.000 mm. Like the TOGGLE bit, the command is alternately set and reset in FB 13. Mode number in QB 64 Override factor in QB 67 Relative distance specification in bytes QB 68 to QB 71 Forward or "Reverse" command in QB 65 L KF +7 T QB 64 L KF +100 T QB 67 L KF +50 T QW 68 L KF +0 T QW 70 BE EWA 4NEB 812 6057-02a 9-27STEP 5 Programming When a job request is allowed and the out must be loaded into QB 65 and the TOGGLE IP 266 put frame has been programmed, the start command bit inverted. Reset flag 3.0 and command flag FY6 Bit 3issetto "1" inFY6 ("Rev" command) Bit 2issetto "1" in FY6 ("Fwd" command) yes Bit 7 issetto "1" in FY 6, FY 6 is loaded into QB 65. Bit 7 issetto "0" in FY 6. FY 6 is loaded into QB 65. inverting the direction of travel in dependence on the last traversing operation. A F 3.0 R F 3.0 L KH 0 T FY 6 A Q 65.2 s F 6.3 Jc = CONT s F 6.2 Inverting the TOGGLE bit and transferring the command byte to the output frame. CONT: A Q 65.7 JC = INVT L FY 6 L KH 0080 Ow T QB 65 BEU INVT: L FY 6 L KH OO7F AW T QB 65 BE 9-28 EWA 4NEB 812 6057-02aIP 266 STEP 5 Programming "Automatic" positioning sequence as per example 2 State 1: Job terminated and flag 3.0=0; no job initiated, drive is at a standstill: Motor must be started by setting F 3.0 to "1". State 2: Job terminated and flag 3.0=1: The TOGGLE FB is entered and a new mode preset. State 3: Job terminated and flag 3.0=0, but no job order has been initiated: Loops are run through but no activities performed. State 4: Job in progress and flag 3.0=0: Flag 3.0 is set to "1", thus making it possible to issue a new job request. The only condition that has not yet been met to enable a new job to be started is the "Job terminated" bit from the IP 266s input message. The next possible state is the same as state 2. Alternate positioning in a positive and negative direction must be programmed in the TOGGLE FB. Summary: The example enables generation of a new job request only when the "Job terminated" bit has been read. It is thus unnecessary to terminate an old job with STOP before starting a new one. e@ Condition for issuing a new request: Job terminated and F 3.0=1 e@ Condition for setting flag bit F 3.0 to "1": Job in progress Once the automatic sequence has been started, positioning continues until the FB 11 call has been deactivated in OB 1. EWA 4NEB 812 6057-02a 9-29EWA 4NEB 812 6057-02aSie eee pee 10.1 Types Of Error... . cece eee eee e nee een e ener e steerer ssneeenceneees 10.2 List of Errors and Possible Causes .......c cece eee e ete n rene c ene nene 10- EWA ANEB 812 6057-02aEWA 4NEB 812 6057-02aIP 266 Troubleshooting 10 Troubleshooting This section provides detailed information on the errors which may occur when using the IP 266. During direct communication between the PLC's CPU and the IP 266, the error code is forwarded in KH (hexadecimal constant) format. When you service the IP 266 via COM 266, the error code and the associated text are displayed on the monitors error line. The error codes flagged on the PLC are identical to those displayed by COM 266. 10.1 Types of Error To simplify troubleshooting, this section provides a complete list of error codes and the associated error texts. EWA 4NEB 812 6057-02a 10-1Troubleshooting IP 266 F02: FOF : Wrong resolution Position tolerance out of range F61: wee sceeeeeee Incorrect hardware limit switch polarity 10-2 F6A: Incorrect following error Machine data errors F10: Inadmissible input F11! Memory overflow Traversing program F2F; Erroneous G-function errors - FDO: Only one continuous loop allowed FD1: No end of loop programmed Mass storage errors : P Prog IM 511 errors F31 i Invalid drive (programmer) : FRR: Incorrect file Module errors : F40: Syntax or name not correct F4i: Notallowed General errors : FSF: Frame error F81! Orderlist PG is full FBD: EEPROM failure FBE: No data in EEPROM/RAM ! FFO? Abort printing (Y/N) ? FFF: Inadmissible input EWA 4NEB 812 6057-02aIP 266 10.2 List of Errors and Possible Causes Troubleshooting Due to the exceptionally large number of errors which may be flagged on the PLC, it is necessary to have at hand a comprehensive list showing the error message for each error code. This list begins on the next page. In some cases, info recovery. For each error listed you will find a cross- manual; these sections provide more detailed information on the error in question. Wrong resolution The resolution must lie in the range from 0.1 to 99.9, and is computed as follows: Travel per encoder revolution Ee Pulses per encoder revolution The unit of resolution depends on the parameter specification. You must take into account that the dimensional unit of resolution is always Basic unit/1000 Pulses Basic unit Resolution mm pm 0.1 inch 0.0001 inch deg 0.001 deg oe Rigen Section 5.1.2 rmation has also been provided on measures for error reference to one or more sections in the FO3 Wrong maximum speed The speed specification must lie in the range from 1 to 65000. Section 5.1.4 FO4 Wrong JOG/INC speed All speeds must be = 1 and = of the specified maximum speed. Section 5.1.4 FOS Wrong reference speed For the IP 266, reference speed 1 must be = 1 and = the specified maximum speed. Reference speed 2 must also be > 1, but = reference speed 1. 1 < reference speed 2 = reference speed 1 = maximum speed. Section 5.1.4 FOG Wrong acceleration The maximum acceleration must be = 10 and = 9999 mm/s? (0.1 inch/s 2, deg/s 2), The remaining acceleration/deceleration values must also be = 10 but < the maximum acceleration rate. Section 5.1.5 EWA 4NEB 812 6057-02a 10-3Troubleshooting FO? IP 266 Wrong software limit switch The traversing range of a linear axis is defined by the coordinates of the Software start limit switch" and the "Software end limit switch "These two coordinates may not be identical (that of the start limit switch must always be lower than that of the end limit switch) and must lie in the range from +/- 32767.999 mm (+ /- 3276.799 inches, +/- 32767.999 degrees). Section 5.1.3 Fos Wrong reference point The reference point coordinate must be < the coordinate of the software end limit switch" and = the coordinate of the software start limit switch". Section 5.1.3 Section 5.3.5 Fos Vinax is too low The low limit of the programmed maximum speed depends on the resolution A {um/pulse] ("travel per encoder revolution"/"pulses per encoder revolution"). Va, must be greater than 4-A [um/pulse]. FOA Loop gain too low The low limit of the KV factor is 0.1 [1 /sec). Section 5.1.6 FOB Loop gain too high The loop gain (KV factor) must be less than 100 [1/sec], but not so high that a voltage corresponding to the maximum speed is output for a system deviation of 1 pulse, i.e. the loop gain in 1/sec must be less than Vmax [mm/min] - 1000 Piet cena ML ct A[pm/pulse] - 60 Section 5.1.6 FOC Wrong module number When <F1 > (Start) is pressed in the PRESETS form, the COM 266 software executes a module identification test. When a set of machine data is entered on the IP 266, the specified module number is compared with the module number in the machine data. The machine data must contain the same number as the one entered. Section 5.1.1 FOD Zero offset too large Every zero offset may assume values in the range + /-32767.999 mm. Among other things, a zero offset changes the coordinates of the software limit switches. Each offset value must be such that the coordinates of the software limit switches still lie in the range from + /-32767.999 mm (+/-32767.999 inches, +/-32767.999 degrees) after being shifted. Section 5.1.7 10-4 EWA 4NEB 812 6057-02aIP 266 Troubleshooting FOE Wrong tool offset Section 5.1.7 Atool offset is restricted to + /-32767.999. The coordinate of the software end limit switch plus zero offset and the coordinate of the software start limit switch plus zero offset must lie in the range + /-32767.999 mm (4 /-32767.999 inches, + /-32767.999 degrees). Remember that the zero offset is a signed value. tn the case of a rotary axis, the tool offset must also lie within the traversing range. FOF Position tolerance out of range Section 5.1.6 The tolerance range for zero-speed monitoring extends from 0.001 to 64.999 mm, and must also be less than the maximum following error. F10 inadmissible input Fil Memory overflow Section 5.4 F12 Separate functions with blanks Section 5.4.2 F13 Program already exists Section 5.4 Fi4 Block syntax incorrect Section 5.5.4 F15 Field cannot be exited Section 5.4 F16 Terminate processing? Section 5.4 F17 End function already present Section 5.4.2 F1i8 Input after L-function prohibited Section 5.4.2 F19 X-function not present Section 5.4.2 FIA Input after last entry prohibited Section 5.4.2 FiB Limit value of the function exceeded Section 5.4.2 Fic X-function incorrect correction Section 5.4.2 FiD Insert prohibited Section 5.4.2 Section 6 FIE Not stored Machining (traversing) program incomplete Section 5.4 F1F Output impossible file DB-No. not identical Section 5.4 EWA 4NEB 812 6057-02a 10-5Troubleshooting IP 266 ANSE! SS F20 Block type inadmissible Section 5.4 F21 Function key inhibited block incomplete Section 5.4 F22 G-function > prohibited input Section 5.4 F23 No other functions with L-function. Delete? Section 5.4 F24 Error in F-function Section 5.4 F25 Block type missing Section 5.4 F26 Block number missing Section 5.4 F27 Block complete Function key Section 5.4 F28 Momentary (current) G-function needs entry Section 5.4 F29 X-function must be followed by F-function Section 5.4 F2A X-function missing entry prohibited Section 5.4 F2B Final block present Function key inhibited Section 5.4 F2C Erroneous L-function Section 5.4 F2D Erroneous M-function Section 5.4 F2E Erroneous Blocknumber Section 5.4 F2F Erroneous G-function Section 5.4 F31 Invalid drive F32 Drive read failed F33 Element list missing F34 Data block missing F35 DB or file already exists F36 DB or file missing F37 File exists F38 Drive (floppy) write protected F39 File write protected F3A New element too long F3B Too many elements F3C File missing F3D Directory full 10-6 EWA 4NEB 812 6057-02aIP 266 Troubleshooting Disk full F3F Incorrect file F40 Syntax or name not correct F441 Not allowed F42 Data block missing F43 Overwrite data block? F44 Data block missing F45 Delete data block? Section 6 F46 Deleted! F48 illegal value! Fac Cable not connected! F50 Data block missing F51 Cable not connected to PG F52 Memory on PCB (module) too small F53 Watchdog error PCB This error is flagged over the programmer interface, i.e. inCOM 266 andin these situations in which it is not possible to communicate with the positioning module. This error is flagged in the following instances: - The cable is not connected or is improperly connected - The positioning module has no power supply F54 Transmission (transfer) error F55 Erroneous data transfer F56 Erroneous data transfer F57 BREAK received F58 PCB (module) does not answer FSA Wrong baudrate F5D Parity error F5E Overflow error FSF Frame error EWA 4NEB 812 6057-02a 10-7Troubleshooting IP 266 Be Semen Incorrect hardware limit switch polarity The only permissible values are "0" (NO contact, positive) and "1" (NC contact, negative). The IP 266 can detect an invalid parameter value only when neither hardware limit switch is actuated at the instant at which the machine data is entered. The hardware limit switches are also evalua- ted when a rotary axis is used. If none have been connected, NO contacts must be programmed. F62 Maximum speed too high for this resolution When a 5V encoder is used, the counter chip can count pulse trains with a maximum baud rate of 500 kHz. At the specified maximum speed in con- junction with the specified resolution [pm/pulse], this value is exceeded. F66 Invalid range limit value This error occurs only in conjunction with a rotary axis. The cause of error is the same as that for error FO7. Section 5.1.3 F68 Invalid dimensional unit Permissible dimensional units are millimeters, inches and degrees. F69 Backlash compensation out of range The backlash compensation value must be in the range 0.001 to 64.999 mm. Section 5.1.7 F6A Following error out of range The following error must be in the range 0.001 to 99.999. Section 5.1.6 F81 (Job) orderlist PG is full Because of the sluggishness of its mechanical parts, the module cannot process job orders as fast as these can be issued. The last job order issued via the programmer or PLC is lost, and must be retried. F82 Inadmissible order The last job order from the PLC or programmer contained either an undefined mode or was meaningless at this point. Example: An attempt to start an axis that was already traversing. The order is ignored. F83 Block stored This error is flagged only in mode 10 (TEACH-IN). Section 5.3.10 F84 Axis operational no inputs possible F85 (Job) orderlist PLC is full Coincides with error F81, but for the PLC. The last job order must be reissued, F86 High-speed change and final block The selected mode cannot be started because of a "0" signal at the external start enable" digital input. Section 2.5.4 10-8 EWA 4NEB 812 6057-02aIP 266 Speed range exceeded Either the override factor is not within the range 1% to 200% or the speed selected via (valid) override factor exceeds the maximum speed. This error occurs only in jog modes 1 and 2 and in incremental mode. The positioning module automatically prevents exceeding of these limiting values. Section 5.1.4 Troubleshooting F8A Reference point missing Section 5.3.5 FSB Max. following error exceeded The maximum following error specified in the machine data was exceeded and the current operation is aborted with a deceleration ramp. The position control loop remains in force and the axis does not reach zero speed until the following error has been reduced. The following-error monitor is not activated unless the maximum following error is exceeded despite axis movement or the actual value no longer changes and the specified maximum following error is such that it is exceeded at an analog voltage of less than 5 volts. Possible causes: - Load torque too high - Acceleration rate too high - Loop gain too low - Value specified as maximum following error too low In these four cases, the axis can be moved in controlled jog mode. The machine data must be adapted accordingly. - The machine data specifications for maximum speed and resolution are incorrect, i.e. were not matched to one another. This can be checked by comparing the speed specified for controlled jog mode with the displayed speed. Section 5.1.6 F8c Wrong PCB (module) number Once the positioning module contains at least one correct machine data record, it is no longer possible to change the module number. The number stored can be viewed in COM 266's PRESETS form. F8D Data block missing F8E Wrong or no machine data F8F Erroneous machine data EWA ANEB 812 6057-02a 10-9Troubleshooting IP 266 F90 PG is offline Section 6.1.3. F91 Overwrite machine data? F92 Program No. limit reached Section 5.4 F93 Data block missing F94 Overwrite machining (traversing) program? F95 Automatic prohibited F97 Stroke limit exceeded (traversing range exceeded) Section 5.1.3 F98 Program stroke limit exceeded (not enough room for traversing program) Section 5.4 F99 Left limit switch tripped Section 5.1.3 F9A Right limit switch tripped Section 5.1.3 FOB External STOP occurred Section 2.5.3 FOC Lower software switch tripped Section 5.1.3 F9D Upper software switch tripped Section 5.1.3 FOE Operating mode prohibited in Teach-in Section 5.3.10 Only jog modes 1 to 3 and increment modes 6 and 7 are permitted in Teach-In mode. FOF Erroneous operating mode processed FAQ Standstill (zero-speed) monitor tripped Section 5.1.6 FA1 Watch-Dog Section 5.3.18 FA2 Watch-Dog Section 5.3.18 FA3 Error at block start FA4 Sub-program DB-No too large The DB number must lie in the range from 1 to 255, FAS G-function prohibited Section 5.5.4 FA6 Loop only as outer loop FA7 Nesting depth exceeded Section 5.4.2 FAS Wrong X-function Section 5.4.2 FAQ Wrong F-function Section 5.4.2 FAA Stroke too long (traversing path too long) FAB Machining speed too high (traversing speed too high) 10-10 EWA 4NEB 812 6057-02aIP 266 Error at block end Troubleshooting End of program precedes end of loop Section 5.4.2 FAE Block not permitted after flying change Section 5.4.2 FBO Machining program erroneous (error in traversing program) Section 5.4 FB1 Machining (traversing) program already exists! Change Prog-No? FB2 Invalid position control direction The encoders position control direction is checked on an IP 266 cold restart. If an error is detected, the IP starts mode 4. You must then switch off the IP 266s 24 V power supply and change the position control direction (see Section 3.4). If no error was detected following a positioning operation during which an analog voltage greater than 5 V was output, the IP 266 deactivates the position control monitor. The monitor is reactivated each time mode 4 is started. FB3 Machining program is active FBS Target position not yet reached The setpoint position is already within the target range. The actual position is still outside the tolerance range of the zero-speed monitor and is no longer approaching the target coordinate, and the following error is lower than the specified maximum. Possible causes: - The tolerance range of the zero-speed monitor is too small - Thegain factor is too low or - The power section has too much drift (drift compensation, mode 18) - The position control loop was interrupted during execution of a traversing operation, and the distance to go is less than the maximum following error. If the distance to go is greater, however, "Maximum following error exceeded" is flagged. FBG Error in position control loop There is no change in the actual position even though the analog voltage (setpoint speed) exceeds 5 V. The current operation is aborted and mode 4 (follow-up mode) automatically started. In follow-up mode, the position controller is off. Follow-up mode can be terminated at any time. The position controller is then reenabled. Possible causes: - Encoder not connected, incorrectly connected or defective - The modules analog output is not wired - The power section is not switched on or not enabled - Theaxisis blocked by an obstacle of some kind or is jammed. EWA 4NEB 812 6057-02a 10-17Troubleshooting IP 266 FB7 PLC failure FBS Invalid path specification FB9 Invalid tool offset Section 5.1.7 FBA Invalid G function for dimensional unit "degrees" Section 5.4.2 FBB Path specification not in BCD code FBC EEPROM not programmable! FBD EEPROM failure! FBE No data in EEPROM/RAM ! FDO Only one continuous loop permitted FD1 No end of loop Section 5.4.2 FEC Printing FED Printer not ready! FEF Printing aborted! FFO Abort printing (Y/N)? FF2 Printer not initialized! COM 266 takes the printer parameters from S5-DOS to print data. When this error is flagged, exit COM 266 and initialize the printer interface with $5-DOS, FF4 * is not allowed here! FF5 Tilde (~) stands for to the power of 2 FF6 Invalid mode Section 5.3 FF7 Invalid time entered Section 6.1.3 FF8 No plant designation entered Section 6.1.3 FF9 No filename entered Section 6.1.3 FFA DB stored FFB Last page! Section 6.9 FFC Key prohibited FFD HELP key not allowed here! FFE Exit COM266? FFF Inadmissible input 10-42 EWA 4NEB 812 6057-02aEWA 4NEB 812 6057-02aEWA 4NEB 812 6057-02aIP 266 Active and Passive Faults in Automation Equipment/ESD Guidelines A Active and Passive Faults in Automation Equipment / Guidelines for Handling Electrostatic Sensitive Devices Active and Passive Faults in Automation Equipment e@ Depending on the particular task for which the electronic automation equipment is used, both active as well as passive faults can result in a dangerous situation. For example, in drive control, an active fault is generally dangerous because it can result in an unauthorized startup of the drive. On the other hand, a passive fault in a signalling function can result in a dangerous operating state not being reported to the operator. e The differentiation of the possible faults and their classification into dangerous and non- dangerous faults, depending on the particular task, is important for all safety considerations in respect to the product supplied. Warning In all cases where a fault in automation equipment can result in severe personal injury or substantial property damage, i.e., where a dangerous fault can occur, additional external measures, additional external measures must be taken or equipment provided to ensure or force safe operating conditions even in the event of a fault (e.g., by means of independent limit monitors, mechanical interlocks, etc.). Procedures for Maintenance and Repair If you are carrying out measurement or testing work on an active unit, you must adhere to the rules and regulations contained in the VGB 4.0 Accident Prevention Regulations of the German employers liability assurance association (Berufsgenossenschaften). Pay particular attention to paragraph 8, Permissible exceptions when working on live parts. Do not attempt to repair an item of automation equipment. Such repairs may only be carried out by Siemens service personnel or repair shops Siemens has authorized to carry out such repairs. The information in this manual is checked regularly for updating and correctness and may be modified without prior notice. The information contained in this manual is protected by copyright. Photocopying and translation into other languages is not permitted without express permission from Siemens. EWA 4NEB 812 6057-02a A-1Active and Passive Faults in Automation Equipment/ESD Guidelines IP 266 Guidelines for Handling Electrostatic Sensitive Devices (ESD) What is ESD? All electronic modules are equipped with large-scale integrated iCs or components. Due to their design, these electronic elements are very sensitive to overvoltages and thus to any electrostatic discharge. These Electrostatic Sensitive Devices are commonly referred to by the abbreviation ESD. Electrostatic sensitive devices are labelled with the following symbol: /\ Caution Electrostatic sensitive devices are subject to voltages that are far below the voltage values that can still be perceived by human beings. These voltages are present if you touch a component module without previously being electrostatically discharged. In most cases, the damage caused by an overvoltage is not immediately noticeable and results in total damage only after a prolonged period of operation. A-2 EWA 4NEB 812 6057-02aIP 266 | Active and Passive Faults in Automation Equipment/ESD Guidelines Electrostatic charging of objects and persons Every object with no conductive connection to the electrical potential of its surroundings can be charged electrostatically. In this way, voltages up to 15000 V can build up whereas minor charges, i.e. up to 100 V, are not relevant. Examples: e Plastic covers up to 5000 V e Plastic cups up to 5000 V e Plastic-bound books and notebooks up to 8000 V e@ Desoldering device with plastic parts up to 8000 V e Walking on plastic flooring up to 12000 V @ Sitting on a padded chair up to 15000 V e@ Walking on a carpet (synthetic) up to 15000 V Limits for perceiving electrostatic discharges An electrostatic discharge is e perceptible from 3500 V e@ audible from 4500 V e visible from 5000 V A traction of those voltages is capable of destroying or damaging electronic devices. Carefully note ad apply the protective measures described below to protect and prolong the life of your modules and components. General protective measures against electrostatic discharge damage e@ Keep plastics away from sensitive devices. Most plastic materials have a tendency to build up electrostatic charges easily. e Make sure that the personnel, working surfaces and packaging are sufficiently grounded when handling electrostatic sensitive devices. e If possible, avoid any contact with electrostatic sensitive devices. Hold modules without touching the pins of components or printed conductors. In this way, the discharged energy cannot affect the sensitive devices. EWA 4NEB 812 6057-02a A-3Active and Passive Faults in Automation Equipment/ESD Guidelines IP 266 Additional precautions for modules without housings Not e the following measures that have to be taken for modules that are not protected against accidental contact: Touch electrostatical sensitive devices only - if you weara wristband complying with ESD specifications or - if you use special ESD footwear or ground straps when walking ona an ESD floor. Persons working on electronic devices should first discharge their bodies by touching grounded metallic parts (e.g. bare metal parts of switchgear cabinets, water pipes, etc.) Protect the modules against contact with chargeable and highly insulating materials, such as plastic foils, insulating table tops or clothes made of plastic fibres. Place electrostatic sensitive devices only on conductive surfaces: - Tables with ESD surfaces - Conductive ESD foam plastic (ESD foam plastic ismostly coloured black) - ESD bags Avoid direct contact of eletrostatic sensitive devices with visual display units, monitors or TV sets (minimum distance to screen > 10 cm). EWA 4NEB 812 6057-024IP 266 Active and Passive Faults in Automation Equipment/ESD Guidelines The following Figures once again illustrates the precautions for handling electrostatically sensitive devices. Grounded connection of switchgear cabinet Grounded chair a Conductive flooring material b Table with conductive, grounded surface c ESD footwear d ESDsmock e Gounded ESD writstband f g Figure A-1. ESD Measures Taking measurements and working on ESD modules Measurements may be taken on electrostatic sensitive devices only if @ the measuring device is grounded (e.g. via protective conductor) or @ the tip of the isolated measuring tool has previously been discharged (e.g. by briefly touching grounded metal parts). EWA 4NEB 812 6057-02a A-5EWA 4NEB 812 6057-02aEWA 4NEB 812 6057-02aEWA 4NEB 812 6057-028IP 266 Index Index A Acceleration - Forward - Reverse Acceleration rate - Forward - Reverse Actual position - Read Actual value Actual-value display - Following a reference point approach - Mode Address assignment - Module Address range Addressing - Input frame Analog addresses ANALOG OUT - Power section Applications Approbations - CSA -UL Assignments - Terminal block Asymmetrical - 24V encoder Asymmetrical encoder Automatic mode Automatic program Automatic single block Automatic synchronization Auxiliary function Auxiliary screen form - Mode select Axis - Position - Status - Test Axis at zero speed - Exec EWA 4NEB 812 6057-02a 5-9 6-16, 6-17 6-16, 6-17 5-9 5-9 2-12, 5-11 5-62 4-5, 6-44, 6-45, 6-47, 6-48 5-30 6-43, 6-44, 6-45 7-1 7-1 7-9 7-1 2-8 8-2 1-2 2-20 2-9 8-3 6-19 5-36, 5-38 8-13 5-37, 5-38 9-3 5-80 6-50 7-11 6-44, 6-45, 6-47 8-10 5-38 Axis status Axis type B Backlash Backlash - Compensation - Compensation value Base unit BCD-coded - Position Binary-coded - Position Blank cycle Block - Number - Syntax diagram Block number -DB Bus module slot C Cable - Shielding Cable connection Cable length Calibrating - Power section Calibrating the axis CE-Marking Clearance distance Closed-loop positioning Coding - Command code - Element - Mode -Pin COM 266 - Error messages - Hierarchical structure -Start Command code - Coding 2-13 1-3, 5-3, 6-14, 6-15 5-14, 5-15, 5-23, 5-31, 5-71, 6-19, 8-2 5-14, 6-19 5-71, 6-18, 6-19 5-3 7-6,7-11 7-7 7-6, 7-11 7-6 9-1 6-12, 6-39, 6-41 5-81 5-38, 5-65 6-54 3-8 3-5, 3-7 3-7 8-3 5-50 5-7 2-20 1-4 43 7-4 3-8 73 3-8 6-1 6-57 6-10 6-3 7-4 7-4Index IP 266 Communication - Between PLC and IP 266 - PLC- CPU/IP 266 Compensation voltage Components - Module - Position control system Computing - Machine data - Reference point CONFIGURATION - Screen form Configuring Connecting cable Continuos loop Continuous belt Control Controller -On - Parameter Controller enable (FUM) Coordinate shift Coordinate zero point Correction parameters Current error code Cycle time D D Sub interface Data - Transfer direction Data area Data block - Selection Data bus Data cycle Data format - Recommended Data interchange Decelation rate - Reverse Deceleration - Forward - Maximum - Maximum rate - Reverse - Time Deceleration rate - Forward 7-1 5-63 10-1 5-52 2-1 4-4 8-6, 3-7 8-13 6-3, 6-4 8-1 2-7 5-70 1-3, 1-5 8-3 6-44, 6-45, 6-47 7-11 5-10 2-19 5-72 5-30 5-13 7-9 7-15 2-3 7-5 6-5 6-12, 6-54 6-12 1-5 7-1 7-2, 7-9 7-1 5-9 6-16, 6-17 6-16, 6-17 5-9 6-16, 6-17 8-6 5-9 Deceleration distance Deceleration rate b pay - Maximum Decimal digit Delete DELETE - Screen form Developer Device Digital-analog converter Dimension -inmm DIN DIN 66 025 - Representation Direction - Offset Direction of rotation - Encoder Direction of travel - Increment mode relative Direction reversal Disable tool offset Disabling the Monitors Distance Distance to go - Read Drift Drift - Compensation - Power electronics Drive Drive system - Mechanics Dwell Dwell time 1-4 8-6 7-6, 7-7, 7-14 6-53 6-53 6-7, 6-39, 6-41 6-39, 6-41, 6-54 2-2 6-35, 6-36, 5-77 5-77 6-32, 6-34 6-30 5-75 5-6, 8-10 5-34 5-34 5-15 5-72, 5-73 5-60 6-44, 6-45, 6-47, 6-48 5-36, 6-44, 6-45, 6-46, 6-48 5-62 5-23, 5-51, 8-10 5-23, 5-50, 5-52 5-50 6-7, 6-39, 6-41 8-2 5-68, 5-79 6-37, 7-11 EWA 4NEB 812 6057-02aIP 266 E EEPROM - Service life EEPROM<>RAM Parameter Electromagnetically Emergengy limit switch EMERGENCY STOP Emergency stop switch Enable - Negative tool offset - Positive tool offset Enable control Enable input Enable offset 1-4 Enabling the Monitors Encoder - Asymmetrical - Symmetrical - Direction of rotation - Installation - Location - Maximum operating frequency - Type Encoder (5 V) - Symmetrical Encoder monitor Encoder revolution - Pulse - Travel Encoder signal Encoder type End - Hardware limit switch End of program Entering - Machine program Equipotential Bonding Error - Acknowledgement - General - List - Possible causes - Analysis - Code - Flag - Line EWA 4NEB 812 6057-02a 5-56, 6-42, 7-5 5-56 7-5 3-2 1-4, 3-7, 8-1, 8-9 3-7 3-7 5-72, 5-73 5-72, 5-73 5-58 2-12 5-74, 5-76 5-61 2-6 2-5, 6-19 2-5, 6-19 5-6, 8-10 8-3 8-3 8-3 5-3 8-3 2-18 8-6, 10-3 8-6, 10-3 2-5 6-18, 6-19 8-6 5-80 6-30 3-4 5-49 10-2 10-3 10-3 9-3 7-9, 7-13, 10-3... 10-12 7-13 6-4, 6-6, 6-57, 10-1 Error messages - COM 266 ET 200 Evaluation - Signal edge Exec - Command - Key - While axis at zero speed Execute bit Exit - Test mode External start - Effect - Enable External STOP - Polarity External switching function F F function Factor - Override Fault LED Feed rate Field contents - Header Filename Firmware - Cycle Flying change Follow-up mode Following error As - Maximum - Monitoring - Read FORWARD Frame FUM (function signal) - Signal 6-57 7-15 9-1 5-37 5-69 5-38 7-4 6-57 2-11 5-36 2-10 2-10 5-80 5-79 6-48 2-17 6-37 6-5 6-7, 6-39, 6-41 6-7 1-6, 7-1, 7-4 5-36, 5-68, 5-69 5-23 4-5,5-11, 5-12, 5-22, 6-44, 6-45, 6-46, 6-47, 6-48, 5-50 5-11, 8-6 5-12, 6-18, 6-19 5-62 6-49, 7-4 7-1 2-9, 2-12 5-52, 8-5 IndexIndex IP 266 Function -1() -2(G) - 3 (X) -4(F) -5(M) - Hardware limit switch - Increment mode absolute - Key menu - Keys <F2> to <F6> FUNCTION SELECT - Screen form - Screen form Function signal> FUM FWD G G function GOO: Rapid traverse G04: Dwell G10: Flying change G20: End of loop G24: Start of loop G25: Approach target over shortest path G26: Approach target in clockwise direction G27: Approach target in counter-clockwise direction G40: Disable tool offset G43: Enable positive tool offset 5-19 6-35, 6-36 6-35, 6-36 6-35, 6-36 6-35, 6-37 6-35, 6-37 8-11 5-33 6-4, 6-6 6-49 6-9 6-53 7-2 5-67 5-67 5-68 5-68, 5-69 5-70 5-70 5-71 5-71 5-71 5-72, 5-73 G43: Enable positive tool offset 5-72, 5-73 G44: Enable negative tool offset 5-72, 5-73 G53: Cancel zero offsets G54 - G57: Enable offset 1-4 G70: Dimensions in 0.1 inch G71: Dimensions inmm G74: Approach to reference Point G90: Absolute position specifications G91: Relative position specifications Generation date Ground wire 5-74, 5-76 5-74, 5-76 5-77 5-77 5-78 5-79 5-79 6-7, 6-39, 6-41 8-5 H Hardware - Configuration - Fault Hardware limit switch -End - Function Hardware limit switch - Polarity - Start Hatching Header - Field contents Help menu Hierarchical structure - COM 266 - TEST form ! /O IM 511 error - Programmer increment mode - Absolute - Relative Increment mode absolute - Rotary axis - Function - Linear axis Incremental encoder Incremental position encoder Incremental speed Information INFORMATION - Screen form - Modes Initialization - IP 266 INPUT - Screen form - Digital - Process image (Pll) 2-1 2-17 1-4, 2-9, 2-10, 3-7, 8-1 8-6 8-11 2-10, 5-16, 6-26, 6-27 8-6 5-67 6-4 6-5 6-50 6-43 6-10 6-43 4-4 10-2 8-13 5-32 5-34 5-33 5-33 5-32 8-11 2-5, 8-2, 8-3 5-8, 5-39, 6-24, 6-25 6-55 6-55 5-62 8-8 6-11 2-9 7-1 EWA 4NEB 812 6057-02aIP 266 Index Input fields Input frame - Addressing - Overview INPUT MACHINEDATA - Screen form INPUT MACHINING PROGRAM - Screen form Input value - Monitoring function Installation - Encoder - Guidelines Integer digit Interchange - Signal line Interface - DSub - PLC - Position encoder Interruption of the traversing program Interruption points Inversion - Signal Invoking - Modes IP - Synchronization IP 266 - Initialization - Removal - Run-up - Synchronized - Teach-in mode IP STOP if CPU STOP EWA 4NEB 812 6057-02a 6-50 7-1, 7-8 7-9 7-9 6-14, 6-16, 6-18, 6-20, 6-22, 6-24, 6-26 6-31 7-14 3-8 8-3 3-1 7-6, 7-7, 7-14 2-19 2-3 2-3 1-6 2-6 5-36 5-37 2-5 5-17 5-63 8-8 3-8 5-56 7-11 7-11 5-16, 6-18, 6-19 J Job - Completed - In progress - Terminated/in progress Jog - Speed - under open-loop contro! Jog 1 - Forward speed - Reverse speed Jog 2 - Forward speed - Reverse speed K KOMI screen form KV (servo gain) factor L L function Last block LED flashes Lightning protection Limit switch - Hardware - Software Linear axis - Increment mode absolute Linear encoder Load statement Location - Encoder Loop - End - Nesting - Pass - Start - Pass 7-11 9-1 5-8 5-22 5-19 6-24, 6-25 6-24, 6-25 5-22 6-24, 6-25 6-24, 6-25 6-3 5-10, 5-11, 5-15, 6-18, 6-19, 8-6 5-66 5-80 2-17 3-3 8-1 1-4, 2-10, 8-1 1-4, 8-1 1-3, 1-4, 5-3, 5-6 5-32 1-6 7-1 8-3 5-70 5-66 5-79 5-70 6-35, 6-37