1^ INTEGRATION MANUAL ^2 Adv 400 Integration Manual
Contents
1. Buttons test if a button is not pressed If PB AUTO MODE 0 test if a button is pressed If PB AUTO MODE 0 Symbol Comment PB MACHINE LOCK Notused PB RESET Reset button PB SINGLE BLOCK Single block button PB OPT STOP Optional stop button PB BLOCK DELETE Block delete button PB CLNT FLOOD Not used PB CLNT MIST Not used PB JOG PLUS Jog Plus button PB JOG MINUS Jog Minus button PB JOG STOP Not used PB JOG RETURN Not used PB HOME Home mode button PB CYCLE START Cycle start button PB CYCLE RESTART Not used PB FEED HOLD Feed Hold button PB DRY RUN Not used PB SPND CW Not used PB SPND CCW Not used PB SPND BRAKE Not used PB SPND NEUTRAL Not used PB PRG REWIND Not used PB CHUCK OPEN Not used PB CHUCK CLOSE Not used PB CHUCK OD GRIP Not used PB CHUCK ID GRIP Not used PB TOOL RELEASE Not used PB TOOL ENGAGE Not used PB AUTO MODI Auto mode button PB MANUAL MODI Manual mode button PB MDI MODE MDI mode button PB HOME MODE Home mode button PB FREE TWO Not used Read a Number Value Buttons Symbol Comment VS SPINDLE RPM M Not used VS SPINDLE MAX RPM Maximum spindle speed VS SPINDLE MAX LIM M Maximum spindle speed VS SPI2. 1 M Oe HEET 11 E 12 VITE T ERR 13 Waiting State of tne 13 DECLINE an Output 13 Testing or Waiting an Information rein nnne 13 Using a Timer sat EE 13 e EE E 13 TEE 14 ele 15 CUSTOM M CODES 0 17 2 edie 19 S b Routine 998 ee Eeer 19 Tool Changer Inter eee 20 APPENDIX TABLE OF 8 00 2 21 ln 21 VIII ERES 21 Inputs False 22 Ke 23 Set Outputs Synchrone for Programming Oh 23 Reset OULPUIS NEEN 24 Reset Outputs Synchronously for Programming Ob 24 Outputs OM T 25 Outputs OFF Y X S 25 d cr 26 Mr e AE 26 hn e 27 Read a Number Value Buttons 27 le 28 Read a Number Value Mode Axis Selected 28 Read
3. Reset Outputs Synchronously for Programming Only Symbol Comment RESETS OUTPUT1 Reset Output synchronously RESETS OUTPUT2 Reset Output 2 synchronously RESETS OUTPUT3 Reset Output 3 synchronously RESETS OUTPUT4 Reset Output 4 synchronously RESETS OUTPUTS Reset Output 5 synchronously RESETS OUTPUT6 Reset Output 6 synchronously RESETS OUTPUT7 Reset Output 7 synchronously RESETS OUTPUT8 Reset Output 8 synchronously RESETS OUTPUTS Reset Output 9 synchronously RESETS OUTPUT10 Reset Output 10 synchronously RESETS OUTPUT11 Reset Output 12 synchronously RESETS OUTPUT12 Reset Output 13 synchronously RESETS OUTPUT13 Reset Output 14 synchronously RESETS OUTPUT14 Reset Output 15 synchronously RESETS OUTPUT15 Reset Output 16 synchronously RESETS OUTPUT16 Reset Output 17 synchronously 24 Appendix A Adv 400 Programming Manual Outputs On Symbol Comment ON OUTPUT1 Output 1 true ON OUTPUT2 Output 2 true ON OUTPUT3 Output 3 true ON OUTPUTA Output 4 true ON OUTPUTS Output 5 true ON OUTPUT6 Output 6 true ON OUTPUT Output 7 true ON OUTPUTB8 Ou
4. IF S_MODE_M SEL_MODE_AUTO IF ON INPUT1 and PB AUTO MODE D FLAG1 1 SET OUTPUT3 ENDIF IF OFF INPUT1 FLAG1 0 RESET_OUTPUT3 ENDIF ENDIF Ln 1 Col 1 Read CAP Custom PLCs 11 Adv 400 Integration Manual When creating a new PLC or editing an existing PLC a text editor is opened and the PLC code can be entered e Download or F2 on the keyboard is sending the PLC to the controller and uses it automatically like the Load button on the Managing PLC page e Close Editor or F10 on the keyboard is providing a quit of this page asking to save to entered code if not done Writing a PLC The Custom PLCs use the symbol table Refer to the Table of Symbols section for a list of all available symbols Personal symbols can be created with Adv 400 free variables The free variables are e P800 to P1023 e 0800 to Q1023 e M800 to M1023 P and Q Variables are 48 bits floating point format and any calculation can be performed or flag designated M Variables are 24 bits format and any calculation can be performed or any flag designated Normally they are used for pointing any memory of the Adv 400 system but the needed memories for writing applications are already done accessible with the Table of Symbols Edit symbols Symbol Name Cancel In the CNC menu there is a table to create symbols for free variables e PLC15 to PLC24 are available for customs PLCs
5. mm Disable Neg Brake on Output a Motor 2 Amp Fault Hardware Limit Soft Limits Max JOG Speed High True C Enable Pos 0 0 mm min Motor 2 with Low True Disable mm Brake on Output Disable Motor 3 e Fault Hardware Limit Soft Limits Max JOG Speed C High True C Enable Pos jo Motor 3 with Brake Low True G pi mm Disable Brake on Output Disable Neg 0 SS Motor 4 a AmpFault Hardware Limit Soft Limits Max JOG Speed High True Pos 0 0 mm min v Motor 4 with Brake Low True mm Disable Brake on Output 4 C Disable I E Motor 5 Amp Fault Hardware Limit Soft Limits 7 High True C Enable Pos 0 0 mm min Motor 5 with Brake Low True mm Brake on Output Disable Disable i If an axis is used box checked on Setting page 1 information on this page must be entered e The Amp Fault amplifier fault signal returning from the drive can be true amplifier on default at level high or at level low Also the management of the amplifier fault signal can be disabled if the drive does not have one e The Hardware Limits plus and minus can be enabled or disabled If enabled if one of these limits is reached the axis will stop automatically Software Limits in millimeters can be used to limit the travel of the axis These limits are only for linear axis X Y Z U and V A zero 0 value disables the software limit e The Max JOG
6. Cycle Start button JOG button etc In addition this sub directory contains the different symbol tables files Sys sbl Errors sbl and Plc sbl containing all symbol names used for PLC or Sub program development e The sub directory SUB will contain the sub programs 2 997 the user may create The sub program 998 and 999 are present already and must be completed by the machine integrator Program 998 is used for integration of a tool changer Program 999 is used to create custom M codes Appendix B 33
7. or stepper pulses and direction type of axis e If Analog axis is selected an encoder must be present on this axis For stepper axis the Adv 400 can work with or without real encoder feedback The maximum frequency for pulse output must be entered also when an axis is used in stepper both cases analog or stepper the resolution counts per millimeters the maximum speed millimeters per minute and the maximum acceleration time in milliseconds from 0 to maximum speed must be indicated If analog axis or stepper encoder is selected perform a position loop tuning before this axis can be used See the Axis Tuning section If stepper without an encoder is selected do not perform the position loop tuning The controller simulates the encoder internally and the axis PID gains are calculated automatically Machine Settings 3 Adv 400 Integration Manual Motor 4 Motor 4 can be an axis linear named U or rotary named A In this case like motors 1 2 and 3 this motor can be analog or stepper with the same setup Motor 4 can be a spindle named S open loop without an encoder open loop with encoder or closed loop automatically with encoder In this case the analog type is used no stepper The resolution counts per millimeters if linear axis U counts per degree if rotary axis A or counts per revolution in case of spindle the maximum speed millimeters per minute if linear axis U degrees per minute if
8. 4 User timer 4 for PLC USER TIMER 5 User timer 5 for PLC USER TIMER 6 User timer 6 for PLC USER TIMER 7 User timer 7 for PLC USER TIMER 8 User timer 8 for PLC Status test if a status is false If CS SPND AT 0 test if a status is true If CS SPND AT SPEED 0 Symbol Comment CS MACHINE LOCK Not used CS RESET Not used CS SINGLE BLOCK Part program single block status CS OPT STOP Part program optional stop status CS BLOCK DELETE Part program block delete status CS CLNT FLOOD Not used CS CLNT MIST Not used CS JOG PLUS Not used CS JOG MINUS Not used CS JOG STOP Not used CS JOG RETURN Not used CS HOME Not used CS CYCLE START Not used CS CYCLE RESTART Notused CS FEED HOLD Not used CS DRY RUN Not used CS SPND CW Not used CS SPND CCW Not used CS SPND BRAKE Not used CS SPND NEUTRAL Not used CS PRG REWIND Not used CS CHUCK OPEN Not used CS CHUCK CLOSE Not used CS CHUCK OD GRIP Notused CS CHUCK ID GRIP Notused CS TOOL RELEASE Not used CS TOOL ENGAGE Not used CS SPND DETECT Spindle speed detection status CS SPND CSS Spindle constant surface speed status CS SPND AT SPEED Spindle at speed status CS SPND AT ZERO Spindle at zero speed status CS SPND FEED Spindle feed per revolution status 26 Appendix A Adv 400 Programming Manual
9. check the desired fast input Home Low True Home High True Limit flag or Limit flag The home speed must be entered in millimeters per minute In addition the direction for the home search must be entered The direction is where the axis 1s going to the selected flag direction The Home Seq box must be set with a number between 1 and 5 indicating the desired sequence of the homing Axis homing will be performed one by one following this sequence first axis will be this with number 1 second axis will be this with number 2 etc If Motor 4 is used as a spindle no homing sequence will be performed on this motor 6 Machine Settings Adv 400 Programming Manual Setting Page 4 Miscellaneous CNC SetUp Page 4 of 4 PeUp PgDown switch page F2 Apply F10 Cancel Motor 1 Machine Type Max Following Error mm Reverse Counting direction C Mil Lathe X Axis is Diameter Input I Motor 2 Use Input 1 for Emergency Stop Max Following Error Use Input 2 for Feed Hold 11 234 ina directi mm Reverse Counting direction Use Input 3 for Cycle Start teg Use Input 4 for Reset Max Following Error EM Use Toolchanger Prog 998 1 mm Reverse Counting direction GER Use Toolchanger Init Dialog Motor 4 Use Custom 3 4 5 Prog 999 Max Following Error 33456 mm deg Reverse Counting direction Use 4 decimal places Motor 5 Max Following Error 44557 mm Reverse Counting direction This page in
10. checked in Machine Setting Page 4 a menu appears at power up of the Adv 400 CNC software Init Toolchanger Do you hve Tool the Spindle Toolnumber 3 F5 These two values tool number magazine position just memorized on some variables so that the tool changing code can be used later first value is entered in the variable P355 named TOOL IN SPINDLE The second value is entered in the variable P356 named MAGAZINE POSITION Use these two variables for a tool changer where an initialization must be made whenever the system is started telling what tool 1s in the spindle and what the magazine position 1s next to the spindle For any other type of tool changer these two variables can be used in another way such as telling what tool is active at power up 20 Tool Changer Adv 400 Programming Manual APPENDIX A TABLE OF SYMBOLS Inputs Inputs True Symbol Comment ON INPUT1 Input 1 true ON INPUT2 Input 2 true ON INPUT3 Input 3 true ON INPUTA Input 4 true ON INPUT5 Input 5 true ON INPUT6 Input 6 true ON INPUT7 Input 7 true ON INPUTS Input 8 true ON INPUT9 Input 9 true ON INPUT10 Input 10 true ON INPUT11 Input 11 true ON INPUT12 Input 12 true ON INPUT13 Input 13 true ON INPUT14 Input 14 true ON 15 In
11. menu of the Adv 400 HMI Reboot the Adv 400 unit Axis Tuning Adv 400 Integration Manual 10 Axis Tuning Adv 400 Programming Manual CUSTOM PLCS Create custom PLCs to managing certain functions of the machine with this feature PLCs numbers 15 to 24 are available for these customs PLCs PLC25 is present already and creates some additional conditions for the use of some machine control buttons PLCs Management Under the CNC menu a management page creates New Edit Delete Load and Unload for a custom PLC PLC e and SUB Programs F10 Cancel Plc15 plc Plc15 plc Plc25 plc F2 New F3 Edit F4 Delete F5 Load F6 Unload e New or F2 on the keyboard creates a new custom PLC opening text editor with blank page e Edit or on the keyboard opens an existing custom PLC opening text editor with this PLC inside for consulting or modification e Delete or F4 on the keyboard removes an existing custom PLC from the list or F5 on the keyboard loads an existing custom PLC in the controller and enables it An X appears in the Loaded section for this PLC and the PLC is used until it is unloaded e Unload or F6 on the keyboard removes an existing custom PLC from the controller The X does not appear in the Loaded section for this PLC ADV400 PLC15 PLC File Edit Tools Offsets Subprogram CNC Language Version Esc C ACNC PLC PLC15 PLC F2 Download F10 Close Editor
12. new tool offset N1000 put the code here RET put the code here after tacking new tool offset N2000 put the code here RET As an example to move X and Y axis to positions 0 before changing tool ask a PLC with variable P810 to make the tool change then move back X and Y axis to position 10 In this example there are some Dwe110 commands Dwe110 command waits until the previous axis movement is finished before starting the next job A Dwe110 command must be present in a While loop of a part program as sub routines are running in part programs Prog 998 Create the tool changer in this file put the code before new tool offset at label N1000 put the code with new tool offset at label N2000 put the code here before tacking new tool offset N1000 GOO XO YO move axis with actual tool offset DwellO this waits previous movement is finished 801 1 ask PLC to make tool change While P810 1 wait that the tool change is finished DwellO this means that PLC puts back P801 to 0 Endwhile Tool Changer 19 Adv 400 Integration Manual put the code here after tacking new tool offset N2000 GOO X10 10 move axis with new tool offset RET Tool Changer Initialization With certain types of Tool Changers it is necessary to initialize some data every time the CNC is started to indicate to the system what tool is present Therefore when the Use Toolchanger Init Dialog box is
13. section of this manual for details The Use Toolchanger Init Dialog box gives a special dialog menu at power up of Adv 400 CNC and then special tool changer positions can be initialized Refer to the Tool Changer section of this manual for details Machine Settings 7 Adv 400 Integration Manual The Use Custom 3 4 5 Prog999 box writes custom M codes for spindle in sub routine 999 If this box is checked these custom M codes must be written otherwise the normal M3 M4 M5 codes of the system will be used Refer to the Custom M Codes section of this manual for details The Use 4 decimal places box allows four decimal digits in the axis position windows Default is three digits 8 Machine Settings Adv 400 Programming Manual AXIS TUNING The tuner tool of the Executive Program Pewin32 or Pewin32Pro is used to tune the axis The following steps must be performed 1 2 3 4 5 Boot the Adv 400 system and let the HMI start Exit from the HMI using the File Exit menu Connect an external computer with the Executive program to the RS232 connector of the Adv 400 Start the Executive Program and tune the axis with this external computer When the tuning is finished quit the Executive program and without shutting down the Adv 400 controller start the Adv 400 HMI again the program is called ADV400 EXE and is located on the Hard Disk CNC directory Save the I Variables using the CNC Save I variables
14. special PLC25 is present in the system already and must be downloaded in the CNC in order to have all buttons Cycle Start Feed Hold etc working Refer to the PLC25 section of this manual for details A PLC is scanned all the time asynchronously as part of the program It reads inputs writes outputs and tests conditions 12 Custom PLCs Adv 400 Programming Manual Testing an Input If ON_INPUT1 test is Inputl true action Endif If OFF_INPUT4 test is Input4 false action Else other action Endif Waiting State of an Input While ON INPUT2 wait as long as Input2 is true action Endw Setting an Output SET OUTPUT2 set Ouput2 RESET OUTPUT3 Reset Ouput3 Testing or Waiting an Information With an If condition or a While loop it is possible to test or wait for some other information coming from the CNC The Table of Symbols gives the list of information available If CS SPND AT ZERO 0 test is spindle is at zero speed action Endif While CS SPND AT SPEED 0 wait that spindle is at programmed speed Endif Using a Timer SET OUTPUT2 set ouput2 USER TIMER 1 150 timer of 150ms While USER TIMER 120 wait timer finished Endw RESET OUTPUT2 reset ouput2 Specific PLC25 The PLC25 adds some conditions to the use of buttons The buttons managed in this PLC25 that have conditions
15. 24 SUB Prog998 ncs Prog999 ncs Part Programs Files with NC extensions e The main directory is called Hard Disk It is the root of the disk and it contains the Windows CE files e The sub directory NCDATA contains the part programs G codes programs created by the user These files are managed automatically by the HMI while creations modifications of part programs They have a NC extension e sub directory CNC contains sub directories 01 02 PLC and SUB and some files needed by the HMI The Adv400 exe file is the HMI software e The Mill Lathe dl files are the system PLCs sent to the controller at power up e Ifa Milling machine was selected in the Machine Setting Page 4 the Mill dl file is used Ifa Lathe machine was selected the Lathe dl file is used e The HMI software creates all other files in this CNC sub directory during the setting of the machine e The sub directory 01 contains the error file and the text file used for first language The first language is English by default e The sub directory 02 contains the error file and the text file used for the second language The second language can be any language The machine integrator must make the translations e The sub directory PLC will contain the PLC15 to 24 the machine integrator may create A PLC25 exists already and can be modified by the machine integrator It is used to put extra conditions on the use of the Adv 400 buttons e g
16. 25 Sat m Output Inverted Input 28 Input 29 Input 30 Input 31 Input 32 e Terminal sends commands to the CNC controller Terminal F10 Cancel The terminal function is used for checks and debugging The commands sent here are the motion controller commands Command Description Symbols and Creates and manages customs PLCs for the machine Refer to the Custom PLCs Manage PLCs section of this manual for details Settings Opens the machine setting pages Refer to the Machine Settings section of this manual for details Save I Variables Performs a backup of the I variables on the system The I variables contains several settings of the machine e g PID gains of axis and any change to these variables must be saved to recover the same setting after shutting down the system Download Raw File Sends a text file to the controller This is used for maintenance as this file must contain only pure Motion Controller code Reset CNC Restarts the CNC system e g after a shutdown If for any reason the configuration must be resent to the controller this menu will perform the job Remove the power of drives or press the E stop button before performing this action Introduction Adv 400 Programming Manual MACHINE SETTINGS Before using the axis the machine must be set There are four pages for the machine setting which define the details about the m
17. INTEGRATION MANUAL Adv 400 Integration Manual DELTA TAU Data Systems Inc NEW IDEAS IN MOTION Single Source Machine Control Power Flexibility Ease of Use 21314 Lassen Street Chatsworth CA 91311 Tel 818 998 2095 Fax 818 998 7807 www deltatau com Copyright Information 2007 Delta Tau Data Systems Inc All rights reserved This document is furnished for the customers of Delta Tau Data Systems Inc Other uses are unauthorized without written permission of Delta Tau Data Systems Inc Information contained in this manual may be updated from time to time due to product improvements etc and may not conform in every respect to former issues To report errors or inconsistencies call or email Delta Tau Data Systems Inc Technical Support Phone 818 717 5656 Fax 818 998 7807 Email support deltatau com Website http www deltatau com Operating Conditions AII Delta Tau Data Systems Inc motion controller products accessories and amplifiers contain static sensitive components that can be damaged by incorrect handling When installing or handling Delta Tau Data Systems Inc products avoid contact with highly insulated materials Only qualified personnel should be allowed to handle this equipment In the case of industrial applications we expect our products to be protected from hazardous or conductive materials and or environments that could cause harm to the controller by damaging co
18. LAG 4 Axis 4 A U User flag hardware input USER FLAG 5 Axis 5 B V User flag hardware input AMP1 ENA M Axis 1 X Amplifier enable hardware output AMP2 ENA M Axis 2 Y Amplifier enable hardware output AMP3 ENA M Axis 3 Z Amplifier enable hardware output AMP4 ENA M Axis 4 A U Amplifier enable hardware output AMP5 ENA M Axis 5 B V Amplifier enable hardware output FATAL FEl M Axis 1 X Fatal following error bit FATAL FE2 M Axis 2 Y Fatal following error bit FATAL FE3 M Axis 3 Z Fatal following error bit FATAL 4 Axis 4 A U Fatal following error bit FATAL FES M Axis 5 B V Fatal following error bit FAUT1 M Axis 1 X Amplifier fault hardware input FAUT2 M Axis 2 Y Amplifier fault hardware input AMP FAUT3 M Axis 3 Z Amplifier fault hardware input AMP FAUTA M Axis 4 A U Amplifier fault hardware input 5 M Axis 5 B V Amplifier fault hardware input DACH OUT DAC 5 output value when motor 5 not used DAC6 OUT DAC 6 output value 30 Appendix A Adv 400 Programming Manual P Variables Symbol Comment TOOL GEOMWEAR Actual tool correction number TOOL NUMBER Actual tool number VERSION NUMBER PLC program version number DATE VERSION PLC program date HOME COMPLETE P axis Ho
19. NDLE CMD RPM M Actual commanded spindle speed VS SPINDLE ACT RPM M Actual spindle speed SPINDLE COUNTS REV M Not used VS SPINDLI Not used VS SPINDLE CSS M Not used VS SPIND Actual spindle override VS HAND STEE Not used VS FEED OVERRIDE Actual feed override VS RAPID Actual rapid override Appendix A 27 Adv 400 Integration Manual Mode Axis Selected test the actual mode If S MODE M SEL MODE AUTO test the axis selected If S AXIS M SEL AXIS X test of spindle status If S SPND M SEL SPND CCW Symbol Comment S MODE M Tell actual mode SEL MODE AUTO Auto mode SEL MODE MANUAL Manual mode SEL MODE MDI MDI mode SEL MODE HOME Home mode Symbol Comment S AXIS M Tell axis selected SEL AXIS X X axis selected SEL AXIS Y Y axis selected SEL AXIS 2 Z axis selected SEL AXIS A A U axis selected SEL AXIS B B V axis selected Symbol Comment S SPND M Tell spindle status SEL SPND CCW Spindle turning CCW SEL SPND OFF Spindle stopped SEL SPND CW Spindle turning CW SEL SPND ORIENT Notused SEL SPND ORIENT2 Not used SEL
20. NT MOTION REQ M SPINDLE MOTOR VEL SPINDLE CSS POS SPINDLE DAC M SPINDLE ENA M ABORT DECEL 1 M ABORT DECEL 2 M ABORT DECEL 3 M DES VEL ZERO 1 M Axis 1 X desired velocity zero bit DES VEL ZERO 2 Axis 2 Y desired velocity zero bit DES VEL ZERO 3 M Axis 3 Z desired velocity zero bit DES VEL ZERO 4 M Axis 4 A U desired velocity zero bit DES VEL ZERO 5 M Axis 5 B V desired velocity zero bit POS BIAS1 M Axis 1 X position bias G92 offset POS BIAS2 M Axis 2 Y position bias G92 offset POS BIAS3 M Axis 3 Z position bias G92 offset POS 54 M Axis 4 A U position bias G92 offset POS BIAS5 Axis 5 B V position bias G92 offset PLUS LIMIT1 Axis 1 X plus limit active hard or soft PLUS LIMIT2 M Axis 2 Y plus limit active hard or soft PLUS LIMIT3 M Axis 3 Z plus limit active hard or soft PLUS LIMIT4 Axis 4 A U plus limit active hard or soft PLUS LIMIT5 M Axis 5 B V plus limit active hard or soft NEG LIMIT1 Axis 1 X minus limit active hard or soft NEG LIMIT2 M Axis 2 Y minus limit active hard or soft NEG LIMIT3 M Axis 3 Z minus limit active hard or soft NEG LIMIT4 M Axis 4 A U minus limit active hard or soft NEG LIMIT5 M Axis 5 B V minus limi
21. SPND LOCK Not used Read a Number Value Mode Axis Selected Symbol Comment VS TOOL NUM M Give active tool and correction numbers VS X ABS M Give actual offset G54 G59 G52 Tool of X axis VS Y ABS M Give actual offset G54 G59 G52 Tool of Y axis VS 2 ABS Give actual offset G54 G59 G52 Tool of Z axis 28 Appendix A Adv 400 Programming Manual Read a Number Value or Bit Mode Axis Selected To write 5 or DAC6 from 512 to 512 for JON to 10V Symbol Comment SERVO COUNTER M Servo counter incremented by one every Servo inter HANDLESIN COUNT M Encoder 5 value if motor 5 not used HANDLEGIN COUNT M Encoder 6 value ADC1 M ADCI value feed potentiometer ADC2 M ADC2 value ADC3 M ADC3 value ADCA M ADC4 value TIMER 1 M TIMER 2 M TIMER 3 M TIMER 4 M FEED HOLD M PROG RUNNING M Program running bit HOME COMPLETE 1 M _ Axis 1 X home completed bit HOME COMPLETE 2 M Axis 2 Y home completed bit HOME COMPLETE 3 M Axis 3 Z home completed bit HOME COMPLETE 4 M Axis4 A U home completed bit HOME COMPLETE 5 M 5 home completed bit PROG STEPPING M MOTION MODE M IN POSITION M Coordinate system one all axis in position CO
22. Speed indicates the maximum speed of the axis on manual JOG moves Ifa motor has an internal Brake vertical axis for example a digital output must be attached to the brake and the Adv 400 will manage this output automatically with the status open loop or closed loop of this motor In this case check the Motor x with Brake box and enter a number for the digital output between 1 and 16 See the Digital Outputs section on Adv 400 connector OUTI Machine Settings Adv 400 Integration Manual Setting Page 3 Axis Homing Setup CNC SetUp Page 3 of 4 PeUp PeDown switch page F2 Apply F10 Cancel S Home Speed Home search Home seq Home Low True Home High True Low True 0 mm min Plus direction 2 OnbCch c Limit flag High True C Minus direction imi None C Limit flag a Motor2 T T NoHome Home Low True Sanne Home search Home seq 2 mm min 5 Plus direction 3 C ch ei d Limit flag Minus direction C Limit flag None Motora C channel Home Speed Home search Home seg Home Home Low True 7 OnCch Home High True ies ie mm min Plus direction 0 ch ne be Limit flag Minus direction Limit flag None Motor 4 Home Low True E channel Ed Home search Home seq No Home Home High True 2 0 mm min v Plus direction Io Only C ch Limit flag igh True SE C Limit flag wes M
23. UT28 Input 28 false OFF INPUT29 Input 29 false OFF INPUT30 Input 30 false OFF INPUT31 Input 31 false OFF INPUT32 Input 32 false 22 Appendix A Adv 400 Programming Manual Set Outputs Non Synchrone Symbol Comment SET OUTPUTI Set Output 1 true SET OUTPUT2 Set Output 2 true SET OUTPUT3 Set Output 3 true SET OUTPUT4 Set Output 4 true SET OUTPUTS Set Output 5 true SET OUTPUT6 Set Output 6 true SET OUTPUT7 Set Output 7 true SET OUTPUTB8 Set Output 8 true SET OUTPUT9 Set Output 9 true SET OUTPUT10 Set Output 10 true SET 11 Set Output 11 true SET OUTPUT12 Set Output 12 true SET OUTPUT13 Set Output 13 true SET 14 Set Output 14 true SET OUTPUT15 Set Output 15 true SET OUTPUT16 Set Output 16 true Set Outputs Synchrone for Programming Only Symbol Comment SETS OUTPUTI Set Output 1 true synchronously for Part Prog only SETS OUTPUT2 Set Output 2 true synchronously for Part Prog only SETS OUTPUT3 Set Output 3 true synchronously for Part Prog only SETS OUTPUTA Set Output 4 true synchronously for Part Prog only SETS OUTPUTS Set Output 5 true synchronously for Part Prog only SETS OUTPUT6 Set Output 6 true synchronously for Part Prog only SETS O
24. UTPUT Set Output 7 true synchronously for Part Prog only SETS OUTPUT8 Set Output 8 true synchronously for Part Prog only SETS OUTPUTS Set Output 9 true synchronously for Part Prog only SETS OUTPUT10 Set Output 10 true synchronously for Part Prog only SETS OUTPUT11 Set Output 11 true synchronously for Part Prog only SETS OUTPUT12 Set Output 12 true synchronously for Part Prog only SETS OUTPUT13 Set Output 13 true synchronously for Part Prog only SETS OUTPUT14 Set Output 14 true synchronously for Part Prog only SETS 15 Set Output 15 true synchronously for Part Prog only SETS OUTPUT16 Set Output 16 true synchronously for Part Prog only Appendix A Adv 400 Integration Manual Reset Outputs l Symbol Comment RESET Reset Output 1 RESET OUTPUT2 Reset Output 2 RESET OUTPUT3 Reset Output 3 RESET OUTPUT4 Reset Output 4 RESET OUTPUTS Reset Output 5 RESET OUTPUT6 Reset Output 6 RESET OUTPUT7 Reset Output 7 RESET OUTPUT8 Reset Output 8 RESET OUTPUT9 Reset Output 9 RESET OUTPUT10 Reset Output 10 RESET OUTPUT11 Reset Output 11 RESET OUTPUT12 Reset Output 12 RESET OUTPUT13 Reset Output 13 RESET OUTPUT14 Reset Output 14 RESET OUTPUT15 Reset Output 15 RESET OUTPUT16 Reset Output 16
25. a Number Value or Bit Mode Axis Selected 29 IA an able m H 31 Guru m 31 APPENDIX HARD DISK CNC 00 33 Table of Contents i Adv 400 Integration Manual Table of Contents ii Adv 400 Programming Manual INTRODUCTION The Adv 400 is a flexible CNC system able to run different types of Milling or Lathe machines This manual describes the different options for setting the CNC controller to a dedicated machine e Setting machine and axis specifications e Tuning the axis e Writing custom M codes e Writing tool changer code Passwords The system contains three levels of use protected with passwords The system password must be entered every time the system is started It also can be called at any time from the File menu Password System Password User Level If a password is not entered F2 is pressed instead the system will be at machine User level The User level homes the axis moves the axis manually and runs the present part program Manager Level If the first password 400USER is entered the system will be at machine Manager level This level permits modification of the part program and accesses the different menus for managing the production Tool menu Work Offset menu subprograms etc Integration L
26. achine that must be managed by this CNC controller number of axis type of each axis spindle limits homing procedure etc Setting Page 1 General Axis Setup 1 CNC SetUp Page 1 of 4 PeUp PeDown switch page F2 Apply F10 Cancel s Max Acc time Analog Max Freq Resolution Max Speed to max speed oi Stepper 0 Hz 4096 10000 mm mn 00 Stepper Encoder 88 Motor 2 Y Axis Max Acc time 5 Analog Max Freq Resolution Max Speed to max speed Stepper Hz 2048 5000 mm min 300 ms Stepper Encoder Motor 3 Z Axis Max Acc time 5 Analog Max Freq Resolution Max Speed to max speed P Stepper 5 0 Hz 104 Csdmm 8000 rm min 400 ms Stepper Encoder Motor 4 Analog Max Freq Acc time Stepper 0 S Resolution Max Speed to max speed Stepper Encoder 16348 Cts mm U 10000 mm min U 600 Open loop Spindle Cts deg deg min A Open loop spindle Encoder Cts rev rev min Closed loop Spindle Motor 5 Max Acc time cy 5 Analog Max Freq Resolution Max Speed to max speed S Stepper 0 Hz 3 5 B 512 Cts mm 2000 mm min 500 ms Stepper Encoder Use 5 as Handwhee The Adv 400 is capable of using up to five axes To use an axis check the box in front of motor number Motor x Motors 1 2 and 3 Motors 1 2 and 3 respectively named X Y and 7 are always linear axis and can be analog 10V
27. are MANUAL mode button AUTO mode button MDI mode button HOME mode button CYCLE START button FEED HOLD button JOG PLUS button JOG MINUS button SINGLE MODE button OPTIONNAL MODE button BLOCK DELETE button As an example here is the standard code no conditions for the Cycle Start button If PB CYCLE START 0 Custom PLCs 13 Adv 400 Integration Manual IPB CYCLE START 1 Else IPB CYCLE START 0 Endif For example to add the condition that Input 1 is ON to allow a Cycle Start of the program modify this section LE PB CYCLE 5 0 and ON INPUT3 IPB CYCLE START 1 Else IPB CYCLE START 0 Endif As another example to reset the Output 2 and 3 when in manual mode If PB MANUAL MODE 0 IPB MANUAL MODE 1 RESET OUTPUT2 RESET Else IPB MANUAL MODE 0 Endif Messages From PLCs it is possible to create messages information warning or error for the machine user These messages will appear then in the message window on the bottom of the main screen 1 X limit switch 2 X limit switch 3 limit switch 33 U A software limit 34 V B software limit 65 A maximum of 96 messages are possible but messages 1 to 59 are reserved for the system So messages 60 to 96 be used by custom PLCs 14 Custom PLCs Adv 400 Programming Manual To display or remove a message use the following code SET 60 this wil
28. d used in the part program to perform some specific actions The sub routine 999 allows this Some M codes are reserved already used by the system and cannot be created in this sub routine List of reserved M codes Program Stop 1 Optional Stop 02 Program End amp Rewind M19 Spindle Orient M30 Program End amp Rewind 50 C Axis Call 51 Spindle Call e M98 Subprogram Call Usually the M03 M04 and M05 M codes are used for a spindle Ifa spindle is present in the system these codes are reserved and cannot be created in this sub routine If no spindle is present use M03 M04 and M05 codes by checking the Use Custom M3 M4 MS Prog999 box on the machine Setting Page 4 The part program M code will call the same label number as the code number M06 code will call sub routine 999 at label N6 M09 code will call sub routine 999 at label N9 M10 code will call sub routine 999 at label N10 M12 code will call sub routine 999 at label N12 252 code will call sub routine 999 at label N252 In the sub routine 999 a RET command must be entered at the end of the program code to exit this sub routine and return to the main program For example the following code uses M07 code to set the output to 1 and the M08 code to reset the output 1 The Dwe110 command waits until a previous move is finished before starting the action of this M code If a Dwe110 command is not entered in front of the action the action 1s perfo
29. dedicated functions to indicate whether to use an external box for manual movements of the axis Input7 will indicate whether to use the internal Adv 400 functions or the external box buttons If INPUT7 is OFF gt use internal Adv 400 functions If INPUT7 is ON gt use external box buttons The external box buttons are INPUT9 INPUT10 and INPUTI10 for axis select With INPUT9 Off and INPUT10 Off and INPUT 11 Off axis X is selected With INPUT9 On and INPUT 10 Off and INPUT 11 Off axis Y is selected With INPUT9 On and INPUT10 On and INPUTI 1 Off axis Z is selected With INPUT9 Off and INPUT10 On and INPUTI 1 Off axis A or U is selected INPUT13 INPUT14 and INPUTIS for step move size with handwheel With INPUT13 On and INPUT14 Off and INPUT15 Off axis moves of 0 001mm per Handwheel step With INPUT13 On INPUT14 On and INPUT15 Off axis moves of 0 01mm per Handwheel step With INPUT13 Off and INPUT14 On and INPUTI15 Off axis moves of 0 1mm per Handwheel step With INPUT13 Off and INPUT14 On and INPUT15 On axis moves of 0 2 mm per Handwheel step INPUTI2 for JOG axis in minus direction INPUT 16 for JOG axis in plus direction 4 Machine Settings Adv 400 Programming Manual Setting Page 2 General Axis Setup 2 CNC SetUp Page 2 of 4 PeUp PeDown switch page F2 Apply F10 Cancel Motor 1 Amp Fault Hardware Limit Soft Limits Max JOG Speed 2 High True C Enable Pos 0 mm min 1 with Brake Low True
30. dicates the Maximum Following Error allowed for an axis in millimeters If for any reason during operation an axis has more following error than the one indicated here all axes will be stopped and disabled and an error message will appear The Reverse Counting Direction box changes the encoder counting direction As the encoder counting direction must be always in correlation with the command output a positive command on the analog or stepper output must move the motor in the direction where the encoder counts positive and a negative command on the analog or stepper output must move the motor in the direction where the encoder counts negative checking this box creates this correlation by inverting the encoder counting direction On the right of this setting page indicate the Machine Type to manage Mill or Lathe A Lathe selection will make the X axis with a diameter input The Use Input 1 for Emergency Stop box uses the INPUTI as the ESTOP input low true If this box is checked the INPUT1 must be high to have the machine running e Use Input 2 for Feed Hold box gives the Feed Hold function to INPUT2 Use Input 3 for Cycle Start box gives the Cycle Start function to INPUT3 e Use Input 4 for Reset box gives the Reset function to INPUTA The Use Toolchanger Prog998 box creates an automatic jump to sub routine 998 when a tool code Txxyy is programmed This creates some tool changing routines Refer to the Tool Changer
31. evel If the second password 400MC is entered the system will be at machine Integration level This level accesses all menus to perform the machine integration PLCs tuning etc This level must be used for the machine integration It is at this level that the password choices are given to the machine operator Integration Menu On the Menu bar the CNC menu accesses the different configuration menus ADV400 AdvT3 NC File Edit Tools Offsets Subprogram Reeg Language Version Esc CANCDATAMAdvT3 NC Switch mmjin IO Check Machine Position Terminal 0 0 U min Symbols 0 4 440 ei Manage PLC s 0 0 U min 0 000 5 Settings Override 0 0 000 Save I Variables ProAktiv Download Raw File InPosition MANUAL Reset CNC This menu gives access to different tools e Switch mm in designates the CNC system to use millimeters or inches IO check shows the digital inputs and outputs state Introduction 1 Adv 400 Integration Manual Input i Output i Input 2 Output 2 Input 3 Output 3 Input 4 Output 4 Input 5 Output 5 Input 6 Output 6 Input Output 7 Input 8 Output 8 Output 9 Input 10 Output 10 Input 11 Output 11 Input 12 Output 12 Input 13 Output 13 Input 14 Output 14 Input 15 Output 15 Input 16 Output 16 Input 17 Input 18 Input 19 Input 20 F2Set Output 73ResetDutpu Input 21 Input 22 Input 23 Input 24 F5 Input Inverted Input
32. inus direction Motor 5 Low True channel Home Speed Home search Home seq Sous A Home ER 8 Tue H mm min Plus direction jo des ee C Minus direction C Limit flag C None If an axis is used box checked in Setting Page 1 the information on this page must be entered This page gives the setting for the homing home reference of each axis The No Home box indicates that no homing routine has to be performed on this axis In this case during the homing sequence the zero position will be forced to this axis If this box is checked all information for this axis on this page is not used An axis reference can be entered on the C channel zero encoder or on one of the fast inputs Home Flag high true or low true Limit or Limit If one of these three fast inputs is selected it is possible to use it in combination with the C channel Depending on the encoder used the C channel active can be low true or high true perform the homing routine on the C channel only check the Only ch box e perform the homing on one of the fast input flags only uncheck the Only ch box Check the None box under the C channel section and check the desired fast input Home Low True Home High True Limit flag or Limit flag perform the homing on combination of the C channel and one of the fast input flags uncheck the Only C ch box check the Low True or High True box under the C channel section and
33. l display message number 60 RESET ER 71 this will remove message number 71 To test if a message is displayed present or not IF ERH 81 test if message 81 is display present IF ERL 68 test if message 68 is not present The text message must be entered in the Adv4Err dtx file which is on the system under the Hard Disk CNC 01 directory for the first language English or under Hard Disk CNC 02 for the second language In this file any message is contained in three lines For the message 60 for example the following lines appear 60 60 1 60 2 The first line of a message is the one displayed on the bottom of the main screen In the detailed message window all three lines will appear giving detailed messages For example to have message 65 give an error about a door open 65 DOOR OPEN 65 1 Please close the door 65 2 to allow cycle starting Table of Symbols The Table of Symbols present on the system contains all symbols permitting access to all system information like Input and Output status of axis status of spindle These symbols can be used mainly in custom PLCs but it is possible also to use them in part programs or in the sub routines Refer to Appendix A Table of Symbols to view the complete list Custom PLCs 15 Adv 400 Integration Manual 16 Custom PLCs Adv 400 Programming Manual CUSTOM M CODES PROGRAMMING In several applications custom M codes are created an
34. me completed bit DES VEL axis Desired Velocity zero bit USER DISABLE OVRD User bit to force feed to 10096 disable feed pot axis amplifier are enabled AMP ARE ENABLED P ATHE MACHINE 0 Milling machine 1 Lathe machine M 4I OK HMI running TOOL PREVIOUS Actual previous tool active when tool change called HAVE TOOL CHANGER Tool changer option checked in setting page 4 S1 IN C AXE Spindle used in C axe TOOL IN SPINDLE Tool in spindle from tool changer initialization page MAGAZIN E POSITION Magazine positive from tool changer initialization page INCH MODE Metric or Inch mode Constants Symbol Comment TRUE Value True FALSE Value False ON Value ON OFF Value OFF Appendix A 3l Adv 400 Integration Manual 32 Appendix A Adv 400 Programming Manual APPENDIX HARD DISK CNC ARCHITECTURE This section explains the structure of directories and files in the flash memory DOM of the Adv 400 This structure is needed for the Adv 400 HMI software Disk Architecture for Adv 400 CNC Hard Disk Adv4Err dtx ADV400 exe Akafe Mill dl Lathe dl Adv400 sbl ADV400 dat Adv4Err dtx ADV400 set Adv4txt dtx Tof dat var pmc Sys sbl Plc sbl Errors sbl
35. mponents or causing electrical shorts When our products are used in an industrial environment install them into an industrial electrical cabinet or industrial PC to protect them from excessive or corrosive moisture abnormal ambient temperatures and conductive materials If Delta Tau Data Systems Inc products are directly exposed to hazardous or conductive materials and or environments we cannot guarantee their operation REVISION HISTORY REV DESCRIPTION DATE CHG APPVD 1 NEW MANUAL CREATION PRELIMINARY 12 20 04 N A N A 2 UPGRADE FROM PRELIM TO FULL RELEASE 11 02 07 VB Adv 400 Integration Manual Table of Contents INTRODUCTION RE 1 SE 1 canes 1 ts 1 Integration Le Vel uve 1 Integration E EE 1 Eer INIGCTRSR le 3 Setting Page 1 General Axis Setup E 3 Motots k 110 EE 3 VL ee A ASEEN E ENA 4 4 Setting Page2 General Axis nei eee EE E P EE Re ded 5 Setting Page 3 Axis Homing Setup nie tienen ne en de e HP E REC E e e 6 S tting Page 4 Miscellaneous sirisser ie ar HO PR 7 AXIS TUNING 9 2202404
36. put 15 true ON INPUT16 Input 16 true ON INPUT17 Input 17 true ON INPUT18 Input 18 true ON INPUT19 Input 19 true ON INPUT20 Input 20 true ON INPUT21 Input 21 true ON INPUT22 Input 22 true ON INPUT23 Input 23 true ON INPUT24 Input 24 true ON INPUT25 Input 25 true ON INPUT26 Input 26 true ON INPUT27 Input 27 true ON INPUT28 Input 28 true ON INPUT29 Input 29 true ON INPUT30 Input 30 true ON INPUT31 Input 31 true ON INPUT32 Input 32 true Appendix A 21 Adv 400 Integration Manual Inputs False Symbol Comment OFF INPUT1 Input 1 false OFF INPUT2 Input 2 false OFF INPUT3 Input 3 false OFF INPUT4 Input 4 false OFF INPUT5 Input 5 false OFF INPUT6 Input 6 false OFF INPUT7 Input 7 false OFF 8 Input 8 false OFF INPUT9 Input 9 false OFF INPUT10 Input 10 false OFF 11 Input 11 false OFF INPUT12 Input 12 false OFF INPUT13 Input 13 false OFF INPUT14 Input 14 false OFF INPUT15 Input 15 false OFF INPUT16 Input 16 false OFF INPUT17 Input 17 false OFF INPUT18 Input 18 false OFF INPUT19 Input 19 false OFF INPUT20 Input 20 false OFF INPUT21 Input 21 false OFF INPUT22 Input 22 false OFF INPUT23 Input 23 false OFF INPUT24 Input 24 false OFF INPUT25 Input 25 false OFF INPUT26 Input 26 false OFF INPUT27 Input 27 false OFF INP
37. rmed before the previous move is finished Prog 999 M07 code N7 DwellO SET OUTPUT1 set Ouputl RET M08 code N8 DwellO RESET OUTPUT1 reset Ouputl RET Custom M Codes Programming 17 Adv 400 Integration Manual 18 Custom M Codes Programming Adv 400 Programming Manual TOOL CHANGER Sub Routine 998 The sub routine 998 is used to create the code for a tool changer To use this function check the Use Toolchanger Prog998 box on the Machine Setting Page 4 In this case when the T code Txxyy is programmed in the part program two jumps to this sub routine will be done automatically first jump on label N1000 will be done with the actual Tool offset creating some axis movements out with the actual tool offset A second jump on label N2000 will then be done with the new tool offset the one called by Txxyy T code permitting to create axis movements in with the new tool offset At the end of these two sections a RET command must be present to indicate that this section is finished jump back to main program Even if one of the two labels has no code because one of these two jumps is not needed the RET command must be present The structure of an empty sub routine 998 Prog 998 Create the tool changer in this file put the code before new tool offset at label N1000 put the code with new tool offset at label N2000 put the code here before tacking
38. rotary axis A or revolution per minute in case of spindle and the maximum acceleration time in milliseconds from 0 to maximum speed must be indicated If analog axis stepper encoder or closed loop spindle is selected perform a position loop tuning before this axis can be used See the Axis Tuning section If stepper without an encoder or open loop spindle with or without an encoder is selected do not perform the position loop tuning For stepper the controller simulates the encoder internally and the axis PID gains are calculated automatically For open loop spindle case the amplifier must be an inverter or an amplifier closing the velocity loop internally Motor 5 Motor 5 can be an axis linear named V or rotary named B This motor is always an analog axis with encoder feedback The resolution counts per millimeters in linear axis V or counts per degree if rotary axis B the maximum speed millimeters per minute if linear axis V degrees per minute if rotary axis B and the maximum acceleration time in milliseconds from 0 to maximum speed must be indicated A position loop tuning must be performed before this axis can be used See the Axis Tuning section When Motor 5 is not used the encoder feedback can be used for an external handwheel To enable this function uncheck the Motor 5 box and check the Use 5 as Handwheel box In this case some Inputs Outputs will not be for general purpose use anymore but must have
39. t active hard or soft Appendix A 29 Adv 400 Integration Manual MOT1 ACTUAL POS M Axis X actual position MOT2 ACTUAL POS M Axis 2 Y actual position MOT3 ACTUAL POS M Axis 3 Z actual position MOT4 ACTUAL POS M_ Axis 4 A U actual position MOT5 ACTUAL POS M Axis 5 actual position CS1 PROG FEED M HOME FLAG 1 Axis X home flag hardware input HOME FLAG 2 Axis 2 Y home flag hardware input HOME FLAG 3 Axis 3 Z home flag hardware input HOME FLAG 4 Axis 4 A U home flag hardware input HOME FLAG 5 Axis 5 B V home flag hardware input HWLIM1 PLUS Axis 1 X limit plus hardware input HWLIM1 MINUS Axis 1 X limit minus hardware input HWLIM2 PLUS Axis 2 Y limit plus hardware input HWLIM2 MINUS Axis 2 Y limit minus hardware input HWLIM3 PLUS Axis 3 Z limit plus hardware input HWLIM3 MINUS Axis 3 Z limit minus hardware input HWLIM4 PLUS Axis 4 A U limit plus hardware input HWLIM4 MINUS Axis 4 A U limit minus hardware input HWLIM5 PLUS Axis 5 B V limit plus hardware input HWLIM5 MINUS Axis 5 B V limit minus hardware input USER FLAG 1 Axis 1 X User flag hardware input USER FLAG 2 Axis 2 Y User flag hardware input USER FLAG 3 Axis 3 Z User flag hardware input USER F
40. tput 8 true ON OUTPUT9 Output 9 true ON OUTPUT10 Output 10 true ON OUTPUT11 Output 11 true ON OUTPUT12 Output 12 true ON OUTPUT13 Output 13 true ON OUTPUT14 Output 14 true ON OUTPUT15 Output 15 true ON OUTPUT16 Output 16 true Outputs Off Symbol Comment OFF Output 1 false OFF OUTPUT2 Output 2 false OFF OUTPUT3 Output 3 false OFF OUTPUT4 Output 4 false OFF OUTPUT5 Output 5 false OFF OUTPUT6 Output 6 false OFF OUTPUT7 Output 7 false OFF OUTPUTS Output 8 false OFF OUTPUTO Output 9 false OFF OUTPUT10 Output 10 false OFF 11 Output 11 false OFF OUTPUT12 Output 12 false OFF OUTPUT13 Output 13 false OFF OUTPUT14 Output 14 false OFF OUTPUT15 Output 15 false OFF 16 Output 16 false Appendix A Adv 400 Integration Manual Timers example of a timer of 100ms USER TIMER 1 100 While USER TIMER 120 H Endwhile B Symbol Comment USER TIMER 1 User timer 1 for PLC USER TIMER 2 User timer 2 for PLC USER TIMER 3 User timer 3 for PLC USER TIMER
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