Used 810D VMC re-comission issues

Background.

I purchased an Emco-Maier Venture 2818L VMC. It was sold non-functional due to corrupted ARC files. I was able to get the original ARC files from the MTB, as well as the backups from the previous owner (they had everything except ARC files).

The machine is built by Finetech, and is very similar to Hardinge and Bridgeport VMCs (many of the PLC files have Bridgeport options)

Machine config is a CCU3/PCU20. Machine originally had a 4th axis, and Renishaw tool probe that were removed before I purchased it.

I re-installed the PLC/NC files, and disabled the 4th axis. I am unable to get past an ESTOP error (3000), and there are no explanatory messages as to why this is set.

I have looked through the PLC code, and found if I comment out this segment in Network 2, which is part of block FC70, I can clear the estop. I am then able to jog the spindle, BUT, XYZ are not enabled.

For some reason, #MC_READY stays at 0. There is clearly something else causing the NC ESTOP, but I am not able to figure out where.

I've checked and rechecked the toolchanger (all errors cleared), and the rest of the estop path.

Any help on what to look for next would be much appreciated.

Matt

Just by deleting the line "S NC.A_Emergency" basically You connect the remaining logic written in network#2 with the logic in network#3. And so You get a RLO=false in network #3.

temporarily solution: disable all information in network#2. 

Better: find out why EMG_Input does not work properly

Hi.

Thanks for the quick answer. I commented out all of network 2, and RLO becomes 1, BUT, the control now cycles through an enable/disable, and disables too quickly to allow more than a slight bump of movement. 

The EMG_INPUT should be 1 I think - if it's 0, it indicates that the physical estop is active.

Attached are some more views of the PLC status.

1st page shows the more complete status when machine is out of estop, can jog spindle, but XYZ are not enabled.

2nd page shows I/R ready module. If I understand correctly, if RLO is 0, that indicates function has not completed? I did note that even though NC ready relay is active, the Z brake will not disengage (although my thought would be that that this would only disengage if Z servo is enabled). I'm looking at this function, since ti's network 3 of OB1, and it shows an RLO of 0.

Any further suggestions are appreciated.

Thanks,

matt

The detected problem are the response signals DB3x.DBX61.5 and DB3x.DBX61.6 (speed ctrl & PosCtrl) That means the axes are not engaged succesfully. Basically You need three IF-signals to activare an axis:

• DB3x.DBX1.5 or 1.6 (Enc1 or 2)
• DB3x.DBX2.1 (ServoON)
• DB3x.DBX21.7 (Pulses ON)

These three IF-signals powerON the axes - independent from other IF-signals (OVR etc.)

There are just two issues to interlock that:

• problem in drive control (interlock from I/R-module, internal drive problems...)
• interlock by SAFETY control

The signal "driver_ready" was disabled. Apparently that signal interlocks the SAFETYcontrol, (No further investigation from here possible) Probably the signal "driver_ready" is used in further networks to control/interlock the axis.

Activate the lines for controling "driver_ready" and find out why the response signal "...E_611D_ready" is still missing. A missing I/R-response signal interlocks the complete 611D-Servo drive.

Hi,

Thank you so much for your help on this. It's really appreciated.

Please see my comments, and images in attachment

I un-commented the DRIVER READY lines, but they end up red, and are not defined as variables as far as I can see. I don't think I have the safety integrated version of the 810D, so maybe this is where this code would be used?

I un-commented the line containing E_611D_ready, and it shows as TRUE when the system is ready, (by commenting out S line in network 2) but the enable lines for XYZ are not active. I think this means that the I/R module is turning on correctly?

I looked at the DBX2.1, and DBX21.7, and these are not activating, since they come after the MC_ready line, which will not become true if I have the S line in network 2 commented out.

Why do the XYZ drives not enable, but the C drive (spindle) does? (I can jog it). Is this a useful clue, or un-related?

I un-comented all of network 2 - the machine then cylces - it estops, but first, you can see the enable lines on the XYZ drives go positive.

So, I'm still quite lost as to what is going on, but these are my thoughts:

-Since the drives do enable under some conditions, the I/R module is likely working correctly?

-The root cause still appears to be "NC".A_EMERGENCY being set. I can't figure out where outside of the FC70 module I'm looking at it would be set? (I can't find a W for that variable).

Is there a way to do a global search for terms? It would be much easier if I could search for that NC emergency term in all blocks :(

Thanks,

matt

-

It's getting more and more confusing...

-Since the drives do enable under some conditions, the I/R module is likely working correctly?

==> You can activate the drive(s) only successfully (including to get the right response signals at the interface) if the I/R-module works correctly. enable signals, electrical functionality atself. 

-The root cause still appears to be "NC".A_EMERGENCY being set. I can't figure out where outside of the FC70 module I'm looking at it would be set? (I can't find a W for that variable).

==> the right way to detect the usage of used global variables is the point "reference data", accessable from the SIMATIC-manager in the overview screen. Unfortunetaly, currently I do not have access to a S7-programming tool. Roughly: mark the folder with all blocks inside and press the right mouse button, try to fing something like "ReferenceData" and follow that.

In your attached screenshot a couple of lines are red: All these lines contains variables which are valid only in that FC/FB. If you want to use that, you have to declare these variables in the header section below TEMP or STATIC (Static only in FB's)

Please note (again): An ended network does not finish the programmed logic inside! In Your screenshot the remaining lines of NW2 becomes effective in NW3 additionally!

Thank you both for the additional suggestions and guidance. I will work through this this week, and come back with any further questions.

Thanks,

matt

Hi,

Providing an update on the status of this.

I was not able to create a PLC program from scratch, but modified OB1 to enable the IR module, then enable the servo drives. This work correctly, and the drives showed enabled.(see attachment for OB1, and monitoring)

I think this tells me that there is not an issue with the I/R module.

On the other hand, I still cannot figure out what would cause the estop error.

To recap:

-There is an alarm 3000 after reset.

-I/R module, and servo drive modules can be forced to enable indicating no hardware issue.

-The wired estop shows 1, which indicates closed circuit on this machine. I don't think this is an open estop.

-DB10.DBX56.1 is the memory location being set which is "NC"A_EMERGENCY.  This is caused when the AN ESTOP input is OR'd with DB8.DBX45.0, which is described as "Basic_PLC_DB".bits[8]

Any suggestions where to go from here?

-Checking the cross reference, there is no indication of where DB8.DBX45.0 is set, only R.

-DB10.DBX56.1 is only set in 1 network (where it's OR'd with the other DB)

Any suggestions would be appreciated.

Thanks,

matt

Long overdue update / closeout on this.

The issue ended up being a shorted brake in the z-axis servo.

When resetting, this short pulled the 24v supply low, and triggered estop.

Replaced brake winding, and machine has been running well for several years now.

Matt