TB0422 Commissioning ZX5 Software 2018

0422 Commissioning ZX5 Software 2018

Difficulté

Medium Moyen

Durée

30 minute(s) minute(s)

comissioning, ZX5, Software

Introduction

The first step in commissioning a new machine is to get the basic software setup correctly installed. Because the software is designed to be very flexible across many machine types, the simplest way to do this is to copy from a recently built similar machine.

Étape 1 - Setup Front End PC

Follow technical bulletin 409 to setup PC with correct naming conventions and TeamViewer.

Étape 2 - Setup Back End PC

Follow TB0451 to set up the Beckhoff PC

Étape 3 - Install TwinCAT if Required

...All Netmatters CNC machines will have TwinCAT already installed, so you can normally skip this step

Install TwinCAT 3.16 from the mainserver (G:\Design\TwinCAT3\TC31-Full-Setup.3.1.4022.16). Go through the wizard and when prompted restart the PC. (2019 PCs will have this)

Étape 4 - Set up a route

Once restarted the TwinCAT icon will appear in the bottom right toolbar. We can now set up a route. Left click the TwinCAT icon once. There will be a menu, go to "Route" then "Add Route...". This is where the machine and the program can be linked. Making sure the machine infeed is on and connected to the local network,

1. Press on add in the bottom left of the window (1).
2. From here perform a broadcast search (2), this will search for any Beckhoff devices on the network.
3. When the machine is found select it (3)
4. and press add route (4).

Étape 5 - Build the Visual Studio Project

There are two ways to approach this

1. Use an existing project from a similar, older machine. This is a shortcut method but relies on having a copy of the setup from a machine with the same EtherCAT setup
2. Build a new project from scratch - use this method if this is the first machine of its type

Étape 6 - Paste the solution

Paste the solution on the ZX5 front end PC in C:/TwinCAT/Stuga.

Étape 7 - Open and rename

Open Solution and...

1: rename the solution to the current build (i.e. Z067).

2: rename the project to the current build.  

Étape 8 - Update MAC address

Device MAC Addresses, Device 4 > Adapter > select OS (NDIS) > Search > EtherCAT. This should automatically update the mac address. And the other device. Device 1 > Adapter > PIC > Search > BUS.

Étape 9 - Select Auto-start boot project

Select Auto-start boot project. This can be found under PLC > PLC_Reset_1_1 and PLC > tc3Multi_6_24

Étape 10 - Update EtherCAT devices

Update EtherCAT devices. This compares the solution’s EtherCAT boxes to the ones on the current build. Any differences between the current solution and the current build will be highlighted and explained by the system. Issues highlighted in RED are completely different to what the solution would expect. Issues highlighted in BLUE are ok, this suggests that a new version of hardware is being used but is compatible with the solution.

To do this right click on the target device and press “Scan”.

NOTE: If this does not work, repeat steps, save changes and online reset (Right click device x).

Étape 11 - TwinSAFE System

AmsNetID the same on SYSTEM > Routes > “Target net ID”, must be the same as: SAFETY > ZX5_2_1 > ZX5_2_1 Project > Target System (Figure 1).

Étape 12 - Check safety options

To get the safety toolbar go to: View > Toolbars > Check TwinCAT Safety. This will show the safety options.

Étape 13 - Check safety

Go to: SAFETY > ZX5_2_1 > ZX5_2_1 Project > Target System. Press the refresh button to update the AmsNetID as it will currently have the ID if the machine that the software was copied from.  

Étape 14 - Copy serial number

Copy the serial number (Figure 2). (Used in step 17)  

Étape 15 - Verify Complete Safety Project

After this Verify Complete Safety Project (Figure 3)

Étape 16 - Verify Complete Safety Project (Hardware Level)

Then Verify Complete Safety Project (Hardware Level) (Figure 3)

Étape 17 - Download Safety Project

Then Download Safety Project (Figure 3)

Étape 18 - TwinSAFE Wizard

TwinSAFE Wizard: When prompted input, username: Administrator, Serial Number: (Copied from step 13), Password: TwinSAFE. Then confirm.

Étape 19 - Press Safety Goggles Icon

Go to SAFETY > ZX5_2_1 > ZX5_2_1 Project > TwinSafeGroup1 > TwinSafeGroup1.sal, and press the Safety Goggles Icon (Figure 3). This should show the Estop circuit in green if working correctly.

Étape 20 - Log on to the machine int c3Multi and PLCreset

Make sure to log onto the machine in tc3Multi AND PLCreset (Figure 4).

Étape 21 - See TB0371 for all parameters that need change

Please see TB0371 for all parameters than need change.  

Étape 22 - Troubleshoot

Scanning for devices: not able to copy revision.

Click on Extended Information, check to see if the hardware revision is lower than the one on the software. If so you may need to change this EtherCAT box out.

Étape 23 - Troubleshoot (2)

TwinSafe Error referencing dip switches. This is regarding the physical switches inside the beckhoff drives. This error will not allow you to complete the full TwinSAFE procedure.  

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