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DONAUMERIC 440 Programming Instructions Manual

Cnc rapid radial drilling machine, digital drives
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Machine-No./ Construction Year:
Programming Instructions
CNC Rapid Radial Drilling Machine
DONAUMERIC 440 Digital Drives
DONAUPORT 540 Digital Drives

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Summary of Contents for DONAUMERIC 440

  • Page 1 For your information Machine-No./ Construction Year: Programming Instructions CNC Rapid Radial Drilling Machine DONAUMERIC 440 Digital Drives DONAUPORT 540 Digital Drives...
  • Page 3 Inquiries and orders should be directed to: Donau Werkzeugmaschinen GmbH Harald-Friedrich-Straße 2 - 8 D-83352 Altenmarkt (Germany) Phone: + 49 (0) 8621/ 88 0 Fax: + 49 (0) 8621/ 88 413 Homepage: www.donau-wzm.de E-Mail: donau@donau-wzm.de...
  • Page 4 Table of Contents 1 Control 6 1.1 General.................................6 1.2 Control Elements ............................6 1.3 Alignment of the Machine ..........................7 3 Switching on the Machine..........................8 3.1 Manual Mode ...............................9 3.1.1 Simple Manual Mode without Saved Tools ..................11 3.1.1.1 Drilling..............................12 3.1.1.2 Tapping ..............................12 3.1.2 Advanced Manual Mode........................13 3.1.2.1 Saving Tools for Manual Mode......................13 3.1.3 Working with Saved Tools ........................14...
  • Page 5 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 3 4.5.8.1 Saving Zero Points ..........................27 4.5.8.3 Deleting Zero Points...........................28 4.6 Actual Value Display..........................29 4.7 Programming with and without Graphics ....................30 4.8 The Programming Menu ..........................30 4.8.1 Functions in the Programming Menu ....................31 4.9 Changing the Program..........................32...
  • Page 6 4.10.12.5 Program Stop ..........................49 4.10.12.6 Approaching the Position without Further Machining..............49 4.10.12.7 Shifting Workpiece .........................49 4.10.12.8 Displaying Coordinates in the Graphic ..................50 4.10.12.9 Graphic in Side View ........................50 4.10.12.10 Actual Value Display........................51 4.10.12.11 Subroutine, Rotating and Mirroring ....................51 4.10.12.12 Skipping a Block ...........................53 4.10.12.13 Incremental Programming ......................53 4.11 Automatic Mode ............................53 4.11.1 Modes of Operation in Automatic Mode....................54...
  • Page 7 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 5 4.12.5.4 Settings for Data Transfer .......................79 4.12.5.5 Lamp Test............................80 4.12.5.6 Tool-Related Factors........................80 4.12.5.7 Entering the Code..........................80 5 Troubleshooting ............................82 5.1 Programming Errors..........................82 5.2 Errors in the Machine System .........................84 6 Programming Examples..........................89 6.1 Programming with Single Coordinates ....................89...
  • Page 8 1 Control 1.1 General Hinweis zum Programmierspeicher der Steuerung. ALLE Maschinenparameter sind in einem statischen Speicher (SRAM) ACHTUNG! abgelegt. Dieser Speicherbereich für Maschinenparameter ist zum Datenerhalt mit einem Kondensator (Goldcap) gepuffert. Um den Datenerhalt sicherzustellen muss dieser Kondensator, ähnlich einem Akku, immer wieder aufgeladen werden. Ist die Maschinensteuerung länger als 8 Wochen ausgeschaltet, entleert sich der Kondensator und die Maschinesteuerung verliert ihre Programmdaten.
  • Page 9 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 7 1.3 Alignment of the Machine • Loosen nuts of the anchor bolts (do not remove) • Place level on work table in central position with an accuracy of 0.02 mm/1 metre in longitudinal direction to the T-slots •...
  • Page 10 3 Switching on the Machine • Turn main switch to position 1 • The manual menu is displayed on the screen • Unscrew EMERGENCY STOP button (if pressed) on the drill head and on the manual control • "RESET" protective device (close safety fence; reset light barrier; reset scanner) •...
  • Page 11 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 9 3.1 Manual Mode The manual mode of the machine allows drilling with no previous knowledge of controls and without previous reference-runs, similar to a hand-held machine. To move the machine manually, the button on the handle must be pressed while simultaneously pulling the quill down approx.
  • Page 12 (F1) Selection Mode Drilling. (F2) Selection Mode Threads; after reaching the depth, the spindle changes direction of rotation. (F3) Set top edge of workpiece to zero; from this point on the entered depth applies. The measure appears on the screen in line "depth" / column "actual".
  • Page 13 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 11 3.1.1 Simple Manual Mode without Saved Tools In simple manual mode, it is necessary to re-enter speed, feed rate, depth and mode again. After every tool change, the data of the last tool is lost.
  • Page 14 3.1.1.1 Drilling Prepare machine as described in machining sequence manual mode Press feed button. First set feed on the potentiometer to 0 and then configure. POTI Note: If the potentiometer on first starting up after the change into the feed's manual mode is not on zero, you are prompted with the message "Turn potentiometer to zero".
  • Page 15 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 13 3.1.2 Advanced Manual Mode For recurring parts, there is the possibility to save up to 10 tools. Speed, feed rate, depth, and type of the tool are saved. 3.1.2.1 Saving Tools for Manual Mode Procedure: (F8) Tool No.
  • Page 16 3.1.3 Working with Saved Tools How to select the saved tools: (F8) Tool No. 1 appears. (F8) Scrolls to the desired tool. (F3) Set tool on workpiece surface to zero. (F4) Spindle starts in connection with pulling the quill down. Press feed button.
  • Page 17 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 15 3.1.4 Importing and Exporting Tool Sets for Manual Mode Saved tools for manual mode can be exported onto data mediums or imported again. (F8) The first tool of the tool set appears.
  • Page 18 4 CNC Operation The control unit enables communication between operator and machine as well as automatic machining of workpieces in CNC operation. As opposed to manual mode, access to the control unit is only possible with access authorization via code entry. 4.1 Access Authorization Certain machine functions are protected by access authorization.
  • Page 19 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 17 4.1.1 Changing or Deleting Access Authorization during CNC Mode During CNC mode, the access authorization can be changed to a higher step or deleted completely in the main menu. NEXT (F8) The code number for higher access authorization can be CODE entered.
  • Page 20 4.2 Main Menu Change from manual menu to main menu via Escape. In the main menu all functions necessary for programming are available. (F1) Changes to the manual menu (F2) Displays the actual values from the last active workpiece zero point on. Repeated pressing closes the window.
  • Page 21 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 19 4.3 From CNC Mode back to Manual Mode With Escape from manual mode to main menu (F1) Back to manual mode (Hand)
  • Page 22 4.4 Approach Machine Reference Points In CNC mode, the machine requires machine reference points on X, Y, Z and W-axis in order to execute program sequences. This reference run is necessary when the machine was switched off via main switch. 4.4.1 Procedure (F6) The menu (Calibration) Reference Points appears.
  • Page 23 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 21 4.5 Setting Workpiece Zero Point In the menu "Set Workpiece Zero Point" you can set geometrically different workpieces to zero. When programming, the X and Y coordinates refer to this workpiece zero point.
  • Page 24 4.5.2 Definition of the Workpiece Zero Point on the Workpiece The following options are available to set zero points on the workpiece. The assignment of zero points to the workpiece takes place in the program info. Rectangular workpieces: left - front right - front right - rear left - rear...
  • Page 25 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 23 Round Workpieces: 10 Circle centre For round workpieces, the workpiece centre can be set by contacting three times. The coordinate system can be rotated around the workpiece centre by aligning the workpiece.
  • Page 26 4.5.4 Setting the Zero Point at a Rectangular Workpiece 4.5.4.1 Workpiece Clamped Parallel to the T-Slots (F1) There are 2 contact points necessary 1. Point: Approach workpiece edge in X-direction and confirm with ENTER 2. Point: Approach workpiece edge in Y-direction and confirm with ENTER 4.5.4.2 Workpiece Clamped Diagonal on the Table (F2) There are 3 contact points necessary 1.
  • Page 27 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 25 4.5.5.2 Mediating only in X-Direction (F6) Contact in X-direction; confirm with ENTER. 4.5.5.3 Mediating only in Y-Direction (F5) Contact in Y-direction; confirm with ENTER. 4.5.6 Setting the Zero Point at Circular Workpiece (F3) There are 3 contact points necessary Approach from 3 points on the inner or outer diameter of the workpiece.
  • Page 28 (F6) Alignment to a slot, gearing, lever arm; contact 2 points (e.g. fourth and fifth tooth space or right and left lever arm contour) and confirm each with ENTER. This way, the perpendicular through the centre of the circle between the two points is determined.
  • Page 29 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 27 Determination of zero point 1. The displayed circle is just an example. The zero point determination can also be performed via a different form (e. g. rectangular). Enter the determined zero point number using the numeric keypad.
  • Page 30 Confirm with Enter In case of double assignment of the numbers the question "Overwrite?" appears on the screen. Confirm; old zero point is replaced by the newly detected zero point If you do not wish to overwrite the old zero point, you can press the Escape button and are led back to "Save?"...
  • Page 31 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 29 (F1) Opens zero point management; the active zero point is indicated with its number and displayed graphically. The zero point to be activated can be activated either by entering the number or the scroll function.
  • Page 32 4.7 Programming with and without Graphics Programming with and without graphics is basically the same. Therefore, programming is only explained with graphics. (F4) Programming with graphics. A maximum of 3 sets of the program are displayed. The graphic provides information about the position and depth of the bores.
  • Page 33 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 31 4.8.1 Functions in the Programming Menu Use the Next button to scroll to the next softkey level. You can then make the change with F6 in the softkeys, which are described below.
  • Page 34 4.9 Changing the Program 4.9.1 Changing the Current Program From the programming menu: (F5) The current program is activated and can be edited.. The cursor is moved within the program via the arrow keys. The change is made on the current cursor position by overwriting. Cursor movement via arrow keys: ...
  • Page 35 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 33 4.9.2 Selecting a Saved Program There are 2 ways to select an existing program: (F4) Scroll through the saved programs in numerical order. Each program is displayed on the screen. alternatively: (F6) Select program management;...
  • Page 36 4.9.4 Saving Programs to Data Medium and Importing Programs from Data Medium If the machine is equipped with the option "Data Medium," it is possible to save programs on the data medium of the machine or to import programs from the data medium. 4.9.4.1 Importing Programs from Data Medium From the programming menu: (F2) Import program from a data medium to machine memory;...
  • Page 37 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 35 4.9.4.2 Saving Programs on Data Medium From the programming menu: (F1) Save programs from the machine's memory on a data medium The screen shows "Export Program" with the associated program number. If necessary change program number via numeric keypad.
  • Page 38 4.10 Creating a new Program 4.10.1 General Information on Programming Each program consists of several parts: the program information and the machining program. In the program information the data required for the machining of the workpiece is entered. In detail, the data includes program numbers, safety distance when traversing across the workpiece, dimensions of the workpiece, material and cutting speed, tool change point and information about the zero point.
  • Page 39 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 37 4.10.2 Program Information (F8) Create a new program. The screen will display the window with the program information. The program information is used to input workpiece-specific data: Program Number: An entry is mandatory. Useful are drawing or part numbers, up to 9 digits possible; input via numeric keypad;...
  • Page 40 Cutting Speed V (m/min): is determined by the selection of the material; overwrite possible with numeric keypad. Tool Change Point X/Y: The desired tool change point can be programmed by entering the coordinates. Alternatively, manually drive machine to the desired tool change point and accept this X/Y position with F5 in the Teach-In.
  • Page 41 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 39 4.10.3 Explanation regarding Programming Screen After leaving the program information the divided programming window appears. Screen left top: Window with 4-line plain text. Here, all the information for the program creation is entered.
  • Page 42 4.10.4 Toolbar Programming tools is done process-related, i.e. individual work steps are programmed completely. The following complete machining options are available in the toolbar: (F1) Centre Drill (F2) Drilling + Centre Drilling (F3) Tapping + Drilling + Centre Drilling (F4) Counterboring + Drilling + Centre Drilling (F5) Countersinking (F6) Reaming + Drilling + Centre Drilling (F7) Line Boring + Drilling + Centre Drilling...
  • Page 43 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 41 4.10.5 Access to the Toolbar After exiting the program information the tool list automatically appears on the screen. Exit the toolbar. The programming bar appears. (F3) Access from the programming bar to the toolbar.
  • Page 44 4.10.7 Displaying and Hiding Tools With a window open for a machining step, individual tools can be displayed or hidden from view. (F1) Hiding/displaying the machining step centering. (F1) Hiding/displaying the machining step drilling.
  • Page 45 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 43 4.10.8 Selecting Tools from the Tool List (F7) Icon appears when the cursor is on the tool number. If a diameter includes several tools, the desired tool can be selected, e.g. M8 x 1.25 and M8 x 0.75.
  • Page 46 (F4) Cycle manually; machine positions the X-and Y-axis in the automatic mode; drilling in Z is done manually. (F5) Cycle manually with W-axis; for bores L 200 mm, machine positions the X-and Y-axis in the automatic mode, drilling in Z is done manually, the W- axis can be driven manually.
  • Page 47 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 45 (F4) Selection of a particular hole pattern (F5) Delete/skip block (icon only appears when the cursor is in plain text in column "Ü"). (F6) Direct acceptance of drilling coordinates (icon only appears when the cursor is in plain text in column X or Y).
  • Page 48 (F1) Set single bores; enter the coordinates directly into the columns X and Y (F2) Row of holes; entering the starting hole is done directly in the X and Y column. A zero shift is not necessary. The selection of the row of holes is done in the same row of the starting point X/Y.
  • Page 49 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 47 An already created drilling pattern window can be reopened using the arrow keys. The cursor is positioned in plain text (top left) in the column function (drilling pattern). By pressing the arrow to the right, the drilling pattern window opens again. Changes can be done by overwriting.
  • Page 50 (F4) Delete block; position the cursor on the desired position in plain text and delete the block via F4. The block row is maintained and can be rewritten. (F5) Direct selection of a block number; After pressing F5, a window with the text "Go to .."...
  • Page 51 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 49 4.10.12.4 Remote Workpieces (F3) Remote workpieces; this function key allows selecting a new machining height. This may be accepted directly in the Teach-In by approaching the new machining height by means of the DONAU probe and pressing F5, alternatively by entering the new machining height via numeric keypad in the plain text column X.
  • Page 52 4.10.12.8 Displaying Coordinates in the Graphic (F1) A new toolbar becomes visible (F2) Display coordinates; each programmed bore is displayed with X and Y coordinates referring to the zero point. By pressing this button again, the coordinates are hidden once more. (F5) Graphical plan view zoom out.
  • Page 53 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 51 4.10.12.10 Actual Value Display (F2) The current spindle position (actual value) in X and Y, based on the latest zero point, is displayed with this button. The position in Z refers to the current program and the tool clamped in the drilling spindle.
  • Page 54 Mirroring: When mirroring an image, note the following: Step 1 1. Call subroutine Definition Subroutine No. 2. Call subroutine Definition Subroutine No. Mirror X X + Y Only one axis per subroutine is possible. That means if the drilling pattern is to be mirrored in several positions, multiple subroutines are necessary.
  • Page 55 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 53 4.10.12.12 Skipping a Block (F5) If the cursor is positioned in plain text in the column "Ü", the function "Skip Block" (delete) appears via function key F5. Only by selecting the button on the control panel (membrane keypad) and the soft key with the same symbol, the function "Skip Block"...
  • Page 56 4.11.1 Modes of Operation in Automatic Mode (F8) selected from the main menu opens up the program sequence menu. (F1) Different modes of the program sequence can be selected via this MODE function. 4.11.1.1 Simple Machining (F1) Simple machining. A program is executed. The desired program number is entered using the numeric keypad and confirmed with F7/OK.
  • Page 57 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 55 4.11.1.4 Pendulum Machining Front-Left Side In the first line, the program number and zero point number for the workpiece on the front work table is entered. In the second line, the program number and zero point number for the workpiece on the side workstation is entered.
  • Page 58 4.11.1.6 Polygon machining with a circular axis (starting from boot software V6.0 of 22.08.2013) 4.11.1.6.1 Polygon machining explanation of the entry mask and softkeys With the circular axis enabled, the following function keys in the program sequence menu are also enabled. These are reached from the main menu at: F8 Program sequence F1 MODE: SINGLE...
  • Page 59 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 57 (F3) Reset Enable program blocks If the F3 key is pressed, two reset keys are enabled with (F4) and (F5). (F4) Reset program blocks with initialization F4 pressed, also with F3, deletes all program entries and sets the four angle statements automatically for machining rectangular casings.
  • Page 60 4.11.1.6.2 Polygon machining explanation With the polygon feature, you can use a single program to machine any polygon with up to maximum of 10 machining surfaces continuously with the B-axis. Each machining surface can also be assigned any machining program from the program editor.
  • Page 61 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 59 Example: Continuous machining of the 4 sides of a casing. Programm 1002 auf 90 Grad Programm 1003 auf 180 Grad Programm 1001 auf 0 Grad Programm 1004 auf 270 Grad...
  • Page 62 4.11.2 Setting Tools To avoid tool breakage by collision all tools used in automatic mode must be set to zero. Two options are available for this: 1. Set all the tools to zero prior to the program sequence or 2. Set the tools to zero during the program sequence after input prompt.
  • Page 63 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 61 Description of option I Load the first tool displayed at the bottom right of the screen. (F3) Run the tool onto the workpiece surface manually and set to zero via (F4) Run the tool onto the work table surface manually and set to zero via Confirm with Enter.
  • Page 64 Description of option II Press the start button in automatic mode START "Clamp Next Part" appears on the screen. Press the start button again. START Load the first tool displayed on the screen. "Reset Length" appears on the screen. (F3) Run the tool onto the workpiece surface manually and set to zero via (F4) Run the tool onto the work table surface manually and set to zero via Confirm with ENTER while quill is extended.
  • Page 65 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 63 If the position of the zero point changes, it must be re-detected. (F1) This function key grants direct access to the "Set Workpiece Zero Point" menu. After setting the workpiece zero point ESC leads back to the automatic mode.
  • Page 66 Feed rate change; the programmed feed rate can be regulated from 0 - POTI 100% . The feed rate change is not saved. The program can be interrupted with the stop button at any point. Using the STOP function keys F1-F8 the following additional intervention options are available: (F1) Change to the "Workpiece Zero Point"...
  • Page 67 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 65 (F6) Scroll forward through drilling positions within a tool. Explanation, see "Scroll Back". (F7) Scroll forward through tools. The currently selected tool is displayed on the screen (right/centre). The first drilling position for the selected tool is shown with the cross on the graph.
  • Page 68 (F7) Parameter PARA (F8) Code CODE Back to main menu 4.12.1 Tool Storage (F1) The tool storage appears on the screen. Approx. 150 tools have already been factory-stored. The function keys are assigned with the following symbols: (F1) Export tool list to a data medium (F2) Import tool list from a data medium (F4) Delete the tool line selected with the cursor (F5) Direct selection of a known tool number...
  • Page 69 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 67 4.12.1.1 Creating a New Tool in the Tool Storage The tool storage can hold up to 500 tools. The data of the tools are stored in 10 columns. Within these columns, the cursor can be positioned via the arrow keys.
  • Page 70 Tools that have not yet been created in the tool storage may be directly saved when creating the program in the tool list. Only permanent changes should be made in the tool storage itself (e.g. old: NC spot drill 10 mm/point angle 120° = new: NC spot drill 10 mm/point angle 90°...
  • Page 71 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 69 (F4) Delete the material description that is not needed. (F7) Enter the material description via alphabetic keypad with F1-F8. Confirm with Enter Position the cursor in column 2: Enter the cutting velocity V in m/min for the respective material. In CNC operation, the speed of the tool is calculated automatically by means of the cutting velocity, tool type and its diameter.
  • Page 72 4.12.3 Special Cycle Storage (F3) The special tools menu and a new toolbar appears on the screen. In the special cycle storage, special tools can precisely be defined (e.g. step drill, backward countersink). (F1) Export special cycle tools to a data medium (F2) Import special cycle tools from a data medium (F4) Enter a description/name for the special tool via alphabetic keypad (F6) Block change0...
  • Page 73 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 71 (F2) Positioning of the Z-axis in feed up to a certain position. (F3) Positioning of the W-axis in rapid traverse up to a certain position. (F4) Positioning of the W-axis in feed up to a certain position.
  • Page 74 (F6) Special cycle program stop. 4.12.3.2 Example for Creating a Special Cycle Creating a special cycle for a particular tool: In the window on the right side of the screen, the tool is defined. Enter a tool number under which the tool should be stored in the special cycle storage.
  • Page 75 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 73 (F1) Select the rapid traverse for the Z-axis; enter the safety plane for the Z- axis (e.g. 2.0). (F2) Select the feed rate for the Z-axis; enter the Z- feed length (e.g.
  • Page 76 4.12.4 Data Medium Mode (Option) Connection data medium (F5) Switch to the menu "Data Medium Management". In the data medium management the window is divided into "Directory" and "File". (F1) Select the target drive DRIVE (F3) Without function for operators MASK If the cursor is positioned in column "File";...
  • Page 77 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 75 4.12.4.1 Importing and Exporting Programs Switch from the main menu to the programming menu. (F4) Programming with graphics (F5) Programming without graphics. 4.12.4.2 Importing and Exporting Tool and Material Lists Switch from the main menu to machine data management with Next.
  • Page 78 4.12.4.3 Uploading System Software Connect data medium with new system software. Switch from the main menu to machine data management with Next. NEXT (F8) Enter the code Step 2 Confirm with Enter. The current step 2 is now active. Exit with Escape, back to main menu. Switch to machine data management.
  • Page 79 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 77 Back to main menu. Switch to machine data management. NEXT (F7) Switch to the parameter menu. Switch to other functions of the parameter menu. NEXT (F5) Switch to system software. WRITE FLASH (F3) + (F8) Press simultaneously. The new system software is loaded onto the read-only storage of the machine.
  • Page 80 4.12.5.1 Setting of Drilling Spindle Values (F2) Spindle settings; a window with the spindle data and a new tool bar SPIND appears. (F1) Export spindle data to a data medium. (F2) Import spindle data from a data medium. NEXT TEST (F5) Used to set the speed values at different speed ranges. The speed values are factory-calibrated.
  • Page 81 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 79 4.12.5.3 Setting Time-Dependent Functions TIMING ELEMENT (F4) For setting time inputs for certain functions: Repeat Rate Repetition rate ⇒ Blink Rate Cursor frequency ⇒ Screen Dark Automatic shutdown of the screen (blank) ⇒...
  • Page 82 4.12.5.5 Lamp Test (F6) Lamp test; a lamp test is done for all sensors located vertically on the LAMP TEST operation panel left. 4.12.5.6 Tool-Related Factors (F7) A window with tool-related factors for feeds and speeds appears on the FACTORS screen.
  • Page 83 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 81 Parameter access to: Potentiometer, timing element and lamp test. Access Step 1 authorization of step 1 is sufficient to perform all program operations and programming sequences. Parameter access to: Basic setting, spindle setting, potentiometer, timing...
  • Page 84 5 Troubleshooting 5.1 Programming Errors (F8) Program sequence; Errors within the program and directly detectable by the control unit are immediately displayed in the menu by pressing F8. A window is displayed on the screen The window is divided into the columns "Hole X", "Hole Y", "Position", and "Note".
  • Page 85 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 83 4.Example for error message: Position 7 Note: Invalid tool height Explanation: The machining height was not specified in the program info. Correction: With F2 back to the program info and the machining height line.
  • Page 86 8.Example for error message: Position 11 Note: End position switch W+ / positioning plane not accessible, cannot continue Explanation: The error message occurs when selecting a positioning plane which is located outside the traversing range of the W-axis. Correction: Clamp shorter tool or clamp workpiece lower. 9.Example for error message: Position 12 Note: Hole too deep or end position switch W+/-, cannot continue...
  • Page 87 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 85 BTB Release: Axis release without operational readiness. Axis release is Error 04 granted without operational readiness of the drives. Error number 26 occurs parallel to this error message. Troubleshooting: - Press the EMERGENCY STOP button - confirm EMERGENCY STOP with RESET - confirm error message by pressing Cancel Error.
  • Page 88 Lag Z: Position lag error in the Z-axis. Error 12 Troubleshooting: Confirm error message by pressing Cancel Error. Check smooth running of the quill, if necessary, clean with kerosene and oil. If the error occurs again, please contact the DONAU service. Lag HZ: Position lag error in W-axis (column).
  • Page 89 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 87 Pressure XY: Pressure switch is defective. The pressure switch monitors Error 21 hydraulic pressure for the clamping of the X-and Y-axis. Troubleshooting: Confirm error message by pressing Cancel Error. If the error occurs again, please contact the DONAU service.
  • Page 90 To scroll within the service menu. NEXT SE After the button is pressed once, the status menu with the inputs and outputs of the control unit appears. Yellow-highlighted inputs and outputs are currently active. Pressing again loads the second status menu. Here, the machine statuses are described.
  • Page 91 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 89 6 Programming Examples 6.1 Programming with Single Coordinates Drilling Drilling 6.5 +10.2 Centering 10 + ... 10.0 10.0 20.0 35.0 Threads Threads 8.0 +20.0 Drilling 6.75 +18.0 Centering 10.0 +... 35.0 25.0 Reaming Reaming 10.0...
  • Page 92 6.2 Bolt Circle Programming Drilling Drilling 8.0 +15.0 Centering 10.0 + ... Circle 200 mm Radius 100 mm Quantity 4 Starting Angle - Step Angle - Circle 160 mm Radius 80 mm Quantity 4 Start Angle 90° Step Angle 22.5° Circle 160 mm Radius 80 mm...
  • Page 93 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 91 6.3 Programming a Row of Holes Drilling Drilling 8.5 +14.0 Centering 10.0 + ... 10.0 10.0 Row Angle 90° Hole Spacing 10.0 Quantity 4 Difference X 0.0 Difference Y 10.0 35.0 10.0 Row Angle 45°...
  • Page 94 6.4 Combined Programming with Bolt Circle, Row and Matrix Drilling Drilling 5.0 +11.6 Centering 10.0 + ... Circle 35.0 Radius 17.5 Quantity 8 Starting Angle - Step Angle - -10.0 -22.5 Row Angle 0° Hole Spacing 20.0 Quantity 2 Difference X 20.0 Difference Y 0.0 -45.0 -17.5 Matrix Distance X 90.0...
  • Page 95 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 93 6.5 Programming with Different Machining Planes Drilling Drilling 5.0 +17.0 Centering 10.0 + ... Circle 30.0 Radius 15.0 Quantity 4 Start Angle 45° Step Angle - Machining Height -5.0 Drilling Drilling 5.0 +12.0...
  • Page 96 6.6 Programming of Subroutines with Repeat Function (similar to Multiple Operation) Subroutine Number 1 Quantity 4 Distance X 25.0 Distance Y 0.0 Rotating - Mirroring - Subroutine start Drilling 10.0 10.0 25.0 20.0 25.0...
  • Page 97 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 95 6.7 Programming with Subroutines and Mirroring Subroutine Number 1 Quantity - Distance X - Distance Y - Rotating - Mirroring - Subroutine Number 1 Mirroring X Subroutine Number 1 Mirroring X and Y...
  • Page 98 6.8 Programming Long Parts/Workpiece Shift Drilling Drilling 10.0 +55.0 Centering 16.0 + ... 100.0 0.00 800.0 1600.0 -1600.0 Workpiece Shift 2400.0 3600.0 3700.0...
  • Page 99 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 97 Explanation: The workpiece is machined to the bore X = 1600.00. The control unit switches to NC-stop. The message "Shift Part" appears on the screen. We distinguish three variants of the shift: The workpiece is shifted parallely to a fixed stop by 1600.00 mm in X...
  • Page 100 The workpiece is shifted arbitrarily. The values X and Y change. Variant 3: (F1) Change to the Workpiece Zero Point menu. (F2) Set workpiece zero point for an angular clamped rectangle part. The contact point in X direction is the latest drilled bore. Back to programming sequence after pressing the NC start button, machining of the part continues.
  • Page 101 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 99 7 Programming a circular axis (4th axis) option Manual mode of a circular axis If a circular axis is enabled, the following function keys and display field are enabled in the Manual menu.
  • Page 102 (F4) The turntable can be moved absolutely to the stated position in the line ….target. (F5) The turntable is moved incrementally by the value in the line …target. (F6) This softkey corrects the 0-position of the turntable. This offset is then computed in the manual and automatic program. To do this, move the axis into the desired position and press the F6 key.
  • Page 103 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 101 7.2 Automatic mode of a circular axis If a circular axis is enabled, the following function keys are enabled in the Program input menu. These are reached from the main menu at:...
  • Page 104 7.2.2 TURN STEP command (F2) TURN STEP Bringing in rows of holes with a statement of the start angle and a statement of the angular division. The machining is given in the first block. The turntable turning angle (starting angle for the borings) is given in the second block.
  • Page 105 Programming Instructions DONAUMERIC 440 / DONAUPORT 540 Page 103 7.2.3 TURN PART command (F3) TURN PART Introducing rows of holes with a statement of the start angle and a statement of the division count relative to a complete circle (360 degrees).

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