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Century Star HNC-180 series HNC-180xp/T3, HNC-180xp/M3, HNC-180GCE. Connection Manual (V2.0) - page 1

1 Precaution

1.1 Transportation and Storage

The product should be transported properly according to its weight.

The number of stacked products must not be more than what stipulated.

Do not climb up or stand on the product. Do not stack heavy things on it.

Dragging its cable to move or lift the product is not allowed.

Protect the front panel and screen from impact and cut.

Keep damp-proof while storing and transporting.

Let us know in time if the product has been stored overtime.

3

1.3 Installation and Wiring

Workers undertaking wiring or inspection must be qualified to do the jobs.

The NC device must be grounded reliably. The earth-resistance must be less

than 4 ohm. Do not take the neutral as a ground. Otherwise, the system may

not work normally and stably because of interference.

Installation and wiring shall be correct and firm to avoid wrong operation.

Any voltage at terminals must have its correct value and polarities (+, -) as

mentioned in the manual. Otherwise, the short circuit or permanent damage to

the machine may occur.

The surge-absorbed diode connected to NC device must be wired as shown in

Figure 1-1 to prevent the damage to device.

It is absolutely not allowed to insert or pull out any plug or open the NC cabinet

door with the power supply on.

PLC output

Relay coil

DC+24V

Figure 1-1 surge-absorbed diode

5

1.4 Operation and Maintenance

Personnel to operate and maintain the device must be competent for their work.

Before plugging in to get the main source, make sure that the main switch is off

to avoid accidental start-up.

Do not refit the device.

Do not turn on and off the system frequently. The interval between on and off

operations must be at least 3 minutes.

The operator’s hands must be kept dry, clean and no greasy dirt during

operation. It is suggested to keep the clear protection film on the panel.

Do not press the keys hard. It is not allowed to strike at the keyboard with

wrench or other sharp-edged and hard articles.

Operators shall not leave the machine while operating the devices.

Power supply shall be turned off before checking, replacing or installing parts or

elements.

When short-circuit or overload happens, do not turn on the power again unless

checking and fixing the breakdown.

When alarm has happened, do not restart the device unless the accident is

cleared off.

Do not install or operate the device if it is damaged or lack of parts and

elements.

6

2 Installation

2.1 Connection

2.1.1 NC Device Type

Specification of NC device:

HNC - 180xp/T3

Century Start

Application Type

M: Milling

180xp

T: Turning

HNC - 180GCE

Century Start

Application Type

G: Grinding

180xp

C: Circular

E: Economic

7

2.1.2 Total Connection Diagram

This section shows the total connection diagram of HNC-180.

AC220/DC

XS1-XS3

Feed device

AC220V Power

24V, 5V

Spindle encoder

XS15

XS6

○ Keyboard

XS5

Spindle unit

XS14

XS7

On-off input

○ USB

XS8

Handheld unit

On-off output

XS9

Figure 2-1 Total Connection Diagram

Note:

(1) Interfaces are all optional except that of power supply.

(2) As it is shown Figure 2-1, HNC-180 controls various types of feed units through

XS1-XS3.

(3) The type of feed units can be same or not. Up to three feed axes can be

connected.

8

2.2 Dimension

This section shows the interface of HNC-180.

Figure 2-2 Interface of HNC-180

XS1, XS2, XS3: feed axis control interface

XS5: spindle control interface

XS6: spindle encoder interface

XS7: PLC input interface

XS8: handheld unit interface

XS9: PLC output interface

XS14: USB interface

XS15: keyboard interface

XT1: Emergency stop

9

2.3 Power Supply Connection

2.3.1 General Requirement

NC device: AC220V 50W, or DC24V/5V;

Cables: Shielded cables or twisted cables;

PLC power: If DC24V power supply is adopted, the power capability depends on PLC

bits and the number of components with DC24V, such as relay, electromagnetic valve

etc. It is noted that PLC power must be grounded with the signal of PLC interface of

NC device. If DC24V power supply is required for brake on Axis Z and

electromagnetic valve, it is better not to share the power with PLC power preventing

the interference from the electromagnetic valve.

As it is shown in Figure 2-3, XS1, XS2, XS3 provides DC24V power supply to PLC

on-off components of feed devices. XS6 provides DC5V power supply to spindle

encoder. XS5 provides DC24V power supply to PLC on-off components of spindle unit.

XS8 provides DC24V and DC5V power supply to PLC on-off components of handheld

unit and manual pulse generator, respectively.

HNC-180

XS1,

XS2, XS3

+24V

6

NC power

+24V

Feed device

AC220

24VG

13

PLC power

DC24V: 1A

24V

+5V

DC5V : 6A

5VG

XS6

1

+5V

Spindle encoder

6

5VG

power

+24V

external devices

PLC power

XS5

(DC24V)

XS7, XS9

3

Spindle unit

+24V

DC24V

24VG

1,

2, 14

2,

8, 10

PLC power

24V

XS8

3,

16

+24V

Handheld

1,

2, 14, 15, 17

PLC power

24V

Casing ground

25

+5V

MPG

13

power

5VG

Figure 2-3 Power supply of HNC-180

The power of NC device is only 75W. Respectively, DC24V and DC5V provide 1A

output and 6A output. It can only provide DC24V 1A and DC5V 1A to XS1, XS2, XS3,

XS4, XS5, XS7. Please use additional power supply grounded with NC power, if the

power of the mentioned interfaces of the connected devices is higher than NC power.

10

3 Interfaces

3.1 Connection to Drive Units

HNC-180 contains the axis control interface with pulse+direction, bidirectional pulse,

or hermite pulse, and feedback interface to control the servo drive and step drive unit.

3.1.1 Interface Description of XS1, XS2, XS3

The pulse interface uses pulse signal and sends position command to control different

kinds of step motor drive and servo drive with pulse interface. It is characterized as

universal interfaces, strong anti-interference ability, and zero drift. However, the

closed loop should be done in drive unit.

There are three pulse axis interfaces (XS1, XS2, and XS3) on HNC-180.

(1) Signal Definition

XS1~XS3 (DB15 PIN)

8:DIR-

15:DIR+

7:CP-

14:CP+

6:+24V

13:24VG

5:X0.*

12:Y0.0

4:Y0.1

11:Z-

3:Z+

10:B-

2:B+

9 :A-

1:A+

Figure 3-1 Interface of XS1~XS3

Table 3-1 Description of XS1~XS3

Signal

Description

A+, A-

feedback signal of encoder phase A

B+, B-

feedback signal of encoder phase B

Z+, Z-

feedback signal of encoder pulse Z

Power output DC24V(it is to supply the power for I/O on

+24V, 24VG

servo.)

Y0.0

reset (logic Address:Y0.0)

Y0.1

enabled (logic Address:Y0.1)

*:

0,

1,

2 stand for axis X, Y, and Z axis are ready

X0.*

respectively.

CP+, CP-

command pulse output (phase A)

DIR+, DIR-

command directional output (phase B)

14

(2)

Technical Specification

-

Maximum pulse frequency: 800KHZ

-

24V power supply: 200mA

-

Encoder signal: RS422 level

(3)

Equivalent circuit

-

Pulse command output

VCC

CP-(DIR-)

CP(DIR)

CP+(DIR+)

Figure 3-2 Pulse command output of equivalent circuit

-

Encoder Input

+5V

10K

10K

A+

+

(B+, Z+)

100

A(B,Z)

A-

-

(B-, Z-)

Figure 3-3 Encoder input of equivalent circuit

(4)

Pulse type

The type of pulse output (pulse+direction, bidirectional direction, and alternating pulse)

can be set by parameters. For more detailed information, please refer to Chapter 4.

Table 3-2 Pulse Type

Pulse Type

CP

DIR

mode 1: pulse+direction pulse

pulse

direction

mode2: bidirectional pulse

positive pulse

negative pulse

mode3: hermite pulse

phase A

phase B

3.1.2 Connection to Stepper Motor Drive Unit

Up to three step motor drives can be connected to HNC-180 through XS1~XS3.

Figure 3-4 shows the overall connection to step motor drive.

HNC-180

Step drive 1

Step drive 2

motor power

motor power

XS1

pulse

Step motor 1

Step motor 2

XS2

pulse

Step drive 3

XS3

pulse

motor power

Step motor 3

Figure 3-4 Overall connection to step motor drive

15

Figure 3-5 shows an example of the connection to SH-50806A (five phases mixed

step motor).

HNC-180

Step drive

drive transformer

AC80

drive power

AC 1P

XS1~XS3

CNI/F

AC80

380/80

shielding

CP+

CW+

14

3

SH-50806A

CP-

CW-

7

4

A

DIR

CCW

15

5

B

DIR-

CCW-

C

8

6

D

motor power

13 GND

E

FG

Step motor

Figure 3-5 Connection to SH-50806A

The other types of step drive can be connected to HNC-180 through I/O. For the

detailed connection, please refer to the relevant manual of drive. If DC24V is

independent, it shall be grounded with I/O of DC power. A relay is required if I/O

interfaces of step motor drives and NC unit are not matched (the type of NC PLC

interface is NPN).

When using step motor, the operator can use the following table to set the parameters.

For detailed information, please refer to Chapter 4 and Chapter 5.

Table 3-3 Parameters related to stepper motor

Parameter

Description

Value

Stepper motor type

45: with feedback; 46: without feedback

45/46

Shoot of Stepper Motor

Actual shoot of stepper motor

4, 6, 10…

Stepper motor

0: no; 1: yes

0, 1

3.1.3 Connection to Servo with Pulse Interface

Up to three servos can be connected to HNC-180 through pulse interface of XS1~XS3.

Figure 3-6 is the overall connection between NC device and servo with pulse interface.

Figure 3-7 and 3-8 are the two examples of connection to servo with pulse interface.

HNC-180

Servo Drive 1

Servo Drive 2

motor power

motor power

pulse

XS1

Position feedback

Encoder

feedback

Encoder

feedback

pulse

XS2

Servo Motor 1

Servo Motor 2

Position feedback

Servo Drive 3

pulse

motor power

XS3

Position feedback

Encoder

feedback

Servo Motor 3

Figure 3-6 Overall connection between NC device and Servo with pulse interface

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HNC-180

≤15m

Servo Drive

XS1~XS3

CNI/F

shielding

CP+

PULS

L1

14

3

Power

CP-

PULS

AC 3P

7

4

Panasonic

L2

DIR

SIGN

15

5

380/200

MSDA103D1A

L3

DIR-

SIGN

8

6

+24V

Servo

Servo

6

7

CO

13

24VG

8

CWL

r

supply

transformer

12

Y0.0

9

CC

t

Y0.1

SRV-O

2

4

34

SRV-RD

X0.*(*:0,1,2)

5

35

SRV-RD

41 COM-

U

1

A+

OA+

21

Motor

V

A-

OA-

9

22

W

B+

OB+

2

48

B-

OB-

P

10

49

Encoder

Z+

OZ+

3

23

feedback

Z-

OZ-

11

24

CN SIG

GND

GND

13

13

Servo

25

Panasonic

MSMA102D1C

Figure 3-7 Connection to Panasonic MINAS A series

HNC-180

≤15m

Servo Drive

XS1~XS3

1CN

shielding

CP+

PULS

14

7

L1

Power

CP-

*PUL

AC 3P

7

8

Yasukawa

L2

DIR

SIGN

15

11

380/200

SGDB-30ADG

L3

DIR-

*SIG

8

12

6

+24V

47

+24

Servo

Servo

24VG

13

42

P-OT

r

supply

transformer

Y0.0

12

43

N-O

t

4

Y0.1

4

S-ON

30

SRV-RDY-

X0.*(*:0,1,2)

5

29 SRV-RDY+

U

A+

PAO

Motor supply

1

33

V

A-

*PA

9

34

W

B+

PBO

2

35

B-

*PBO

P

10

36

Encoder

Z+

PC

3

19

feedback

Z-

*PCO

11

20

2CN

GND

SG

Servo motor

13

1

50

Yasukawa

SGMG-30A2ABG

18NM no keys

Figure 3-8 Connection to Yasukawa SGDB

The following list is the basic conceptions related to servo with pulse interface:

1. Position closed loop is constructed within servo driver rather than NC device.

2. Position feedback signals of pulse interfaces are only used for position monitoring,

not for position closed loop.

3. To construct fully closed loop control, a servo driver with fully closed loop interface

must be used.

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4. Servo controller parameters should be set in servo driver. Please refer to the

related manuals of the servo driver.

The following table is the list of parameters related to servo with pulse interface. For

more detailed information, please refer to Chapter 4 and Chapter 5.

Table 3-4 List of parameters related to servo with pulse interface

-

Machine Parameters

Parameter

Description

Value

0: unidirectional pulse,

0/1/2

1: bidirectional pulse,

Pulse output

[10000]

2: Hermite pulse

(default)

It shall be consistent with the setting of servo drive.

-

Servo Parameters

Parameter

Description

Value

45: with feedback

Servo type

45/46

46: without feedback

It is used in the alarm message--―too much track

error‖ (unit: μm). If the value is 0, it means that this

alarm function is deactivated. It is used according to

0~65535

Maximum

the highest speed and the lag performance of servo

[12000]

Track Error

loop. In general, the following formula is used:

(default)

max.speed*(10000-position.loop.feedforward.coeffici

ents*0.7)/proportion coefficients of velocity loop/3.

It refers to the number of pulses which NC can get

0~65535

Motor

from each revolution of the motor. It is usually set as

[10000]

revolution

pulses of position encoder of servo motor * 4.

(default)

0~65535

E-gear(NC)

Egear(NC)

NC command



[4:1]

E-gear(Servo)

Egear(Servo)

Servo feedback

(default)

0: no

Stepper motor

0/1

1: stepper motor

-

Axis Parameters

Parameter

Description

Value

It refers to the maximum offset when setting C.S.

(unit: μm). It depends on the motor size, the

performance and load of drive unit. It is usually

10~50. If this parameter is too small, the system

would be held. If it is too large, the machining

0~100

Positioning

precision would be affected. Generally, the bigger the

[20]

tolerance

machine, this value is larger. The worse the precision

(default)

and transmission, the value is larger.

If the stepper motor is used, this value can be set as

integral times each step’s pulses.

If this value is less than backlash, the system would

be held when the axis is moving backwards.

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3.2 Connection to Spindle device

Different kinds of spindle can be connected to HNC-180 by XS5 to implement CW

rotation, CCW rotation, spindle orientation, speed regulation. Spindle encoder can

also be connected by XS6 to implement threading of turning and grid tapping of

milling.

3.2.1 Relevant Interfaces

3.2.1.1Spindle Interface XS5

As it is shown in Figure 3-9, XS5 includes the outputs of spindle speed analog voltage

and PLC I/O.

XS5(DB26 PIN)

Figure 3-9 Interface of XS5

Table 3-5 Description of XS5

Description

Signal

Turning

Milling

+24V, 24VG

PLC power DC24V

PLC power DC24V

X1.0

Tool 1

Spindle orientation done

X1.1

Tool 2

Spindle speed arrived

X1.2

Tool 3

Zero spindle speed

X2.3

Spindle alarm

Spindle alarm

Y0.2

Spindle CW rotation

Spindle CW rotation

Y0.3

Spindle CCW rotation

Spindle CCW rotation

Y0.4

Spindle Mode Switch

Spindle Mode Switch

Y0.5

U6

Spindle orientation

Y2.2

Spindle Reset

Spindle Reset

Y2.3

Spindle Enabled

Spindle Enabled

A+, A-

Feedback signal of phase A

Feedback signal of phase A

B+, B-

Feedback signal of phase B

Feedback signal of phase B

Z+, Z-

Feedback signal of phase Z

Feedback signal of phase Z

CP+, CP-

Command pulse output (phase A)

Command pulse output (phase A)

DIR+, DIR-

Command pulse output (phase B)

Command pulse output (phase B)

AOUT

Spindle analog command: -10~+10V output

GND

Analog output grounding

19

The characteristics of interface:

-

PLC I/O

This PLC I/O is connected to the same name of I/O on XS7 and XS9 in parallel. For

more information, please refer to section 3.4.

-

Spindle speed analog voltage output

Voltage: -10V~+10V

Load current: max. 10mA

The following table shows some I/O related to spindle gear control, which are on XS7

(PLC input) and XS9 (PLC output).

Table 3-6 I/O related to spindle gear control

Description

Signal

Interface

Pin

Milling

Turning

Inputs

X1.0

Spindle orientation done

Tool 1

9

X1.1

Spindle speed arrived

Tool 2

21

XS7

X1.2

Spindle zero speed

Too 3

8

X1.3

Spindl ready

Tool 4

20

Outputs

Y0.2

Spindle CW rotation

Spindle CW rotation

12

Y0.3

Spindle CCW rotation

Spindle CCW rotation

24

XS9

Y0.4

Spindle mode switch

Spindle mode switch

11

Y0.5

Spindle orientation

U6

23

3.2.1.2Spindle Encoder XS6

XS6 (DB9 PIN)

5:5VG

9:SZ-

4:SZ+

8:SB-

3:SB+

7:SA-

2:SA+

6:5VG

1:+5V

Figure 3-10 Interface of XS6

Table 3-7 Description of XS4

Signal

Description

SA+, SA-

Spindle encoder phase A signal

SB+, SB-

Spindle encoder phase B signal

SZ+, SZ-

Spindle encoder pulse Z signal

+5V, 5VG

Power DC5V

The characteristics of interface:

-

Interface of spindle encoder

Power: +5V, max. 200mA

Encoder signal: RS422 level

20

3.2.7 Connection Example―Three-phase Asynchronous Motor

If the asynchronous motor without regulation device is taken as spindle motor, the

spindle rotation (CW and CCW) and stop can be controlled by the outputs of NC

device with the help of the relay and contact. As it is shown in Figure 3-11, KA3 and

KM3 are to control the motor CW rotation. KA4 and KM4 are to control the motor

CCW rotation. Spindle gear can be added to implement step speed regulation. An

external spindle encoder can be used to implement thread cutting or grid tapping.

Note: The single-phase arc-extinguisher of contact is not shown in the figure.

Contact power

U11 V11 W11

HNC-180

XS5

25

24

Y0.2

Y0.3

RC1

KA3

KA4

KM3

KM4

U1

V1

W1

Arc extinguisher

U V W

Spindle motor

+24V

Contact power

Figure 3-11 Connection example—Three-phase Asynchronous Motor

3.2.8 Connection Example―Spindle Drive

Generally, the servo drive includes AC frequency converter and spindle amplifier

(characteristics: a broader speed regulation and the better low speed-torque). The

signal of AOUT (-10~+10V) on XS5 can define the speed of spindle drive. Therefore,

the non-step spindle regulation can be done within the reasonable range. Spindle

rotation (CW and CCW), spindle stop, running status of spindle can be controlled by

I/O. The connection is shown in Figure 3-12.

If AC frequency converter spindle is used, a mechanical gear should be used to be in

the range of low speed-torque and speed regulation.

22

XS6

SA+

A+

2

SA+

SA-

A-

7

SA-

<15m

SB+

B+

3

SB+

Spindle

SB-

B-

8

SB-

SZ+

Z+

Encoder

4

SZ+

SZ-

Z-

9

SZ-

+5V

+5V

1

+5V

5VG

0V

6

5VG

HNC-180

5

5VG

XS5

Speed Control interface

<15m

9

DAS+

Speed control

-10~+10V

8

DAS-

signal

-10~+10V

Spindle drive

Control and status feedback

Such as spindle CW/CCW rotation,

spindle speed arrived, alarm, etc.

Figure 3-12 Connection to spindle drive (if there is not encoder, the contents in the dotted line is nothing)

As it is shown in Figure 3-12, spindle speed/position feedback is done by the external

spindle encoder. Some spindle drive contains the similar motor speed/position output

interface of encoder. Spindle speed/position feedback can be directly got from spindle

drive, if the transmission ratio of spindles to spindle motors is 1:1 (Figure 3-13).

XS6

SA+

A+

2

SA+

SA-

A-

7

SA-

<15m

speed/position

SB+

B+

3

SB+

feedback

SB-

B-

8

SB-

output interface

SZ+

Z+

4

SZ+

SZ-

Z-

9

SZ-

+5V

+5

1

+5V

5VG

0V

6

5VG

HNC-180

5

5VG

Spindle drive

XS5

<15m

Speed control Interface

9

DAS+

interface

Speed control

signal

-10~+10V

8

DAS-

-10~+10V

Control and status feedback

such as spindle CW/CCW rotation,

spindle speed arrived

Figure 3-13 Connection to spindle drive with feedback output interface

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