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

3.2.9 Parameters related to Spindle device

The digital value relevant to spindle speed control signal takes two bytes, i.e. 16 bits,

of PLC output Y[28] and Y[29] (Y[29] takes higher 8 bits). The relationship between

output (digital value) and its relevant analogue voltage is shown below:

Table 3-8 Relationship between output and analog voltage

OUTPUT (HEXADECIMAL)

-0x7FFF~+0x7FFF (-32767~+32767)

AOUT

-10V~+10V

There are two kinds of parameter related to spindle device:

1. Spindle speed analog voltage

2. Spindle status feedback and control I/O

The above two functions are implemented by PLC program. For the detailed

information, please refer to the definition of parameter P of HNC-180 in PLC program.

3.3 Connection to Handheld Unit

As it is shown in Figure 3-14, the handheld unit is equipped with the emergency stop

button, pilot lamps, axis switch (OFF, X, Y, Z), magnification switch (X1, X10, X100),

and the manual pulse generator. It is connected to XS8 of HNC-180.

DB25 PIN

Figure 3-14 Interface of Handheld unit

3.3.1 Handheld Interface on HNC-180

Handheld unit is connected to HNC-180 by XS8 (DB25 pin).

XS8(DB25 PIN)

1: 24VG

14:24VG

2: 24VG

15:24VG

3: +24V

16:+24V

4: X3.7

17:24VG

5: X2.7

18:X2.6

6: X3.6

19:X3.5

7: X3.4

20:X3.3

8: X3.2

21:X3.1

9: X3.0

22:Y2.4

10: Y2.5

23:Y2.6

11:Y2.7

24:HA

12:HB

25:+5V

13:5VG

Figure 3-15 Interface of XS8

Table 3-9 Interface description of XS7

Description

Signal

Turning

Milling

+24V, 24VG

PLC power DC24V

X2.6

2^nd cycle start

X2.7

2^nd feed hold

X3.0

Axis X selected

X3.1

Undefined

Axis Y selected

X3.2

Axis Z selected

X3.3

Undefined

X3.4

Ratio x1 on handheld unit

X3.5

Ratio x10 on handheld unit

X3.6

Ratio x100 on handheld unit

X3.7

2^nd E-stop

Null

Y2.4

Y2.5

Y2.6

2^nd cycle start pilot

Y2.7

2^nd feed hold pilot

Null

Phase A on handheld unit

Phase B on handheld unit

+5V, 5VG

Handheld power DC5V

3.3.2 Connection to Standard Handheld Unit

The interface of standard handheld unit provided by our company is DB25 pin, which

can be directly connected to XS8 on HNC-180 device.

XS8

+5VG

+5V

MPG

Y2.4

Y2.5

Y2.6

OFF

Y2.7

Axis X

X3.0

Axis

Axis Y

X3.1

HNC-180

Axis Z

X3.2

X3.3

NC device

Ratio

X3.4

x10

X3.5

x100

X3.6

X2.6

X2.7

E-stop

24VG

X3.7

+24V

pilot

24VG

Handheld

unit

Figure 3-16 Connection to Standard Handheld Unit

3.3.3 Connection to Custom Handheld Unit

Please refer to standard handheld unit while designing I/O such as coordinate

selection, ratio selection, and pilot lamps etc. Moreover, the handheld unit can also be

in the form of external operation box or auxiliary control panel.

The type of I/O shall be NPN with DC24V. Please refer to section 3.4

The specification of MPG

(Manual Pulse Generator) is DC5V, TTL level,

phase-A output, and phase-B output.

3.4 I/O on NC device

3.4.1 I/O Interface

There is 32/24 NPN I/O interface on HNC-180.

3.4.1.1Characteristic of input interface

(1) Equivalent circuit

24V

+5V

IF=5~9mA

24VG

24VG - common ground of NPN input

Figure 3-17 Equivalent circuit of Input interface

(2)

Technical parameters

The optically coupled technique is adopted. The highest isolated voltage is

2500VRMS (one minute).

The supply voltage is 24V.

Turn-on current I_F=5~9mA.

Maximum leakage current≤0.1mA

Filtering time is approximately 2msec.

Note: Any active I/O components (such as non-contact switch, Hall switch etc.)

must be NPN type with DC24V.

(3)

Typical application circuit

Connecting to external passive switches or relay contacts;

As it is shown in Figure 3-17, one contact of interface is connected with input,

the other contact of interface is connected with 24VG.

Connecting to external active switches

The type of NPN output with DC24V shall be selected as the active switch.

Please refer to the description of components, if necessary. The following

figure is the connection of active input switch.

Figure 3-18 Connection of active input switch

3.4.1.2Pin of I/O input interface

PLC input interfaces are on XS7 (PLC input interface) and XS8 (handheld interface)

of HNC-180. Some PLC input interfaces can also be connected with XS5 (spindle

interface) or XS1~XS3 (feed axis interface) in parallel.

XS7(DB25 PIN)

XS8( D B 2 5 P

1: 24VG

1: 2 4 V G

14:24VG

14:24V

2: 24VG

2: 2 4 V G

15:X2.5

15:24V

3: X2.4

3: + 2 4 V

16:X2.3

16:+24

4: X2.2

4: X 3 . 7

17:X2.1

17:24V

5: X2.0

5: X 2 . 7

18:X1.7

18:X2.

6: X1.6

6: X 3 . 6

19:X1.5

19:X3.

7: X1.4

7: X 3 . 4

20:X1.3

20:X3.

8: X1.2

8: X 3 . 2

21:X1.1

21:X3.

9: X1.0

9: X3 . 0

22:X0.7

22:Y2.

10:X0.6

10: Y 2 .

23:X0.5

23:Y2.

11:X0.4

11:Y2

24:X0.3

24:HA

12:X0.2

12:HB

25:X0.1

25:+5V

13:X0.0

13: 5 G

Figure 3-19 Interface of XS7 and XS8

Table 3-10 Inputs of XS7 and XS8

Description

Signal

Turning

Milling

+24V, 24VG

PLC power DC24V

X0.0

Axis X Ready

X0.1

Tailstock forward Ready

Axis Y Ready

X0.2

Axis Z Ready

X0.3

REF point on axis X

X0.4

Tailstock backward Ready

REF point on axis Y

X0.5

REF point on axis Z

X0.6

Turret Locked

Tool Locked

X0.7

Chuck Locked

Tool Released

X1.0

Tool 1

Spindle orientation is done.

X1.1

Tool 2

Spindle speed is reached.

X1.2

Tool 3

Zero spindle speed

X1.3

Tool 4

Undefined

X1.4

Tool 5/Spindle gear 4

Spindle gear 4

X1.5

Tool 6/Spindle gear 3

Spindle gear 3

X1.6

Tool 7/Spindle gear 2

Spindle gear 2

X1.7

Tool 8/Spindle gear 1

Spindle gear 1

X2.0

Overtravel input

X2.1

E-stop input

X2.2

External alarm

X2.3

Spindle alarm

X2.4

Foot pedal switch

Undefined

X2.5

Operational door switch

Undefined

X2.6

2^nd cycle start

X2.7

2^nd feed hold

X3.0

Axis X selected

X3.1

Undefined

Axis Y selected

X3.2

Axis Z selected

X3.3

Undefined

X3.4

Ratio x1 on handheld unit

Ratio X1 on handheld unit

X3.5

Ratio x10 on handheld unit

Ratio X10 on handheld unit

X3.6

Ratio x100 on handheld unit

Ratio X100 on handheld unit

X3.7

2^nd E-stop

Null

Note: X0.0 (Axis X Ready), X0.1 (Axis Y Ready), X0.2 (Axis Z Ready), X1.0 (Spindle

orientation is done), X1.1 (Spindle speed reached), X1.2 (Zero spindle speed), and

X2.3 (Spindle alarm) are parallel connection with the signals of feed axis interface and

spindle interface. The operator can use one of them.

3.4.1.3Characteristic of output interface

(1) Equivalent circuit

Figure 3-20 Equivalent circuit of output interface

(2) Technical parameters

The optically coupled technique is adopted. The highest isolated voltage is

2500VRMS (one minute).

The supply voltage is 24V.

The maximum output current is 100mA.

(3) Typical application circuit

To drive a LED

A resistance about 10mA is required in series to control the current flowing

through LED.

+24V

HNC-180

2.5K

Il=10mA

NPN output

Figure 3-21 Output to drive LED

To drive a filament pilot lamp

A preheating resistance is required to reduce the current shock while turning

the pilot on. The ohm value of the resistor should be large enough to keep the

pilot dark when it is off.

+24V

HNC-180

preheating

resistance

24VG

NPN output

Figure 3-22 Output to drive a filament pilot lamp

To drive an inductive load (such as relay)

A flywheel diode shall be connected in parallel with the coil of the relay to

protect the output circuit from interference (some relays have been equipped

with flywheel diodes).

Note: The voltage of coil shall be DC24V.

+24V

HNC-180

flywheel diode

NPN output

Figure 3-23 Output to drive an inductive load

3.4.1.4Pin of I/O output interface

PLC output interfaces are on XS9 (PLC output interface) and XS8 (handheld interface)

of HNC-180. Some PLC output interfaces can also be connected with XS5 (spindle

interface) or XS1~XS3 (feed axis interface) in parallel.

XS9(DB25 PIN)

XS8( D B 2 5 P

13:Y0.0

1: 2 4 V G

25:Y0.1

14:24V

12:Y0.2

2: 2 4 V G

24:Y0.3

15:24V

11:Y0.4

3: + 2 4 V

23:Y0.5

16:+24

10:Y0.6

4: X 3 . 7

22:Y0.7

17:24V

:Y1.0

5: X 2 . 7

21:Y1.1

18:X2.

:Y1.2

6: X 3 . 6

20:Y1.3

19:X3.

:Y1.4

7: X 3 . 4

19:Y1.5

20:X3.

:Y1.6

8: X 3 . 2

18:Y1.7

21:X3.

:Y2.0

9: X3 . 0

17:Y2.1

22:Y2.

:Y2.2

10: Y 2 .

16:Y2.3

23:Y2.

:Null

11:Y2

15:Null

24:HA

:24VG

12:HB

14:24VG

25:+5V

:24VG

13: 5 G

Figure 3-24 Interface of XS9 and XS8

Table 3-11 Outputs of XS9 and XS8

Description

Signal

Turning

Milling

24VG

PLC power DC24V

Y0.0

Reset (clear the alarm)

Y0.1

Enabled

Y0.2

Spindle CW rotation

Y0.3

Spindle CCW rotation

Y0.4

Spindle brake

Y0.5

Spindle orientation

Y0.6

Chuck Locked

Tool Locked

Y0.7

Chuck Released

Tool Released

Y1.0

Turret CW

Y1.1

Turret CCW

Y1.2

Coolant

Y1.3

Lubrication

Y1.4

Spindle gear 4

Y1.5

Spindle gear 3

Y1.6

Spindle gear 2

Y1.7

Spindle gear 1

Y2.0

U0/Tailstock forward

Y2.1

U1/Tailstock backward

Y2.2

Spindle Reset

Y2.3

Spindle Enabled

Y2.4

Y2.5

Y2.6

2^nd cycle start pilot

Y2.7

2^nd feed hold pilot

null

Note: Y0.0 (Reset), Y0.1 (Enabled), Y0.2 (Spindle CW rotation), Y0.3 (Spindle CCW

rotation), Y0.4 (Spindle brake), and Y0.5 (U6) are parallel connection with the signals

of feed axis interface and spindle interface. The operator can use one of them.

3.4.2 Description of PLC Address

In the system program and PLC program, the on-off inputs from machine tool are

defined as X. The on-off outputs to machine tool are defined as Y.

There are 8 bits (one byte) in each group of on-off inputs or outputs. For example,

X0.0~X0.7 of XS6 on HNC-180 is in X[00]. (X0.0 takes the first bit of X[00], and X0.1

takes the second bit of X[00]…).

There are three kinds of PLC input/output:

1. I/O on PLC interface

For HNC-180, there are 32 bits of inputs, and 24 bits of outputs. Every 8 bits is

composed of a byte. The inputs are in X[00]~X[03], and the outputs are in

Y[00]~Y[02].

2. Digital outputs relevant to spindle analogue voltage

They are in Y[28] and Y[29].

Note: The process of outputting the signal analog voltage command: PLC

program calculates the digital outputs. Then, it is converted to analog voltage by

internal D/A module.

PLC program manages the digital outputs, which takes 16bits(two bytes) i.e. two

groups of output signal.

Thus, the spindle analog voltage is regarded as the output signal to handle.

3. The inputs to keys and the outputs to pilots on MCP (machine control panel).

There are three rows of buttons on MCP and two ratio switches:

The first row (9 buttons): the inputs are in X[30] and 0 bits of X[31].

3.5 Design of E-Stop and Overtravel Released

There is an E-stop (emergency stop) input pin on both XS7 (PLC input interface) and

XS8 (handheld unit). At least one E-stop button shall be connected in the following

case.

if there is an emergency, it is used to stop NC machine immediately or turn off the

main supply of power devices (such as servo drivers).

if there is an alarm message, E-stop button shall be pressed. Do not release

E-stop button until the alarm message has been fixed.

There is no overtravel released button on the control panel of HNC-180. An external

overtravel released button can be used to release the overtravel, if the overtravel limit

switch is pressed (Figure 3-25). If the overtravel released button is not used, the

overtravel is released after the resetting (Figure 3-26).

HNC-180

Handheld unit

XS7

24VG

Axis-1 Overtravel limit switch

Overtravel release

button

2^nd ESTOP

XS8

X2.0

Axis-2 Overtravel limit switch

X3.7

Axis-3 Overtravel limit switch

24V

ESTOP

X2.1

Figure 3-25 Recommended design of E-stop and Overtravel (with overtravel released button)

HNC-180

Axis-1 Overtravel limit switch

Handheld unit

XS7

X2.0

Axis-2 Overtravel limit switch

2^nd

E-stop button

XS8

24VG

Axis-3 Overtravel limit switch

X3.7

E-stop button

X2.1

24V

24VG

Figure 3-26 Recommended design of E-Stop and Overtravel (no overtravel released button)

The following table shows the input interface of E-stop.

Table 3-12 Input Interface of E-stop

Signal

Interface

Signal

Interface

Type

Description

X2.1

E-stop input

XS7

PLC input

DB25 (male plug, female socket)

X3.7

2^nd E-stop input

XS8

Handheld unit

DB25 (male plug, female socket)

More than one E-stop button can be used if necessary. The normally closed contacts

of each emergency stop button are connected to input interface of NC device in series.

Generally, E-stop buttons are released and its contacts are closed. While E-stop

button is pressed, the contacts are open and E-Stop signal is sent to NC device. Then,

the devices (such as feed motor, spindle motor, tool magazine/turret motor etc.) are

stopped.

The normally closed contacts of the positive/negative overtravel limit switches are

connected to the overtravel loop of NC device in series. Generally, the overtravel limit

switch is open. If the overtravel limit switch is pressed, the contacts are closed. Then,

the overtravel loop of NC device is closed, and the alarm message is shown.

Same as E-stop alarm, NC device are stopped and the system shows the alarm

message if there is an overtravel. To release the overtravel, the following steps can be

done:

1) If there is no overtravel released button, press RESET key to reset the system.

2) If there is an overtravel released button, press this button. Then, press RESET

key. Note: Do not release this button until NC device is released.

3) Press the axis key with the correct direction to release the overtravel limit

switch.

4) Release the overtravel release button

4.1 Checking before Operation

4.1.1 Inspection of Wiring

Make sure that all cables are connected correctly, especially:

The polarity of damper diodes for relays and solenoid valves (please refer to

Chapter 1).

The phase sequence of strong current cables on motor.

Position control cable and position feedback cable of feeding device and strong

current cable on motor shall be connected to the corresponding interface as

shown in Figure 5-1.

HNC-180

HSV-16 servo driver

Servo motor

XS1

Command

Feedback

Power supply

Connect to the same

servo driver

Connect to the same servo driver

Figure 4-1 Connect to HSV-16, HSV-20D, Yaskawa or Matsushita servo with pulse interface

Ensure that the type of analog speed command received by spindle unit is voltage,

and check the wires to avoid damages to the related interfaces. The analog output

of XS5 on NC device is -10V~+10V.

Make sure that all grounding wires are reliable and correctly connected.

Make sure that the emergency stop button and emergency stop circuit are

effective. Pressing the emergency stop button down or cutting off the emergency

stop circuit can cut out the power source of moving units such as feed driver,

spindle drive unit etc. Please refer to Chapter 3.5 for the design of emergency

stop circuit.

4.1.2 Power Inspection

Make sure that the voltage and the polarity of each part of the circuit are correct,

especially, the polarity of DC24V, and the circuit of power supply shall not be short

circuit.

Make sure that the specification of each part of the power supply in the circuit is

correct.

Make sure that the specification of each transformer in the circuit is correct, and

the directions of I/O wires are connected in correct direction.

4.2 Trial Operation

4.2.1 Power On

Press E-stop button before the NC device is turned on or off.

Ensure the power of servo drive is off to prevent from the wrong action

or malfunction due to the wrong setting of parameters, before doing the

following steps:

1) Press E-stop button to ensure all the air switches in the system are

open;

2) Turn the air switch of main power supply in the cabinet is on.

3) Turn the air switch or fuse with AC220V on, and ensure that the

voltage of NC device is DC24V, and the power is DC5V.

4) Check the power supply of other parts.

4.2.2 Setting Parameters

After HNC-180 device is turned on, please check the system parameters

according to the hardware. For detailed information, please refer to Chapter 4.

Note: Please set the servo parameters and internal parameters of servo

according to servo manual, before the servo is powered on.

Do read the PLC programming manual and set PLC parameters

according to the hardware configuration.

Attention: In PLC programming, the parameter shall not be set as 0, if

one [P] parameter is taken as denominator(such as spindle speed

transmission ratio denominator). Otherwise, the system would crash.

4.2.3 Inspection of External Status

Do the following inspections before the servo power is on:

Check each feed drive unit and spindle drive unit, after the power is on.

Check the required status reply signal, such as feed drive, spindle drive etc.

4.2.3.1PLC I/O Status

The operator can check the status of I/O signal (X, Y) by inspecting PLC status.

Moreover, the user can debug PLC program by inspecting the status of intermediate

relay (R relay, not refer to actual relay in control cabinet), which is used for PLC

programming.

To monitor PLC status, the operator can press DGN function key on MCP of NC

device. For detailed information, please refer to the operation manual of HNC-180.

The value of X and Y is shown in binary. A group is composed of 8 bits, and each bit

represents one bit of external on-off input or output signal. For example, X[00]

includes 8 bits, which represents the inputs of X0.1~X0.7 from right to left, respectively,

and X[01] represents the inputs of X1.0~X1.7 etc. Similarly, Y[00] represents the

outputs of Y0.0~Y0.7, and Y[01] represents the outputs of Y1.0~Y1.7.

If the status of the connected input component varies (such as over-travel switch

being pressed), the corresponding display of on-off numerical status would vary, from

which the connection of the on-off I/O circuit can be checked.

4.2.3.2PLC I/O Address

PLC I/O addresses of HNC-180 device are defined as follows:

External on-off input signal: X[00]~X[03];

Input signal from button on panel: X[30]~X[45];

External on-off output signal: Y[00]~Y[02];

External on-off output signal: Y[28]~Y[29]; spindle speed control D/A;

Output signal from pilot on panel: Y[30]~Y[37].

4.2.4 Servo Power On

4.2.4.1Checking before Servo Power On

If any parameter has been modified, the operator shall turn the power supply of

NC device off for 3 minutes, and turn it on again. Then, do the following steps:

If the spindle encoder is used, the operator can rotate the axis of encoder to

monitor the spindle speed and the spindle rotation, which can check the setting of

spindle encoder.

When the servo unit is connected to the control power supply, the position

feedback control circuit is in the working mode. The operator can see the actual

coordinate value including MCS (machine coordinate system), WCS (workpiece

coordinate system), and RCS (relative coordinate system) to check the actual

position feedback of motor by press

POS→

ALL soft keys on NC device. For

example, when the operator rotates the motor spindle (without brake) manually,

the actual coordinate value on NC device would change. Then, the setting of axis

parameters and the connection between servo and NC device can be checked.

Do not turn the servo on after manually rotating the motor.

4.2.4.2Turn Servo Power On

Ensure the PLC control logic for the servo including power on, enabled, and

disabled function and the circuit are correct.

Turn on the circuit breaker of servo power supply.

Ensure that the brake of motor is released. To check the brake, the operator can

measure the power supply of brake control (DC24V), or hear the clatter when the

brake is released at the instant of turning on the power supply.

If handheld encoder is associated with the servo drive, this handheld unit can be

used to directly control the motor operation and verify the correct connection of

servo unit to the motor.

Check the function of reference point return for each axis, once all feed axes are

debugged.

For Stepper Motor Driver

Ensure the type of pulse signal received by the stepper driver is the same as the

setting of the pulse type in HNC-180.

Ensure the correct number of beats of step motor is correct. Otherwise, the

reference point would not be returned.

Rotate the motor slowly and then quickly in jog or handheld mode. If there is

abnormal sound or blocking during the motor rotation, please properly increase

the value of jerk time for rapid traverse, jerk for rapid traverse, jerk time for

machining, and jerk for machining.

For Servo Driver with Pulse Interface

Ensure the type of pulse signal received by the servo driver is the same as the

setting of the pulse type in HNC-180.

Ensure the correctness of the motor revolution. It is usually feedback pulse from

motor or servo * 4.

Ensure the consistency of the variation of the feedback value during motor

rotation with NC device command value. The operator can control the motor to

move a short distance. Then, according to the variation of command value and

feedback value, correct the sign of E-gear(NC) and E-gear(Servo), until the

variation of the feedback value is same as that of the command value.

Control the motor to move a short distance (such as 0.1mm), and check if the

feedback value is same as the command value of the coordinate axis. If they are

not same, the operator shall adjust the command multiple frequency of servo unit

(usually there are two parameters: numerator and denominator of command

multiple frequency) until the command value and the feedback values displayed

on the screen of NC device are identical.

Example: Given that NC device command value is 0.1mm, the feedback value is

0.05mm, and E-gear(NC):E-gear(Servo)=1:1. Then, the operator can adjust the

parameters in three ways to get the same variation between the feedback value

and the command value of NC device:

1) Set the command multiple frequency of servo unit as 2.

2) Set as twice as the feedback pulses of servo unit.

3) Set the E-gear(NC) as 2.

Thereafter, to fit with the variation of lead screw pitch and transmission ratio in the

machine connection, only two parameters i.e. pulse1 and pulse2 in axis

parameter is required to adjust. For more detailed information, please refer to

chapter 4.

4.3 PLC Debugging

PLC function is offered in HNC-180. In aid of standard PLC applications with settings

of related PMC user parameters, most NC turning machines and NC milling machines

can be controlled. For the detailed information, please refer to HNC-180 PLC

programming manual.

4.3.1 Main Elements of PLC Debugging

Operate NC device to monitor on-off I/O status, and check PLC I/O points one by

one for correct connection and logic relation against machine tool circuit diagram.

Check the machine tool over-travel limit switch for correct operation.

4.3.2 Process of PLC Debugging

Check each button on the operation panel, the on-off input signals, the system

response and external logic circuit for correct operation. For instance, if the

coolant button is pressed, then, the button lamp is on and AC contactor of coolant

motor starts to work. If it is pressed once again, the lamp is turned off and AC

contactor of coolant motor stops working.

Return the reference point on each axis. Manually put the reference point

response signal, and examine whether every coordinate axis can implement the

reference point return with the correct operation or not.

Connect the limit switch and the reference point return signal for every coordinate

axis correctly, manually control the limit switch and reference point switch, and

repeat the above two debugging steps to examine the effect of these switches.

Check the correctness of the system alarm messages, the external alarm

messages defined in PLC program, and the corresponding system action, when

the on-off input alarm signal is inputted. For example, when the spindle alarm

signal is valid, the spindle and the machining program would stop.

4.3.3 Methods for PLC Debugging

When PLC program cannot be executed in the expected procedure, the operator can

follow the following steps to debug PLC:

Check PLC input status (register X), if not, check the external circuit. For the

command M, S, T, the operator can write a program including these commands,

and then execute this program in AUTO (automatic) or SBL (single block) mode

(PLC status cannot be monitor in MDI mode during the running) to monitor the

related registers during execution.

Check PLC output status (register Y). If not, check the input condition or the

corresponding setting of PLC user parameters.

Check if the electronic switch or the relay directly controlled by the on-off output

(register Y) can work. If not, check the connecting wire.

Check if the contactor controlled by the relay or other switches (solenoid valve)

can work. If not, check the connecting wire.

Check the performance unit, including motor, hydraulic circuit, pneumatic circuit

etc.

4.4 Machine Debugging

4.4.1 Emergency Stop and Limit

There are software limit in system. For the safety, it is suggested to use the hardware

limit. The route limit switch is installed at the positive and negative direction of axes.

The parameters related to emergency stop and limit:

PLC parameter 007078

no detection of MCP emergency stop signal: check if the emergency stop is

controlled by MCP emergency stop signal.

PLC parameter 007079

no detection of handheld emergency stop signal: check if the emergency stop is

controlled by handheld emergency stop signal.

PLC parameter 007075

individual limit signal: check if there are individual limit switch to control hardware

over-travel on each axis.

PLC parameter 007081

no detection of limit alarm signal: check if there are detection of limit alarm

If the limit switch is installed, please do ensure the over-travel limit switch is

valid before machine debugging.

Check the on-off I/O status of NC device, and press the over-travel limit switch on

the machine to observe the change of the corresponding on-off input status, and

check the correct connection of the over-travel limit switch.

Move the axis slowly in jog or handheld mode to verify the validity of over-travel

limit switch, the correctness of alarm message display, and the validity of

over-travel released button (please refer to Chapter 3.5 for the operation of the

over-travel released button).

4.4.2 Axis setting

The parameters related to axis are 100003~100036 and 200003~200036.

Check the consistency of the direction and distance of machine with the

corresponding commands from NC device. If not, the operator can modify the

value and sign of Pulse1 and Pulse2 of axis parameters.

Pulse1 and Pulse2 can be set according to the lead-screw and the transmission

ratio to keep the consistency of the command value with the actual value of

machine. There are two ways (calculation, measurement) to set :

1) Calculation

Given that HSV-16 is used, the transmission ratio is 2:5, the lead-screw is

6mm, and the revolution of motor encoder is 2500pulses. There are four

subdivisions for servo driver and NC device, respectively. The motor

revolution is

2500*4*4=40000p/r. The distance of tool movement is

6*1000*2/5=2400μm. Thus, Pulse1:Pulse2=2400:40000=3:50.

2) Measurement

pulse

m)

movingdistance

for each revolution

(m)



pulse2

pulsesfor each revolution

Please do the measurement more than once and try to increase the

distance of measurement, because there is measurement error.

According to the condition of mechanical transmission and the requirement of

design, please set the rapid traverse speed, the maximum feedrate, the rapid

traverse speed at REF, and the positioning speed at REF for each axis, correctly.

Note:

1) The rapid traverse speed is the maximum among these parameters.

2) The setting of speed should not lead to the over-rated revolution of servo

motor.

3) The rapid traverse speed at REF shall be higher than the positioning

speed at REF.

Set the characteristics of jerk for each axis according to the running status and

mechanical transmission:

The more the jerk time and jerk is, the acceleration/deceleration is slower, the less

impact of machine motion is, the machining efficiency is lower. The less the jerk

time and jerk is, the quicker the acceleration/deceleration is, the more impact of

machine motion is, and the higher the machining efficiency is.

The principle of setting acceleration and deceleration is that reducing the

acceleration and deceleration time and jerk time on the premise of no alarm of

drive unit, no stepper of motor and no obvious shock of machine motion to

increase the response of coordinates and machining efficiency. If the acceleration

and deceleration time or jerk time are set too small, it would lead to alarm of drive

unit, out of step of motor, or machine vibration. the current of servo should not be

too heavy during the start-up and the shut-down of the acceleration and

deceleration. The recommended current is not more than 60% rated current of

servo.

4.4.3 Reference point return setting

Mechanical reference point return switch can be installed, floating zero can also be

set in the software. The mechanical reference point can be set in these two ways. The

related parameters are as followed:

PLC parameter 007017

REF switch on machine: mechanical REF return mode or floating zero of REF

return mode

PLC parameter 007000

Alarm when axis returns to REF point once powered: determine whether there is

an alarm message about REF point return.

PLC parameter 007084

Detection of floating zero lost: check if the floating zero is lost.

Axis parameter 100008~100012 and 200008~200012

the direction, speed, and offset of mechanical REF return, etc

Note: Do check the validity of over-travel limit switch before the operation of

reference point return.

Check the validity of over-travel switch for the reference point return.

Generally, the mechanical reference point is installed at the maximum travel. The

valid travel of REF return block is more than 25mm to guarantee the enough

deceleration distance and return the reference point precisely. The quicker the

mechanical REF return is, the longer the REF switch is. Otherwise, there would be

no enough deceleration distance to affect the accuracy of REF return, causing by

the carriage moved by CNC acceleration and deceleration and machine inertia

and passing REF block.

1) Manually press the reference point switch during the movement of machine

tool to check the validity of the reference point return process.

2) Operate the machine tool and press the reference point switch by the

reference point block to check the validity of the process of reference point

return. The recommended speed of reference point return is under

1000mm/min.

Note: The block of reference point shall be put within the certain distance.

The recommended length is above 30mm of the valid travel distance.

Otherwise, the block of reference point would be rushed over as the high

speed of reference point return.

Century Star HNC-180 series HNC-180xp/T3, HNC-180xp/M3, HNC-180GCE. Connection Manual (V2.0) - page 2