Content      ..     1      2      3     

Century Star HNC-180 series HNC-180xp/T3, HNC-180xp/M3, HNC-180GCE. Connection Manual (V2.0) - page 3

Note: There shall be a certain amount of overlap between the block for

reference point and the nearby over-travel limit switch to ensure that the

reference point return switch is not released, even if the over-travel limit switch is

pressed. Thus, the reference point return can be done correctly, when the

reference point switch just stops between the block of reference point and the

pressed over-travel limit switch. Figure 5-2 shows the installation of REF switch

and the over-travel limit switch. In the figure, ―A‖ means the block of reference

point, ―B‖ means the block of nearby over-travel limit, ―a‖ means the reference

point switch, and ―b‖ means the nearby over-travel limit switch.

REF direction

REF direction

b

B

b

B

A

a

A

a

(a) Correct Installation-overlap

(b) Incorrect Installation-without overlap

Figure 4-2 Installation of REF switch and over-travel limit switch

-

Check the effective travel range of each axis, and correctly set the positive

software limits, the negative software limits in axis parameters (the software limit

position is usually set between the two over-travel limit switches). Check the

validity of software limit protection after the reference point is returned.

4.4.4 Spindle Function

-

Check the direction and the speed of spindle rotation and set the related axis

parameters (in general, they are the transmission ratio of spindle transmission

part, the initial voltage/slope/the final voltage of D/A, the minimum speed, the

maximum speed etc.), to reach the running requirement of spindle.

-

Check other elements of PLC design, mainly including M, S and T commands, the

safety interlock relations etc.

4.4.4.1Spindle D/A

The output voltage of interface AOUT of spindle D/A is -10V~+10V.

Please set the type of speed command of spindle driver unit as the

voltage to connect with NC device, as the speed command of some

spindle driver unit can be in the form of both the voltage and current.

Otherwise, the related interface of spindle unit would be destroyed.

49

CCW locked time should be set properly. If the time is set too long, it would destroy

motor. If the time is too short, the knife rest would not be locked. The way to check the

lock of knife rest is: use the dial indicator to approach the knife rest, move the knife

rest manually, the fluctuation of point of dial indicator should not be more than

0.01mm.

In the debugging, each tool position and the maximum tool switch should change tool

once, monitor the validity of tool change and time parameters.

4.4.5 Machine Error Compensation

Please read section 4.3.6 Axis Compensation Parameters before setting the machine

error. Machine tool error compensation mainly includes the backlash and the pitch

error compensations, and these errors can be measured by the dial gauge, the block

gauge or the laser interferometer.

4.4.5.1Backlash Error Compensation

For the small machine, the pitch error compensation is usually neglected, while the

backlash is required to measure by using a dial gauge. The measurement is shown as

below:

G01command under MDI mode (not more than 1mm)

A

same tool movement

B

Reverse position

Reading data

Figure 4-3 Measurement of Backlash

Backlash error compensation (μm) = |A - B|; in which ―A‖ is the value read from the

dial gauge at position A, and ―B‖ is the value read from the dial gauge at position B.

Example: A=3mm, B=2.975mm, then,

Backlash error compensation=3-2.975=0.025mm=25μm

Note:

-

Set the backlash error compensation to 0 before the measurement.

-

Both backlash and pitch error compensation values can be measured by the laser

interferometer.

-

If the bi-directional pitch error compensation is used, then the backlash can be

omitted, as it can be done through the bi-direction pitch error compensation.

53

4.4.5.2Pitch Error Compensation

There are two kinds of pitch error compensation: unidirectional, and bi-directional.

The same offset for the positive and negative movement of feed axis is set in the

unidirectional compensation, while the different offset for the positive and negative

movement of feed axis is set in the bidirectional compensation. Generally, the

unidirectional pitch error compensation is used. The measurement is shown as below:

Reading data

A1

A2

An

An+1

……

……

B1

B2

Bn

Bn+1

Clear backlash

Clear backlash

Figure 4-4 Measurement of Pitch Error

A₁~A_n+1: actual MCS position when the feed axis is moving in the positive direction;

B₁~B_n+1: actual MCS position when the feed axis is moving in the negative direction;

Offset(μm)=Programming coordinate value in MCS-Actual coordinate value in MCS;

Please refer to section 4.3.6 for the program of measuring the pitch error.

In general, the offset interval is about 50mm.

Please set the offset parameters as 0 before the measurement of compensation.

Take axis Y for example, the related parameters and data are given as follows:

REF point position: 0 (axis parameter);

REF direction: + (axis parameter);

Pitch comp point interval: 50mm (axis compensation parameter);

Travel distance: 400mm (machine data)

Then, the measuring points are -400, -350, -300, -250, -200, -150, -100, -50, 0, in

which 0 is the reference point.

The actual value of measurement is as below:

-

negative direction:

-400.1,

-350.08,

-300.05,

-250.06,

-200.04,

-150.02,

-100.01, -50.005, 0;

-

positive direction: -400.15, -350.12, -300.1, -250.1, -200.07, -150.06, -100.04,

-50.05, 0.03;

Note: When the direction of reference point return is positive, the data at the

negative side is measured first.

54

Therefore, the compensation parameters for axis Y shall be set as below:

-

Unidirectional pitch error compensation

Parameter Name

Value

Description

Backlash (μm)

30

Take -200 as the coordinate value

Pitch compensation type

1

Unidirectional pitch error compensation

Pitch compensation point

9

Index of REF point

8

Pitch comp point interval (μm)

50000

50mm

Offset (μm) [0]

100

(-400)-(-400.10)

Offset (μm) [1]

80

(-350)-(-350.08)

The data in the

Offset (μm) [2]

50

(-300)-(-300.05)

negative direction

are used.

Offset (μm) [3]

60

(-250)-(-250.06)

The offset for the

Offset (μm) [4]

40

(-200)-(-200.04)

reference point is

Offset (μm) [5]

20

(-150)-(-150.02)

usually zero, as

Offset (μm) [6]

10

(-100)-(-100.01)

REF point is at the

initial position.

Offset (μm) [7]

5

(-50)-(-50.005)

Offset (μm) [8]

0

(0)-(0) (reference point)

-

Bidirectional pitch error compensation

Parameter Name

Value

Description

Backlash (μm)

0

It is usually set as 0.

Pitch compensation type

0

Bidirectional pitch error compensation

Pitch compensation point

9

Index of REF point

8

Pitch comp point interval (μm)

50000

50mm

Offset (μm) [0]

150

(-400)-(-400.15)

Offset (μm) [1]

120

(-350)-(-350.12)

Offset (μm) [2]

100

(-300)-(-300.10)

Offset (μm) [3]

100

(-250)-(-250.10)

the data in the

Offset (μm) [4]

70

(-200)-(-200.07)

positive direction

Offset (μm) [5]

60

(-150)-(-150.06)

Offset (μm) [6]

40

(-100)-(-100.04)

Offset (μm) [7]

50

(-50)-(-50.05)

Offset (μm) [8]

30

(0)-(-0.03) (reference point)

Offset (μm) [9]

100

(-400)-(-400.10)

Offset (μm) [10]

80

(-350)-(-350.08)

Offset (μm) [11]

50

(-300)-(-300.05)

Offset (μm) [12]

60

(-250)-(-250.06)

the data in the

Offset (μm) [13]

40

(-200)-(-200.04)

negative direction

Offset (μm) [14]

20

(-150)-(-150.02)

Offset (μm) [15]

10

(-100)-(-100.01)

Offset (μm) [16]

5

(-50)-(-50.005)

Offset (μm) [17]

0

(0)-(0) (reference point)

Note: When the laser interferometer is used to measure the pitch error, it is necessary

to measure more than once. And the measurement software can automatically

calculate the offset data based on the groups of measured data. In order to keep the

precision of machine tool within specification, the offset data calculated in this way is

usually different from the data from the manual calculation.

55

5 Fault Diagnosis

5.1 Fault and Solution

5.1.1 Abnormal Start-up

-

No Display

Category

Reason

Solution

Reference

incorrect

Check power supply socket;

Wiring

power

Check power supply: AC24V or DC24V;

Section 2.3

supply

Check wiring polarity;

too bright or

Adjustment

Adjust the knob on the back

too dark

mainboard

Hardware

Contact with us

error

-

System is crashed or restarted during the operation.

Category

Reason

Solution

Reference

Incorrect

Check parameters in E-stop mode after restart;

Parameter

setting of

Check axis parameters, PMC user parameters;

parameter

The parameter as denominator shall not be 0;

Reading

program

Wait for a moment;

Operation

from DNC

Stop the calling of the program;

or network

System

Software

Reinstall the system.

damaged

Check power supply socket;

Insufficient

Check the voltage of power supply;

Wiring

power

Section 2.3

Check the capacity of power supply;

supply

Check whether there is short circuit.

5.1.2 E-Stop and Reset

-

Unable to initiate reset signal

Category

Reason

Solution

Reference

Check the normal closed contact of over-travel

limit switch;

E-stop

Check the normal closed contact of E-stop

Hardware

circuit is not

button;

Section 3.5

closed

If the handheld unit is not used or there is on

E-stop button on the handheld unit, pin 4 and

17 of XS8 shall be short circuited.

56

-

Fail to reset

Category

Reason

Solution

Reference

Check the logical circuit;

If HSV-20 servo is used, the reason

Requirement for reset

is usually the power supply of servo

is not reached, such as

drive is not ready; Check the power

Hardware

power supply of servo

supply module;

Section 3.1

is not ready, spindle

Check the wiring of power supply

drive is not ready etc

module;

Check air switch of servo drive

power supply.

5.1.3 Abnormal Running of Servo

The interchange method is frequently used to verify the faulty of servo, which

includes:

-

Interchange the motors connected to the servo drives;

-

Interchange the cables for servo drives;

-

Interchange the interfaces of HNC-180 used for servo drives.

Please turn off the power supply first, if adding or removing the cables or the

connectors is necessary to fix the problem. Please turn off the power supply for

three minutes and restart the system, after the parameters are modified.

Ensure the signal ground of feed drive unit or spindle drive is reliably connected with

the signal ground of NC device.

HNC-180

Servo driver

Servo motor

XS1~3

Position FB cable

Position FB cable

(Encoder cable)

Axis control cable

Heavy current cable

of servo

Figure 5-1 Connection between HNC-180 and Servo unit

-

There is an alarm message, once the power supply of servo drive is on.

Category

Reason

Solution

Reference

Error in phase order of

Check the phase order of servo

servo motor strong

motor

current cable

Connection error in

Check the position feedback cable

Section

Wiring

position feedback cable

4.1.1

Position feedback cable

is not corresponding to

Check the motor wiring

motor strong current

cable

57

-

Servo motor is dithering when it stops

Category

Reason

Solution

Reference

Error in the wiring of

Wiring

position feedback

Check the position feedback cable

Section

cable

4.1.1

Abnormal running

Motor

Check servo motor and servo drive

of motor encoder

Check the parameters related to gain

adjustment of servo drive, and adjust

Error in the

them carefully.

Parameters

parameter

Proportion coefficients and integration

time of speed loop can be reduced

properly.

-

Servo motor rotates slowly with zero drift.

Category

Reason

Solution

Reference

Servo drive is set to be controlled by

the external command.

Check the consistency between the

Operational

Error in parameter

Parameter

internal control mode of servo drive

manual of

of servo drive

and the actual condition. Example: For

Servo drive

the drive with pulse interface, it is set

as position control mode.

Error in the servo

Setting of servo type shall match with

Parameters

parameters

the actual condition

Weak connection of

axis control cable

Check the axis control cable

(XS1,

Section

Wiring

between NC unit

XS2, and XS3)

4.1.1

and Servo drive

Make coordinate axis control cables

shielded with reliable grounding;

Interference to the

Do not twist, if possible;

Wiring

Section 3.5

axis control cable

Keep the strong current cables as far

possible;

Do not lay with them in parallel.

-

Servo motor does not rotate.

Category

Reason

Solution

Reference

Disconnected

Check the strong cable of motor;

control cable

Check the control cable of axis;

Section

Wiring

No servo power

4.1.1

Check the power supply of servo;

supply

Error in the

The internal parameter of servo drive

Parameters

parameter of servo

shall be set as the external command

drive

control, i.e. controlled by NC device

Check if servo drive can correctly

Error in the servo

receive the enabled signal;

Parameters

parameter

Check the servo type of servo

parameters in NC device;

Check the consistency between the

Error in machine

Parameters

pulse type of NC unit and the setting of

parameter

servo drive.

Press the machine locked button to

Operation

Machine is locked

release the locked status.

Motor rotation

Check if brake on motor is on;

Installation

blockage

Check if mechanical load is too much.

58

-

Motor can only rotate a short distance.

Category

Reason

Solution

Reference

Check if the position feedback cable

is corresponding to the motor strong

Wrong connection

current cable;

between the position

Section

Wiring

Check the phase order of motor

feedback cable and

4.1.1

strong current cables;

strong cable of motor

Check if the position feedback cable

is disconnected.

Set the correct motor revolution;

Error in the servo

For the servo with pulse interface,

Parameters

parameter

E-gear(NC)/E-gear(Servo) shall be

set correctly.

Error in the setting of

Parameters

motor pole pairs of

For GK motor, it is set as 3.

servo drive

Too much mechanical

Check if the mechanical load is too

Installation

load

much

-

Motor jitters when rotating.

Category

Reason

Solution

Reference

Ground the whole system as

required;

Each unit or device shall be

No reliable grounding

grounded reliably;

Signal ground of drivers and NC

device shall be reliably common

grounded.

No reliable power

Check the connection of servo drive

supply of servo drive

power supply control circuit;

Position feedback cables and axis

control cables must be shielded

cables with reliably grounding;

Wiring

In the position feedback cable, the

Section 3.6

power supply wire and its ground

wire shall be thicker. Two or three

wires are connected in parallel;

The length of axis control cables or

Interference

position feedback cables shall be

within 15m;

The axis control cables and position

feedback cables must be laid

separately from the strong current

cables;

Do not twist axis control cable and

position feedback cable, if possible.

Check if the motor strong current

cable is corresponding to the

Wrong connection of

position feedback cable;

encoder cable and

Check the phase order of motor

motor power supply

Section

Wiring

strong current cables;

cable

4.1.1

Check if the encoder cable is

disconnected.

Disconnected position

Check and repair the position

feedback cables

feedback cables

59

Check the parameters of servo

drive, and run the motor by using

servo internal command to verify

the correctness of parameters.

Then, connect to NC device.

Check the parameters related to

Operational

Error in the parameter

Parameters

gain adjustment of servo drive, and

manual of

of servo drive

adjust them carefully.

Servo drive

Proportion coefficients and

integration time of speed loop can

be reduced properly.

Use GK servo motor, and set the

pole pairs of motor as 3.

Uneven mechanical

Installation

Check the mechanical load

load

Motor

Motor encoder broken

Repair or Replace the motor

-

Motor is creeping

Category

Reason

Solution

Reference

No reliable motor

Check motor strong current cables;

Wiring

Section 3.6

grounding

Check the axis control cable

Mechanics

Too much load

Check the servo power supply

Check the parameters related to

gain adjustment of servo drive, and

Operational

Error in the parameters

adjust them carefully.

Parameters

manual of

of servo drive

Proportion coefficients and

Servo drive

integration time of speed loop can

be reduced properly.

-

Incorrect motor positioning and Accumulative Error

Category

Reason

Solution

Reference

Check the motor strong current

No reliable motor

cables;

grounding

Check the axis control cable

Use the shielded cable or

twisted-pair double shielded cable

with good quality;

Use the thicker power supply wire

Wiring

Section 3.6

for position feedback cable, such as

No reliable position

take several wires connected in

feedback cable

parallel;

Shield layer of cable is grounded

reliably;

Add the magnetic rings on both

sides of cable.

Unreliable mechanical

Mechanics

Adjust the mechanical connection.

connection

Motor

Motor encoder broken

Replace the motor

-

Weak torque output from motor axis

Category

Reason

Solution

Reference

No reliable motor

Check motor strong current cables;

Wiring

grounding; being

Check the position feedback cable;

Section 3.6

interfered

Check the axis control cable;

Motor

Motor encoder broken

Replace the motor

60

-

Driving axes slips down when starting

Category

Reason

Solution

Reference

No balancing device;

Add a balancing device;

Mechanics

Invalid balancing unit

Check the balancing device;

Too early brake from

Check if the connection of X0.2

Wiring

the motor

(axis Z ready) is correct.

-

Reference point return error

Category

Reason

Solution

Reference

Check if the parameter - stepper

It automatically stops

motor pulses - is set.

Parameters

when reference point is

Check the setting of the parameter

positioning.

- motor revolution. It shall be pulses

from servo to NC unit*4.

5.1.4 Abnormal Frequency Converter and Servo Spindle

-

Spindle overspeed and uncontrollable

Category

Reason

Solution

Reference

Check the setting of spindle drive;

Error in the setting of

Parameters

Spindle drive should be controlled

spindle drive

by the external command.

Speed control signal cables shall be

shielded cables with reliable

grounding;

A resistance of 500-1000 ohms and

Section 3.2

Wiring

Interference

ceramic plate capacitance of 1000p

Section 3.6

shall be connected to the spindle

drive side of speed control signal

cables in parallel.

Hardware

D/A circuit faulty

Repair or replace NC unit

-

Failed pitch machining

Category

Reason

Solution

Reference

Check the consistency between the

Error in the direction of

Parameters

spindle encoder direction and the

spindle encoder

actual direction of spindle rotation.

-

Incorrect pitch machining

Category

Reason

Solution

Reference

Error in the setting of

Parameters

Check the spindle revolution

spindle revolution

Replace spindle encoder. Turn the

spindle manually and monitor the

Spindle encoder faulty

spindle speed to check whether the

Mechanics

encoder is damaged.

Spindle encoder

Repair or replace

coupling faulty

Check the power supply of spindle

encoder. If it is higher than the

Not enough power of

output capacity of XS9 of HNC-180,

Hardware

Section 3.2

spindle encoder

the independent power supply with

DC5V for spindle encoder shall be

used.

61

5.1.5 Abnormal Running of I/O

Note: Each DC solenoid valve and brake must be connected to damper diode.

Otherwise, the performance of DC24V power supply would be affected by the current

shock when the solenoid valve is turned on. This would cause the random alarms

from NC device or servo drive.

Each AC contactor and AC asynchronous motor such as cooling motor, hydraulic

motor and AC asynchronous spindle motor controlled by contactors must be

connected to RC arc damper. Otherwise, the performance of AC power supply would

be affected and the interference would be produced by the current or voltage surge at

the instant of turning on these devices. This would cause the random alarms from NC

device or servo drive.

-

No input or output signal

Category

Reason

Solution

Reference

DC24V power supply for external

on-off I/O must have common

Signals without

Wiring

ground with DC24V power supply

Section 2.3

common grounding

for HNC-18i/18xp NC unit through

XS6 and XS9.

-

Unstable I/O

Category

Reason

Solution

Reference

It is recommended to use the

independent shielded cables for

connecting on-off input and output

signals with reliable grounding,

when separating HNC-180 device

Wiring

Interference

Section 3.6

and strong current cabinet;

The length of cable wire shall be

within 15m;

HNC-180 NC device shall be

grounded reliably.

Check the input/output voltage of

Wiring

Abnormal power

Section 2.3

HNC-180 NC unit

Too much interference

Check the anti-interference circuit of

from other devices

this kind of devices. For example,

Section 2.3,

Wiring

sharing DC24V power

check the damper diodes in the

Section 3.6.

supply with PLC

band brake and the solenoid valve.

62

5.2.2 List of Alarm Messages

No.

Alarm Message

System status

Solution

Initialization

Set the axis parameters and servo

01h

Emergency stop

Error

parameters correctly.

02h

Parameter Error

Emergency stop

Set the parameters correctly.

05h

Position Lost

None

Move the axis

Check the parameter, wiring and power

09h

Unknown Error

Emergency stop

supply, and turn on power supply again.

Positive

No axis

Press the over-travel released button, move

20h

overtravel

movement

the axis to the negative direction.

Negative

No axis

Press the over-travel released button, move

21h

overtravel

movement

the axis in the positive direction.

the overtravelled

Positive

axis stops moving

22h

Move the axis to the negative direction.

software limit

to the positive

direction

the overtravelled

Negative

axis stops moving

23h

Move the axis to the positive direction.

software limit

to the negative

direction

Turn on the power again, after it has been

30h

Hardware Error

Emergency stop

off for three minutes.

Abnormal

Check the position feedback cable of

38h

Emergency stop

feedback

HNC-180 NC unit.

Check the axis control cable of servo drive.

40h

Overspeed

Emergency stop

Set the value of maximum feedrate higher.

Check the mechanical load;

Check the power supply of servo drive;

Check the brake of servo;

Tracking error

Check if the rapid traverse speed is higher

41h

Emergency stop

too much

than the rated motor rotation speed;

Check the internal parameter of servo drive;

Check the motor revolution;

For servo, check E-gear(NC)/E-gear(Servo)

Check the reference point switch;

No reference

44h

Emergency stop

Check the encoder feedback cable;

point return

Check the zero (Z, /Z) pulse of encoder;

64

6.2 Example of Design

6.2.1 Brief Introduction

-

Machine: 2-coordinate parallel lathe, with 4-position automatic cutter saddle;

-

Structure of control cabinet: strong current control cabinet + operation station

-

Spindle: frequency converter + normal asynchronous motor

The following table shows the main components in the design of NC turning system.

Table 6-1 Main components in the design of NC turning system

No.

Name

Specification

Description

Notes

1

NC device

HNC-180xp/T3

Control system

HCNC

2

Handheld unit

HWL-1013-3

Manual control

HCNC

Power supply for servo

control, Power supply for

AC380/220V 250W

switch

Control

3

/110V 150W

Power supply for heat

HCNC

transformer

/ 24V 100W

exchanger and AC

contactor

Power supply for spotlight

Servo

Power supply servo supply

4

3P AC380/200V 2.5KW

HCNC

transformer

module

Switch power

5

AC220/DC24V 35W

I/O and intermediate relay

Ming Wei

supply

6

Servo driver

HSV-160B⁺-030

Axis X/Z motor drive

HCNC

7

Servo motor

130ST-M06025LFB(6NM)

Axis X feed motor

HCNC

8

Servo motor

130ST-M07720LFB(7.5NM)

Axis X feed motor

HCNC

Frequency

Spindle frequency

9

SJ300-075HF

Yaskawa

converter

converter

66

6.2.2 Overall Diagram

XS6

On-off input (machine inspection)

XS9

On-off output (controlled by relay)

HNC-180xp/T3

Encoder on Axis X

USB

XS12

XS1

HSV-160B+ servo X

Servo motor X

PC keyboard

XS10

Encoder on Axis Z

XS3

HSV-160B+ servo Z

Servo motor Z

XS4

Handheld

XS7

unit

XS5

SPDL f.converter

SPDL motor

Encoder

Figure 6-1 Overall Diagram of Typical Design of NC Milling System

6.2.3 I/O Specification

For detailed information, please refer to Chapter 3.

6.2.4 Circuit Diagram

The following section describes the main parts of the circuit diagram. As to the wire

number, only those appeared in different pages are given.

6.2.4.1Connection to Power Supply

There is no solenoid valve in the system. Only one power supply with DC24V 35W is

used. A low pass filter is used at the lead-in wire of switch power supply to separate

from the power supply of servo(AC220V)

In Figure

7-2, QF1~QF5 are 3φ air switches. QF6~QF8 are 1φ air switches.

KM1~KM3 are 3φ AC contactors. RC1 and RC2 are 3φ RC absorbers (arc damper).

RC3~RC5 are 1φ RC absorbers (arc damper). KA1~KA3 are DC24V relays.

Note: The magnetic rings and the high voltage ceramic plate capacitors at the main

power lead-in wire and the transformer input side are not shown in this figure.

67

AC380V 3φ

QF1

Servo Transformaer

32A

R

QF2

AC380/220

Servo

S

HSV-160B

+

10A

2.5KW

T

X,Z

U11

Spindle frequency converter

QF3

V11

Spindle

20A

5.5KW

W11

motor

KM2

RC1

QF4

KM1

Knife rest

0.4A

motor

RC2

QF5

KM3

Coolant

1A

motor

Lowpass filter

QF6

AC220V

AC250V

3A

300W

6A

Power supply

AC220V/

QF7

35W

DC24V

AC24V

Suspension fan

6A

AC380V

100W

500W

Spotlight

24V

100

220A

220B

To: Relay

QF8

To: NC unit

AC110V

Servo

23A

100W

KA1

KA2

KA3

KM2

KM1

Cabinet fan

Control

RC3

RC4

RC5

transformer

KM1

KM2

KM3

Knife rest Knife rest Coolant

motor CW

motor CCW

Motor

Figure 6-2 Circuit diagram of typical turning system - power supply

68

6.2.4.2Connection to Relay and I/O

Relay is controlled by the on-off output signals, and the on-off input signals mainly

refer to the status and alarm messages of feed unit, spindle unit, machine tool electric

part etc.

As it is shown in Figure 7-3, KA1~KA3 are intermediate relays.

Knife rest

Knife rest

Coolant

CW

CCW

Start

Y1.0 Y1.1 Y1.2

KA2

KA1

24V

KA1

KA2 KA3

Figure 6-3 Circuit diagram of typical turning system - Relay

XS6

X0.0

13

25

X0.2

12

X0.3

SQX-2

24

REF switch on Axis X

11

SQZ-2

X0.5

23

REF switch on Axis Z

10

22

X1.0

SQ1

9

Tool-1 Ready

X1.1

SQ2

21

Tool-2 Ready

X1.2

SQ3

8

Tool-3 Ready

X1.3

SQ4

20

Tool-4 Ready

7

Hall Switch

19

6

24V

18

X2.0

5

Overtravel input

X2.1

17

QF5

E-stop input

X2.2

QF4

4

External alarm

SQX-1

X2.3

16

Overtravel

3

released button

SQZ-1

X2.5

15

2

14

Axis overtravel limit switch

100

1

(Relay DC24VG)

Figure 6-4 Circuit diagram of typical turning system - I/O 1

As it is shown in Figure 6-4, X0.0~X0.2, X1.1, X1.2, and X2.3 are from XS1~XS3

(feed axis interface), and XS5 (spindle interface). If there is no related alarm input

signals, then the corresponding input signals shall be connected to DC24VG. ―100‖

69

and ―24V‖ in the graph is the output of DC24V 35W switching power supply.

XS7

XS9

5VG

Y0.0

13

5VG

13

+5V

Y0.1

25

+5V

25

Y0.0~Y0.3 are from

HB

MPG

Y0.2

12

B

12

XS1~XS3 and XS5.

HA

Y0.3

24

A

24

11

11

23

23

Axis

10

10

OFF

22

22

X3.0

X

Y1.0

9

9

Turret motor CW

X3.1

Y

Y1.0

21

21

Turret motor CCW

X3.2

Z

Y1.2

8

8

Coolant relay

X3.3

20

20

X3.4

X1

7

7

X3.5

X10

19

19

X3.6

X100

6

6

Override

18

18

5

5

E-Stop

24VG

17

17

4

X3.7

4

16 +24V

+24V

Pilot

16

3 +24V

3

15 24VG

24VG

15

2 24VG

Handheld unit

2 24VG

100

14 24VG

(Relay DC24VG)

14 24VG

1 24VG

1 24VG

Figure 6-5 Circuit diagram of typical milling system - I/O 2

70

6.2.4.3Connection to Spindle

Brake RC

50Ω 1000W

Spindle motor

B1

B2

U

Spindle encoder

U11

R(L1)

U(T1)

V

V11

S(L2)

V(T2)

5.5KW

W

W11

T(L3)

W(T3)

From KM2

Spindle frequency

(Figure 7-2)

converter

HNC-18xp/T

Spindle fan

SJ300-075HFE

XS6

7.5KW

+5V

XS5

1

Y0.2

5VG

25

FW

Spindle CW

5，6

Y0.3

SA+

24

8

Spindle CCW

2

+24V

SA-

14

PLC

+24V

7

100

SB+

24VG

9，15

AL0

3

DAS+

SB-

AOUT

1

O

8

DAS-

SZ+

2

L

4

X2.3

SZ-

20

AL1

Spindle alarm

9

HNC-180xp

Figure 6-6 Circuit diagram of typical turning system - Spindle

71

6.2.4.4Connection to Servo Drive Unit

R

S

R

R

Axis X

R

Axis Z

R

T

220A

220A

AC1

S

AC1

S

S

S

220A

220A

AC2

T

AC2

T

220A

T

Axis X

T

Axis Z

HSV-160B+

HSV-160B+

220B

UX

2

UZ

2

U

U

XS3

XS3

V

VX

4

V

VZ

4

CMD signal

CMD signal

WX

3

WZ

3

NC unit

W

W

XS1

XS4

XS4

XS2

XS

XS2

XS

Encoder

Encoder

HNC-180xp

I/O

Encoder

PG

I/O

Encoder

PG

Cables

Cables

PE

PE

XS3

Figure 6-7 Circuit diagram of typical turning system - Servo Drive Unit

HNC-180xp/T3

HSV-160B+

ST motor

XS1,3

COMMAND

ENCODER

XS

Y0.1

4

1Enabled

+5V 16,17

Y0.0 12

2Reset

+5V 18,19

12 +5V

X0.*

5

8Ready

5VG 23,24

GND 13

19 24VG

13 GND

+24V 6

A 1

2

A

B 3

4

B

*:0,1,2

Z 5

16 Z

23,24 GND

U 7

6

U

A+

1

32 A+

V 9

8

V

A-

9

33 A-

W 11

10

W

B+

2

18 B+

/A 2

3

/A

B- 10

36 B-

/B 4

5

/B

Z+

3

35 Z+

/Z 6

17 /Z

Z- 11

34 Z-

/U 8

7

/U

CP+ 14

14 CP+

/V 10

9

/V

CP-

7

15 CP-

/W 12

11 /W

DIR+ 15

16 DIR+

PE 14,15

1 PE

DIR-

8

17 DIR-

Axis control cable

Axis encoder cable

Figure 6-8 Circuit diagram of typical turning system - Servo drive cable

Content      ..     1      2      3