HNC-8 System Commissioning Manual (Milling System) V2.4 Series

Name

Function

Signal standard

A+/SINA+

Motor encoder A+ phase pulse input

A-/SINA-

Motor encoder A- phase pulse input

B+/COSB+

Motor encoder B+ phase pulse input

Wire driver and receiver

RS422 standard

B-/COSB-

Motor encoder B- phase pulse input

Z+

Motor encoder Z+ phase pulse input

Z-

Motor encoder Z- phase pulse input

7,8

Reserved

9,10

Reserved

11,12

Reserved

Power supply of motor encoder DC +5V

1. Supply +5V power to the motor encoder

16,17

connected to XS5.

+5V

DC +5V/150mA

18,19

2. Connect to the power pin of the motor encoder.

3. When cable is too long, multiple core wires

should be connected in parallel.

23,24,25

GNDD

Power ground of motor encoder 0V

KT+

Signal input of motor temperature sensor

KT_

Reserved

Shielding signal

14,15

Connect to PE signal of motor encoder

Note: 1. Pins of the same name have been connected on the internal circuit board.

Name

Function

Signal standard

A+/SINA+

Motor encoder SINA+ phase pulse input

A-/SINA-

Motor encoder SINA- phase pulse input

B+/COSB+

Motor encoder COSB+ phase pulse input

Analog input voltage:

1Vp-p

B-/COSB-

Motor encoder COSB- phase pulse input

Z+/R+

Motor encoder Z+ (or R+) phase pulse input

Z-/R-

Motor encoder Z- (or R-) phase pulse input

7,8

Reserved

9,10

Reserved

11,12

Reserved

Power supply of motor encoder DC +5V

1. Supply +5V power to the motor encoder

connected to XS5.

16,17

+5V

2. Connect to the power supply pin of the motor

DC +5V/150mA

18,19

encoder.

3. When cable is too long, multiple core wires

should be connected in parallel.

23,24,25

GNDD

Power ground of motor encoder 0V

KT+

Signal input of motor temperature sensor

KT_

Reserved

Shielding signal is connected to PE signal of motor

14,15

encoder

Note: 1. Pins of the same name have been connected on the internal circuit board.

4.6.3

XS5 ENCODER1 Interface Connects to Rotary Encoder

Name

Function

Signal standard

1,2

Reserved

3,4

Reserved

5,6

Reserved

SIN+

Motor encoder SIN+ phase input

SIN-

Motor encoder SIN- phase input

Analog input voltage:

2.4V- 3.0Vp-p@10kHz

COS +

Motor encoder COS+ phase input

COS-

Motor encoder COS- phase input

EXC1

Motor encoder EXC1 phase output

Analog output voltage:

4.8V- 6.0Vp-p@10kHz

/EXC1

Motor encoder /EXC1 phase output

Reserved

16,17

Reserved

18,19

SX5 ENCODER1 interface

23,24,25

GNDD

Internal power ground 0V

KT+

Signal input of motor temperature sensor

KT-

Reserved

Shielding signal

14,15

Connect to PE signal of motor encoder

Note: 1. Only SV-180US-035R～150R spindle drive unit can match this type of encoder.

2. Pins of the same name have been short-circuited on the internal circuit board.

3. Resolution of rotary transformer is 14bit, namely 16384 ppr.

4.7 Definition of Second Encoder Interface of Spindle Servo Drive

XS6 ENCODER2 spindle encoder input interface diagram

4.7.1 XS6 ENCODER2 Interface Connects to Incremental Optical Encoder

Name

Function

Signal standard

Spindle encoder power supply DC +5V

1. Supply +5V power to the spindle encoder connected

to XS6.

+5V

2. Connect to the power supply pin of the spindle

encoder.

DC +5V/150mA

3. When cable is long, multiple core wires should be

connected in parallel.

1. Connect to 0V pin of the spindle encoder.

GNDD

2. When cable is long, multiple core wires should be

connected in parallel.

A+/SINA+

Connect to A+ phase of the spindle encoder

A-/SINA-

Connect to A- phase of the spindle encoder

B+/COSB+

Connect to B+ phase of the spindle encoder

Wire driver and

receiver

B-/COSB-

Connect to B- phase of the spindle encoder

RS422 standard

DATA+

Connect to Z+ phase of the spindle encoder

DATA-

Connect to Z- phase of the spindle encoder

Reserved

4.7.2 XS6 ENCODER2 Interface Connects to Incremental Sin-cos Encoder

Name

Function

Signal standard

Power supply of motor encoder DC +5V

1. Supply +5V power to the motor encoder

connected to XS5.

+5V

2. Connect to the power supply pin of the

motor encoder.

DC +5V/150mA

3. When cable is too long, multiple core

wires should be connected in parallel.

1. Connect to 0V pin of spindle encoder.

GNDD

2. When cable is long, multiple core wires

should be connected in parallel.

A+/SINA+

Connect to spindle encoder SINA+

A-/SINA-

Connect to spindle encoder SINA-

Analog input voltage:

1Vp-p

B+/COSB+

Connect to spindle encoder COSB+

B-/COSB-

Connect to spindle encoder COSB-

DATA+

Connect to spindle encoder Z+ (or R+)

Analog input voltage:

0.5Vp-p

DATA-

Connect to spindle encoder Z- (or R-)

Reserved

1） Definition of industrial Ethernet communication module (HIO-1061)

Signal

Description

24V

DC 24V power supply

24VG

DC 24V power ground

Connect to ground

NCUC bus interface

Signal

Description

The first pin and the second

pin of X2A and X2B are

interconnected and they have

no electric definition.

TXD+

Data transmission

TXD-

RXD+

Data receiving

RXD-

2） Definition of switch value input/output module interface

Description

Signal

HIO-1011N XA, XB

HIO-1011P XA, XB

Switch value input

NPN input

interfaces XA and XB

0-7

N0-N7

N/A

Low level is valid

NPN input

0-7

N/A

N0-N7

High level is valid

GND

DC24V ground

Definition of input module (HIO-1011N, HIO-1011P) interface

5） Definition of HIO-1031 module interface

HIO-1031

Port function

port

+24V output

Empty

Note:

1. Three groups of input of this module occupy four groups of input points of the system, 8 bytes for each group,

and the last group is reserved by default. Two groups of output occupy two groups of output points.

2. If the input configuration ports COM0 to COM2 are empty, PNP type is defaulted.

3. If COM0 port is connected to GND, Xm+0.0 ~ Xm+0.7 can be configured as PNP type input. If COM0 port

is connected to 24V, Xm+0.0 ~ Xm+0.7 can be configured as NPN type input. Likewise, Xm+1.0 ~ Xm+1.7

and Xm+2.0 ~ Xm+2.7 corresponding to COM1 and COM2 can be configured as PNP type input or NPN type

input. Please configure COMx port under power off and restart to validate it.

4. It is valid when the current flowing through the input port is greater than 6mA.

4) Encoder input interface XS4

Signal

Port function

+5V

5V output

GND

PA1+

PA1-

PB1+

PB1-

PZ1+

PZ1-

Null

5) Digital input/output interface XS5

Symbol

Port function

Symbol

Port function

GND

+24V

24V output

X0.0

X0.1

X0.2

X0.3

X0.4

X0.5

X0.6

X0.7

X1.0

X1.1

I10

X1.2

I11

X1.3

I12

X1.4

I13

X1.5

I14

X1.6

I15

X1.7

I16

X2.0

I17

X2.1

I18

X2.2

I19

X2.3

I20

X2.4

I21

X2.5

I22

X2.6

I23

X2.7

COM0

COM port of X0

COM1

COM port of X1

COM2

COM port of X2

Null

Y0.0

Y0.1

Y0.2

Y0.3

Y0.4

Y0.5

Y0.6

Y0.7

Y1.0

Y1.1

O10

Y1.2

O11

Y1.3

O12

Y1.4

O13

Y1.5

O14

Y1.6

O15

Y1.7

DOCOM

24V input

DOCOM

24V input

DOCOM

24V input

DOCOM

24V input

1. Please share 0V with pin 1 (GND) of I/O interface CN5 and input signal source. Pin 2 (+24V) of CN5 is 24V

output inside the board and is used for input type configuration only. If pin 27 (COM0) of CN5 is empty or

grounded, pins I0-I7 can be configured as PNP type input. If COM0 is connected to 24V, pins 10-17 can be

configured as NPN type input. Likewise, COM1 can be configured for I8-I15 pin input types and COM2 can be

configured for I16-I23 pin input types. Please configure COMx port under power-off state and restart to validate it.

Pins I0-I7 correspond to X0, pins I8-I15 correspond to X1 and pins I16-I23 correspond to X2. Definition and

usage of I/O extension board interface is similar to baseboard. The PNP type input is valid when greater than 19V

and NPN type input is valid when less than 4V.

2. Pins 47-50 (DOCOM) of I/O interfaces are digital output common ports and are connected to load +24V power

supply externally. The rated current of PNP digital output is 100mA. If it is ≧140mA, output port will undergo

overcurrent protection. Restart to recover it after fault removal. Capacity of load +24V power supply is determined

according to total quantity of I/O and load power and must not be connected to the one-way load greater than 120mA

for a long time to avoid irreversible damage.

Additional Description:

Picture of HIO-1200-K terminal board where I0-I7, I8-I15 and I16-I23 are set as NPN type input:

Digital output command terminal

External load +24V power supply

5. Preparation for Commissioning

5.1 Verification and Record

Please check whether objects are consistent with purchase order and packing list. If not, please contact HCNC

company immediately.

5.2 View System Information

Steps for viewing HNC-8 software version information: Press "Maintain" on the MDI panel→F8 "System

information". The system information page displays system information, system software information, servo

software information and user version information.

5.3 Software Upgrade and Parameters, PLC Backup/Loading

HNC-8 software upgrade includes application program upgrade, parameter upgrade, PLC upgrade and BTF

full-package upgrade.

For parameter, PLC or BTF full-package upgrade, users need to back up PLC and parameters first. Otherwise,

PLC and parameters in the original system will be covered by standard parameters and PLC after upgrade is

completed.

5.3.1

Parameters and PLC Backup

Operating steps:

1) Press "Maintain" on the MDI panel→ press F9 "Permission management"→ press F4 "Logout"→select user

level (the backup is allowed only for workshop manager or above) → press F2 “Login”→Enter the password→

press "Enter" on the MDI panel to confirm (if the permission password is correct, parameter of this level can be

modified; otherwise, the system will give a prompt message "Incorrect password".) ;

Default permission password:

Operator: Need not to enter a password

Workshop manager: GOD

Machine tool manufacturer: HOG

CNC manufacturer: HIG

System administrator: HNC8

Enter administrator

password

2) Press F1 "↑" to return-Press F7 "Data management";

3) Select type of data to be backed up by “↑”, “↓”, “←” and “→” in the MDI panel. e.g.: To back up parameter

file, select "Parameter file". To back up PLC file, select "PLC file". Then, press "Enter" on the MDI panel to

confirm and “√” is displayed in front of corresponding item;

6) Press F3 "Backup" and the system will give a prompt message "Whether to back up the selected file? (Y/N)",

"Y": Yes, "N": No, which correspond to "Y" and "N" on the MDI panel. Select Y and the system will give a

prompt message that the backup succeeds, and generates corresponding file name suffixed with date and time.

Generated backup

file

5.3.2 Software Upgrade

Note: For the sake of safety, it is better to disconnect the bus at the rear of the system after PLC or

parameter upgrade; otherwise, standard PLC or parameter may differ from current machine tool and

consequently the machine tool works abnormally

1） Enter permission as per operating step 1) in 4.3.1;

2） Press "Maintain" on the MDI panel→ press F7 "System upgrade";

3） Press "Window switch" to switch to the upgrade option and select "Type of upgrade option" and "Backup

or not" by “↑”, “↓”, “←” and “→” on the MDI panel: Application program, parameter, PLC and BTF. Generally,

select BTF upgrade and then press "Enter" on the MDI panel to confirm. Backup or not: Select whether backup

is needed according to actual situation. After selection, “√” is displayed in front of corresponding option.

4） Select USB flash disk, switch to USB flash disk directory by "Window switch" and select corresponding

upgrade patch by “↑” and “↓” on the MDI panel. After selection, press "Enter" on the MDI panel to confirm. If

the backup is selected, the system will start the backup automatically and corresponding file to be backed up

will be saved in the path of CF card. After the backup is completed, the system will start the automatic

verification of upgrade patch after passing the verification. After upgrade is completed, the system will give a

prompt message "Upgrade succeeds, please power off and restart". After the system is powered off and restarted,

the loaded file is validated.

2） Press F1 "↑" to return→Press F7 "Data management";

3） Select type of data to be loaded by “↑”, “↓”, “←” and “→” on the MDI panel. e.g.: To load parameter file,

select "Parameter file". To load PLC file, select "PLC file". Then, press "Enter" on the MDI panel and "√" is

displayed in front of corresponding option;

4） Select the loading path by "USB flash disk" and "User disk". For loading from USB flash disk, insert USB

flash disk into USB interface of the system. When

in the upper part of the screen turns to

it means that USB flash disk has been loaded;

USB flash disk has

been loaded

5） Select the file to be loaded by “↑” and “↓” on the MDI panel, press "Load" and the system will give a

prompt message "Whether to load the selected file? (Y/N)", "Y": Yes, "N": No, which correspond to "Y" and

"N" on the MDI panel. Select Y and if there is a file of the same name in the system, the system will give a

prompt message "Whether to cover the file? (Y/N)", select Y and the system will start to load the file. After the

file is loaded, the system will give a prompt message "Loading succeeds and the system has been restarted!".

After the system is powered off and restarted, the loaded file is validated.

A prompt whether to load the selected file will be given

A prompt whether to cover the original file will be given

Select path of load and backup by F2 “USB flash disk” and F3 “User disk”;

Select corresponding operation by F4 "Load" and F5 "Backup".

4) This function is mainly used for commissioning of several machine tools. When a machine tool reaches the

correct condition, back up all parameters in a USB flask disk according to the above steps. Then, insert the USB

flask disk into a machine tool system to be commissioned and load parameters in the USB flask disk in the

system according to the above steps. Optimization and commissioning of the machine tool have been completed.

The machine tool manufacturer can start inspection.

Note:

1. For this function, the CNC controller type, drive and motor types, electric points, and machine tool type must

be consistent.

2. This function must ensure consistency of system version number.

5.4 Offline Commissioning

In order to prevent an accident, drive and motor should undergo offline commissioning before connected to

actuator.

This step is extremely important while commissioning large machine tools.

Specific steps:

1) Place drive and motor in a flat and safe position (such as ground);

2) Connect drive and motor only, set the drive as the internal enable (for details, refer to User Manual of

HSV-180UD AC Servo Drive Unit) and test operating condition;

Note: If an absolute motor rotates automatically after powered on, it means that zero setup is needed.

(For specific steps of zero setup, please refer to User Manual of HSV-180UD AC Servo Drive Unit)

3) Connect the system to drive and drive to motor (for details, please refer to Hardware Connection

Specification), as shown in Fig. 1.3. Recover drive parameters to the external enable and determine whether

communication is normal through observing drive light or viewing device interface, (to view device interface

parameters, refer to 3.1). If parameters of some devices cannot be displayed, connect them and eliminate faults

one by one.

Fig. 1.3 Offline commissioning

Other key points of commissioning:

 Check whether phase sequences U, V and W of power line are correct. For Golden Age absolute motor,

phase sequence should be U, W and V. For Huada absolute motor, phase sequence needs not to be

exchanged.

 Check whether the CNC controller can control action of drive and motor correctly and whether drive and

motor are stable and reach designed power;

4) Commission PLC and check emergency stop points;

5.5 Step-by-step Power-on Principle

In order to ensure safety of commissioning personnel and intactness of machine tool and for ease of fault

diagnosis, comply with "step-by-step power-on" principle in the earlier commissioning period:

1) Power on the CNC controller and power off other parts. Check parameters and PLC and ensure correctness

of power-on parts of PLC, especially when the gravity axis brakes.

2) Power on the feed axis and check whether device cables are connected correctly and whether the drive and

the system are connected normally;

3) Power on the power device (motor) and check whether the motor is controlled normally, whether the

machine tool works normally and whether all limits are valid;

4) Power on the spindle module and check whether the spindle speed is normal;

5) Power on the magazine module and check correctness of tool change;

5.6 HNC-8 System Boot Failure and Cause

Fault and cause that the system returns to Linux backstage after startup

1. Return to the backstage and there is printed information: Step 1/11: KernelInitErr

Cause: System kernel failed to apply for memory.

Solution: System memory failure.

2. Return to the backstage and there is printed information: Step 2/11: ReadCfgErr

Cause: Error occurs while reading system configuration file LNC32.CFG file.

Solution: Load normal LNC32.CFG file.

3. Return to the backstage and there is printed information: Step 3/11: NcguiErr

Cause: System memory is insufficient and interface startup fails

Solution: System memory failure.

4. Return to the backstage and there is printed information: Step 3/11: BmpLoadErr

Cause: System memory is insufficient and BMP picture module initialization is abnormal

Solution: System memory failure.

5. Return to the backstage and there is printed information: Step 3/11: FontErr

Cause: Loading word stock fails and word stock file may be missing or damaged

Solution: Load a correct word stock file

6. Return to the backstage and there is printed information: Step 4/11: ParmXmlLoadErr

Cause: Loading parameter configuration file PARM-CN.XML fails

Solution: Re-copy a normal PARM-CN.XML file to the system

Note: After returning to Linux backstage, characters still can be entered by keyboard normally. Due to Bug of

Linux system, characters printed after returning to Linux system for the first time are invisible. When power is

not off, start software of the CNC system manually, the system will return to Linux backstage again and users

can see the printed incorrect characters.

How to start the software of the CNC system:

Enter "cd /h/lnc8” in the # interface and press the return key.

Enter "./n” in the # interface and press the return key.

If the start interface is normal, red color on the interface displays the abnormal start

Red color displays: 3---Interface initialization fails [2]

Cause: There is damaged file or missing file in BMP files

Solution: Replace BMP files again.

Red color displays: 4---Parameter initialization fails [-2]

Cause: Parameter "Original file and backup file are damaged (file verification fails) or "Two files have

inconsistent data".

Solution: Alarm is eliminated after system restart. If the alarm is still not eliminated after system restart,

enter "Data management" menu, delete backup file and restart the system. If the alarm still cannot be

eliminated, re-import a normal parameter file to the system.

Red color displays: 5---Program manager initialization fails [-1]

Cause: System memory is insufficient

Solution: System memory failure.

Red color displays: 6---PLC initialization fails [-1]

Cause: Loading DIT ladder diagram to the system fails

Solution: Ladder diagram file is damaged

Red color displays: 7---Alarm module initialization fails [-2]

Cause: Opening grammatical alarm text SYTAX.ERR fails

Solution: The system imports a normal SYTAX.ERR file

Red color displays: 7---Alarm module initialization fails [-3]

Cause: Opening system alarm text SYS.ERR fails

Solution: The system imports a normal SYS.ERR file

Red color displays: 8---Saving previous power-off data fails, please check UPS power [0x0010]

Cause: Data is not stored normally after system power-off

Solution: UPS is not fully charged or UPS is abnormal

8. Red color displays: 8---Data file import module initialization fails [0x0001]

Cause: Workpiece coordinate system CRD.DAT file of the system, "Original file and backup file are

damaged (file verification fails)" or "Two files have inconsistent data".

Solution: Alarm is eliminated after system restart. If alarm is still not eliminated after system restart, reset

the workpiece coordinate system and restart the system.

9. Red color displays: 8---Data file import module initialization fails [0x0002]

Cause: Loading system tool file TDATA.DAT file fails

Solution: Alarm is eliminated after system restart. If alarm is still not eliminated after system restart, reset

tool data and restart the system.

10. Red color displays: 8---Data file import module initialization fails [0x0004]

Cause: Loading system B register file REG.DAT fails

Solution: Alarm is eliminated after system restart.

Note 1: Different values in the brackets after 7, 8, 9 and 10 have different meanings and can be combined.

Note 2: Machining of 3 types of files in 8, 9 and 10 is the same as machining of parameter files. For

specific methods, refer to parameter machining methods in 2.

11. Red color displays: 9---"Gear ratio" and "Encoder offset" are not set [0X0003]

Cause: Gear ratio" and "Encoder offset" of key axis parameters are not set and values in the square brackets

represent the mask of the faulted axis number

Solution: Set parameters such as "Gear ratio" and "Encoder offset" of the alarm axis

12. Red color displays: 10---Loss of motor position [0X0003]

Cause: Motor position recorded during previous power-off exceeds the error compared with that during

startup and values in the square brackets represent the mask of the faulted axis number

Solution: Enter "Help" menu under "Diagnosis" for solution.

13. Red color displays: 11---GUI module initialization fails [3]

Cause: System memory is insufficient and initialization of GUI related modules fails

Solution: System memory failure.

6. Parameter Debugging

6.1 Parameter List

6.1.1 Distribution of Parameter Number

Parameter number (ID) of HNC-8 CNC system is distributed as shown below:

Parameter type

ID distribution

Description

NC parameter

000000-009999

Occupy 10000 ID numbers

Machine user parameters

010000-019999

Occupy 10000 ID numbers

Channel parameter

040000-049999

Every channel occupies 1000 ID numbers

Coordinate axis parameter

100000-199999

Every axis occupies 1000 ID numbers

Error compensation parameter

300000-399999

Every axis occupies 1000 ID numbers

Device interface parameter

500000-599999

Every device occupies 1000 ID numbers

Data table parameters

700000-799999

Occupy 100000 ID numbers

 NC parameters are basic parameters of the CNC system used to set interpolation period, operational

resolution and other parameters.

 Machine user parameters are used to set machine tool structure, number of channels and other parameters,

such as lathe or milling machine and used channels, etc.

 Path of interpolation motion in channel. Different channels can execute different interpolation motions and

they do not affect each other. Dual channel refers to that two types of interpolation motions can be

executed simultaneously. Channel parameters are used to set relevant parameters in different channels.

 Coordinate axis parameters are used to set relevant parameters of logical axes used in the channels.

 Error compensation parameters are used to set backlash, pitch error and other error compensation

parameters.

 Device interface parameters are used to set relevant parameters of axis, I/O and other physical devices.

 Data table parameters are used to set error compensation, temperature and other data tables.

6.1.2 Data Type of Parameter

Data type of HNC-8 CNC system parameters includes:

 INT4: Parameter value can only be an integer.

 BOOL: Parameter value can only be 0 or 1.

 REAL: Parameter value can be an integer or a decimal.

 STRING: Parameter value is a string containing 1-7 characters.

 HEX4: Parameters are inputted and displayed in hexadecimal.

 ARRAY: Parameters are inputted and displayed in the form of array, data is separated by "," or "." and the

value range of array element is 0-127.

6.1.3 Parameter Access Level and Modification Permission

 Parameters of different levels must be modified and saved after corresponding password is entered for

 Low-level parameters can be modified after login of higher-level parameters.

 Curing parameters (access level 5) cannot be modified manually and are configured by the CNC system

automatically (cured at the factory).

 Parameter access level is shown below:

Parameter access level

Object-oriented

English sign

Normal user

ACCESS_USER

Machine tool manufacturer

ACCESS_MAC

CNC manufacturer

ACCESS_NC

Administrator

ACCESS_RD

Curing

ACCESS_VENDER

6.1.4 Parameter Validation

Validation mode of parameters of HNC-8 CNC system includes:

 Save: Press Save to validate the modified parameters

 Immediate: The parameters take effect immediately after modification (mainly used for adjustment of

servo parameters)

 Reset: Press Reset to validate the modified parameters

 Restart: Restart the CNC system to validate the modified and saved parameters

HNC-8 System Commissioning Manual (Milling System) V2.4 Series - page 2