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

The mapping relationship between

Device #4-SPDL

analog spindle and logical axis

Device #5

Logical axis

Coordinate axis

Device #6

X axis

Y axis

Coordinate axis

Device #7-AX

Channel 0

Z axis

Coordinate axis

Device #8-AX

c. Inverse encoder feedback mark



0: Encoder feedback is directly inputted into the CNC system



1: Inverse encoder feedback is inputted into the CNC system

When spindle feedback rotation speed is displayed oppositely to the actual rotation direction, the parameter

can be set as 1.

d. Spindle DA output type



0: Not distinguish from spindle CW and CCW rotation, output voltage value of 0-10V



1: Distinguish from CW and CCW rotation of spindle, output voltage value of -10- 10V

e. Zero drift adjustment of spindle DA output (mv)

When spindle DA output voltage has zero drift, output voltage can be calibrated through setting this

parameter and actual output voltage of port will substract the set value of the parameter.

Example

When the spindle rotation speed is not output, the voltage value of corresponding DA output port measured

by multimeter is 0.2V (it should be around 0V normally). At this time, to calibrate the output voltage, the

parameter should be set as 200.

f. Feedback position cycle pulse count

The parameter is used to set number of spindle encoder feedback cycle pulses. Generally, pulse count per

revolution of spindle should be filled out.

g. Spindle encoder feedback device number

When the analog spindle gives feedback of encoder pulse count through axis interface board device of bus

IO module, the parameter is used to correlate analog spindle and encoder feedback device. Generally, the

parameter should be set as axis interface board device number in bus IO module.

If the spindle has no encoder feedback, the parameter can be set as -1.

Figure

Device

Analog spindle encoder feedback device

#4-SPDL

No.is 7

Logical axis

Device #5-

Coordinate

Device #6-

X axis

axis 0

Device #7-ENC

Coordinate

Channel 0

Z axis

axis 2

Device #8-AX

Coordinate

S axis

axis 5

Device #9-AX

h. Spindle DA output device number

The parameter is used to correlate analog spindle and DA output device. Generally, the parameter should be

set as IO device number with AD/DA function.

Figure

Device

Analog spindle DA output device No.is 6

#4-SPDL

Logical axis

Device #5-

Coordinate

Device #6-

X axis

axis 0

Device #7-ENC

Coordinate

Channel 0

Z axis

axis 2

Device #8-AX

Coordinate

S axis

axis 5

Device #9-AX

i. Spindle encoder feedback interface number

An axis interface board device includes two encoder feedback interfaces. The parameter is used to specify

the serial number of interfaces used by current analog spindle.



0: Use encoder feedback interface A



1: Use encoder feedback interface B

j. Spindle DA output port number

A DA output port occupies 2 groups of Y registers (16-bit output). After IO device number corresponding to

spindle DA output, the parameter is used to locate DA output Y registers, namely offset relative to initial

group number of IO device output point.

Note

Before the parameter is configured, users must fully understand connection of bus IO module and confirm

the position (group number) of spindle DA output Y registers in order to avoid mutual intervention between

DA output and IO output arising from parameter setting error.

Example

Suppose DA output device is the bus IO module IO_NET (device #6), initial group number of output point

of this device is 10. Where, Y10-Y13 are used for IO output and Y14-Y19 are used for DA output. Thus,

analog spindle DA output can be configured as follows:

Parm500017 “Spindle DA output device number” is set as 6.

When the specified spindle DA output port number is 2, the position of DA output Y register is Y14-Y15;

When the specified spindle DA output port number is 3, the position of DA output Y register is Y16-Y17;

When the specified spindle DA output port number is 4, the position of DA output Y register is Y18-Y19.

7. PLC Commissioning

7.1 HNC-8 PLC Structure

HNC-8 ladder diagram PLC adopts cyclic scanning mode. In the beginning of program execution, PLC

will be initialized once when it is powered on or reloaded. Then, all inputted states is sent to the input map

results will be transmitted to the output map register to control actual output of PLC, and so on.

Start scanning

Initialization (finish with iend, execute once only

during power-on and PLC reloading)

input map register

PLC1 (execute every scanning period, finish with 1end)

Subprogram

PLC2 (execute every scanning period, finish with 2end)

Subprogram

Output map register

Finish scanning

7.2 Working Principle of PLC Interface Signal

PLC interface signal is responsible for information exchange between PLC and NC.

User data

B0~B1721

G2960~G3099

To NC

F2960~F3099

From NC

G2640~G2720...

G2560~G2639

To NC

Channel

F2640~F2720...

F2560~F2639

From NC

G160~G239…

G80~G159

G0~G79

To NC

Axis/

spindle/drive

F160~F239…

F80~F159

F0~F79

From NC

PLC alarm

G3010~G3041

PLC prompt

G3056~G3087

 F register is a status flag register used to input CNC input signal to PLC control module from CNC.

 G register is a control flag register used to output CNC output signal to CNC from PLC control

module and signals processed by CNC.

 B register is a data register (its value can remain at the state before power-off). The data register can

also be used as PLC parameter and users can define usage of every parameter.

7.3 PLC Specification

Specification

HNC8

Programming language

Ladder，STL

The first-level program execution cycle

1ms

Program capacity

Ladder diagram

5000 lines

Statement list

10000 lines

Symbol name

1000 Pcs.

Command

Basic command, function command

Single-byte internal relay (R)

2048 bytes (R0-R2047)

Double-byte internal register (W)

512 bytes (W0-W255)

Four-byte internal relay (D)

1024 bytes (D0-D255)

Timer (T)

512（T0--T511）

Counter (C)

512

(C0--C511）

Subprogram (S)

253（S0-S252）

Mark number

（L）

10000（L0-L9999）

User-defined parameter (P)

700 （P0-P699）

Single-byte internal register (I)

128 bytes (I0-I127)

Single-byte internal register (Q)

128 bytes (Q0-Q127)

Hold storage area

Four-byte register (B)

6888 bytes (B0-B1721)

Hold relay (K)

128 bytes (K0-K15)

I/O module (X)

X0--X511

（Y）

Y0--Y511

7.4 Ladder Diagram Operation on CNC Controller

To realize functions of ladder diagram on the CNC system end, permission of machine tool manufacturer or

above should be inputted.

Press "Ladder " in the diagnosis operation interface to enter the ladder diagram operation interface.

2） Find

Search according to type:

1. Address: Search according to address

2. Command: Search according to function instruction

3. Output: Search according to output result

4. Line number: Search according to line number of PLC

Continue searching:

1. Find next: Continue searching downwards

2. Find previous: Continue searching upwards

Search range:

1、 Search mode: Fuzzy search mode, accurate search mode

2、 Search range: Local search, global search

3） Disable

Function key "Disable". Move the cursor to an element and press this key to shield the element. As shown

below, move the cursor to an element, press this key and the element turns red. It means that the element is

shielded and cannot be outputted.

Note: The inhibited conditions here are valid for current line only. As shown above, after R2.0 normally-closed

is disabled, it is turned off for this line only.

4） Allow

Function key "Allow". Move the cursor to an element and press Allow to activate the element. As shown below,

move the cursor to an element, press Allow and the element turns green. It means that the element is activated.

As shown in the figure, X3.0 is the normally open. Move the cursor to X3.0, press "Allow", the element turns

green.

Note: The inhibited conditions here are valid for current line only. As shown above, after X3.0 normally open is

allowed, it is turned on for this line only.

5） Restore

Function key "Restore". Move the cursor to an element, press Restore to cancel operation of the aforesaid

shielded or activated element. Press Restore after the Disable and red color of the element disappears. It means

that functions of the element are restored, as shown below.

6） Lock list

Lock list (register lock list) is mainly used to write specified data of register and lock register value. Presently,

only write, lock and unlock of X/Y register are supported.

Add: Add index

Delete: Delete index (current index item is at unlock state)

Write: It is used for a write of register (bit). If other logics in PLC also modify the current register (bit)

where data is written, the written value may be eliminated by other bits.

Lock: Assign the set value to register forcibly. While adding register (bit) in the lock list interface, the

system sets mutual exclusion rules for registers. That is, only register value or register bit can be inputted when

index number of registers of the same type is the same. e.g.: After X0 is inputted, subsequent data including the

inputted X0. Likewise, after Y0.0 register bit is inputted, the newly added data must be register bit data between

Y0.1 and Y0.7 and Y0 register value cannot be inputted.

Unlock: Release lock state.

Format:

Format value range:

0: Binary

1: Decimal

7） Cross reference

Similar to finding register, the cross reference is mainly used to search reference relationship of register (bit)

information in a global range. How to use: Move the cursor to the register to be searched, press this key and the

block diagram of cross reference will pop up automatically.

7.4.2 Ladder Editing

Select "Ladder edit" to enter the ladder diagram edit interface. The ladder diagram edit interface includes 16

function keys, including program list, straight line, normally open, normally closed, logical output, inverse

output, vertical line, delete vertical line, find, delete element, function module, edit network, list edit, double

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coil, update modification and abandon modification.

1） Program list

Function: Display PLC program block. Consistent with program list function in ladder diagram monitoring.

2） Straight line

Press this key to insert a straight line in the ladder diagram.

3） Normally open

Move the cursor to the position where normally open needs to be inserted and press this key to insert normally

open in the specified position in the ladder diagram.

4） Normally closed

Move the cursor to the position where normally closed needs to be inserted and press this key to insert normally

closed in the specified position in the ladder diagram.

5） Logical output

Move the cursor to the position where logical output needs to be inserted and press this key to insert logical

output in the specified position of the ladder diagram.

6） Inverse output

Move the cursor to the position where inverse output needs to be inserted and press this key to insert the inverse

output in the specified position in the ladder diagram.

7） Vertical line

Press this key to insert a vertical line after the cursor.

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8） Delete vertical line

Press this key to delete the vertical line after the cursor.

9） Find

Consistent with the find function in ladder diagram monitoring.

10） Delete element

Move the cursor to the element to be deleted and press this key to delete the element in the ladder diagram.

Before deletion:

After deletion:

11） Function module

Function module includes all function ommand lists and corresponding help files of the CNC system.

e.g.:

When the cursor moves to the position of axis working mode, press Help and the system will display the help

instructions of corresponding function module.

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If it is unnecessary to view help file, Press Enter on the function module of corresponding cursor in the function

instruction list and the system will insert the function module into current PLC.

12） Edit network

Edit network includes insert line, delete line, insert column, select network, copy network, cut network, paste

network and delete network.

a. Insert line

Move the cursor to the next line of the line to be inserted and press this key to insert a line, as shown below. It

should be noted that the inserted line is often above the line where the cursor is inserted.

Before inserting line:

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e. Update modification

This function can update and save the modified PLC file.

f. Abandon modification

This function can abandon saving the current modified file.

14） Double coil

Double coil function is used to check problems of double coil output in PLC.

Note: The parameter is used to inspect all coils or coils of current line according to double coil inspection mode

in ladder diagram option function. While inspecting coils of current line, the cursor should move to the line

where it is necessary to inspect whether there is double coil output. While inspecting all coils, the cursor can be

in any position.

e.g.:

Line 76 and line 1631 in the original PLC output R0.0 simultaneously.

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15） Update modification

This function can update and save the modified PLC file.

16） Abandon modification

This function can abandon saving the currently modified file.

7.4.3 Ladder Diagram Information

This function includes ladder diagram title, symbol table, IO comparison table, K parameter, timer, counter,

alarm setting, run stop and online commissioning.

1） Ladder diagram title

Ladder diagram title stores some descriptive information of current PLC file, including project version, project

name, writer, comments, machine tool manufacturer information, manufacturer information and PLC running

status, etc.

2） Symbol table

Symbol table is mainly used to store symbol names and comments of register (bit) information.

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3） IO comparison table

IO comparison table is a new function of HNC-8 new version of ladder diagram which is mainly used to

standardize ladder diagram PLC writing. That is, in the standard ladder diagram, input and output of standard

functions that offered to users are replaced by I and Q, in which I is mapped to X and Q is mapped to Y. Users

can correspond X and Y points to I and Q according to the electrical schematic diagram of machine tool. In this

case, it is unnecessary to modify element parameters of ladder diagram PLC but to update data of corresponding

IO comparison table in order to ensure normal operation of PLC. As a result, developer and commissioning

personnel's work is greatly simplified and work efficiency improves.

The ladder diagram software specifies the range of IQ registers according to usage scenario. The number of IQ

comparison tables (users) is 80 and the range is indexes 0-79. The number of IQ comparison tables (system

panels) is 48 and the range is indexes 80-127.

In the ladder diagram software interface, IQ register is edited in 2 interfaces (user IO comparison table and

panel IO comparison table). The index values of IQ registers which can be edited in different interfaces are

different.

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Used to view and set alarm and prompt messages of system PLC.

8） Stop operation

Run stop function is used to stop running of current PLC.

Note: After running is stopped, press Run stop again to rerun PLC.

9） Online commissioning

Online commissioning function enables the user to monitor running status of NC remotely and commission

specific points and program state. The communication with HNCLadder software can be realized.

6.4.4 Signal Tracking

Signal tracking is mainly used to display data of real-time sequence chart of register points X, Y, F, G, R, I, Q

and K.

8 groups of data can be acquired simultaneously. If the default sampling period is 1ms, the maximum sampling

time is 60s.

7.4.5 Ladder Diagram Option

1) Double coil inspection

 Not ticked: Inspect all

 Ticked: Inspect current line of coils

Note: This function should be used cooperatively with double coil function in ladder diagram edit.

2） Ladder diagram monitoring register value

 Not ticked: Latched value

 Ticked: Current value

This function is mainly used to eliminate conflicts incurred during inspection of values in PLC assignment

statement. This function is mainly used to check the investigation work when the assignment conflicts in the plc

assignment statement

Current value is ticked by default and values of registers displayed in the ladder diagram monitoring screen are

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consistent.

When latched value is displayed, values of registers displayed in the ladder diagram monitoring screen are

displayed independently for each module.

8. Design Example of CNC Milling System

With the section 1.1 as an example, corresponding bus should be connected as per section 2.1.

8.1 Electrical Schematic Diagram

In the design, AC24V power supply of floodlight, DC24V power supply used by magnetic valve of large

operating current and DC24V power supply used by output switch value (such as relay and servo control signal,

etc.) are independent and separated by a low pass filter.

Anti-interference magnet ring and high-voltage ceramic capacitor at the main power supply inlet and

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transformer input end are not indicated in the figure. As shown below.

In the figure below, QF0-QF4 are three-phase air switches; QF5-QF11 are single-phase air switches; KM1-KM4

are three-phase AC contactors; RC0-RC3 are three-phase RC absorbers (arc extinguishers); RC4-RC12 are

single-phase RC absorbers (arc extinguishers); KA0-KA11 are DC 24V relays; VX is freewheel diode; YVZ is

magnetic valve and Z axis motor brake.

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QF0

63A

RC0

L11

QF1

KM9

L12

Feed axis drive power

25A

L13

Three-phase isolation transformer

RC1

380V 3P/220V 3P

L21

QF2

KM10

L22

Spindle drive power

20A

L23

Spindle drive

RC2

resistor

QF3

KM1

Magazine power

RC3

QF4

KM2

Cooling motor

QF8

110VA

QF5

AC110V

250W

KA8

KA9

KA6

KA7

KA3

KA4

QF7

AC24V

RC7

RC9

100W

KM5

KM6

KM7

KM8

AC380V

KM3

KM2

750W

Electric

RC3

KM6

RC4

KM5

RC5

KM8

RC6

KM7

Floodlight

cabinet fan

110VB

Positive

Negative

Lubrication

Positive

Negative

Cooling motor

rota tion of

rotation of

motor

magazine tool magazine tool

cutter

QF6

AC220V

KM11

300W

Switching power

switching power

AC220V/

50W

DC24V

100W

DC24V

Control transformer

UPS power

KM3

Automatic

QF10

QF9

lubrication station

24V2

100

24V1

24V UPS

Power output

To:

Relay

To:

CNC device

24V2

110VA

To Z axis servo

KA0

101

-SB2

-KA11

KA10

2100

KM11

YVX

NC ON/OFF

RC10

RC11

RC12

-SB1

button

Z axis brake

100

110VB

-KA11

-KA10

KM11

KM9

KM10

NC ON/OFF control

Electrical schematic diagram of typical CNC system-power supply diagram

119

8.2

Commissioning Procedure

8.2.1 First Power-on and Commissioning Procedure of Machine Tool

Note: Do not turn on the emergency stop button of the system. If conditions permit, it's best not to connect the

power line of traverse axis servo motor and power line of spindle servo motor.

Parameters to be set or checked when the machine tool is powered on for the first time:

Machine user parameters:

Parm010000, maximum number of channels: 1

Parm010001, cutting type of channel 0: 0 (milling system)

Parm010009, selection mark of channel 0: 1

Parm010017, display axis mark [1] of channel 0: 0x27

Parm010033, load current display axis customization of channel 0: 0,1,2,5

Channel parameters (channel 0):

Parm040001, X coordinate axis number: 0

Parm040002, Y coordinate axis number: 1

Parm040003, Z coordinate axis number: 2

Parm040010, axis number of spindle 0: 5

Parm040028, display axis number of spindle: 5

Coordinate axis parameters:

Logical axis 0:

Parm100000, display axis name: X

Parm100001, axis type: 1 (linear axis)

Logical axis 1:

Parm101000, display axis name: Y

Parm101001, axis type: 1 (linear axis)

Logical axis 2:

Parm102000, display axis name: Z

Parm102001, axis type: 1 (linear axis)

Logical axis 5:

Parm105000, display axis name: C

Parm105001, axis type: 10 (spindle)

Device interface parameters:

Device 4:

Parm504000, device name: SP

Parm504011, logical axis number: -1

Device 5:

Parm505000, device name: MCP_NET

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Parm505010, MCP type: 7

Parm505012, initial group number of input point: 480

Parm505013, number of input point groups: 10

Parm505014, initial group number of output point: 480

Parm505015, number of output point groups: 10

Device 6:

Parm506000, device name: MCP_NET

Parm506010, MCP type: 7

Parm506012, initial group number of input point: 490

Parm506013, number of input point groups:10

Parm506014, initial group number of output point: 490

Parm506015, number of output point groups: 10

Device 7:

Parm507000, device name: AX

Parm507010, working mode: 3 (speed mode)

Parm507011, logical axis number: 5

Parm507014, feedback position cycle mode: 1

Parm507015, feedback position cycle pulse count: 4096 (spindle encoder is of 1024 PPR and quadruple

frequency)

Parm507016, encoder type: 1 (incremental encoder with Z pulse signal feedback)

Device 8:

Parm508000, device name: AX

Parm508010, working mode: 1 (position increment mode)

Parm508011, logical axis number: 0

Parm508014, feedback position cycle mode: 0

Parm508015, feedback position cycle pulse count: 131072 (absolute encoder single-turn 131072 PPR)

Parm508016, encoder type: 3 (absolute encoder without Z pulse signal feedback)

Device 9:

Parm509000, device name: AX

Parm509010, working mode: 1 (position increment mode)

Parm509011, logical axis number: 1

Parm509014, feedback position cycle mode: 0

Parm509015, feedback position cycle pulse count: 131072 (absolute encoder single-turn 131072 PPR)

Parm509016, encoder type: 3 (absolute encoder without Z pulse signal feedback)

Device 10:

Parm510000, device name: AX

Parm510010, working mode: 1 (position increment mode)

Parm510011, logical axis number: 2

Parm510014, feedback position cycle mode: 0

Parm510015, feedback position cycle pulse count: 131072 (absolute encoder single-turn 131072 PPR)

Parm510016, encoder type: 3 (absolute encoder without Z pulse signal feedback)

Device 11:

Parm511000, device name: IO_NET

Parm511012, initial group number of input point: 0

Parm511013, number of input point groups: 10

Parm511014, initial group number of output point: 0

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