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Hnc-21-Connection Manual - 2.0 PDF
Hnc-21-Connection Manual - 2.0 PDF
Connection Manual
V2.0
2010/11
2010/11
Preface
This connection manual is for HNC-21/22 unit. It is recommended that the operator
read this manual before operating the machine.
i
HNC-21/22 Connection Manual
Introduction
1. HNC-21/22
HNC-21/22
HNC-21/22 (HNC-21/TD, HNC-21/MD, HNC-22/TD, HNC-22/MD) possesses the
advanced open-structure, built-in industrial control computer, and high-performance
32-bit CPU. There are 8.4 (HNC-21)/10.4 (HNC-22) LCD and standard panel for
machine tool engineering. It integrates feed axis interface, spindle interface,
handwheel unit interface, and built-in PLC (Programmable Logic Circuits) interface
as a whole. It supports the program storage form, and also supports the program
exchange through USB, DNC (Direct Numerical Control), Ethernet. According to its
high performance, compact structure, being easy to use, reliability, and reasonable
price, the Device is mainly suitable for numerical control of turning machines, milling
machines, and machining centers.
- Maximum coordinate axes: 6;
- Compatible with various pulsed AC servo drives, step motor drives;
- Standard panel for machine tool engineering is used. No PLC input/output
interfaces are taken up. The color of machine control panel and the name of key
on the panel can be customized for different users.
- There are 40 bit (extended to 60 bit) input interfaces, 32 bit optical isolated
output interfaces (extended to 48 bit), handwheel unit interface, analog spindle
control interface and spindle encoder interface.
- With 8.4 (HNC-21)/10.4 (HNC-22) LCD (the resolution is 640480), it is easy to
display the alarm message and simulation of tool-path.
- The program is written in ISO G code, compatible with any common CAD/CAM.
It can implement the linear interpolation, the circular interpolation, the helical
interpolation, the canned cycle, the rotation, the scale, the mirror image, the tool
compensation, the macro-program, etc.
- Machining a specified segment incrementally is especially suitable for machining
the complicate moulds.
- The breakpoint can be saved and resumed, which provides the convenience and
safety for customers.
ii
HNC-21/22 Connection Manual
- The backlash and the uni-/bi-directional pitch error compensation can improve
the machining precision effectively.
- It can save G code program up to 2GB.
- The data can be exchanged through RS232 or Ethernet.
- Flash RAM: 2GB is used to save the program (no cell is required).
- RAM: 32MB is used as a buffer for machining program.
Note: the default configuration of Flash RAM and RAM would not be notified
once again, if the size is increased.
- The dimension of device is 420310110mm (WHD).
iii
HNC-21/22 Connection Manual
5. Relay Terminal Board (optional)
It is connected to the optically isolated PLC outputs through cables to facilitate wiring,
commissioning and maintenance for the control cabinet.
- 8-bit PLC direct terminal outputs + 8-bit relay normally open contact point
outputs
- Two independent double-pole relays. Both normally open + normally closed
contact points are supported.
- Pilot lamp on each input or output interface.
II 1 1
6. Safety Placard
: encoder : motor
: gearbox
iv
HNC-21/22 Connection Manual
Table of Contents
Preface.................................................................................................................................................................... i
Introduction............................................................................................................................................................ ii
Table of Contents..................................................................................................................................................v
1 Precaution.................................................................................................................................................... 1
1.1 Safety...................................................................................................................... 2
1.1.1 Transportation and Storage........................................................................2
1.1.2 Installation..................................................................................................... 2
1.1.3 Wiring............................................................................................................. 3
1.1.4 Commissioning............................................................................................. 3
1.1.5 Operation.......................................................................................................4
1.1.6 Maintenance................................................................................................. 4
1.1.7 Waste Treatment..........................................................................................5
1.1.8 General Instructions.....................................................................................5
1.2 Unpacking and Checking........................................................................................6
1.2.1 List.................................................................................................................. 6
1.2.2 Product Type.................................................................................................6
1.3 Dimensions............................................................................................................. 7
1.4 Installation.............................................................................................................. 8
1.5 Environmental Requirement................................................................................. 10
1.5.1 Weather Condition..................................................................................... 10
1.5.2 Elevation......................................................................................................10
1.5.3 Transportation and Storage......................................................................10
1.5.4 Mechanical Environment...........................................................................10
1.5.5 Environmental Pollution............................................................................ 10
2 Connection................................................................................................................................................. 11
2.1 Total Connection Diagram....................................................................................12
2.2 Interface................................................................................................................ 13
2.2.1 NC Device................................................................................................... 13
2.2.2 DNC unit (optional).................................................................................... 14
2.2.3 Handwheel unit (optional)......................................................................... 14
2.2.4 I/O Terminal Boards (optional)................................................................. 15
2.3 Power Supply Connection.................................................................................... 17
2.3.1 General Requirement................................................................................ 17
2.3.2 Grounding....................................................................................................18
2.4 Connection to DNC unit....................................................................................... 20
2.5 Connection to Computer.......................................................................................21
2.5.1 RS232 Interface......................................................................................... 21
2.5.2 Ethernet Interface.......................................................................................21
2.6 PLC I/O Interface................................................................................................. 24
2.6.1 Input interface............................................................................................. 24
2.6.2 Output interface..........................................................................................27
2.6.3 Direct Connection to NC device...............................................................32
2.6.4 Connection to NC device through I/O terminal board...........................33
2.6.5 Description of PLC Address..................................................................... 34
2.7 Connection to Handwheel Unit.............................................................................36
2.7.1 Handwheel Interface..................................................................................36
2.7.2 Connection to Standard Handwheel Unit............................................... 37
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HNC-21/22 Connection Manual
2.7.3 Connection to Customized Handwheel Unit.......................................... 38
2.8 Connection to Spindle device............................................................................... 39
2.8.1 Relevant Interfaces.................................................................................... 39
2.8.2 Spindle Start and Spindle Stop................................................................ 40
2.8.3 Spindle Speed Control.............................................................................. 41
2.8.4 Spindle Orientation Control...................................................................... 42
2.8.5 Spindle Gear Control................................................................................. 43
2.8.6 Connection to Spindle Encoder............................................................... 43
2.8.7 Connection ExampleAC Induction Motor........................................... 44
2.8.8 Connection ExampleSpindle motor with driver..................................45
2.8.9 Parameters related to Spindle device..................................................... 46
2.9 Connection to Feed Drive..................................................................................... 47
2.9.1 Interface Description..................................................................................47
2.9.2 Connection to Stepper Motor Drive Unit.................................................48
2.9.3 Connection to Servo with pulse command.............................................50
2.10 Design of E-Stop and Overtravel Released.......................................................... 53
2.11 Design of Electromagnetic Compatibility............................................................ 56
2.11.1 EMC of NC Device.....................................................................................56
2.11.2 Grounding....................................................................................................57
2.11.3 Check Interference from Power Network............................................... 66
2.11.4 Anti-Interference.........................................................................................71
2.11.5 Prevention of Producing Interference..................................................... 73
2.11.6 Summary of Design Guide........................................................................79
3 Parameters................................................................................................................................................ 83
3.1 Overview.............................................................................................................. 84
3.2 Setting Parameters................................................................................................ 85
3.3 Description of Parameters.....................................................................................86
3.3.1 Machine Parameters................................................................................. 86
3.3.2 Axis Parameters......................................................................................... 88
3.3.3 Servo Parameters...................................................................................... 94
3.3.4 Axis Compensation Parameters.............................................................. 95
3.3.5 PMC User Parameters.............................................................................. 98
3.3.6 DNC Parameters........................................................................................ 98
3.3.7 Quadrant Transition Parameters..............................................................99
4 Commissioning........................................................................................................................................101
4.1 Checking before Operation.................................................................................102
4.1.1 Inspection of Wiring................................................................................. 102
4.1.2 Inspection of Power................................................................................. 102
4.1.3 Inspection of Device................................................................................ 103
4.2 Trial Operation....................................................................................................104
4.2.1 Power On.................................................................................................. 104
4.2.2 Setting Parameters.................................................................................. 104
4.2.3 Inspection of External Status..................................................................106
4.2.4 Servo Power On....................................................................................... 108
4.3 PLC Commissioning...........................................................................................112
4.3.1 Main Elements of PLC Commissioning................................................ 112
4.3.2 Process of PLC Commissioning............................................................ 112
4.3.3 Methods for PLC Commissioning.......................................................... 113
4.4 Machine Commissioning.................................................................................... 114
4.4.1 Commissioning of Servo Parameters....................................................114
4.4.2 Machine Error Compensation.................................................................116
vi
HNC-21/22 Connection Manual
4.5 Commissioning of Spindle D/A Parameters....................................................... 120
5 Typical Design......................................................................................................................................... 121
5.1 Overview............................................................................................................ 122
5.2 Typical Design NC Milling System.................................................................123
5.2.1 Brief Introduction...................................................................................... 123
5.2.2 Overall Diagram....................................................................................... 124
5.2.3 I/O Specification....................................................................................... 124
5.2.4 Circuit Diagram.........................................................................................127
5.3 Typical Design NC Turning System................................................................ 135
5.3.1 Brief Introduction...................................................................................... 135
5.3.2 Overall Diagram....................................................................................... 135
5.3.3 I/O Specification....................................................................................... 136
5.3.4 Circuit Diagram.........................................................................................138
6 Appendix.................................................................................................................................................. 144
6.1 Product Type....................................................................................................... 145
6.2 Dimension...........................................................................................................146
6.2.1 NC Device................................................................................................. 146
6.2.2 DNC Unit................................................................................................... 147
6.2.3 Handwheel Unit........................................................................................ 147
6.3 Interface Description.......................................................................................... 149
6.3.1 NC Device................................................................................................. 149
6.3.2 DNC Unit (optional)..................................................................................154
6.3.3 Handwheel Unit (optional)...................................................................... 154
6.4 Standard PLC I/O in milling system...................................................................156
6.5 Standard PLC I/O in turning system...................................................................158
vii
viii
HNC-21/22 Connection Manual
1 Precaution
To protect the user and prevent damage to the machine, please read the following
precautions before attempting to use the machine.
1
1. Precaution
1.1 Safety
1.1.1 Transportation and Storage
The number of products stacked must not be more than what stipulated.
Do not climb up or stand on the product. Do not stack heavy things on it.
Protect the front panel and screen from impact and cut.
1.1.2 Installation
Because its casing is not of waterproof design, the product shall be installed in
a cabinet to prevent from being rained on or directly sun-scorching.
There shall be enough space as required between the product and the cabinet
case or other devices.
The product shall work in the environment with good ventilation, without
inflammable air, and without the erosion by corrosive material such as abrasive,
oil-mist, metal powder etc. Any conductor as metal or machine oil is prohibited
to get into the product.
The installation shall be firm and without vibration. Do not throw or strike the
product while installing. Neither any colliding against nor loading on the product
is allowed.
2
1. Precaution
1.1.3 Wiring
Do not transfer either the position signal from NC device to servo driver unit or
the position feedback signal from position frequency converter to servo driver
unit and NC device through terminals or sockets. Otherwise, the NC device may
not work owing to interference.
Any voltage at terminals must have its correct value and polarities (+, -) as
mentioned in the manual. Otherwise, the short circuit or permanent damage to
the machine may occur.
The surge-absorbed diode of DC relay controlled by PLC output signal from NC
device must be wired as shown in Figure 1-1 to prevent the damage to device.
A personnels hands must be kept dry while touching the plugs or switches to
avoid getting an electric shock or resulting in device damage.
Any tear on electric wires is not allowed. The wires shall not be squeezed to
avoid leakage or even short-circuit.
It is absolutely not allowed to insert or pull out any plug or open the NC cabinet
door with the power supply on.
PLC output
Relay coil
DC+24V
Figure 1 1 the surge-absorbed diode
1.1.4 Commissioning
Before putting the device in motion, check the parameter setting at first.
Incorrect settings would lead to unexpected results.
Set parameter in its permissible range. Oversetting may lead to unstable
operation or even the damage to the device.
Check if the cables of servomotor and the encoder wires are corresponding to
each other.
1.1.5 Operation
3
1. Precaution
Before plugging in to get the main source, make sure that the main switch is off
to avoid accidental start-up.
While doing electrical design, it shall take into account that the emergency stop
button of NC device could cut the power supplies for servo motion, spindle
motion and motions of all other moving parts when the system accidents occur.
For example, cut off the power supply (section 2.9 for details).
While designing or modifying the PLC programs, make sure that the operation
signal has been off before the reset alarm signal. For example, the spindle
rotation signal must be off before resetting the spindle alarm signal.
Operators shall not leave the machine while operating the devices.
1.1.6 Maintenance
Power supply shall be turned off before checking, replacing or installing parts or
elements.
When short-circuit or overload happens, do not turn on the power again unless
checking and fixing the breakdown.
When alarm has happened, do not restart the device unless the accident is
cleared off.
Do not install or operate the device if it is damaged or lack of parts and
elements.
The aging of electrolytic capacitors may lead to low performance. To avoid the
damages arising from there, the electrolytic capacitors should be replaced,
under the normal operation conditions, every ten years. Please contact with us
at any time to solve the relevant problems.
4
1. Precaution
While putting the device in operation, install the cover plate and safety
equipment perfectly and operate the device as mentioned in manuals.
Read over chapter 2.10 Electrical Design in detail and notice all the
emphasized points.
5
1. Precaution
HNC 21 M D 32 H 02
21: NC of standard type Unit Type Storage Size Memory Size
22: NC of advanced type M: Milling MB Flash RAM MB
T: Turning Hard disk -- GB
6
A B C E
X Y Z G Esc
I
D
U
S
J
H
V
T
K
R
W
F
P
Q
L
Tab
N
O
1. Precaution
" ; : \
1 2 3 4
# ^ [ ]
5 6 7 8 SP
* / + =
9 0 . - BS
F1 F2
1.3 Dimensions
F3 F4 F5 F6 F7 F8 F9 F10
Pgup Pgdn Alt
Del
Upper
Enter
/
- 100 + +4TH -Y +Z
1 10 100 1000
- 100 + -X +X
Z
- 100 + -Z +Y -4TH
A B C E
X Y Z G Esc
D H R Q
M S T F Tab
U V W L O
I J K P N
" ; : \
1 2 3 4
# ^ [ ]
5 6 7 8 SP
* / + =
9 0 . - BS
Del
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
/ - 100 + +4TH -Y +Z
1 10 100 1000
- 100 + -X +X
Z
- 100 + -Z +Y -4TH
aHNC-21
bHNC-22
7
A B C E
X Y Z G Esc
1. Precaution M
D
S
H
T
R
F
Q
Tab
U V W L O
I J K P N
" ; : \
1 2 3 4
# ^ [ ]
1.4 Installation 5 6 7 8 SP
* / + =
9 0 . - BS
Del Enter
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
- 100 + +4TH -Y +Z
/
1 10 100 1000
- 100 + -X +X
Z
- 100 + -Z +Y -4TH
15
100
15
Figure 1 4 Dimension of Installation (HNC-21 as an example)
Please note the following items when designing the cabinet (control cabinet, console,
and pendant box).
1. As shown in Figure 1-4, it needs to have at least a 100mm-space between NC
device and the rare wall of the cabinet to facilitate plugging the cables and heat
radiation.
2. The cabinet structure must be of IP54 protection class. Some requirements
should be met:
1) The material used to make the cabinet must bear any mechanical, chemical,
or heat stress and the moisture influence normally happened.
2) It needs to stick the adhesive tape along the door crack to eliminate the
gap.
3) The cable entrances must be sealed properly, so that it can be unsealed
easily if necessary.
4) Fans or heat exchanger must be equipped to radiate the heat from cabinet.
5) If fans are used, the air filters are required at both inlets and outlets.
6) Be careful not to let the dust come into the cabinet through heat dissipation
holes. Dust or other materials such as cutting lubricant, mist can get into the
device and attach itself to circuit board to make the insulation aging and
even lead to circuit damage. Therefore, it needs to know the environment
and the direction of air discharge; the warm air stream should be directed
8
1. Precaution
against the pollution source, as shown in Figure 1-5.
Air flow
Machine tool
NC cabinet
3. Temperature in the cabinet shall not be higher than 50. Alternatively, more
9
1. Precaution
1.5.2 Elevation
The NC device works normally with an elevation of less than 1000m.
10
HNC-21/22 Connection Manual
2 Connection
This chapter would introduce:
- Total connection diagram
- Interface
- Power supply connection
- Connection to DNC
- Connection to computer
- I/O on NC device
- Connection to handwheel unit
- Connection to spindle device
- Connection to feed drive
- Design of E-Stop and Overtravel Released
- Design of Electromagnetic Compatibility
11
2. Connection
[Note]
(1) As it is shown Figure 2-1, HNC-21/22 controls various types of feed units
through XS30-XS35. Up to six different types of feed device can be connected.
(2) PLC I/O (maximum: 60/48) can be connected through XS10-XS12 (input),
XS20-XS22 (output).
(3) The interface to connect to the third axis on HNC-21 or the fourth axis on
HNC-22 is optional.
(4) The interfaces XS12 and XS22 which provide 20/16 I/O are optional.
(5) Ethernet interface XS3 is optional.
12
2. Connection
2.2 Interface
2.2.1 NC Device
This section shows the interface of HNC-21.
13
2. Connection
XS1: Power supply interface XS2: Keyboard interface
XS3: Ethernet interface XS5: RS232 interface
XS7: USB interface XS8: Handwheel unit interface
XS9: Spindle control interface X10~X12: PLC inputs interface
X20~X22: PLC outputs interface X30~X35: feed axis control interface
Ethernet Interface
Ethernet switcher
PC keyboard interface
RS232 switcher
RS232 switcher
PC keyboard switcher
PC keyboard switcher
14
2. Connection
DB25 PIN
Each input terminal board or output terminal board contains both NPN and PNP
terminals.
Each input terminal board contains 20 bit input terminals. Each output terminal
board contains 16 bit output terminals, 2 bit emergency-stop terminal, and 2 bit
overtravel terminal.
15
2. Connection
16
2. Connection
Casing ground
XS1
External supply +24V 1,2
2.3.2 Grounding
- Protective Grounding
The ground wire of power supply (pin 6 of XS1) is connected with PE
interface of NC device. An additional copper ground wire at least 2.5 mm2
shall be taken as the ground wire and connected with PE interface of NC
unit, since the ground wire of the power cable is thin.
- Signal Grounding
The pin 4 of XS1 (DC 24VG) is connected to pin 1, 2, 14, and 15 of XS10,
XS11, XS12, XS20, XS21, and XS22. Moreover, to reduce the current
passing the pin 4 (DC 24VG) of XS1 and to raise the anti-interference ability
of PLC signals, those pins (1, 2, 14, 15) shall be connected to the ground of
external supply DC 24V (Figure 2-10).
18
2. Connection
XS1 XS8
+24V +24V
2 3,16 +24V
External
24VG
2 4V GND 1,1 4 24V
supply 2 4 2,1 5
ground
+5V
Internal 25
DC24V 50W 6 5VG
circuit 13
XS
110,11,1 2
Power supply 2
XS20,21,2 2
DC24V150W 24V GND 1,14 24VG
2,15
Handheld unit
HNC-21/22
19
2. Connection
Since there are DNC (RS-232) interface, PC keyboard (PS2) interface, and USB
interface on HNC-21, DNC unit is mainly used on HNC-22.
The following figure is the connection between DNC unit and NC device.
DNC unit NC device
XS2 Keyboard switcher XS2
The distance between DNC unit and NC device should not be longer than one meter.
The following figure shows the detailed connection between DNC and NC unit.
DNC unit HNC-21/22
XS2 Cable length <1m XS2
DATA 1 1 DATA
GND 3 3 GND
VCC 4 4 VCC
CLOCK 5 5 CLOCK
XS3 XS3
TX_D1+ 1 1 TX_D1+
TX_D1- 2 2 TX_D1-
RX_D2+ 3 3 RX_D2+
BI_D3+ 4 4 BI_D3+
BI_D3- 5 5 BI_D3-
RX_D2- 6 6 RX_D2-
BI_D4+ 7 7 BI_D4+
BI_D4- 8 8 BI_D4-
XS5 XS5
RXD 2 2 RXD
TXD 3 3 TXD
GND 5 5 GND
20
2. Connection
PC NC device
21
2. Connection
- Using cables
PC NC device
Ethernet XS3
<50m
TX_D1 + 1 1 TX_D1+
TX_D1 - 2 2 TX_D1-
RX_D2 + 3 3 RX_D2+
BI_D3 + 4 4 BI_D3+
BI_D3 - 5 5 BI_D3-
HNC-21
RX_D2 - 6 6 RX_D2-
BI_D4 + 7 7 BI_D4+
BI_D4 - 8 8 BI_D4-
HNC-21/22
Figure 2 15 Use cables to connect with PC by Ethernet interface (no DNC unit)
Cabinet HNC-21/22
Figure 2 16 Use cables to connect with PC by Ethernet interface (with DNC unit)
- Using HUB
HUB NC device
interface <50m XS3
TX_D1+ 1 1 TX_D1+
TX_D1- 2 2 TX_D1-
RX_D2+ 3 3 RX_D2+
BI_D3+ 4 4 BI_D3+
BI_D3- 5 5 BI_D3-
RX_D2- 6 6
HNC-21
RX_D2-
BI_D4+ 7 7 BI_D4+
BI_D4- 8 8 BI_D4-
HNC-21/22
22
2. Connection
23
2. Connection
IF=5~9mA
24V GND
24V GND
NPN input: 24V GND
+ 24V +5V
IF =5~9mA
24V GND
Figure 2 20 Equivalent circuit of PNP input interface
Note::
Note
- The type of the input interfaces on HNC-21/22 unit is NPN.
- The input terminal board includes two types of input terminal: NPN and
PNP.
24
2. Connection
2500V RMS (one minute).
- The supply voltage is 24V.
- Turn-on current IF=5~9mA.
- The leak current0.1mA
- Filtering time is approximately 2msec.
Note: The power supply of any active switch units (such as non-contact switch,
Hall switch etc.) must be DC24V.
IF =59mA I F=59mA
N P
25
2. Connection
+24V +24V
IF =59mA IF=59mA
N P
26
2. Connection
27
2. Connection
(1) Equivalent circuit
- NPN output interface
+5V +24V
I L100mA
24V Ground
Figure 2 26 Equivalent circuit of NPN output interface
- PNP output interface
+5V +24V
IL100mA
24V Ground
2.5k P
IL=10mA
N 2.5k
IL=10mA
+24V +24V
Preheating
resistance
N IL 100mA P IL 100mA
Preheating
resistance
29
2. Connection
+24V
Flywheel
diode P
IL100mA
KA Relay coil
KA Relay coil
N
IL100mA Flywheel
diode
30
2. Connection
31
2. Connection
HNC-21/22
Pilot lamp, relay,etc <15 m
XS2022
+ -
613
Y0.0Y5.7 1825
+ - Cabinet
32
2. Connection
The relationship between J1 and J2 on the input terminal board is shown as below:
33
2. Connection
Table 2 5 Relationship between J1 and J2 on the input terminal board
24VG NI0 NI1 NI18 NI19
J1 DB25 PIN
(1,2,14,15) (13) (25) (4) (16)
N0 N1 N18 N19
J2 GND
P0 P1 P18 P19
The relationship between J1 and J2 on the output terminal board is shown as below:
Table 2 6 Relationship between J1 and J2 on the input terminal board
J1DB25 24VG NO0 NO1 NO14 NO15 ESTOP1 ESTOP3 OTBS1 OTBS2
PIN (1,2,14,15) (13) (25) (6) (18) (4) (17) (3) (16)
N0 N1 N14 N15
J2 GND ES1 ES3 OT1 OT2
P0 P1 P14 P15
Each PLC input/output on terminal board contains both NPN and PNP terminal and
its LED to make the commissioning and fault detection easier.
The following figure shows the connection between J1 on I/O terminal board and
XS10, XS11, XS12, XS20, XS21, and XS22 of HNC-21/22.
24 24
25 25
34
2. Connection
Table 2 7 PLC inputs/outputs of HNC-21/22
No. X/Y address Interface Descriptions
PLC inputs
X0.0X2.3 XS10 PLC inputs
PLC inputs
1 X2.4X4.7 XS11, XS8
two interfaces of X4.0~X4.7 are connected in parallel.
X5.0X7.3 XS12 PLC inputs
X30.0X31.6 inputs for the button at the first row of MCP
2 X32.0X33.5 MCP inputs for the button at the second row of MCP
X34.0X35.6 inputs for the button at the third row of MCP
PLC outputs
Y0.0Y1.7 XS20 PLC outputs
PLC outputs
1 Y2.0Y3.7 XS21, XS8
two interface of Y3.4~Y3.7 are connected in parallel.
Y4.0Y5.7 XS22 PLC outputs
2 Y28.0Y29.7 XS9 Spindle analog voltage outputs
Y30.0Y31.6 outputs for the pilot of button at the first row of MCP
3 Y32.0Y33.5 MCP outputs for the pilot of button at the second row of MCP
Y34.0Y35.6 outputs for the pilot of button at the third row of MCP
35
2. Connection
XS8DB25 PIN
1 :24VG
14:24V GND
2 :24VG
15:24V GND
3 :+24V 1 14
16:+24V
4 :ESTOP2
17:ESTOP3
5 :NC
18:X4.7
6 :X4.6
19:X4.5
7 :X4.4
20:X4.3
8 :X4.2
21:X4.1
9 :X4.0
22:Y3.7
10:Y3.6
23:Y3.5
11:Y3.4 13 25
24:HA
12:HB
25:+5V
13:5VG
The inputs/outputs of axis selection, override selection, enable button, and pilots of
handwheel unit are on X4.0X4.7 (8 bits) and Y3.4Y3.7 (4 bits) of XS8 on the
handwheel unit.
36
2. Connection
The interface of standard handwheel unit provided by our company is DB25 pin,
which can be directly connected to XS8 on HNC-21/22 device. The following table
shows I/O interface for the handwheel unit on HNC-21/22.
Table 2 9 I/O interface for the handwheel unit on HNC-21/22
Pin Signal Description
13 5V GND Power supply DC5V for MPG on the handwheel unit
25 +5V It is provided by HNC-21/22.
12 HB Phase B from MPG
24 HA Phase A from MPG
11 Y3.4 UndefinedReserved for the pilot of cycle start button
23 Y3.5 Undefined (Reserved for the pilot of feed hold button)
10 Y3.6 Pilot lamp of handwheel unit
22 Y3.7 Undefined
9 X4.0 Axis selection: X
21 X4.1 Axis selection: Y
8 X4.2 Axis selection: Z
20 X4.3 Axis selection: 4
7 X4.4 Override selection: X1
19 X4.5 Override selection: X10
6 X4.6 Override selection: X100
18 X4.7 Undefined
5 NC
17 ESTOP3 Pin of emergency stop (ESTOP) button on the handwheel unit
4 ESTOP2 (Pin 4 and 17 should be short circuited, if there is no ESTOP button.)
3,16 +24V Power supply DC24V for some modules of the handwheel unit
1,2,14,15 24V GND It is provided by HNC-21/22.
If the handwheel unit is not used, pin 4 (ESTOP2) and pin 17 (ESTOP3)
of XS8 should be short circuited by DB25 male plug. Otherwise, there
would be an alarm message caused by the non-working emergency stop
button on the machine control panel of NC unit. For more detailed
information, please refer to chapter 2.10.
37
2. Connection
XP8
XS8
GND
+5V GND 13 5VG
MPG
+5V
+5V 25 +5V
B
HB 12 HB
A
A 24 HA
11 Y3.4
23 Y3.5
pilot 10 Y3.6
pilot 22 Y3.7
X Axis X 9 X4.0
Y Axis Y 21 X4.1 HNC-21/22
Axis
Z Axis Z 8 X4.2
th
4 4 axis 20 X4.3
X1 X1 7 X4.4
override
X10 X10 19 X4.5
X100 X100 6 X4.6
18 X4.7
ESTOP 5 NC
ESTOP 2 17 ESTOP3
ESTOP 2 4 ESTOP2
+24V 16 +24V
Enabled
3 +24V
24V GND 15 24V GND
2 24V GND
Handheld unit 14 24V GND
1 24V GND
PE
The type of I/O is NPN with DC24V. Please refer to section 2.6.
38
2. Connection
XS9DB15 PIN
8:GND
15:GND
7:GND
14:AOUT2
6:AOUT1
13:5VG
5:5VG
12:+5V
4:+5V
11:SZ-
3:SZ+
10:SB-
2:SB+
9 :SA-
1:SA+
40
2. Connection
related to spindle start and stop in the standard PLC of milling and turning.
Table 2 12 I/O related to spindle start and stop
Register X/Y
Signal Interface Pin
Milling Turning
Inputs
Spindle speed arrived X3.1 X3.1 23
XS11
Zero spindle speed X3.2 10
Outputs
Spindle enable Y0.3 Y0.3 24
Spindle CW rotation Y1.0 Y1.0 XS20 9
Spindle CCW rotation Y1.1 Y1.1 21
Y1.0 and Y1.1 are to control spindle CW/CCW rotation and stop. Usually, they are
set as on. If Y1.0 is on, the operator can control the spindle CW rotation. If Y1.1 is on,
the spindle CCW rotation can be controlled. If none of them is on, the spindle stops
rotation. Y1.0 and Y1.1 are used as the enable signal of spindle unit, when some
spindle frequency converter or spindle servo is used.
Some spindle unit contains spindle speed arrived and zero spindle speed, so that
they are used to monitor the spindle rotation by PLC.
Y0.3 can be used, when the individual spindle enable (enable control) is required.
Two analog outputs of XS9 are used to control the spindle speed in HNC-21/22.
AOUT1(output range: -10V~+10V) is used for spindle motors with drivers or
frequency converters with bipolar speed command input, and the enable signal is
used to control spindle start and stop. Another output, AOUT2(output range: 0~+10V)
is used for those driver units or frequency converters with unipolar speed command
41
2. Connection
input, and spindle CW and CCW rotation signals are used to control the spindle CW
and CCW rotation, respectively.
The corresponding spindle speed control signals in register are Y[28] and Y[29].
Y[28] is lower 8 bits, and Y[29] is higher 8 bits. In PLC program, the data from the
register are transferred to analog voltage signal by D/A circuit, and outputted through
pin 6, 7, 8, 14, and 15 of XS9 (pin 7, 8, and 15 are GND).
The correspondence between Y[28], Y[29] (digital value) and analog voltage is
shown as below:
Table 2 13 Correspondence between outputs of digital value (hex) and analog voltage
Digital
-0x7FFF~0x0000 0x0000~0x7FFF
(-32767~0) (0~32767)
Analog voltage
Pin 6 -10V~0V 0V~+10V
Pin 14 0V~+5V +5V~+10V
The spindle orientation command is sent by PLC, i.e. Y1.3 is on. Then, X3.3 is
sent back after the spindle orientation is done.
42
2. Connection
3. Use the mechanic method.
Depending on the different situation, operators can define the related PLC I/O
by themselves and write PLC programs.
When spindle frequency converter or spindle servo is employed, the value of spindle
speed command (analog voltage) should be set in PLC program depending on
different gears.
When the turning machine is at manual gear control mode, the current spindle gear
should be automatically set, by the actual spindle rotation from spindle encoder in
PLC program, to regulate the spindle speed command (analog voltage).
As for automatic spindle gear control, please refer to PLC Programming Manual.
The relevant PLC programs are required to support the above mentioned
functions..
functions
43
2. Connection
Generally, the difference encoder is recommended to ensure the reliability of
long-distance transmission and anti-interference ability. For the detailed connection,
please refer to Figure 2-44.
XS20
O8 O9
Y1.0 Y1.1
RC1
U V W
+24V Contact power Spindle motor
44
2. Connection
2.8.8 Connection ExampleSpindle motor with driver
Example
Generally, the servo drive includes AC frequency converter and spindle amplifier.
The non-step spindle regulation can be done within the reasonable range. AOUT on
XS9 is used to define the speed of spindle motor with driver. Spindle start and stop
(or CW and CCW rotation) can be controlled by I/O (XS20, XS21).
If the spindle amplifier is used, a broader speed regulation and a better low
speed-torque can be got.
XS9
1 SA+
9 SA-
2 SB+
10 SB-
3 SZ+
11 SZ-
4 +5V
12 +5V
HNC-21/22 5 GND Speed
13 GND <15m control Speed control interface
6 AOUT1 signal -10+10V
14 AOUT2 or
7 GND 0+10V
15 GND
8 GND PE
Spindle motor
AOUT1: -10+10V with drive unit
XS10XS12,XS20XS22
AOUT2: 0+10V
I/O Control and status feedback
Such as spindle CW/CCW rotation,
PE spindle speed arrived, alarm, etc. PE
45
2. Connection
XS9
1 SA+ SA+ A+
9 SA- <15m SA- A-
2 SB+ Feedback
SB+ B+
10 SB- SB- B- interface
3 SZ+ SZ+ Z+
11 SZ- SZ- Z-
4 GND 0V
12
HNC-21/22 5 GND Speed
13 GND PE <15m control Speed control interface
6 AOUT1 signal -10+10V
14 AOUT2 or
7 GND 0+10V
15 GND
8 GND PE
Spindle motor
AOUT1-10+10V with drivers
XS10XS12,XS20XS22
AOUT2 0+10V
I/O Control and status feedback
Such as spindle CW/CCW rotation,
PE spindle speed arrived, alarm, etc. PE
Figure 2 43 Connection to spindle motor with drivers - feedback from spindle motor
XS9
SA+ A+
1 SA+ SA- A-
9 SA- <15m SB+ B+
2 SB+ SB- B- Spindle
10 SB- SZ+ Z+ encoder
3 SZ+ SZ- Z-
11 SZ- +5V +5V
4 +5V GND 0V
12 +5V
HNC-21/22 5 GND Speed
13 GND PE
<15m control Speed control interface
6 AOUT1 signal -10+10V
14 AOUT2 or
7 GND 0+10V
15 GND
8 GND PE
Spindle motor
AOUT1-10+10V with drivers
XS10XS12,XS20XS22
AOUT2 0+10V
I/O Control and status feedback
Such as spindle CW/CCW rotation,
PE spindle speed arrived, alarm, etc. PE
Figure 2 44 Connection to spindle motor with drive feedback from external spindle
encoder
47
2. Connection
XS30XS35DB15
8:DIR-
15:DIR+
7:CP-
14:CP+
6:NC
13:GND
5:GND
12:+5V
4:+5V
11:Z-
3:Z+
10:B-
2:B+
9 :A-
1:A+
48
2. Connection
VCC
CP-(DIR-)
CP(DIR)
CP+(DIR+)
49
2. Connection
Figure 2 48 Overall connection to stepper motor drive
HNC-21/22 Stepper drive unit Drive transformer
Figure 2 50 the closed loop between NC unit and stepper drive unit
If I/O signals are used in stepper drive unit, the detailed connection can be referred
to the relevant manual of drive unit. If DC24V is an independent power supply, it
shall be grounded with DC power of I/O. An auxiliary relay is required if I/O interfaces
of step motor drives and NC units are not matched.
When using stepper drive unit, the related parameters are shown as below (for
detailed information, please refer to Chapter 3 and Chapter 4).
50
2. Connection
- Servo parameters
Parameters Value
Servo Type (45: with feedback, 46: without feedback) 46
Stepper motor pulses 4
Stepper motor (1: yes, 0:no) * 1
- Machine parameters
Parameters Value
Pulse output (0: uni-direction; 1: bi-direction; 2: phase AB) 0/1/2
Position
Encoder Encoder
Pulse
feedbac k
XS33
feedback
Figure 2 51 Overall connection between NC device and Servo with pulse command
The following list is the basic conceptions related to servo with pulse command:
1. Position closed loop is constructed within servo driver rather than NC device.
2. Position feedback signals of pulse interfaces are only used for position
monitoring, not for position closed loop.
3. To construct fully closed loop control, a servo driver with fully closed loop
51
2. Connection
interface is necessary.
4. For the parameters of servo drive unit, please refer to the related manuals of the
servo driver.
15m
XS30XS35 Shielding CNI/F
14 CP+ PULS+ 3 L1 Servo power
7 CP- PULS- 4 L2
AC 3P
15 DIR+ SIGN+ 5 380/200
DIR- SIGN- L3
8 6
1 A+ OA+ 21 Servo
9 A- OA- 22 r transformer
2 B+ OB+ 48
B- OB- t Servo control power
10 49
3 Z+ OZ+ 23 Servo drive unit
11 Z- OZ- 24
GND GND Panasonic
13 13
MSDA103D1A
25
+24V 7 COM+ U
HNC-21/22 DC24V 24V GND 8 CWL Motor power
V
9 CCWL
29 SRV-ON W
Enabled
XS10XS12 34 SRV-RDY- PE
relay Encoder
35 SRV-RDY+
Inputs *Notes 36 ALM- feedback
CN SIG
37 ALM+
41 COM- Servo motor
Panasonic
MSMA102D1C
Notes:
Signal ready (SRV-RDY-, SRV-RDY+) and signal alarm (ALM-, ALM+) are closed,
when the drive unit is working normally. If the signal is the relay terminal output in the
drive unit, the same kind of signals of several drive units are connected in series.
Then, it only takes one bit of PLC input.
For the treatment about fault chain during the connection of servo drive unit, please
refer to chapter 5.2.4.4.
52
2. Connection
15m
XS30XS35 Shielding 1CN
14 CP+ PULSE 7 R Servo power
7 CP- *PULSE 8 S AC 3P
15 DIR+ SIGN 11 380/200
T
8 DIR- *SIGN 12
1 A+ PAO PE Servo
33
9 A- *PAO 34 transformer
r
2 B+ PBO 35
B- *PBO t
10 36 Servo control power
3 Z+ PCO 19 Servo drive unit
11 Z- *PCO 20
GND SG Yasukawa
13 1
50 SGDB-30ADG
+24V
47 +24V
HNC-21/22 DC24V 24V GND 42 P-OT U
43 N-OT V Motor power
40 S-ON W
XS10XS12 Enabled relay SRV-RDY-
30
Servo ready PE
29 SRV-RDY+ Encoder
Inputs *Note 32 ALM- feedback
Servo alarm 31 ALM+ 2CN
Servo motor
Yasukawa SGMG-30A2ABG
18NM no keys
The parameters related to servo drive unit are shown as below (for more detailed
information, please refer to Chapter 3 and Chapter 4).
- Servo parameters
Parameters Value
Servo Type (45: with feedback, 46: without feedback) 45
Motor revolution 2500
Stepper motor pulses 0
E-gear(NC) 1
E-gear(Servo) -1
Stepper motor (1: yes, 0:no) 0
- Machine parameters
Parameters Value
Pulse output (0: uni-direction; 1: bi-direction; 2: phase AB) 0/1/2
53
2. Connection
It is recommended to use the design of the internal and external circuit (Figure 2-54).
In the following figure, the bold lines show the emergency stop circuit, while the thin
lines are the overtravel released circuit. KA is an auxiliary relay, controlling the power
supply for servo, spindle etc. It is suggested that one of the normally open contacts
of KA is connected to PLC input of PLC to produce an external operation enable
signal.
54
2. Connection
KA
Axis4-Overtravel limit switch
+24V
Except for the emergency stop button from the machine control panel and
handwheel unit, more than one E-stop button can be used if necessary. The
normally closed contacts of each emergency stop button are connected to the
emergency stop circuit in series. Generally, E-stop buttons are released and its
contacts are closed. While E-stop button is pressed, the contacts are open and the
auxiliary relay (KA) controlled by the emergency stop circuit is turned off. The power
supply of motion components (such as feed motor, spindle motor, tool
magazine/turret motor etc.) is turned off. Meanwhile, a group of normally open
contacts of the auxiliary relay (KA) connected at PLC input send the alarm signal of
emergency stop. This signal is taken as the system reset signal, when the
emergency stop button is on.
In the system, the normally closed contacts of the positive/negative overtravel limit
switch on each axis are connected to the overtravel loop of NC device in series.
Meanwhile, one normally open contact from each overtravel limit switch is
connected to PLC input. Then, the status of each overtravel limit switch can be
monitored. Generally, the overtravel limit switch is released. If the overtravel limit
switch is pressed by the operator, its normally closed contacts are off, and the
overtravel circuit of NC device is disconnected. Meanwhile, the auxiliary relay (KA)
55
2. Connection
of emergency stop circuit is turned off, and the power supply of motion components
is off automatically. The normally open contacts of the overtravel limit switch
connected at PLC input send the overtravel alarm signal to the system (the relevant
axis and the direction of overtravel). And the pilot lamp on the overtravel released
button is on.
If there is an overtravel, same as the emergency stop alarm, the auxiliary relay (KA)
is powered off, and one group of normally open contacts from the auxiliary relay (KA)
would send the emergency alarm signal through PLC inputs. PLC cannot monitor
the normally open contacts of the auxiliary relay (KA), but also the status of normally
open contacts of every overtravel limit switch. Thus, the emergency alarm and the
overtravel alarm can be distinguished.
When the overtravel occurs, NC device are stopped and the system shows the
alarm message. To release the overtravel, the following steps can be done:
1) Press the overtravel released button to reset system. Do not release this button
until the overtravel is released.
2) Press the axis key with the correct direction to release the overtravel limit switch.
Then, the pilot lamp on the overtravel released button is off.
3) Release the button.
56
2. Connection
2.11.2 Grounding
There are three kinds of grounding: protection grounding (safety grounding), working
grounding (working grounding), shield grounding (shield grounding).
Device in
electric unit
Supply
ground
Operators Case or other Operators
electric unit conductive part electric unit
T T
The outer conductive part of electrical equipment is connected to
ground directly. This ground is independent from the supply ground.
Figure 2 55 TT type
58
2. Connection
L1
L2
L3
N
PE
Device in
electric unit
Supply
ground Case or other
Operators Operators
conductive part
electric unit electric unit
L1
L2
L3
PEN
Device in Grounding
electric unit
59
2. Connection
- Essentials of safety grounding design
a) Protection ground terminals shall be used in electric unit. It can be marked
Servo drive Z
Servo supply
Trans ducer
Supply
Grounding
bus
PE
X -axis Y-axis Z-axis Spindle Control cabinet
motor motor motor motor
60
2. Connection
1 2 3 1 2 3
Servo drive
(Transducer)
M
1 2 3 Servo drive
(Transducer)
M
Grounding Grounding
bus bus
61
2. Connection
Metallic cover
case
Protection ground
Working ground
Shielding ground case
1 2 3 1 2 3
1 2 3 1 2 3 1 2 3 1 2 3
2 4
1 3
These points are labeled with symbol . The connection of common reference
potential point shall be taken at an independent point as close as possible to PE
terminal and connected directly to ground or to its own external (no interference)
earth. The terminals labeled with are generally treated as shield grounds.
US US
65
2. Connection
Metallic case
>30cm
Signal line
Controller
Servo
Servo motor
driver A
S
A Optical
B encoder
B
Z
Z
67
2. Connection
2.11.3.2 Absorbent Filter
Absorbent filter can check the inference of rapid transient pulses series in the
transmission lines. It is made of the energy consumption component. The ferrite
absorbent filter is commonly used. It absorbs the interference energy in a given
frequency band and converts to heat loss to make the filtering effect.
- Essentials of interference filter made of ferrite rings design
1) The cables shall be nestled closely to the inner wall of the ring (no large gap
is allowed) to concentrate the most possible magnetic flux within the ring
body. Thus, the filtering effect is improved.
2) Let both AC and DC supply lines pass through the ferrite rings to check the
interference of rapid transient pulse series.
3) Pass the wires through the ferrite rings with the same direction and same
turns. The more the turns are, the better the filtering effect is. Generally, 4~5
turns are taken at the input side of power equipments (servo drivers or
frequency converters). If the wires are quite thick, then more than two ferrite
rings can be used, the total turns is 4~5. However, the turns at output side
shall be less than 4.
PE
Ground bus
68
2. Connection
2 turns 2 turns
L1 L1 Servo Driver
L2
L 2 (Frequency converter)
L3
L3
PE
+
+
DC supply
DC supply
+
Device
Device
+
- -
- -
L1
L2
L3
Figure 2 71 A typical circuit to check the transient pulse interference for AC supply
69
2. Connection
case
Input Output
Surge absorber
As for the under-voltage, overvoltage, and voltage undulation of the power network
during a quite long period, an AC voltage stabilizer shall be used to provide the
supply for NC device.
L1
L2
L3
N
PE
71
2. Connection
2.11.4 Anti-Interference
There are many ways to prevent signals from interference. Laying the power lines
and the signal wires separately, selecting proper grounding type, employing required
wires etc., are the common and effective ways to prevent signals from interference.
In addition, some methods depended on signal type may also be used. The ways to
check interference for both analogue and digital signals are introduced below.
Frequency
converter
Speed
regulation
Servo driver
C (Frequency
NC device converter)
Ferrite ring
0.022uf/50v
72
2. Connection
R
Transducer Amplifier
C
Figure 2 77 RC Lowpass
4. Use the current transmission line instead of the voltage transmission line. Then,
the current is converted to voltage signal again by the parallel resistance at the
end of long transmission wires. In this case, the wires shall be shielded and
single-end grounded.
Servo driver
NC D/A
R or
device
Transducer
R Bead
Circuit 2
Circuit 2
Circuit 1
Circuit 1
A
Position A
loop board Optical
B encoder
B output
Z
(NC device)
Z
0V 6C (ceramic)
C: 1nf~0.1uF
NC device
RT CT
RT: 51~200
CT: 47~220PF
74
2. Connection
2.11.5.1 Shielding
Shielding is the most effective and frequently adopted method. The shield technique
has been applied to check the electromagnetic interference propagated in the air, i.e.
to cut off the route the interference moves along. Generally, use the metallic or
magnetic material to separate the internal and external field of the shielded body
from each other.
Shielding is in principle divided into electrical field shielding, magnetic field shielding,
and electromagnetic field shielding.
Note: Good grounding is the prerequisite for the metallic plate producing
electrical field shielding. No grounding or bad grounding may result in even more
serious interference than that of the situation without the metallic plate equipped.
76
2. Connection
approximately) to the induced circuit, which greatly reduces the magnetic
coupling between them.
g. Keep the sensitive equipments at least 30cm away from the interference
source (such as power equipments, transformers).
B. Overlap joint
The electrical continuity of cases is the critical factor of shielding
effectiveness of the shell. Thus, decreasing the electrical discontinuity of
the shell is to limit the electromagnetic field leakage and radiation from the
base plate and cabinet.
77
2. Connection
a) Make the best overlap joint at any gaps and discontinuity area of chassis
and cabinet.
b) Ensure that the corresponding metallic contacts are connected firmly at any
gap of joint to prevent from the leakage and radiation of electromagnetic
field.
c) Weld the gaps of joints if possible. In the limited condition, dot welding, close
riveting, or screw fixing is used.
d) Any fixture shall be strong enough to keep surfaces contact to each other
under stress, shock, and vibration.
e) The material made of conductive liner or finger setting bolt spring shall be
used at any uneven gap of joint or the removable panel.
f) Be sure there is no insulated protective layer (such as paint, plastic film) on
the metallic surface where the liner is used.
g) When the moving contact is required, use finger setting bolt spring, rather
than grid liner, and keep the pressure of the finger setting bolt spring.
Note: There are some kinds of liners, such as radiofrequency metallic grid liner,
copper-coated alloy liner, conductive rubber liner, conductive covering cloth liner,
and foamed liner.
78
2. Connection
d) Add metallic caps on fuses and sockets etc.
e) Use conductive liners, washers and nuts to prevent the leakage of toggle
switches.
f) The cellular plate is used to shield the vent where the shielding, ventilation,
and strength are strongly required and the weight is not limited harshly. It is
better to weld the cellular plate firmly to prevent the electromagnetic
leakage.
g) It is better to shield indicators/screens in the rear, and filter all the lead-wires
with the hollow capacitors. If it is hard to implement those measures, use the
metallic net or the conductive glass connected to the case to shield in front
of these indicators or screens (the shield glass embedded with metallic
thread, or the glass or clear plastic coated with clear conductive film is
recommended.).
79
2. Connection
+24V
IN4001 KM
J
J
MC1413
R50~1 K
C0.1uf~2uf
R C
KM
Arc Extinguisher
M
3~
81
2. Connection
*2 *3
L1
L2
L3
PE KM1
*5
*1
Asynch.
motor
*3
*3
*4
Supply for
Grounding bar contactors
I solat ion t ransformer Isolation transformer
*6 *6 *7
*7 *7 *5
Low-pass KM1
*8 Low-pass
*7 *8 DC valve supply
+
Drive power
Control
power *9 *5
*7 YV
*7
*7 *9
AC24V
valve
DC24V
*10
Power -
*11 *10
feedback
*11 *11 *11
Command I/O
Drive unit
terminal
board
*10 HNC-21/22
feedback *7
*10
Drive motor
*7
82
2. Connection
4. The grounding bar is made of copper plate not less than 3mm high. Good
contact and perfect conductibility are required.
5. RC extinguisher is used for large inductance loads (AC contactor coils, 3-phase
AC induction motors, AC electromagnetic value coils, etc.) to absorb
high-voltage back electromagnetic force and to check the interference.
6. Isolation transformers are used for servo supply, control supply and supply for
NC systems.
7. The shell of components and their shield shall be grounded reliably. The ground
wires of some important components and the ground wires among the control
cabinets shall not be less than 2.5 mm2.
8. Some important components, such as AC supply for NC system, shall work with
low-pass filters to reduce the high-frequency interference from industrial
frequency supply.
9. If the power of NC unit is DC24V, the power supply can be shared with I/O
switches. The switching supply is suggested. However, an independent source
is required to supply DC coils of valves and brakes.
10. Adding hollow ferrite cores at both ends of shielded cables, especially for the
position feedback cables and the command given cables, can effectively raise
the reliability of signal transmission.
11. The shield layer of shielded cables must be thick and dense, without gap or
crevice. Each wire must be multiple-core, not less than 0.2 mm2. Several wires
connected in parallel are used for the signal power cables (generally, supply
wire and supply ground wire use their own three wires connected in parallel,
respectively.). It is better to use double-twisted and double-shielded cables.
83
HNC-21/22 Connection Manual
3 Parameters
This chapter mainly describes the settings of parameters on HNC-21/22.
- Overview
- Setting Parameters
- Description of Parameters
84
3. Parameters
3.1 Overview
Before parameter updating, its function and original setting shall be clearly
shall
understood, as incorrect parameter setting or updating may cause the serious
result..
result
Machine parameter
85
3. Parameters
86
3. Parameters
Diameter/Radius [Operator]
Value: 0, 1. The default value is 1.
Description: diameter/radius programming
0: radius programming
1: diameter programming
Metric/Inches [Operator]
Value: 0, 1. The default value is 1.
Description: measurement unit
0: unit of dimension is thousandth of an inch
1: unit of dimension is thousandth of a mini-meter
87
3. Parameters
Decimal number for inches [Operator] (only used in HNC-21/22 v7.11)
Value: 0, 1.
Milling: the default value is 0.
Turning: the default value is 1.
Description: 0: the number of digits is four in inch measurement.
1: the number of digits is five in inch measurement.
88
3. Parameters
The number of digits after the decimal point of coordinates value (not used in
HNC-21/22 v7.11)
Value: 0, 1. The default value is 0.
Description: 0: the number of digits is three in metrics measurement, and
the number of digits is four in inch measurement.
1: the number of digits is four in metrics measurement, and
the number of digits is five in inch measurement.
90
3. Parameters
Rapid traverse speed at REF [machine manufacturer]
Unit: mm/min or degree/min
Value: 0~65535.
Milling: the default value is 500.
Turning: the default value is 3800.
Description: Rapid traverse speed before reaching the reference switch.
Note: (1) This value must be less than the highest rapid traverse
speed.
(2) If the speed is set too high, please ensure that there is
enough distance between reference switch and the limit
switch (usually it is positive limit switch) to prevent the
emergency stop caused by pressing the limit switch in
high speed.
(3) In addition, the valid distance of reference point return
should not be short to prevent the failure of reference
point return caused by the high speed of the machine
tool.
91
3. Parameters
If the offset is less than 0, it is negative positioning.
92
3. Parameters
Value: 0~800.
Milling: the default value is 64.
Turning: the default value is 32.
Description: It refers to the required time from 0m/min to 1m/min (or from
1m/min to 0m/min), when G00 is used for positioning. The
larger this value is, the slower the acceleration/deceleration
is.
Note: It is usually set between 16 and 250, which is based on the
motor, the performance of driver, and the capability. For
example, it is set around 32 for 14NM motor with load.
93
3. Parameters
motor, the performance of the drive, and the capability. For
example, it is set around 32 for 14NM motor with load.
94
3. Parameters
backlash must within the range of the position tolerance.
95
3. Parameters
96
3. Parameters
97
3. Parameters
Value: -32768~32767. The default value is 0.
Description: Offset = Programming coordinate value in M.C.S Actual
coordinate value in M.C.S
If it is the bi-directional pitch compensation, the offset in the
positive direction shall be input first. Then, the offset in the
negative direction can be input. This input sequence depends
on the position of compensation points in M.C.S. For
example, there are two points: -150 and -100. -150 should be
input at first, since this point is located at the left of the point
-100.
If there are ten compensation points with bi-directional pitch
compensation. Points 0~9 are for the compensation in
forward direction, and points 10~19 are for that in backward
direction.
For example, the programming coordinate value in MCS is
100mm, the actual coordinate value in MCS is 100.01mm,
then the offset=100-100.01=-0.01mm=-10m.
Please pay attention particularly to the sign of coordinate
value in calculating the offset. For example:
The programming coordinate value in MCS is -100mm, the
actual coordinate value in MCS is -100.01mm, then, the
offset=-100-(-100.01) =0.01mm=10m.
98
3. Parameters
%0110 ; program name
G92 X0 Y0 Z0 ; set coordinate system
WHILE [TRUE] ; unlimited cycles, i.e. dead cycle
G91 X1 F2000 ; move the tool 1mm in the positive direction
G04 P4 ; feed hold for 4 seconds
G91 X-1 ; move the tool 1mm in the negative direction
; to return and clear backlash,
; reset the measuring system,
G04 P4 ; feed hold for 4 seconds to collect the data
M98 P1111 L15 ; call the subprogram (1111) fifteen times
G91 X-1 F1000 ; move the tool 1mm in the negative direction on X axis
G04 P4 ; feed hold for 4 seconds
G91 X1 ; move the tool 1mm in the positive direction on X axis to return
G04 P4 ; feed hold for 4 seconds to collect the data
M98 P2222 L15 ; call the subprogram (2222) fifteen times
ENDW ; end of the cycle
M30 ; stop
aquadrant error
100
3. Parameters
Minimum speed (operator)
Unit: mm/min
Maximum speed (operator)
Unit: mm/min
Description: Do the compensation within the range of the secondary
speed.
101
HNC-21/22 Connection Manual
4 Commissioning
This chapter would introduce the steps for the first start-up:
- Checking before Operation
- Trial Operation
- PLC Commissioning
- Machine Commissioning
- Commissioning of Spindle D/A Parameters
102
4. Commissioning
104
4. Commissioning
Ensure the power of servo drive is off to prevent from the wrong action
or malfunction due to the wrong setting of parameters, when doing the
following steps:
1) Press E-stop button to ensure all the air switches in the system are
open;
2) Close the air switch of main power supply of the cabinet;
3) Turn the air switch or fuse with AC220V on, and ensure that the
voltage of power supply is AC24V;
4) Check the power supply of other parts.
5) Turn HNC-21/22 device on.
105
4. Commissioning
- Axis Parameters
It can be set as the default value for the commissioning.
Parameters Value
External pulse equivalent(numerator) (m) 1
External pulse equivalent(denominator) 1
Positive software limits (m) 8000000
Negative software limits (m) -8000000
Reference point return direction (+, -) +
Reference point position (m) 0
Reference point switch offset (m) 0
Rapid traverse speed at reference point return (mm/min) 1000
Positioning speed at reference point return (mm/min) 200
Uni-direc positioning offset (m) 1000
Rapid traverse speed (mm/min) 2000
Maximum feedrate (mm/min) 1000
Acceleration time for rapid traverse (ms) 32
Jerk for rapid traverse (ms) 16
Jerk time for machining (ms) 32
Jerk for machining 16
Positioning tolerance (m) 20
- Machine Parameters
Parameter
arameters s Value
Spindle encoder revolution 1024
Turret direction (0/1) * 0
Diameter/Radius programming (1/0) * 1
Metric/Inches (1/0) 1
Power-off protection (1/0) 0
Tool offset type (0: absolute, 1: incremental) * 0
Tool wear off accumulation (0: off, 1:on) * 0
The number of digits after the decimal point of coordinates value
0
(0: default, 1: one more digit)
The disk name of USB (0: A, 1: D, 2: E, 3: F, 4: G) 1
System time (0: shown, 1: hidden) 0
PMC axis (0: hidden, 1: shown) 0
Spindle encoder direction (32: positive, 33: negative) 32
Pulse output (0: uni-direction; 1: bi-direction; 2: phase AB) 0
Compensation type
0
(0: Axis Z compensation, 1: plane compensation) **
Reserved [0]~Reserved [9] 0
*: those four parameters are only for the turning system.
**: this parameter is only for the milling system.
Note: please read the servo operation manual to set the parameters correctly,
106
4. Commissioning
before turning the servo on.
- DNC parameters
(Keep the default value, when DNC is activated.)
Parameter
arameters s Value
COM 1
Data bit (5, 6, 7, 8) 8
Stop bit (1, 2) 1
Parity check (0:none, 1:odd, 2:even) 0
Baud rate (300.., 9600.., 38400.., 115200) 115200
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-21/22.
Figure 4-2 shows the PLC status on the screen of NC device.
If the status of the connected input component varies (such as the over-travel switch
being pressed), the corresponding status of digital value would change, from which
the connection of the PLC I/O circuit can be checked.
108
4. Commissioning
X5.0X7.3 XS12 PLC inputs
X30.0X31.6 inputs for the button at the first row of MCP
2 X32.0X33.5 MCP inputs for the button at the second row of MCP
X34.0X35.6 inputs for the button at the third row of MCP
PLC outputs
Y0.0Y1.7 XS20 PLC outputs
PLC outputs
1 Y2.0Y3.7 XS21, XS8
two interface of Y3.4~Y3.7 are connected in parallel.
Y4.0Y5.7 XS22 PLC outputs
2 Y28.0Y29.7 XS9 Spindle analog voltage outputs
Y30.0Y31.6 outputs for the pilot of button at the first row of MCP
3 Y32.0Y33.5 MCP outputs for the pilot of button at the second row of MCP
Y34.0Y35.6 outputs for the pilot of button at the third row of MCP
Axis parameters
Parameters Value
Jerk time for rapid traverse (ms) 64
Jerk for rapid traverse (ms) 32
Jerk time for machining (ms) 64
Jerk for machining 32
110
4. Commissioning
Machine parameters
Parameters Value
Pulse output (0: uni-direction; 1: bi-direction; 2: phase AB) 0/1/2
111
4. Commissioning
Machine parameters
Parameters Value
Pulse output (0: uni-direction; 1: bi-direction; 2: phase AB) 0/1/2
112
4. Commissioning
In addition, PLC programming package can be offered, if there are some special
requirements. Customers can edit PLC based on the standard PLC application.
114
4. Commissioning
b B b B
A a A a
B Reversed position
Reading data
Reading data
A1 A2 An An+1
B1 B2 Bn Bn+1
Clear backlash Clear backlash
118
4. Commissioning
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.
Note: When the laser interferometer is used to measure the pitch error, it is
necessary to measure more than once. And the measurement software application
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.
120
4. Commissioning
- Check the parameters of the spindle frequency converter drive or spindle servo
drive.
- Turn off the power supply and disconnect the cable plug connecting NC device
with spindle frequency converter drive or spindle servo drive. Then, turn on the
power supply again. When NC device is just turned on, the output voltage of
spindle speed control signal AOUT1 and AOUT2 (pin 6 and 7, pin 14 and 15 of
XS9) shall be 10V. When the system is started up, the voltage of AOUT1 shall
be 0V (pin 6 and 7 of XS9), and the voltage of AOUT2 shall be 5V (pin 14 and
15).
- Use the spindle speed control command (command S controlled by PLC
program) to set the spindle speed. Check the voltage variation of speed control
signal AOUT1 or AOUT2.
- Turn off the power supply and connect the cable plug connecting NC device with
spindle frequency converter drive or spindle servo drive. Then, turn on the power
supply again. Use the spindle speed control command (command S controlled
by PLC program) to set the spindle speed, and check the variation of spindle
speed.
- Set the parameter setting of spindle frequency converter drive or spindle servo
drive to optimize their performance.
121
HNC-21/22 Connection Manual
5 Typical Design
This section would introduce the typical design of NC device:
- Overview
- Typical Design-NC Milling system
- Typical Design-NC Turning system
122
5. Example of Typical Design
5.1 Overview
PLC input/output signals of HNC-21/22 are X4.0X4.7 (8 bits) /Y3.4Y3.7 (4 bits),
which are on XS8 of the handwheel unit, XS11, and XS21. They are connected in
parallel. Generally, those PLC input/output signals are reserved for the handwheel
unit. If the handwheel unit is not used, those pins of XS11 and XS21 are better to
save for the handwheel unit. Please use the other pins first.
Usually, I/O signals are from the control cabinet and the machine tool. The
commissioning of control cabinet and the machine commissioning are performed
separately. Therefore, it is better to set I/O signals at the different interfaces, which is
easier for the commissioning.
The input signals of the control cabinet are less than the output signals. On the
contrary, the input signals of the machine tool are more than the output signals.
Therefore, XS11 (8 bits of the input signals are reserved for the handwheel unit) are
usually used for the input interface of the control cabinet, and XS21 (4 bits of the
output signals are reserved for the handwheel unit) are used for the output interface
of the machine tool.
I/O signals of the control cabinet can be directly connected to the other components
by the interfaces or transferred by I/O terminal board or terminals (when there is an
operation console or a suspension controller). I/O signals of the machine tool must
be transferred by I/O terminal board or terminals to make the commissioning easier.
123
5. Example of Typical Design
124
5. Example of Typical Design
HNC-21MD Encoder
Note: The anti-interference magnetic rings and the high voltage ceramic chip
capacitors at the main power lead-in wires and the transformer input terminals are
not shown in the following figure.
In Figure 5-2, QF0~QF4 are 3-phase air switches. QF5~QF11 are 1-phase air
switches. KM1~KM4 are 3-phase AC contactors. RC1~RC4 are 3-phase RC
absorbers (arc damper). RC5~RC8 are 1-phase RC absorbers (arc damper). KA1,
KA6~KA10 are relays with DC24V. V1, V2, V3 and VZ are damper diodes. YV1, YV2,
YV3 and YVZ are solenoid valves and axis Z motor brake.
128
5. Example of Typical Design
AC380V 3-phase
QF0
50A RC1 Feeding servo electric reactor
R To:
QF1 KM1 AC380/200 S Servo drive unit on
20A 6KW
25A T axis X, Y, Z, C
RC3
QF3 KM3
3A 9A Hydraulic motor
RC4
QF4 KM4
1A 9A Coolant motor
QF8 KA1
QF5 AC110V
3A
3A 250W
KA8
QF7
AC24V
100W
6A RC5 RC6 RC7 RC8
AC380V
750W Cabinet fan Heat KM1 KM2 KM3 KM4
Spotlight Pilot lamp exchanger
QF6
AC24V NC device
6A
100W HNC-21MD Servo power Spindle Hydraulic Coolant
power motor motor
24V1
129
5. Example of Typical Design
SQX-1
KA2 KA4
SQX-3
SQY-1
SQY-3
KA3 KA2 KA5
HNC-21
SQZ-1
XS20
OTBS1 3 SQZ-3
OTBS2 16
ESTOP1 4
ESTOP3 17
24V
KA1 KA2 KA3 KA4 KA5 KA6 KA7 KA8 KA9 KA10
130
5. Example of Typical Design
XS10 XS11
X0.0 SQX-1 X2.4 KA2
X0.0 13 Positive limit switch on Axis X X2.4 13 External operation
X0.1 SQX-3 X2.5 enabled
X0.1 25 Negative limit switch on Axis X X2.5 25
X0.2 SQY-1 X2.6 KA3
X0.2 12 Positive limit sw itch on Axis Y X2.6 12 Servo drive unit OK
SQY-3 QF3 QF4
X0.3 24 X0.3 Negative li mit switch on Axis Y X2.7 24 X2.7 Air switch OK
X0.4 SQZ-1 X3.0
X0.4 11 SQZ-3
Positive limit sw itch on Axis Z X3.0 11 Spindle alarm
X0.5 23 X0.5 Negative limit switch on Axis Z X3.1 23 X3.1 Spindle arrived
X0.6 10 X3.2 10 X3.2 Spindle zero speed
X0.7 22 X3.3 22
X1.0 SQX-2 X3.4
X1.0 9 REF switch on Axis X X3.4 9 Axis X ready
X1.1 SQY-2 X3.5
X1.1 21 REF switch on Axis Y X3.5 21 Axis Y ready
X1.2 SQZ-2 X3.6
X1.2 8 REF switch on Axis Z X3.6 8 Axis Z ready
X1.3 SQC-2 X3.7
X1.3 20 REF switch on Axis C X3.7 20 Axis C ready
X1.4 7 X4.0 7 X4.0
X1.5 SQ3 X4.1
X1.5 19 Lubricant alarm X4.1 19
X1.6 SQ4 X4.2
X1.6 6 Under-hydraulic alarm X4.2 6
X4.3 Refer to XS8
X1.7 18 SQ1
X4.3 18
X2.0 5 X2.0 1st spindle gear X4.4 5 X4.4 (handheld unit)
X2.1 SQ2 nd X4.5
X2.1 17 2 spindle gear X4.5 17
X2.2 4 X4.6 4 X4.6
X2.3 16 X4.7 16 X4.7
NC 3 NC 3
24VG 15 100 24VG 15 100
24VG 2 (Relay DC24V GND) 24VG 2 (Relay DC24V GND)
24VG 14 24VG 14
24VG 1 24VG 1
131
5. Example of Typical Design
XS8 XS20
5VG 13 5VG Y0.0 13 Y0.0 Operation enabled relay
+5V 25 +5V Y0.1 25 Y0.1 System reset
MPG Y0.2
HB 12 B Y0.2 12 Servo enabled
HA 24 A Y0.3 24 Y0.3 Spindle enabled
Y3.4 11 Y0.4 11 Y0.4 Axis Z brake relay
Y3.5 23 Pilot lamp Y0.5 23 Y0.5 Coolant on relay
Y3.6 10 Y3.6 Y0.6 10 Y0.6 Tool released relay
Y3.7 22 Y0.7 22
X4.0 9 X4.0 X
Y1.0 9 Y1.0 Spindle CW relay
X4.1 Y Axis Y1.1
X4.1 21 Y1.1 21 Spindle CCW relay
X4.2 8 X4.2 Z
Y1.2 8
X4.3 C
X4.3 20 Y1.3 20
X4.4 X1 Y1.4 Spindle gear switch relay
X4.4 7 Y1.4 7
X4.5 19 X4.5 X10
Y1.5 19
X4.6 6 X4.6 X100 Override Y1.6 6 Notes:Y0.1Y0.3 is outputted to the servo and
spindle unit. Please refer to Figure 6-32
X4.7 18 Enabled Y1.7 18
about the connection to the different relays.
NC 5 ESTOP
NC 5
ESTOP3 17 ESTOP3 17 External operation
ESTOP2 4 ESTOP1 4 ESTOP limit enabled relay KA2
+24V 16 OTBS2 16 chain
132
5. Example of Typical Design
HNC-21MD HSV-18S
XS9 XS4
GM7 motor
GND 7 31 AN-
AOUT1 6 29 AN+
5VG 5 3 0 GNDDM XS3 XS
5VG 13
SZ+ 3 34 ENZ+ +5V 16,17
SZ- 11 33 ENZ- +5V 18,19 12 +5V
SB+ 2 36 ENB+ 5VG 23
SB- 10 35 ENB- 5VG 24,25 13 GND
SA+ 1 17 ENA+ A 1 2 A
SA- 9 18 ENA - B 3 4 B
Z 5 16 Z
/A 2 3 /A
From KA4 /B 4 5 /B
Spindle CW 22 FWD 17 /Z
From KA5 /Z 6
Spindle CCW 20 REW PE 14,15 1 PE
Spindle reset Y0.1
Y0.3 24 ALM_RST
Spindle enabled 25 EN
Spindle alarm X3.0
X3.2 3 ALM
Spindle zero speed 1 ZSP
Spindle speed arrived X3.1
100 4 GET
24V GND
100
26 COM Encoder cables
27 COM
Command cables
Figure 5 7 Circuit diagram of typical milling system spindle motor with driver
133
5. Example of Typical Design
R
P ower supply S
-servo Axis X Axis Y
XS6 XT1 XS6 XT1
T 220A 1 AC220 R 3
R 220A 1 AC220 R 3
R
From Figure 5-2 220B 3 AC220 S 4 S 220B 3 AC220 S 4 S
O perational
220A T T
220B HSV-18D T 5 HSV-18D T 5
p ower-servo
XS5 PE 9 XS5 PE 9
1 MC1 1 MC1
2 MC2 2 MC2
XS4 XS4
Axis X Ready X3.4 2 READY Axis Y ready X3.5 2 RE ADY
Y0.1
Reset 24 ALM-RST 24 ALM-RST
Enabled Y0.2 25 EN 25 EN
24V GND 100
Axis Y
26 COM 26 COM
U 6 UX 2 U 6 UY 2
Axis control
cables V 7 VX 4 V 7 VY 4
W 8 WX 3 W 8 WY 3
NC unit
XS30 XS3 XS X S3 XS
Encoder Encoder
cables PG cables PG
XS31
Axis control cables
Axis X
HNC-21/MD
XS33
Axis C Axis Z
220A XS6
1 AC220
XT1
R 3 R 220A XS6
1 AC220
XT1
R 3 R
XS32
220B 3 AC220 S 4 S 220B 3 AC220 S 4 S
T T
HSV-18D T 5 HSV-18D T 5
XS5 PE 9 XS5 PE 9
1 MC1 1 MC1
Fault chain
440 2 MC2 2 MC2
XS4 XS4
Axis C ready X3.7 X3.6
2 READY Axis Z read y 2 READY
24 ALM-RST 24 ALM-RST
25 EN 25 EN Ax is Z
26 COM 26 COM
U 6 UC 2 U 6 UZ 2
Axis control V 7 VC 4 V 7 VZ 4
cables
W 8 WC 3 W 8 WZ 3
XS3 XS XS3 XS
Encoder Encoder
cables PG cables PG
Axis C
Axis control cables
101
KA7 2100
24V1
134
5. Example of Typical Design
HNC-21MD HSV-18D
XS3033 XS4 GK6 motor
DIR- 8 16 DIR- XS3 XS
DIR+ 15 15 DIR+
CP- 7 14 CP- +5V 16,17
CP+ 14 13 CP+ +5V 18,19 12 +5V
5VG 5 30 GNDDM 5VG 23
5 VG 13 5VG 24,25 13 GND
Z+ 3 34 ENZ+ A 1 2 A
Z- 11 33 ENZ- B 3 4 B
B+ 2 36 ENB+ Z 5 16 Z
B- 10 35 ENB- U 7 6 U
A+ 1 17 ENA+ V 9 8 V
A- 9 18 ENA- W 11 10 W
/A 2 3 /A
/B 4 5 /B
/Z 6 17 /Z
Axis ready X3.* /U 8 7 /U
Y0.1 2 READY /V 10 9 /V
R eset Y0.2 24 ALM_RST 11 /W
Enabled 25 EN /W 12
100 PE 14,15 1 PE
24V GND 100 26 COM
24V GND 27 COM
*:4,5,6,7
Control cables Encoder cables
135
5. Example of Typical Design
HNC-21TD
Front panel Spindle encoder
XS9
PC keyboard XS2 Spindle motor
136
5. Example of Typical Design
5.3.3 I/O Specification
This section would introduce I/O of typical NC turning system. Some inputs/outputs
in this example are not used, even though they are defined.
The interface of XS8 on the turning system is same as the milling system.
XS12 (DB25/F), XS21, and XS22 (DB25/M) are not used.
The inputs of XS10 (DB25/F): X0.0~X2.3
Pin Signal Description
Overtravel positive-limit switch on axis X, normally open
13 X0.0
contact, close valid
Overtravel negative-limit switch on axis X, normally open
25 X0.1
contact, close valid
Overtravel positive-limit switch on axis Z, normally open
12 X0.2
contact, close valid
Overtravel negative-limit switch on axis Z, normally open
24 X0.3
contact, close valid
Overtravel positive-limit switch on axis C, normally open
11 X0.4
contact, close valid (not used)
Overtravel negative-limit switch on axis C, normally open
23 X0.5
contact, close valid (not used)
Chuck clamped, normally open contact, close valid (not
10 X0.6
used)
Chuck released, normally open contact, close valid (not
22 X0.7
used)
Reference point return switch on axis X, normally open
9 X1.0
contact, close valid
Reference point return switch on axis Z, normally open
21 X1.1
contact, close valid
Reference point return switch on axis C, normally open
8 X1.2
contact, close valid (not valid)
20 X1.3 Undefined
7 X1.4 Coolant alarm, normally close contact, open valid
Lubrication alarm, normally close contact, open valid (not
19 X1.5
used)
Hydraulic alarm, normally close contact, open valid (not
6 X1.6
used)
18 X1.7 Undefined
1st spindle gear (low speed), normally close contact, open
5 X2.0
valid (not used)
2nd spindle gear (high speed), normally open contact, close
17 X2.1
valid (not used)
4 X2.2 Undefined
16 X2.3 Undefined
3 NC
1,2,14,15 24V GND External DC 24V Ground
137
5. Example of Typical Design
Pin Signal Description
13 X2.4 Operation enabled, normally open contact, close valid
Servo power OK, normally open contact, close valid (not
25 X2.5
used)
12 X2.6 Servo drive OK, normally open contact, close valid
Air switch of control cabinet OK, normally open contact,
24 X2.7
close valid
11 X3.0 Spindle alarm, normally close contact, open valid
Spindle speed arrived, normally open contact, close valid
23 X3.1
(not used)
10 X3.2 Tool 1 OK, normally open contact, close valid
22 X3.3 Tool 2 OK, normally open contact, close valid
9 X3.4 Tool 3 OK, normally open contact, close valid
21 X3.5 Tool 4 OK, normally open contact, close valid
8 X3.6 Tool 5 OK, normally open contact, close valid (not used)
20 X3.7 Tool 6 OK, normally open contact, close valid (not used)
They are connected to XS8 in parallel, and used for the
inputs of axis selection, override, and enable button on the
4-7, 16-19 X4.0-X4.7
handwheel unit. For more detailed information, please refer
to XS8.
3 NC
1,2,14,15 24V GND External DC 24V Ground
Note: The anti-interference magnetic rings and the high voltage ceramic chip
capacitors at the main power lead-in wires and the transformer input terminals are
not shown in the following figure.
In Figure 5-11, QF0~QF4 are 3-phase air switches. QF5~QF10 are 1-phase air
switches. KM1~KM6 are 3-phase AC contactors. RC1~RC4 are 3-phase RC
absorbers (arc damper). RC5~RC10 are 1-phase RC absorbers (arc damper).
139
5. Example of Typical Design
AC380V 3-phase
KM2
RC2
QF2 KM3
20A 5.5KW Spindle motor
KM4
RC3
QF3 KM5
Turret motor
0.4A
RC4
QF4 KM6
1A Coolant motor
To: relay
To: servo drive
Suspension fan NC unit unit
Servo drive unit
QF8 KA1
AC110V
2A
100W KA4 KA5 KA6 KA7
KA8
KM3 KM2 KM5 KM4
Cabinet
fan RC5 RC6 RC7 RC8 RC9 RC10
Control
transformer KM1 KM2 KM3 KM4 KM5 KM6
140
5. Example of Typical Design
KA2
SQX-1
SQX-3
SQZ-1
KA3 KA5 KA4 KA7 KA6
HNC-21
SQZ-3
XS20
OTBS1 3
OTBS2 16
ESTOP1 4
ESTOP3 17
24V
KA1 KA2 KA3 KA4 KA5 KA6 KA7 KA8
141
5. Example of Typical Design
XS10 XS11
SQX-1 K A2 External operation
X0.0 13 X0.0 P ositive limit switch on Axis X
X2.4 13 X2.4
SQX-3 enabled
X0.1 25 X0.1 N egative limit switch on Axis X X2.5 25 X2.5
X0.2 SQZ-1 X2.6 KA3
X0.2 12 Positive limit switch on Axis Z X2.6 12 Servo drive OK
SQZ-3 QF3 QF4
X0.3 24 X0.3 N egative limit switch on Axis Z X2.7 24 X2.7 Air switch OK
X3.0 QF2
X0.4 11 X3.0 11 Spindle alarm
X0.5 23 X3.1 23 Hall switch
X3.2 SQ1
Tool 1 OK
X0.6 10 X3.2 10
X0.7 22 X3.3 22 X3.3 SQ2
Tool 2 OK
X1.0 SQX-2
X1.0 9 Reference switch on Axis X X3.4 9 X3.4 SQ3
Tool 3 OK
X1.1 SQZ-2 X3.5 SQ4
X1.1 21 Reference switch on Axis Z X3.5 21 Tool 4 OK
X3.6 Axis X ready
X1.2 8 X3.6 8
X1.3 20 X3.7 20 X3.7 Axis Z ready
X1.4 7 X4.0 7
X1.5 19 X4.1 19
X1.6 6 X4.2 6
X1.7 18 X4.3 18
X2.0 5 X4.4 5
X2.1 17 X4.5 17
X2.2 4 X4.6 4
X2.3 16 X4.7 16
NC 3 NC 3 24V
24VG 15 100 24VG 15 100
24VG 2 (Relay DC24V GND) 24VG 2 DC24V
24VG 14 24VG 14 S witc h power
output gr ound
24VG 1 24VG 1
In the Figure 5-13, 100 and 24V are the outputs of the switch power supply with
DC24V 50W (Figure 5-11).
142
5. Example of Typical Design
XS8 XS20
5VG 13 Y0.0 13 Y0.0 Operation enabled relay
+5V 25 Y0.1 25 Y0.1 System reset
Y0.2
HB 12 Y0.2 12 Servo enabled
HA 24 Y0.3 24
Y3.4 11 Y0.4 11
Y3.5 23 Y0.5 23 Y0.5 Coolant on relay
Y3.6 10 Y0.6 10 Y0.6 Turret motor CW relay
Y3.7 22 Y0.7 22 Y0.7 Turret motor CCW relay
X4.0 9 Y1.0 9 Y1.0 Spindle CW relay
X4.1 21 Y1.1 21 Y1.1 Spindle CCW relay
X4.2 8 Y1.2 8
X4.3 20 Y1.3 20
X4.4 7 Y1.4 7 Notes: Y0.1 and Y0.2 are outputted to the
X4.5 19 Y1.5 19 servo drive unit. Please refer to Figure
X4.6 6 Y1.6 6 6-32 about the connection to the different
X4.7 18 Y1.7 18 relays,
NC 5 NC 5
ESTOP3 17 ESTOP3 17 External operation
ESTOP2 4 ESTOP1 4 ESTOP limit enabled relay KA2
+24V 16 OTBS2 16 chain
+24V 3 OTBS1 3 100 (Relay DC24V GND)
24VG 15 24VG 15
24VG 2 24VG 2
24VG 14 24VG 14
24VG 1 24VG 1 100 (Relay DC24V GND)
As it is shown in Figure 5-14, the handwheel unit is not used. Therefore, two pins of
emergency stop on XS8 should be short-circuited (Figure 5-14).
143
5. Example of Typical Design
Servo R
power S
supply Axis X R R Axis Z R
T 220A 220A R
AC1 S AC1 S
From Figure 5-11 220B S 220B S
Servo 220A AC2
T
T AC2
T
T
control 220B HSV-160 H SV-1 60
power
100
MC1 MC MC1 M C
Fault chain
420 MC2 MC2
24V GND
100 19 24V GND
100 19
A xis X ready X3.6 8 READY Axis Z ready
X3.7 8 READY
Reset Y0.1 2 A-CL 2 A-CL
Y0.2
Enabled 1 EN 1 EN
Axis
U UX 2 U UZ 2
control
cables V VX 4 V VZ 4
COMMAND COMMAND
NC unit W WX 3 W WZ 3
XS30 XS XS
E NCOD ER Encoder ENCODER Encoder
HNC-21/TD cables PG cables PG
PE PE
XS32
Axis control
cables
Axis X Axis Z
HNC-21TD HSV-160
XS30,32 COMMAND GK6 motor
GND 5
ENCODER XS
20 COM
A+ 1 32 A+ +5V 16,17
A- 9 33 A- +5V 18,19 12 +5V
B+ 2 18 B+ 5VG 23
B- 10 36 B- 5VG 24,25 13 GND
Z+ 3 35 Z+ A 1 2 A
Z- 11 34 Z- B 3 4 B
CP+ 14 14 CP+ Z 5 16 Z
CP- 7 15 CP- U 7 6 U
DIR+ 15 16 DIR+ V 9 8 V
DIR- 8 17 DIR- W 11 10 W
/A 2 3 /A
/B 4 5 /B
Y0.2 /Z 6 17 /Z
Enabled
Y0.1 1 EN /U 8 7 /U
Reset 2 A-CL /V 10 9 /V
Axis ready X 3.* 8 RE ADY
100 /W 12 11 /W
24V GND 19 COM PE 14,15 1 PE
*:6,7
144
HNC-21/22 Connection Manual
6 Appendix
This chapter would introduce the description of product type, the dimension and the
interfaces of HNC-21/22.
145
6. Appendix
HNC 21 M D 32 H 02
21: NC of economic type Unit Type Storage Size Memory Size
22: NC of advanced type M: Milling MB Flash RAM MB
T: Turning Hard disk -- GB
146
A B C E
X Y Z G
6. Appendix
Esc
D H R Q
M S T F Tab
U V W L O
I J K P N
" ; A: \B C E
1 2 X3 Y4 Z G Esc
# ^ [ ]
5 6 7D 8 H SP R Q
M S T F Tab
6.2 Dimension
* / + =
9 0 . - BS
U V W L O
I J K P N
Pgup Pgdn Alt Upper
" ; : \
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 1 2
Del Enter
3 4
# ^ [ ]
5 6 7 8 SP
- 100 + +4TH -Y +Z
/
* / + =
- 100 + 9-X 0 +X . - BS
6.2.1 NC Device
1 10 100 1000
Z
- 100 + -Z +Y -4TH
Pgup Pgdn Alt Upper
Del Enter
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
- 100 + +4TH -Y +Z
/
1 10 100 1000
- 100 + -X +X
Z
- 100 + -Z +Y -4TH
A B C E
X Y Z G Esc
D H R Q
M S T F Tab
U V W L O
I J K P N
" ; : \
1 2 3 4
# ^ [ ]
5 6 7 8 SP
* / + =
9 0 . - BS
Del
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
/
- 100 + +4TH -Y +Z
1 10 100 1000
- 100 + -X +X
Z
- 100 + -Z +Y -4TH
aHNC-21
bHNC-22
15
100
15
Figure 6 3 Dimension of Installation
147
6. Appendix
148
6. Appendix
149
6. Appendix
150
6. Appendix
XS7: USB interface XS8: Handwheel unit interface
XS9: Spindle control interface X10~X12: PLC input interface
X20~X22: PLC output interface X30~X35: feed axis control interface
1DATA
6 5
2NC
4 3 3GND
4VCC
5CLOCK
2 1 6NC
8BI_D4-
7BI_D4+
6RX_D2-
5BI_D3-
4BI_D3+
3RX_D2+
2TX_D1-
1TX_D1+
151
6. Appendix
Pin Signal Description
1 TX_D1+ Send data
2 TX_D1- Send data
3 RX_D2+ Receive data
4 BI_D3+ NC
5 BI_D3- NC
6 RX_D2- Receive data
7 BI_D4+ NC
8 BI_D4- NC
XS5
5GND
3TXD
2: RXD
XS8
1 :24VG 14:24VG
2 :24VG
15:24VG
3 :+24V 1 14
16:+24V
4 :ESTOP2
17:ESTOP3
5 :NC
18:X4.7
6 :X4.6 19:X4.5
7 :X4.4
20:X4.3
8 :X4.2
21:X4.1
9 :X4.0
22:Y3.7
10:Y3.6
23:Y3.5
11:Y3.4 13 25 24:HA
12:HB
25:+5V
13:5V GND
Signal Description
+24V, 24V GND Power supply DC24V
ESTOP2, ESTOP3 Emergency stop on the handwheel unit
X4.0~X4.7 Inputs on the handwheel unit
Y3.4~Y3.7 Outputs on the handwheel unit
152
6. Appendix
HA Phase A on the handwheel unit
HB Phase B on the handwheel unit
+5V, 5V GND Handwheel power supply DC5V
XS9DB15 PIN
8:GND
15:GND
7:GND
14:AOUT2
6:AOUT1
13:5VG
5:5VG
12:+5V
4:+5V
11:SZ-
3:SZ+
10:SB-
2:SB+
9 :SA-
1:SA+
Signal Description
SA+, SA- Spindle encoder phase A
SB+, SB- Spindle encoder phase B
SZ+, SZ- Pulse Z of spindle encoder
+5V, 5VG Power supply: DC5V
AOUT1 Spindle analog output: -10V~+10V
AOUT2 Spindle analog output: 0~+10V
GND Analog output grounding
Signal Description
24VG External switch power DC24V Ground
X0.0~X7.3 PLC input (60 bit)
153
6. Appendix
- XS20, XS21, XS22: PLC outputs (DB25 PIN)
Signal Description
24VG External switch power DC24V Ground
Y0.0~Y5.7 PLC output (48 bit)
- XS30~XS35: Servo drive with pulse command and stepper motor drive control
interface (DB15 PIN)
XS30XS35DB15
8:DIR-
15:DIR+
7:CP-
14:CP+
6:NC
13:GND
5:GND
12:+5V
4:+5V
11:Z-
3:Z+
10:B-
2:B+
9 :A-
1:A+
Signal Description
A+, A- feedback signal of encoder phase A
B+, B- feedback signal of encoder phase B
Z+, Z- feedback signal of encoder pulse Z
+24V, 24VG Power: DC5V
CP+, CP- command pulse output (phase A)
DIR+, DIR- command directional output (phase B)
154
6. Appendix
Ethernet Interface
Ethernet switcher
PC keyboard interface
RS232 switcher
RS232 switcher
PC keyboard switcher
PC keyboard switcher
DB25 PIN
155
6. Appendix
XP8
1:24VG 14:24VG
2:24VG 15:24VG
3 :24V 1 14
4 :ESTOP2
16:24V
17:ESTOP3
5 :NC 18:NC
6 :X100
19:X10
7 :X1
20:4 th axis
8 :Axis Z 21:Axis Y
9 :Axis X
22:NC
10:NC
23:NC
11:Pilot 13
25 24:HA
12:HB
25:+5V
13:5VG
Signal Description
+24V, 24V GND Power supply DC24V
ESTOP2, ESTOP3 Emergency stop on the handwheel unit
x1, x10, x100 Override selection on the handwheel unit
Axis X, Y, Z, 4th Axis selection on the handwheel unit
Pilot lamp Pilot lamp on the handwheel unit
HA Phase A on the handwheel unit
HB Phase B on the handwheel unit
+5V, 5V GND Handwheel power supply DC5V
156
6. Appendix
Y3.4~Y3.7 of XS21 are connected to XS8 (handwheel unit interface) in parallel. Y3.6
is the signal of pilot lamp on the handwheel unit. Others are not defined.
158
6. Appendix
159
6. Appendix
Air switch of control cabinet OK, normally open contact,
24 X2.7
close valid
11 X3.0 Spindle alarm, normally close contact, open valid
Spindle speed arrived, normally open contact, close valid
23 X3.1
(not used)
10 X3.2 Tool 1 OK, normally open contact, close valid
22 X3.3 Tool 2 OK, normally open contact, close valid
9 X3.4 Tool 3 OK, normally open contact, close valid
21 X3.5 Tool 4 OK, normally open contact, close valid
8 X3.6 Tool 5 OK, normally open contact, close valid (not used)
20 X3.7 Tool 6 OK, normally open contact, close valid (not used)
They are connected to XS8 in parallel, and used for the
inputs of axis selection, override, and enable button on the
4-7, 16-19 X4.0-X4.7
handwheel unit. For more detailed information, please refer
to XS8.
3 NC
1,2,14,15 24V GND External DC 24V Ground
Y3.4~Y3.7 of XS21 are connected to XS8 (handwheel unit interface) in parallel. Y3.6
is the signal of pilot lamp on the handwheel unit. Others are not defined.
160
Wuhan Huazhong Numerical Control Co. Ltd
Address: Sci.&Tech. Park of HUST, Miao Shan, East Lake high-tech Development Zone,
Wuhan, Hubei, 430223, P.R. China
Tel: 86-27-87180031
Fax:86-27-87180306 86-27-87180307
http://www.huazhongcnc.com
Email: market@huazhongcnc.com