Hnc-21-Connection Manual - 2.0 PDF

HNC-21/22 CNC Device
Connection Manual
V2.0
2010/11
2010/11
Wuhan Huazhong Numerical Control Co. Ltd

HNC-21/22 Connection Manual
Preface
This connection manual is for HNC-21/22 unit. It is recommended that the operator
read this manual before operating the machine.
The organization of this manual:

(1) Precaution
(2) Connection
(3) Parameters
(4) Commissioning
(5) Typical Design
(6) Appendix
i
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
- 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).
2. DNC unit (optional)

DNC unit is a unit for interface switcher, which are DNC (RS-232) interface, PC
keyboard (PS2) interface, Ethernet interface.
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.
3. Handwheel unit (optional)

- Standard four-wire manual pulse generator
- Four-axis switch
- Three kinds of magnification switch
- Emergency stop button
- Handwheel enable button
- Pilot lamps
4. I/O Terminal Board

The I/O terminal board is connected to the optically isolated PLC inputs and outputs
through cables to facilitate wiring, commissioning and maintenance for the control
cabinet.
- 20-bit PLC inputs or 16-bit PLC outputs
- Pilot lamp on each input or output interface
- Both NPN and PNP interfaces are provided.
iii
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
: must do. : shall not be done.
; especially important : default, initial setting
: line or boundary : a set of cable
: signal direction : exchange
: point connected : terminal
: cable bunched/diverged : cable bunched/diverged
: shielding layer : grounding
: passive NO and NC : coil
: plug and socket : transducer
: encoder : motor
: pilot lamp : mechanical linkage
: gearbox
iv
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
v
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
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
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 product should be transported properly according to its weight.
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.
Dragging its cable to move or lift the product is not allowed.
Protect the front panel and screen from impact and cut.
Keep damp-proof while storing and transporting.
Let us know in time if the product has been stored overtime.
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.
Do not put the product near any inflammable or explosive matter.
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
Workers undertaking wiring or inspection must be qualified to do the jobs.
The NC device must be grounded reliably. The earth-resistance must be less

than 4 ohm. Do not take the neutral as a ground. Otherwise, the system may
not work normally and stably because of interference.
Wiring shall be correct and firm to avoid wrong operation.
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
Personnel to operate the device must be competent for their work.
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.
Do not refit the device.
To prevent from or reduce the influence of electromagnetic interference on NC

device, refer to section 2.10 Electromagnetic Compatibility Design.
To reduce the electromagnetic interference, a low-pass filter can be added if
there are electronic devices.
Do not turn on and off the system frequently. The interval between on and off
operations must be at least 3 minutes.
The operators hands must be kept dry, clean and no greasy dirt during
operation. It is suggested to keep the clear protection film on the panel.
Do not press the keys hard. It is not allowed to strike at the keyboard with
wrench or other sharp-edged and hard articles.
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
1.1.7 Waste Treatment
Treat the wastes as ordinary industrial wastes.
1.1.8 General Instructions
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
1.2 Unpacking and Checking

1.2.1 List
After unpacking, please make sure that:
- The product is what you ordered.
- No damage occurs during transportation.
- The received components included the accessories are complete and without
damage.
Please Contact us in time if any problem exists.
1.2.2 Product Type

The following is the description of HNC-21.
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
Type of feed axis Memory type:

D: pulse interface for pulse servo or stepper motor driver F: Flash RAM
H: IDE hard disk
Figure 1 2 Description of HNC-21
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
PgUp Shift Upper
Del
PgDn Alt 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
aHNC-21
bHNC-22
Figure 1 3 Dimension of HNC-21/22
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
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
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
Figure 1 5 Air flow direction in NC cabinet
3. Temperature in the cabinet shall not be higher than 50. Alternatively, more
effective steps shall be applied to dissipate the heat.

4. The control panel must be placed where the coolant or other liquid does not
reach.
5. To reduce electromagnetic interference, keep cables or electric components
having supply voltage higher than 50V apart from NC device at least 100mm.
6. The NC device should be installed where the commissioning and maintenance
can be done conveniently.
9
1. Precaution
1.5 Environmental Requirement

1.5.1 Weather Condition
The NC device works normally in the environment shown as follows.
- Ambient temperature: 0~40
- Relative humidity: 30%~95% (without dew)

- Atmospheric pressure: 86~106kPa
1.5.2 Elevation
The NC device works normally with an elevation of less than 1000m.
1.5.3 Transportation and Storage

It is proper to transport and store the NC device within a temperature range of
(-40~+55). The device can survive up to 70 in a short-term, less than 24
hours, transportation or storage. It is necessary to adopt moisture-proof, shockproof

and impact-resistant measures to avoid damage.
1.5.4 Mechanical Environment

The NC device shall be installed far from any shock resource to prevent from the
influence of shock, impulse and impact. If the device has to be installed near these
resources, additional measures are necessary to ensure the NC device against
resonance, and the vibration amplitude must be less than 0.05mm (frequency range:
5-55 Hz).
1.5.5 Environmental Pollution

While transporting, storing or operating, keep the NC device out of the strong
microwave radiation and the strong electromagnetic interference. Do not let
excessive pollutants (dust, acid, corrosive gas, salty matter) intrude into NC device.
The device should not work in an environment accompanied with strong vibration.
10
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
2.1 Total Connection Diagram

This section shows the total connection diagram of HNC-21/22.
Power supply XS1 XS30-XS35 Feed device
Keyboard XS2 XS8 Handheld unit
Ethernet XS3 XS9 Spindle unit
RS232 XS5 XS10-XS12 On-off input
USB XS7 XS20-XS22 On-off output
Figure 2 1 Total Connection Diagram of HNC-21/22
[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.
Figure 2 2 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
2.2.2 DNC unit (optional)

There are RS232, PC keyboard and Ethernet interfaces on DNC unit. The following
Figure 2-4 shows the interface of DNC unit.
Ethernet Interface
Ethernet switcher RS232 Interface
Ethernet switcher
PC keyboard interface
RS232 switcher
RS232 switcher
PC keyboard switcher
Figure 2 4 Interface of DNC unit

As it is shown in Figure 2-4, the interfaces are used to connect with PC or other
devices, and the switchers are used to connect with HNC-21/22. The interfaces on
DNC unit correspond with the interfaces shown in Figure 2-2 or Figure 2-3.
2.2.3 Handwheel unit (optional)

As it is shown in Figure 2-5, the handwheel unit is equipped with the emergency stop
button, pilot lamps, axis switch (OFF, X, Y, Z), magnification switch (X1, X10, X100),
and the manual pulse generator. It is connected to XS8 of HNC-21/22.
14
2. Connection
DB25 PIN
Figure 2 5 Interface of Handwheel unit
2.2.4 I/O Terminal Boards (optional)

There are two kinds of I/O terminal boards input terminal boards and output
terminal boards. They are usually used as a switcher unit to connect XS10, XS11,
XS12, XS20, XS21, and XS22 of HNC-21/22.
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.
- Input terminal board
15
2. Connection
Figure 2 6 Input terminal board
- Output terminal board
Figure 2 7 Output terminal board
16
2. Connection
2.3 Power Supply Connection

2.3.1 General Requirement
NC device (External supply 1): AC24V, or DC24V/100W;
PLC power (External supply 2): DC24V, no less than 50W;
Cables: Shielded cables or twisted cables;
If the external supply 1 is of AC 24V, an independent power supply for NC device is

suggested to use (refer to Figure 2-8).
External supply 1 XS1

AC 24V 1
AC 24V 100W AC 24V 5

HNC-21
6
External supply 2 1
+24V 2
1
DC 24V 50W 24V GND 4
Casing ground
Figure 2 8 Power Supply 1
It is suggested to use a switch supply of DC 24V for the external supply 2. It is

proper to increase the supply capacity in case there are many DC 24V relays
controlled by PLC outputs, or to have an additional power supply, having a common
ground with the external supply 2. If the brake of Z axis (spindle) and
electromagnetic valves also require DC 24V supply, try to use another supply (not
the external supply 2) to prevent NC device from interference induced by loads with
large inductance.
If the external supply 1 is of DC 24V, it is allowed to have a shared switching supply,

having capacity of no less than 145W for both the external supply 1 and the external
supply 2 (refer to Figure 2-9).
17
2. Connection
As shown in Figure 2-10, the external supplies 1 and 2 provide power for PLC
elements and manual pulse generator of handwheel unit through the interface XS8
on NC device.
XS1
External supply +24V 1,2
DC24V 24V GND 4,5

150W HNC-21/22
6
1
Casing ground
Figure 2 9 Power Supply 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
Figure 2 10 Signal grounding
In case some electrical components (such as relays, pilots in buttons,

approach switches, and Hall switches) to control or receive signals from
I/O have their independent power supply, the supply should have common
ground with the supply of these inputs and outputs, Otherwise, NC device
cannot control those electrical components or receive signal from those
components reliably.
19
2. Connection
2.4 Connection to DNC unit

DNC unit is a unit for interface switcher, which are DNC (RS-232) interface, PC
keyboard (PS2) interface, Ethernet interface.
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
XS3 Ethernet switcher XS3

HNC-21/22
XS5 RS232 switcher XS5
Figure 2 11 Connection between DNC and NC unit
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
Figure 2 12 Detailed connection between DNC and NC unit
20
2. Connection
2.5 Connection to Computer

HNC-21/22 can be connected to PC by using RS232 or Ethernet interface, so that
the data can be shared and exchanged. The operator can directly use the interface
XS3 or XS5 on NC device, or use the optional DNC unit to connect NC device with
PC.
2.5.1 RS232 Interface
PC NC device
RS232 Cable length<15m XS5

RXD 2 2 RXD
TXD 3 3 TXD
GND 5 5 GND
PE
Figure 2 13 Connect with PC by RS232 (no DNC unit)
PC DNC unit NC device
RS232 <15m XS5 XS5 <1m XS5

RXD 2 2 RX D RXD 2 2 RXD
TXD 3 3 TX D TXD 3 3 TXD
GND 5 5 GND GND 5 5 GND
PE
Cabinet
Figure 2 14 Connect with PC by RS232 (with DNC unit)
2.5.2 Ethernet Interface

It is easy and reliable to connect NC device with the computer through Ethernet
interface. The operator can use the cable to directly connect with PC (Figure 2-15,
Figure 2-16), or use an HUB to connect with any computer in local area network
(Figure 2-17, Figure 2-18). The connection can be made either through Ethernet
interface at the rare of NC device, or through the interface of DNC unit.
Note:
1. The special network cables shall be used while wiring.
2. The type of Ethernet interface is RJ45.
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)
PC DNC unit NC device
Ethernet XS3 XS3 XS3

<50m <1m
TX_D1 + 1 1 TX_D1+ 1 1 TX_D1+
TX_D1 - 2 2 TX_D1- 2 2 TX_D1-
RX_D2 + 3 3 RX_D2+ 3 3 RX_D2+
BI_D3 + 4 4 BI_D3+ 4 4 BI_D3+
BI_D3 - 5 5 BI_D3- 5 5 BI_D3-
RX_D2 - 6 6 RX_D2- 6 6 RX_D2-
BI_D4 + 7 7 BI_D4+ 7 7 BI_D4+
BI_D4 - 8 8 BI_D4- 8 8 BI_D4-
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
Figure 2 17 Use HUB to connect with PC (no DNC unit)
22
2. Connection
HUB DNC unit NC device
interface <50m XS3 XS3 <1m XS3

TX_D1+ 1 1 TX_D1+ 1 1 TX_D1+
TX_D1- 2 2 TX_D1- 2 2 TX_D1-
RX_D2+ 3 3 RX_D2+ 3 3 RX_D2+
BI_D3+ 4 4 BI_D3+ 4 4 BI_D3+
BI_D3- 5 5 BI_D3- 5 5 BI_D3-
RX_D2- 6 6 RX_D2- 6 6 RX_D2-
BI_D4+ 7 7 BI_D4+ 7 7 BI_D4+
BI_D4- 8 8 BI_D4- 8 8 BI_D4-
Cabinet HNC-21/22
Figure 2 18 Use HUB to connect with PC (with DNC unit)
23
2. Connection
2.6 PLC I/O Interface

Built-in I/O (40/32 bit, extended to 60/48 bit) on HNC-21/22 unit are connected to I/O
terminal board or output relay.
2.6.1 Input interface

(1) Equivalent circuit
+24V
+5V
IF=5~9mA
24V GND
24V GND
NPN input: 24V GND
Figure 2 19 Equivalent circuit of NPN input interface
+ 24V +5V
IF =5~9mA
PNP input: 24V
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.
(2) Technical parameters

- The optically coupled technique is adopted. The highest isolated voltage is
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.
(3) Typical application of circuit

- Connection to external passive switches or relay contacts;
As it is shown in Figure 2-21, NPN or PNP input terminal can be used. One
contact is connected to the input interface, and the other contact is
connected to 24V (NPN input), or 24VG (PNP input).
+24V +24V PNP input: 24V
IF =59mA I F=59mA
N P
NPN input: 24V GND
24V GND 24V GND

aNPN input bPNP input
Figure 2 21 Connection to passive switch or relay contacts

- Connection to external active switches
Selecting NPN or PNP input depends on the output type of module. Please
refer to the description of components, if necessary.
a) NPN input terminal shall be selected for NPN output type of the module
(Figure 2-22 a).
b) PNP input terminal shall be selected for PNP output type of the module
(Figure 2-22 b).
25
2. Connection
+24V +24V
IF =59mA IF=59mA
N P
24V GND 24V GND
aNPN input bPNP input

Figure 2 22 Connection of active input switch
(4) Pin of PLC input interface

Input interface on NC device
XS10 DB25 PIN XS11 DB25 PIN XS12 DB25 PIN

1 :24VG 14:24VG 1 :24VG 1 :24VG
14:24VG 14:24VG
2 :24VG 2 :24VG 2 :24VG
15:24VG 15:24VG 15:24VG
3 :NC 1 14
16:X2.3 3 :NC 1 14 3 :NC 1 14
16:X4.7 16:X7.3
4 :X2.2 4 :X4.6 4 :X7.2
17:X2.1 17:X4.5 17:X7.1
5 :X2.0 18:X1.7 5 :X4.4 5 :X7.0
18:X4.3 18:X6.7
6 :X1.6 19:X1.5 6 :X4.2 6 :X6.6
19:X4.1 19:X6.5
7 :X1.4 20:X1.3 7 :X4.0 7 :X6.4
20:X3.7 20:X6.3
8 :X1.2 8 :X3.6 8 :X6.2
21:X1.1 21:X3.5 21:X6.1
9 :X1.0 9 :X3.4 9 :X6.0
22:X0.7 22:X3.3 22:X5.7
10:X0.6 23:X0.5 10:X3.2 10:X5.6
23:X3.1 23:X5.5
11:X0.4 13 25 24:X0.3 11:X3.0 13 25 24:X2.7 11:X5.4 13 25 24:X5.3
12:X0.2 25:X0.1 12:X2.6 25:X2.5 12:X5.2 25:X5.1
13:X0.0 13:X2.4 13:X5.0
Figure 2 23 Interface of XS10, X11 and XS12
Table 2 1 Description of XS10, XS11 and XS12

Signal Description
24VG External switch power DC24V Ground
X0.0~X7.3 PLC input (60 bit)
Interface of input terminal board
26
2. Connection
Figure 2 24 Input terminal board

J1 DB25/F PIN
25:NI1 13:NI0
12:NI2
24:NI3
23:NI5 11:NI4
22:NI7 10:NI6
21:NI9 9 :NI8
20:NI11 8 :NI10
19:NI13 7 :NI12
6 :NI14
18:NI15
17:NI17 5 :NI16
16:NI19 4 :NI18
15:24VG 3 :NC
14:24VG 2 :24VG
1 :24VG
Figure 2 25 Interface of J1 on input terminal board
Table 2 2 Description of input J1 and J2

Interface Signal Description
J1 (DB25/F)
NI0~NI19 PLC input
+24V
External switch power DC24V
GND
J2
N0~N19 NPN input terminal
P0~P19 PNP input terminal
Note: NPN and PNP can be used on the same bit.
2.6.2 Output interface
27
2. Connection
- 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
Figure 2 27 Equivalent circuit of PNP output interface

Note::
Note
- The type of the output interfaces on HNC-21/22 unit is NPN.
- The output terminal board includes NPN and PNP input terminal.
(2) Technical parameters

- The optically coupled technique is adopted. The highest isolated voltage is
2500V RMS (one minute).
- The supply voltage is 24V.
- The maximum output current is 100mA.
(3) Typical application of circuit

- Drive a LED
NPN or PNP output terminal can be used to drive a LED. A resistance about
28
2. Connection
10mA is connected in series to control the current flowing through LED.
+24V
2.5k P
IL=10mA
N 2.5k
IL=10mA
24V GND 24V GND

aNPN output bPN P output
Figure 2 28 Using PLC output to drive LED

- Drive a filament pilot lamp
NPN or PNP output terminal can be used to drive a filament pilot lamp. A
preheating resistance is required to reduce the current shock while turning
the pilot on. The ohm value of the resistance should be large enough to
keep the pilot off.
+24V +24V
Preheating
resistance
N IL 100mA P IL 100mA
Preheating
resistance
24V GND 24V GND

aNPN output bPNP output
Figure 2 29 Using PLC output to drive a filament pilot lamp

- Drive an inductive load (such as relay)
NPN or PNP output terminal can be used to drive an inductive load. A
flywheel diode shall be connected in parallel with the coil of the relay to
protect the output circuit from interference (some relays have been
equipped with flywheel diodes).
Note: The voltage of coil shall be DC24V.
29
2. Connection
+24V
Flywheel
diode P
IL100mA
KA Relay coil
KA Relay coil
N
IL100mA Flywheel
diode
24V GND 24V GND

aNP N output bPN P output
Figure 2 30 Using PLC output to drive an inductive load
(4) Pin of PLC output interface

Output interface on NC device
XS20DB25 PIN XS21DB25 PIN XS22DB25 PIN

13:Y0.0 25:Y0.1 13:Y2.0 25:Y2.1 13:Y4.0 25:Y4.1
12:Y0.2 12:Y2.2 12:Y4.2
24:Y0.3 24:Y2.3 24:Y4.3
11:Y0.4 11:Y2.4 11:Y4.4
23:Y0.5 23:Y2.5 23:Y4.5
10:Y0.6 22:Y0.7 10:Y2.6 22:Y2.7 10:Y4.6 22:Y4.7
9 :Y1.O 9 :Y3.O 9 :Y5.O
21:Y1.1 21:Y3.1 21:Y5.1
8 :Y1.2 8 :Y3.2 8 :Y5.2
20:Y1.3 20:Y3.3 20:Y5.3
7 :Y1.4 7 :Y3.4 7 :Y5.4
19:Y1.5 19:Y3.5 19:Y5.5
6 :Y1.6 6 :Y3.6 6 :Y5.6
18:Y1.7 18:Y3.7 18:Y5.7
5 :NC 5 :NC 5 :NC
17:NC 17:NC 17:NC
4 :NC 16:NC 4 :NC 16:NC 4 :NC 16:NC
3 :NC 15:24VG 3 :NC 15:24VG 3 :NC 15:24VG
2 :24VG 14:24VG 2 :24VG 14:24VG 2 :24VG 14:24VG
1 :24VG 1 :24VG 1 :24VG
Figure 2 31 Interface of XS20, XS21 and XS22

Table 2 3 Description of XS20, XS21 and XS22
Signal Description
Y0.0~Y5.7 PLC output (48 bit)
Interface of output terminal board
30
2. Connection
Figure 2 32 Output terminal board

J1 DB25/M PIN
13:NO0
25:NO1
12:NO2 24:NO3
11:NO4
23:NO5
10:NO6 22:NO7
9 :NO8
21:NO9
8 :NO10 20:NO11
7 :NO12
19:NO13
6 :NO14
18:NO15
5 :NC 17:ESTOP3
4 :ESTOP1
16:OTBS2
3 :OTBS1 15:24VG
2 :24VG
14:24VG
1 :24VG
Figure 2 33 Interface of J1 on output terminal board

Table 2 4 Description of output J1 and J2
Interface Signal Description
NO0~NO15 PLC output
ESTOP1
J1 (DB25/M) Emergency stop
ESTOP3
OTBS1
Overtravel released
OTBS2
+24V
External switch power DC24V
GND
NC Not connection
J2
N0~N15 NPN output terminal
ES1, ES3 Emergency stop
P0~P15 PNP output terminal
Note: NPN and PNP can be used on the same bit.
31
2. Connection
2.6.3 Direct Connection to NC device

The external I/O signal can be directly connected to XS10, XS11, XS12, XS20, XS21,
or XS22 of HNC-21/22. It is widely used when I/O ports are less required and NC
device is installed in the control cabinet. This way of connection is simple and cost
effective. However, it is not convenient to assemble or disassemble cables, and no
PNP I/O terminals are available to use.
Field on-off input module HNC-21/22

<15 m
XS1012
413
X0.0X7. 3
1625
Cabinet
Common GND 24V GND

1,2,14,15
External supply 2+24V

24V GND
Power of on-o ff signal
Figure 2 34 Connection between PLC input and NC unit
HNC-21/22
Pilot lamp, relay,etc <15 m
XS2022
+ -
613
Y0.0Y5.7 1825
+ - Cabinet
External supply +24V

24V GND
1,2,14,15
External supply 24V GND

External supply 2+24V
+24V Power of on-off signal
Figure 2 35 Connection between PLC output and NC unit
32
2. Connection
2.6.4 Co nnection to NC device through I/O terminal board

Connection
As it is shown in Figure 2-36, XS10, XS11 and XS12 of HNC-21/22 are connected to
J1 on the input terminal board, and XS20, XS21 and XS22 are connected to J1 on
the output terminal board. NPN or PNP inputs/outputs are connected to J2 on the
terminal boards.
This way of connection is used when NC device and strong-current circuit are
installed in the different cabinets. It is convenient for the circuit installation,
commissioning and maintenance.
Pendant box Cabinet
HNC-21/22 15m J1 DB25/F Input terminal board

J2
+24 GND NC NC N0N19
XS10 V+24 GND NC NC P0P19
DB25/F V
NPN PNP X0.0X2.3
XS11 15m J1 DB25/F Input terminal board
DB25/F J2
+24 GND NC NC N0N19
V+24 GND NC NC P0P19
XS12 V
DB25/F NPN PNP X2.4X4.7
15m J1 DB25/F
XS20 Input terminal board
DB25/M J2
+24 GND NC NC N0N19
V+24 GND NC NC P0P19
XS21 V
NPN PNP X5.0X7.3
DB25/M
On-off inputs
XS22 15m J1 DB25/M Output terminal board
DB25/M E-stop &
J2
+24 GND NC NC N0N15 NC NC ES3 OT2 Overtravel
V+24 GND NC NC P0P15 NC NC ES1 OT1 released
V
NPN PNP Y0.0Y1.7
15m J1 DB25/M Output terminal board
J2
+24 GND NC NC N0N15 NC NC ES3 OT2
V+24 GND NC NC P0P15 NC NC ES1 OT1
V
NPN PNP Y2.0Y3.7
External supply 2 15m J1 DB25/M Output terminal board
On-off I/O power J2
+24 GND NC NC N0N15 NC NC ES3 OT2
V+24 GND NC NC P0P15 NC NC ES1 OT1
DC24V +24V V
GND NPN PNP Y4.0Y5.7
50W
On-off outputs
Figure 2 36 Connection to NC device through I/O terminal board
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.
HNC-21/22 Terminal board

XS10XS12 15m J1
XS20XS22 1
1
2 2
3 3

24 24
25 25
Figure 2 37 Connection between I/O terminal board and NC device
2.6.5 Description of PLC Address

In NC system, PLC inputs are defined as X, and the PLC outputs are defined as Y.
One byte is composed of 8 bits. For the information about I/O interface (XS10, XS11,
XS12, XS20, XS21, XS22) of HNC-21/22, please refer to the chapter 2.6.1 and
2.6.2.
The following table shows PLC inputs/outputs of HNC-21/22.
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.
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.
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
2.7 Connection to Handwheel Unit

2.7.1 Handwheel Interface
Handwheel unit is connected to HNC-21/22 by XS8 (DB25 pin).
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
Figure 2 38 Interface of XS8

Table 2 8 Interface description of XS8
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
HA Phase A on the handwheel unit
HB Phase B on the handwheel unit
+5V, 5V GND Handwheel power supply DC5V
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.
Notes: If no handwheel unit is used or there is no emergency stop button on the

handwheel unit, pin 4 and pin 17 of XS8 shall be short circuited by DB25 male plug.
36
2. Connection
2.7.2 Connection to Standard Handwheel Unit
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
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
Figure 2 39 Connection to Standard Handwheel Unit
2.7.3 Connection to Customized Handwheel Unit

Please refer to I/O design of the standard handwheel unit (such as axis selection,
override selection, and pilot lamps etc), while customizing a handwheel unit.
If there is no emergency stop button on the handwheel unit, 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.
The type of I/O is NPN with DC24V. Please refer to section 2.6.
The specification of MPG (Manual Pulse Generator) is DC5V, TTL level,

phase-A output, and phase-B output.
38
2. Connection
2.8 Connection to Spindle device

Different kinds of spindle can be connected to HNC-21/22 by XS9 to implement CW
rotation, CCW rotation, spindle orientation, speed regulation etc. Spindle encoder
can also be connected to implement threading of turning and grid tapping of milling.
2.8.1 Relevant Interfaces
2.8.1.1 Spindle Interface XS9

2.8.1.1Spindle
As it is shown in Figure 2-40, XS9 includes the spindle speed analog voltage outputs
and spindle encoder feedback inputs.
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+
Figure 2 40 Interface of XS9

Table 2 10 Description of XS9
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
The characteristics of signals:

- Spindle speed analog voltage signal
Voltage: AOUT1: -10V~+10V
AOUT2: 0V~+10V
Load current: max.10mA
- Spindle encoder interface
39
2. Connection
Power supply: +5V, max.200mA
Encoder signal: RS422 level
Ensure the type of spindle analog output interface, before it is connected

to the spindle frequency converter drive or spindle servo drive. If it is
-10V~+10V, AOUT1 (pin 6) and GND should be used. If it is AOUT2 (pin
14) and GND should be used.
2.8.1.2 I/O related to Spindle

PLC inputs/outputs are required to control spindle start-up and stop, receive signals
about the various status and alarm messages, when the spindle device is connected
to NC unit.
The definitions of PLC inputs/outputs relevant to spindle control are listed as below,
which would be mentioned in the typical design (Chapter 5).
Table 2 11 I/O related to spindle control
Register X/Y
Signal Interface Pin
Milling Turning
Inputs
Spindle gear 1 X2.0 X2.0 5
Spindle gear 2 X2.1 X2.1 17
XS10
Spindle gear 3 X2.2 4
Spindle gear 4 X2.3 16
Spindle alarm X3.0 X3.0 11
Spindle speed arrived X3.1 X3.1 23
XS11
Zero spindle speed X3.2 10
Spindle orientation X3.3 22
Outputs
System rest Y0.1 Y0.1 25
Spindle enable Y0.3 Y0.3 24
Spindle CW rotation Y1.0 Y1.0 9
Spindle CCW rotation Y1.1 Y1.1 21
Spindle mode switch/brake Y1.2 Y1.2 8
XS20
Spindle orientation Y1.3 20
Spindle gear 1 Y1.4 Y1.4 7
Spindle gear 3 Y1.6 6
2.8.2 Spindle Start and Spindle Stop

The spindle start and stop are controlled by PLC. The following table shows I/O
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
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.
The direction of some spindle rotation depends on the polarity (positive/negative) of

spindle speed signal. In this case, spindle CW signal can be used as spindle enable
control, and the spindle CCW signal is not 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.
2.8.3 Spindle Speed Control

As it is shown in Table 2-4, AOUT is to control spindle revolution. The output range is
0V~+10V. Y0.2 and Y0.3 control the direction of spindle rotation.
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
2.8.4 Spindle Orientation Control

There are three ways to control the spindle orientation.
1. Use a spindle motor with driver including spindle orientation function.
The relevant input/output signals were defined in standard milling machine PLC
program as listed below.
Table 2 14 I/O related to spindle orientation
Signal Register X/Y (milling) Interface Pin
Inputs
Spindle orientation
X3.3 XS11 22
done
Outputs
Spindle orientation Y1.3 XS20 20
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.
2. Use a spindle servo, working in positioning mode.

The spindle is controlled as the spindle servo. It can be positioned at any angle
by writing PLC program.
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.
2.8.5 Spindle Gear Control

Spindle gear can be controlled by PLC. The following table shows I/O related to
spindle gear control in the standard PLC of milling and turning.
Table 2 15 I/O related to spindle gear control
Register X/Y
Milling Turning
Inputs
Spindle gear 1 OK X2.0 X2.0 5
Spindle gear 2 OK X2.1 X2.1 17
XS10
Spindle gear 3 OK X2.2 4
Spindle gear 4 OK X2.3 16
Outputs
XS20
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
2.8.6 Connection to Spindle Encoder

The spindle encoder can be connected by XS9 to implement thread cutting, tapping
etc. Two types of output of spindle encoder can be connected: one type of output is
the difference TTL square-wave, and the other type of output is single-polar TTL
square-wave.
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.
The specification of spindle encoder:

- Power: +5V (within 200mA, use external power supply if it is higher than 200mA)
- TTL level output
- Difference outputs: A, B, Z
The commonly used spindle encoder is: LEC-BM-G05D(L, H)
2.8.7 Connection ExampleAC Induction Motor

Example
If AC induction motor without regulation device is taken as spindle motor, the
auxiliary relay and contact are controlled by the outputs of NC device. Then, the
spindle rotation (CW and CCW) and stop can be controlled. As it is shown in Figure
2-42, KA3 and KM3 are to control the motor CW rotation. KA4 and KM4 are to
control the motor CCW rotation.
Spindle gear can be added to implement step speed regulation. An external spindle
encoder can be used to implement thread cutting or grid tapping.
Note: The single-phase arc-extinguisher of contact is not shown in the figure.
Contact power U11 V11 W11
HNC-21/22
XS20
O8 O9
Y1.0 Y1.1
RC1
KA3 KA4 KM3 KM4

U1 V1 W1
Arc extinguisher
U V W
+24V Contact power Spindle motor
Figure 2 41 Connection exampleThree-phase AC Induction 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 AC frequency converter spindle is used, a mechanical gear can be used to get a

better low speed-torque and a broader speed regulation. For more detailed
information, please refer to chapter 2.8.5.
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
Figure 2 42 Connection to spindle motor with driver without feedback
As it is shown in Figure 2-44, the spindle speed/position information feedback from

the spindle motor with driver unit (Figure 2-43) or an external encoder (Figure 2-44)
to XS9 on NC unit can be used for thread cutting or tapping.
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
13 GND PE <15m control Speed control interface
14 AOUT2 or
7 GND 0+10V
15 GND
8 GND PE
Spindle motor
AOUT1-10+10V with drivers
XS10XS12,XS20XS22
AOUT2 0+10V
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
13 GND PE
<15m control Speed control interface
14 AOUT2 or
7 GND 0+10V
15 GND
8 GND PE
Spindle motor
AOUT1-10+10V with drivers
XS10XS12,XS20XS22
AOUT2 0+10V
Figure 2 44 Connection to spindle motor with drive feedback from external spindle
encoder
2.8.9 Parameters related to Spindle device

The parameters related to spindle device are in machine parameters:
Parameters Value
Spindle encoder revolution 1024
Direction of spindle encoder (32: positive, 33: negative) 32/33
46
2. Connection
47
2. Connection
2.9 Connection to Feed Drive

HNC-21/22 units use the pulse axis control interface with pulse+direction,
bidirectional pulse, or hermite pulse, and feedback interface to control the servo
drive and step drive unit with pulse command.
2.9.1 Interface Description

There are six pulse axis interfaces (XS30~XS35) on HNC-21/22.
(1) Signal Definition
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+
Figure 2 45 Interface of XS30~XS35

Table 2 16 Description of XS30~XS35
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)
(2) Technical Specification

- Maximum pulse frequency: 800KHZ
- Power supply of encoder: +5V@150mA
- Encoder signal: RS422 level

- Pulse command output
48
2. Connection
VCC
CP-(DIR-)
CP(DIR)
CP+(DIR+)
Figure 2 46 Equivalent circuit of pulse command output

- Encoder feedback Input
+5V
A+ 10K 10K
(B+, Z+) +
100 A(B,Z)
A- -
(B-, Z-)
Figure 2 47 Equivalent circuit of encoder feedback input
(4) Pulse type

The type of pulse output (pulse+direction, bidirectional direction, and alternating
pulse) can be set by parameters. For more detailed information, please refer to
Chapter 3.
Table 2 17 Pulse Type
CP DIR
mode 1 pulse direction
mode2 positive pulse negative pulse
mode3 phase A phase B
2.9.2 Connection to Stepper Motor Drive Unit

Up to six step motor drives can be connected to HNC-21/22 through XS30~XS35.
Figure 2-48 shows the overall connection to stepper motor drives. Figure 2-49
shows an example of the connection to SH-50806A (five phases step motor)
XS10XS12 Inputs (status information of driver)
XS20XS22 Outputs (status information of driver)

HNC-21/22
Stepper drive 1 Stepper drive 2
XS30 pulse Mot or power Motor power
Stepper motor 1 Stepper motor 2

XS31 pulse

Stepper drive 3 Stepper drive 4

XS32 Mot or power Motor power
pulse

Stepper motor 3 Stepper motor 4

XS33 pulse

49
2. Connection
Figure 2 48 Overall connection to stepper motor drive
HNC-21/22 Stepper drive unit Drive transformer
AC80 Drive power AC 1P

XS30XS35 CNI/F AC80 380/80
Shielding
14 CP+ CW+ 3 SH-50806A A+
7 CP- CW- 4 A-
15 DIR+ CCW+ 5 B+
8 DIR- CCW- 6 B-
C+
13 GND C-
Motor power
D+
D-
E+
E- Stepper motor
FG
Figure 2 49 Connection to SH-50806A (five-phase stepper drive unit)
If it is required, an external encoder is used to be a closed loop to prevent the

step-out of stepper motor.
Stepper drive Drive
HNC-21/22
unit transformer
XS30XS35 Shielding CNI/F Drive power
AC80 AC 1P
14 CP+ CW+ 3
7 CP- CW- AC80 380/80
4
15 DIR+ CCW+ 5
DIR- CCW- SH-50806A
8 6 A+ Stepper
1 A+ A-
motor
A- B+
9 B-
2 B+ C+ Motor power
10 B- C-
3 Z+ D+
D- SH-50806A
11 Z-
E+
4 +5V E- 1
12 +5V Optical
FG
5 GND encoder
13 GND Encoder feedback Shielding
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
2.9.3 Connection to Servo with pulse command

Up to six servos can be connected to HNC-21/22 through pulse interface of
XS30~XS35. Figure 2-51 is the overall connection between NC device and servo
with pulse command. Figure 2-52 and 2-53 are the two examples of connection to
servo with pulse command.
XS10XS12 Inputs (Status information of servo)
XS20XS22 Outputs (servo control signal, axis brake control)
HNC-21/22 Servo drive 1 Servo drive 2

Pulse Motor power Motor power
XS30
Position feedback
En coder Encoder
feedb ack feedback
Pulse
XS31
Servo motor 1 Servo motor 2
Position

Pulse Servo drive 3 Servo drive 4
XS32

Motor power Motor power
Position
Encoder Encoder
Pulse
feedbac k
XS33
feedback
Position Servo motor 3 Servo motor 4

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
Figure 2 52 Connection to Panasonic MINASA
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
Figure 2 53 Connection to Yasukawa SGDB
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
Motor revolution 2500
E-gear(NC) 1
E-gear(Servo) -1
Stepper motor (1: yes, 0:no) 0
- Machine parameters
Parameters Value
53
2. Connection
2.10 Design of E-Stop and Overtravel Released

There is an E-stop (emergency stop) button on both machine control panel of
HNC-21/22 and handwheel unit.
- It is used to stop NC machine immediately or turn off the main supply of power
devices (such as servo drivers), if there is an emergency.
- E-stop button shall be pressed, if there is an alarm message. Do not release
E-stop button until the alarm has been fixed. This E-stop button and one
normally open contact of auxiliary relay controlled by related circuits should be
connected to the inputs of HNC-21/22, so that the system reset signal can be
used.
There is an overtravel released button on the control panel of HNC-21/22. It is used

to release the overtravel, if the overtravel limit switch is pressed.
Table 2 18 Signals related to E-stop and overtravel released.
No. Signal Signal description Interface Pin Interface Interface
description type
1 ESTOP2 4 Handwheel
XS8
17 unit
2 ESTOP3 E-Stop loop terminal
17
DB25
3 ESTOP1 4 Y0.0~Y1.7
XS20
4 OTBS1 3 outputs
Overtravel Released terminal
5 OTBS2 16
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
Handheld unit HNC-21/22 24V GND

XS20 Axis1+Overtravel limit switch
3 OTBS1
Overtravel
released Axis1-Overtravel limit switch
but to n 16 OTBS2
E-stop button XS8 E-stop button Axis2+Overtravel limit switch
ESTOP2 4 4 ESTOP1
Axis2-Overtravel limit switch
ESTOP3 17 17 ESTOP3
Axis3+Overtravel limit switch
Axis4+Overtravel limit switch
KA
+24V
Figure 2 54 Recommended connection to E-stop and Overtravel released signal
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.
Suggestion for design:

PLC programs are required to implement the above mentioned contents such as
system reset signal, turning on and off the pilot lamp of overtravel released button,
and checking the overtravel axis and its direction. For more detailed information,
please refer to PLC Design Manual.
When the operator is writing PLC programs, please ensure that the axis would not
move if the overtravel is released in the wrong direction. The axis moves only when
its overtravel is released in the correct direction. Otherwise, a serious damage to the
ballscrew would happen. For more detailed information, please refer to PLC Design
Manual.
56
2. Connection
2.11 Design of Electromagnetic Compatibility

NC device shall be accorded with the requirement of electromagnetic compatibility in
JB/T 8832-2001 (General requirements for numerical control systems of machine
tools).
Electromagnetic Compatibility (EMC) refers to

- EMI (electromagnetic interference) level of electrical equipments shall not be
higher than the permitted level in the expected working environment.
- The anti-interference ability of device shall be strong enough to ensure working
normally in the expected working environment.
2.11.1 EMC of NC Device

EMC of NC device contains four elements:
- Voltage interruption and Temporary downwards voltage
NC system can work even if one of the following situations happens: AC power
supply is interrupted for the half of cycle during any cycle; the time of voltage
dropping is not more than one cycle, and the value is decreased to 40% rating.
- Anti-interference test with high-speed transient pulses
a) NC system can work, even if the peak of voltage pulses of 2KV and the
repetition rate of 5KHz are set between its AC power supply terminal and
the protection grounding.
b) NC system can work, even if the peak of voltage pulses of 1KV and the
repetition rate of 5 KHz are appended to I/O signal cables, data cables and
control cables through coupling clips.
- Anti-interference test with surge voltage
NC system can work even if a surge voltage of 10KV has been appended to AC
power supply, or a surge voltage of 2KV is overlapped across AC supply ground
terminal.
- Anti-interference test with static discharge
NC system can work, even if the touch discharge voltage of 6KV or the air
discharge voltage of 8KV is imposed where the operators often touch.
57
2. Connection
2.11.2 Grounding
There are three kinds of grounding: protection grounding (safety grounding), working
grounding (working grounding), shield grounding (shield grounding).
2.11.2.1 Safety Grounding

To prevent persons and equipments from thunderstroke, electrical leakage, and
static discharge, a ground, called protection ground, is connected to case or chassis.
It should be connected firmly with the real earth. For the basic requirements of
protection ground, please refer to Section 8.2 in GB5226.1-2008 (Electrical safety
of machinery-Electrical equipment of machines-Part 1: General requirements).
- Grounding type of TT (Figure 2-55) or TN-S (Figure 2-56) is recommended for

machine tool NC systems. TN-C type (Figure 2-57) is not allowed to use.
L1
L2
L3
PE
Device in
electric unit
Supply
ground
Operators Case or other Operators
electric unit conductive part electric unit
Ground of electric unit Ground of electric unit
T T
The outer conductive part of electrical equipment is connected to
ground directly. This ground is independent from the supply ground.
One point of the supply is connected to ground directly.
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
The neutral is separate from the protection earth (PE).

T N-S
supply ground directly.
Figure 2 56 TN-S type
L1
L2
L3
PEN
Device in Grounding
electric unit
Supply Case or other

Operators Operators
ground conductive part
electric unit electric unit
The neutral and the protection earth (PE) are combined.

T N-C
supply ground directly.
Figure 2 57 TN-C type

Note::
Note
It would be better not to lay a neutral in control cabinet. If it is used, identify the
neutral distinctively by N in installation diagrams, in schematic diagrams, and on
terminal boards.
It is not allowed to either connect neutral to ground within the control cabinet or
use a common terminal PEN (it refers to the terminal connecting neutral N to
protection earth PE).
59
2. Connection
- Essentials of safety grounding design
a) Protection ground terminals shall be used in electric unit. It can be marked
as or yellow-green double-colored sign. It is not allowed to replace the

protection ground terminal with a screwed joint on outer case or chassis.
b) The protection ground terminal shall be connected to case, chassis etc. The
continuity of protection ground circuit shall be met the criterion of
GB5226.1-2008 Section 8.2.
c) A grounding bus (the recommended thickness 3mm copper bar) shall be
connected to earth. The grounding resistance must be less than 4.

d) As it is shown in Figure 2-58, the protection ground terminals of electric unit
should be connected to the ground bus with the shortest and thickest
yellow-green double-colored wires.
Servo driver Y
Serv o driver X
Servo drive Z
Servo supply
Trans ducer
Supply

Grounding
bus
PE
X -axis Y-axis Z-axis Spindle Control cabinet
motor motor motor motor
Figure 2 58 Example of Protection Ground

e) Do not loop the protection ground wire. Figure 2-59 and Figure 2-60 show
the correct connection of safety grounding and the wrong connection of
safety grounding, respectively.
60
2. Connection
1 2 3 1 2 3
Servo drive
(Transducer)
M
Grounding Grounding Grounding

bus bus bus
Figure 2 59 Correction connection of protection ground
1 2 3 Servo drive
(Transducer)
M
Grounding Grounding
bus bus
Figure 2 60 Wrong connection of protection ground

f) Connecting the outer case to earth is the most effective measure to restrain
the static discharge interference. In case of discharging, the current flows
along outer case to earth directly, and the internal circuits would not be
affected.
g) Connecting the case to earth plays a role of shielding to reduce the
electromagnetic interference among equipments.
2.11.2.2 Working Grounding

It refers to the reference potential (0V) for electrical signals. The working ground
shall be connected correctly. Otherwise, it would even produce the interference,
such as common ground reluctance interference, ground loop interference,
common-mode current radiation, etc. There are four modes of working grounding:
floating grounding, single-point grounding, multi-point grounding, and mixed
grounding.
- Floating grounding
As it is shown in Figure 2-61, the working ground is insulated from metal case. It
is floated to protect internal circuits from external common-mode interference.
61
2. Connection
Metallic cover
case
Protection ground
Working ground
Shielding ground case
Figure 2 61 Floating Grounding

- Single-point grounding
Only one physical point is defined as reference ground in single-point grounding.
All other points in the circuit or equipment, which need to be grounded, are
connected to this point. If a system includes many devices, the ground of each
device is independent. The internal circuit of every device has its own
single-point ground. Then, the grounds of every device in this system are
connected to the unique reference point of the system. There are three types of
single-point grounding: series, parallel, and mixed.
1 2 3 1 2 3
(a) Single-point series (b) Single-point parallel
1 2 3 1 2 3 1 2 3 1 2 3
Analog ground Digital ground Noise ground Metallic ground
(c) Single-point mixed
Figure 2 62 Single-point Grounding

Single-point grounding is simple and easy to install, and its wiring is similar to
circuit diagram. The drawback is its long ground wire. When system frequency is
rather high, the ground reluctance increases, and the common ground
reluctance interference is produced. Meanwhile, the high frequency
tremendously increases the mutual interference among two grounds, or between
the ground and other wires, induced by capacitive or inductive coupling.
- Multi-point grounding
62
2. Connection
Connecting all the grounding points of equipment (or a system) directly to the
nearest grounding plane is referred to as multi-point grounding. It makes ground
wires as short as possible. The equipment chassis, the special ground wire, or
even the frame of the equipment may be taken as the grounding plane.
2 4
1 3
Figure 2 63 Multi-point Grounding

Multi-point grounding is simple to install, and it greatly reduces the
high-frequency stationary wave phenomena appeared in grounding wires.
However, it requires more maintenance on the wire in grounding loops of
multi-point grounding system. Some factors such as erosion, shock, and
temperature variation would increase the system reluctance and decrease the
grounding effectiveness.
- Mixed grounding
Based on the analysis of system, connect the points which require the nearest
grounding (or high frequency grounding through by-pass capacitors), directly to
the grounding plane. The single-point grounding is used to the rest of points.
- Essentials of working grounding design
a) Do not make any closed loop while designing the ground, because the
closed loop would induce an electromagnetic force (EMF) by the effect of
the external electromagnetic field, and then a current is produced. The
voltage drop of this current on the ground reluctance may result in the
common-reluctance.
b) The isolation measures, such as optoelectrical coupling, isolation
transformer, relay, and common-mode choke, are recommended to cut off
the grounding loops among devices or circuits, and to check the
common-reluctance coupling interference induced by the grounding loops.
c) Each circuit in the equipment, such as analogue circuit, digital circuit, main
circuit, interference circuit etc., shall be equipped with its own ground
(sub-ground), and connected to the general ground finally.
d) Generally, the low frequency circuits (f<1MHz) use dendriform emanant
63
2. Connection
single-point grounding. The length of ground wire shall not be longer than
one twentieth of the wave length of high frequency current of the ground
wire (i.e. =c/f, 1<<20, c: light speed). For the longer ground, it needs to
make their reluctance, especially inductance, as low as possible, for
example, increase the width of ground wires, use conductors having
rectangular cross section instead of round one as the ground wires, etc.
e) Generally, the high frequency circuits (f>1MHz) use multi-point grounding or
mixed grounding. For example, the circuit boards and chassis of industrial
control computer often use multi-point grounding.
f) The floating grounding (working ground is insulated from the metal case) is
only suitable for the small-scale equipments (the distribution of capacity
between circuits and the case is small) or the low speed circuits (its
frequency is low). For the large-scale equipments with complex circuits and
higher frequency, the floating grounding is not used.
g) In case there are a few electrical devices (or electrical units) equipped in the
control cabinet, the working ground, the protection ground, and the shielding
ground are connected to the central ground of the cabinet (grounding bus).
Then, they are connected to the earth to keep the cabinet, the devices, the
case, the shield, and working ground at the same potential level.
2.11.2.3 Shield Grounding

To check the interference, the shields of cables and transformers should be
grounded. The relevant ground wires are called shield ground wires. In a network
with low-reluctance, conductors with low-resistance are used to reduce interferences.
Therefore, the low-reluctance network (such as the case or the grounding board) is
often taken as the reference level of high-frequency signals in electrical equipments.
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.
- Essentials of shield grounding design

64
2. Connection
a) For the low-frequency circuits (f<1MHz), it is usually single-ended grounding.
The shielded cables shall be single-ended grounded. The single-ended
grounding plays the role of both active and passive shielding against
electrical fields. However, no shielding role against magnetic fields exists.
US US
(a) grounding at input end (b)grounding at output end
Figure 2 64 Shield grounding for low-frequency circuits

b) Single-point grounding is used, when the cable length L<0.15 (where =c/f).
In the power supply or load circuits, no matter what single-core or
multiple-core shielded cable, is connected to the ground at one end, and the
other end is insulated from the ground. The grounding point is the shield
ground. The best way of grounding the shielded cables is the grounding at
output end without a loop. Grounding at the input end can also work.
24V DC
(+) (-)
Step Motor
Drive
Stepper Motor
CP +
controller
CP -
NC device
DIR+
DIR-
Figure 2 65 Example of single-point shield grounding

c) For the high-frequency circuits (f>1MHz), it usually uses the double-ended
grounding. The shield of shielded cables shall be double-ended grounded.
Double-ended grounding plays the role of shielding against both electric
fields and high-frequency magnetic fields. The shield of shielded power
cables shall also be double-ended grounded.
65
2. Connection
Metallic case
Noise Frequency Noise

filter filter M
converter
>30cm
Signal line
Controller
Figure 2 66 Double-ended grounding of shielded cable
Servo
Servo motor
driver A
S
A Optical
B encoder
B
Z
Z
Figure 2 67 Double-ended grounding for encoder cables

d) When the cable length L>0.15 (=c/f), the multi-point grounding shall be
used. Grounding the cable shield at intervals of 0.05 or 0.1 is
recommended (at least to ground both ends of the shield) to decrease the
ground reluctance and reduce the interference induced by ground potential.
e) It is recommended to use shielded twisted pair to transmit signals between
NC device and servo drivers or frequency converter. In this case,
double-ended grounding is used.
f) The shield of input signal cables shall be grounded just where it enters the
device case. And the external interference signal is directly grounded to the
entrance of device case, rather than be grounded within the case to let it
rush into the device.
g) For the circuit with high input or output reluctance, especially in the
environment with the high static voltage, the double shielded cables can be
used. In this case, the internal shield is grounded at the source end, and the
external shield is grounded at the load end.
h) Avoid the so called pigtail effect while grounding the shield. To ground the
shield of multiple-core cables, the special metal clips are used.
66
2. Connection
2.11.3 Check Interference from Power Network

A good environment of power network is one of the key points to ensure safe and
reliable work to equipments. There are three measures commonly used to check the
network interference.
2.11.3.1 Supply Filter

The supply filter can check the network interference from coming into the equipment.
It can also check the interference of equipment from polluting the network.
- Essentials of supply filter design
1) The filter is installed where AC supply lines enter the cabinet. Do not make
the long distance of connection between AC supply lines and supply filter,
which is to check the radiating interference from cabinet.
2) In case the supply lines must be connected to the filter through fuses and
switches, the wires shall be shielded.
3) It is better to fix and connect the metal case of the filter directly onto the
metal cabinet, being as close as possible to the ground point on the cabinet.
4) The input and output lines of the filter shall be laid separately. Do not lay
them in parallel, especially not bundle up them together. Otherwise, the
interference from the input lines would be directly coupled to the output lines
without through the filter.
5) Use the double-twisted wires for the filter output wires to strengthen the
anti-interference ability.
6) In case there is much high voltage pulse interference in the power network,
the filter having better attenuation in a broader frequency band or connecting
to the ferrite ring filter in series is recommended to obtain better filtering
effect.
7) The current through the filter shall not be more than its maximum rating.
Otherwise, the inductance will decrease much and the filter will not effect,
because of the saturation in magnetic cores.
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.
5 turns Supply filter 4 turns

L1 L1 U Servo driver
L2 L2 V (Transducer) M
L3 L3 W
PE
Ground bus
Figure 2 68 Filter circuit for servo driver or frequency converter

Note: In Figure 2-68, the supply filter shall be only put at the input side of
servo driver (or frequency converter), instead of its output side. The ground
wire can also not be turned through the ring. In some cases, the ground wire
not passing through the ring makes the effect of filtering better.
68
2. Connection
2 turns 2 turns
L1 L1 Servo Driver
L2
L 2 (Frequency converter)
L3
L3
PE
Figure 2 69 Two magnetic rings connected in series

4) EMC filter, constructed by connecting the magnetic ring and the supply filter
in series, possesses better filtering effect.
5) While using the magnetic ring to check the common-mode interference in DC
supply and signal wires, it is better to pass either the positive and negative
lines or signals through the ring. Then, the ring is not easy to be saturated.
Magnetic ring Magnetic ring
+
+
DC supply
DC supply
+
Device
Device
+
- -
- -
(a) checking common-mode interference (b) checking difference-mode interference
Figure 2 70 Filtering circuit for DC supply

6) If the load reluctance using the magnetic ring or magnet ring is high, then the
magnetic ring will not be effective. The reason is that the reluctance of the
ring is only hundreds of ohm when the frequency is hundreds of mega-Hz.
Therefore, the ring is suitable for the circuits with low reluctance. Adding
capacitors in parallel after the ring to construct a filter similar to L-C type
would decrease the load reluctance much to improve the filtering effect.
L1
L2
L3
Figure 2 71 A typical circuit to check the transient pulse interference for AC supply
69
2. Connection
2.11.3.3 Isolation Transformer

The isolation transformer, a commonly used device to check the interference from
supply, acts basically the role of implementing the electrical isolation between
circuits. It prevents equipments from being disturbed by currents flowing in ground
loops. It reduces the common-mode interference to a certain extent. It works well in
checking the transient pulse series and the thunderstroke surge interferences
Generally, there are three types of isolation transformers: simple isolation

transformer, isolation transformer with shield, and super (multilayer) isolation
transformer.
Primary Primary Secondary

Secondary
(a) simple isolation transformer (b) isolation transformer with shield
Primary Secondary Primary Secondary
case
(c) super (multilayer) isolation transformer
Figure 2 72 Isolation Transformer

- Essentials of isolation transformer design
1) The isolation transformer with shield is widely used. The supper isolation
transformer is used only under special conditions.
2) Shield shall be grounded directly and with short and thick connection wires.
Otherwise, it wont work well in checking the high frequency common-mode
interference.
3) Separate the primary and secondary wires of isolation transformer. Do not
lay them in parallel, especially not bundle up them together. It is better to use
double-twisted wire for the secondary output line to improve the ability of
anti-interference from magnetic fields.
70
2. Connection
4) The isolation transformer works quite well in checking the high-voltage pulse
surged by the thunderstroke. With an additional surge blocked device, the
AC supply transformer works as an anti-thunderstroke transformer.
5) A collocation of isolation transformer and magnetic rings checks effectively
the interference induced by high speed transient pulse series.
Lightening rod Static shield C
Input Output
Surge absorber
Figure 2 73 Anti-thunderstroke Transformer

In Figure 2-73, the lightening rod is a gas discharge tube. The surge absorber is a
voltage sensitive resistance. The transformer with shield and capacitance at its
secondary side can check the remaining common-mode interference in surging.
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
AC Machine tool Other

voltage NC system equipment
stabilizer ss
PE
Figure 2 74 AC Voltage Stabilizer
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.
2.11.4.1 Check Interference in Analog Signals

1. Because of being apt to be disturbed, the analog signal wires shall have been
shielded and be laid as shortly as possible.
Frequency
converter
Speed
regulation
(the common end of

analogue signals
No connection to earth (floating potential)
Figure 2 75 Speed Regulation of Frequency converter

2. While servo drive or frequency converter is connected to the device with analog
output (NC device), there would be a wrong action caused by the interference
from the device with analog output, the servo drive, or frequency converter. In
this case, the capacitors with ferrite rings can be connected to the device with
external analog output signal to check the interference.
Passing or winding 2-3 turns in the same direction
Servo driver
C (Frequency
NC device converter)
Ferrite ring
0.022uf/50v
Figure 2 76 Filtering circuit for analogue signal wires
3. R-C lowpass is used to the analog signals with slow variation.
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
Figure 2 78 Current Transmission of Analogue Signal
2.11.4.2 Check Interference in Digital Signals
1. A resistance connected in series or a lowpass filter can be used to check the

wave oscillation of digital signals caused by the improper cabling and a large
loop of signal wires.
R Bead
Circuit 2
Circuit 2
Circuit 1
Circuit 1
(a) Inserting a damping resistance in series (b) Inserting a lowpass filter
Figure 2 79 Checking the digital signal oscillation

2. High frequency decoupling capacitors should be set at the connector ends of
input/output transmission wires. Generally, the frequency of I/O signals is lower
than the clocks. The selection of a high frequency decoupling capacitance
connected between I/O and the ground should ensure that I/O signals can work
normally and filter high clock frequency and its harmonics. Capacitance should
be connected between I/O wires and the ground wires.
3. A data circuit filter equipped at signal wires can check the high frequency
73
2. Connection
common-mode interference effectively. The filter is composed of ferrite rings or
hollow capacitors. For example, the cable can be equipped a ferrite ring near
the transformer. The best way is to use a connector with filter. Each socket of
this kind of connector contains a filter composed of a ferrite bead and hollow
capacitor.
4. The output signals coming from the optical encoder, electronic hand-wheel, and
raster ruler etc at the receiving end are connected to the capacitances in parallel,
which can check the interference with high frequency.
A
Position A
loop board Optical
B encoder
B output
Z
(NC device)
Z
0V 6C (ceramic)
C: 1nf~0.1uF
Figure 2 80 Connection with capacitance in parallel

5. Reduce the input reluctance of sensitive circuits. A capacitance or a resistance
with low ohm is connected in parallel to the input side of a CMOS circuit, which
can reduce the static electricity interference. For the differential transmission of
digital signal, a capacitance and a resistance are connected in parallel to the
input side of digital signals, which can improve the anti-interference ability.
NC device
RT CT
RT: 51~200
CT: 47~220PF
Figure 2 81 Reducing Input Reluctance
2.11.5 Prevention of Producing Interference

Besides checking the interference coming from outside, it also needs to take proper
measures to reduce the interference from NC unit. Shielding and the absorbent
circuit for inductive load are recommended.
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.
1. Electrical field shielding

If the interference is from the high-voltage and low-current, its radiation field is
mainly electrical. The electrical field shielding is to check the interference
induced by the electrical field coupling between the interference source and the
sensitive equipments.
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.
- Essentials of Electrical field shielding design

a. Grounding firmly with the metallic outer cases of power equipments (such as
servo drivers, frequency converters, stepper drivers, switching supply,
motors) is to construct active shielding.
b. Grounding firmly with the outer cases of sensitive equipments (such as NC
devices etc.) is to construct passive shielding.
c. Keep the power equipments far away from the sensitive equipments.
Generally, the equipment with strong current should be more than 30cm (at
least 10cm) far away from the equipment with light current in the same
cabinet.
d. Keep the power wires with high-voltage and large-current separate from the
signal wires. For example, use the independent slot, and keep more than
75
2. Connection
30cm (at least 5~7.5cm) far away. Try to avoid laying the wires in parallel.
up..
Do not tie those two kinds of wires up
e. Lay the signal wires as close as possible to the ground wires (or ground
plate), or use the ground wires to surround them.
f. The prerequisite for the shielded cables providing the passive and active
shield is that the shielding is grounded. More electrical field coupling
produced,, if the shielding is not grounded
would be produced grounded.
g. If the power wires cannot be laid separately from the signal wires, the power
wires shall be shielded and grounded reliably.
2. Magnetic field shielding

If the interference source is with low-voltage and large-current, its radiation is
mainly of magnetic field. The magnetic field shielding is to check the interference
induced by the magnetic coupling between the interference source and the
sensitive equipment. It is characterized as the low magnetic resistance of the
material with high magnetic conductibility, which can bypass the flux and reduce
the strength of magnetic field in the shield a lot.
- Essentials of Magnetic field shielding design

a. Use the material with high magnetic conductibility, such as permalloy, and
increase the thickness of shield properly.
b. Do not set the shielded items near the shied. Try to reduce the flux flowing
through the shielded objects,
c. Pay attention to the structure design of shield. For shield a stronger field, the
double-layer magnetic shielding can be employed.
d. Reduce the loop area of the interference source and the sensitive circuit. The
best way is to use the twisted wires or the shielded wires and make the
signal wire and the ground wire (or carrier loop) twisted together, which
makes the shortest distance between them.
e. Increase the distance between the interference source and the induced
circuits to make their mutual inductance as less as possible.
f. If possible, lay the circuit of the interference source perpendicular (or
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).
3. Electromagnetic field shielding

Electromagnetic field shielding is to check the interference from the
electromagnetic field coupling when the interference source is far away from the
sensitive equipment. It must shield both the electrical and the magnetic fields.
The materials with low resistance and good conductibility are usually used. The
electromagnetic waves are reflected and absorbed when they are reached the
metallic surfaces. The electromagnetic energy is then reduced a lot, so that the
shielding takes effect.
- Essentials of shielding box design

A. Structural Material
a) Plates made of copper, iron, aluminum or zinc-coated iron with the
thickness around 0.2~0.8 mm is generally taken as the shielding materials.
These plates shield the electrical field, the high frequency magnetic field,
and the electromagnetic field effectively (over 100dB).
b) The ferromagnetic material with high-conductibility is not used to make a
case, but on the components requiring the low-frequency magnetic
shielding.
c) For the plastic case, spray its inner surface with a conducting layer, or add
the metallic powder or fiber with high-conductivity during molding to make a
plastic case conductive.
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.
C. Inlets and Outlets

Generally, there are lead-in and lead-out of the supply lines and control
wires in the chassis. There are also some operational keys on the panel,
the interface for screen, vent etc. All of these may lead to serious leakage of
electromagnetic waves.
a) Pay attention to the reduction degree of the whole shielding effect, when the
cables are through the case. A typical unshielded cable decreases more
than 30dB of shielding effect, when it is passing through a shielded body.
b) All the supply lines shall pass through filter boxes while entering into the
case.
c) Any signal or control wires shall pass through a proper filter while coming
into or going out of the case.
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.).
bsorberr Circuit for Inductive Load

2.11.5.2 Absorbe
While being turned off, the inductive loads, such as relays, contactors,
electromagnetic valves, and motors, would produce intensive pulse interferences
and hinder other circuits from working normally. An absorber circuit is required to
check the transient interference. Figure 2-82 shows the schematic diagrams of the
absorber circuits.
Note: According to different requirements, the ends of inductive load can be

connected in parallel to the absorber circuits, such as resistance, voltage-sensitive
resistance, voltage reference diode, etc. However, R-C (arc extinguisher) circuit is
recommended because of its good absorbent effect. The extinguisher should be
installed as close as possible to the inductive load.
79
2. Connection
+24V
IN4001 KM
J
J
MC1413
R50~1 K
C0.1uf~2uf
R C
Output Arc Extinguisher

Interface
(b) The shunt R-C (arc extinguisher) for coils of

(a) The shunt diode for DC relay coil
AC relay, contactor, and electromagnetic valve.
KM
Arc Extinguisher
M
3~
(c) The arc extinguisher for AC three-phase AC induction motor
Figure 2 82 Absorber components for inductive loads
2.11.6 Summary of Design Guide

- The control cabinet must be made of cold-rolled steel plates. To keep the
electromagnetic consistency of cabinet, the single-body structure or welding is
recommended.
- The cabinet is made of zinc-coated steel plate to improve the grounding effect of
the system.
- In cabinet, each component is installed and laid separately according to the
power level (strong or light).
- The shield layer of all the shielded cables shall be grounded at their entrance
into the cabinet.
- The power wires and feedback wires of every feed drive motor or spindle motor
with drive shall be connected to the drive unit directly, not through the terminals.
80
2. Connection
- Use the shielded cables for the signal wires with the light current, such as the
position feedback wires, the command given wires, and the communication
wires. The cross section area of every single lead shall not be less than 0.2 mm2.
It is better to use the double-twisted, double-shielded cables.
- The twisted multiple core wires are recommended for the power supply cables in
the shielded cables of I/O terminal boards and encoder feedback, to raise the
anti-interference ability of signal supply and relevant components.
- The case of each component must be grounded reliably.
- A reliable common ground is required among components.
Figure 2-83 shows an example of comprehensive electromagnetic compatibility

design for a system including NC device, driver, AC induction motor, contactors and
valves. The logic control components (such as air switches, contactors, relays) and
their circuits are omitted.
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
Figure 2 83 Comprehensive electromagnetic compatibility design

Note:
1. The system should be connected reliably to ground and PE ground bar in the
control cabinet as close as possible. The grounding resistance must be less
than 4 ohm.
2. Grounding with the high-voltage (2000V) ceramic capacitances at the entrance
of power wires to cabinet (before the main air switch) with 3 phases reduces the
interference (pulse, surge) propagated along the supply cable obviously.
3. Wind the wire through the magnetic ring 4-5 turns.
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
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
The modified parameters would be effective only if NC device is restarted.

Thus, NC device shall be restarted once the parameters are modified.
parameters
Description of common terminology and buttons:

1. The index of parameters is shown in Figure 3-1.
Machine parameter
Axis parameter Axis 0~5
Servo parameter Axis 0~5
Parameter Axis compensation parameter Axis 0~5

index
PMC user parameter
DNC parameter
Quadrant transition parameters Axis 0~5
Figure 3 1 Index of Parameters

2. Screen: An area to display and modify the parameter values.
3. Buttons:
F1~F10: press one of these keys to implement the specific operation.
Enter: It is to confirm the operation.
, , , : It is to move the cursor.
Pgup, Pgdn: Press this key to move up/down one page.
85
3. Parameters
3.2 Setting Parameters

To edit a certain parameter, the operator must input the correct password first. Those
parameters are divided into three groups: CNC vendor, Machine tools vendor and
the operator. Users from different group have different password. If the password is
wrong or the privilege is low, then the parameter is not allowed to modify. For more
detailed information, please refer to HNC-21/22 operation manual.
86
3. Parameters
3.3 Description of Parameters

3.3.1 Machine Parameters
Spindle encoder RPM [CNC manufacturer]
Value: -32768~32767. The default value is 1024.
Description: The number of pulse per revolution of spindle sending from
the encoder to NC unit.
Turret direction [Operator]

Value: 0, 1. The default value is 0.
Description: 0: the positive direction of axis X is downward.
1: the positive direction of axis X is upward.
Diameter/Radius [Operator]
Description: diameter/radius programming
0: radius programming
1: diameter programming
Metric/Inches [Operator]
Description: measurement unit
0: unit of dimension is thousandth of an inch
1: unit of dimension is thousandth of a mini-meter
Power-off protection [Operator]

Description: 0: Power-off protection is disabled.
1: Power-off protection is enabled.
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.
Storage device [Operator] (only used in HNC-21/22 v7.11)

Description: 0: Floppy disk, 1: USB
System time [Operator]

Description: 0: enabled, 1: disabled
PMC axis [Operator]

Description: 0: disabled, 1: enabled
Spindle encoder direction [Operator]

Description: 32: +; 33: -.
Tool offset type [Operator] (not used in HNC-21/22 v7.11)

Description: 0: the type of tool offset is absolute.
1: the type of tool offset is incremental.
Tool wear-off accumulation [Operator] (not used in HNC-21/22 v7.11)

Description: 0: no, 1: yes
88
3. Parameters
The number of digits after the decimal point of coordinates value (not used in
HNC-21/22 v7.11)
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.
Disk name of USB (not used in HNC-21/22 v7.11)

Description: 0: A, 1: D, 2: E, 3: F, 4: G
3.3.2 Axis Parameters

In this section, Axis 0 is taken as an example.
External pulse equivalent(m)/External pulse equivalent [machine manufacturer]

Value: -32768~32767.
Milling: the default value is 1/1.
Turning: the default value is -2/5.
Description: It is the actual pulse equivalent of the coordinate axis, i.e. each
position unit corresponding to the moving distance or turning
degree of actual coordinate axis, namely the electronic gear
ratio of the system.
External pulse equivalent( m) moving distance or degree at each revolution( m)
=
External pulse equivalent pulses for each revolution
It is used to set the gear ratio. It can also be used to set the
motor direction by changing the sign of electronic gear ratio.
Take the servo motor encoder with 1000p/r as an example, the
lead screw is 6mm, and the gear reduction ratio is 2:3. Then,
External pulse equivalent(m) is 6mm*2/3=4mm (i.e. 4000m),
4000/10000=2/5.
External pulse equivalent(m) is 2 and External pulse
equivalent is 5, which equals to 4/10.
89
3. Parameters
Positive software limit position [machine manufacturer]

Unit: m or 0.001
Description: One axiss positive software limit position in M.C.S. It is only
valid after the reference point return.
Negative software limit position [machine manufacturer]

Unit: m or 0.001
Value: -2147483648~2147483647. The default value is -8000000.
Description: One axiss positive software limit position in M.C.S. This is
only valid after the reference point return.
REF direction [machine manufacturer]

Value: [+], -. The default value is +.
Description: The initial movement direction when approaching the
reference point. The tool would move towards the opposite
direction, if the reference point switch is pressed while
sending the reference point return command.
REF point position [machine manufacturer]

Unit m or 0.001
Description: Generally, MCS origin is set as the reference point return. It is
usually set as 0.
REF point offset [machine manufacturer]

Unit m or 0.001
Description: The certain distance the tool is moved after the pulse Z is
found. Then, the reference point is set.
90
3. Parameters
Rapid traverse speed at REF [machine manufacturer]
Unit: mm/min or degree/min
Value: 0~65535.
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.
Positioning speed at REF [machine manufacturer]

Unit mm/min or degree/min
Value: 0~65535. The default value is 200.
Description: Speed after reaching the reference switch
Note: It must be less than the rapid traverse speed for homing.
Uni-directional positioning offset [machine manufacturer]

Unit: m or 0.001
Value: -32768~32767.
Description: When G60 is used, the offset is the deceleration distance
from rapid traverse speed to positioning speed.
Note: If the offset is more than 0, it is positive positioning.
91
3. Parameters
If the offset is less than 0, it is negative positioning.
Rapid traverse speed [machine manufacturer]

Value: 0~65535.
Description: When G00 is used, the tool is moved at this speed.
Note: Rapid traverse speed is the highest speed among the
parameters. This speed is related with External pulse of
equivalent(m)/External pulse of equivalent or External pulse
of equivalent(0.001)/External pulse of equivalent. And it
should be set properly, so that it would be within the range of
motor revolution.
For example, the rated speed is 2000rpm, and the motor is
connected to ballscrew (the screw-pitch is 6mm) through a
pair of synchronous notched belts (the transmission ratio is
1:1.5). Then, the rapid traverse speed is equal or less than
8000mm/min (speed2000*(1/1.5)*6=8000mm/min).
Maximum feedrate [machine manufacturer]

Value: 0~65535.
Description: When G01 and G02 are used, the tool is moved at this speed.
Note: This parameter is related with the machining request,
mechanical revolution and load capability. This speed should
be less than the rapid traverse speed.
Jerk time for rapid traverse [machine manufacturer]

Unit: ms
92
3. Parameters
Value: 0~800.
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.
Jerk for rapid traverse [machine manufacturer]

Unit: ms
Value: 0~150.
Description: It refers to the acceleration during the rapid traverse
movement. It is usually set as 8, 16, 32, 64, or 100. The larger
this value is, the less variation of jerk is.
Note: It is usually set between 8 and 100, which depends on the
motor, the performance of the drive, and the capability. For
Jerk time for machining [machine manufacturer]

Unit: ms
Value: 0~800.
Description: It refers to the required time from 0m/min to 1m/min (or from
1m/min to 0m/min), when G01 (or G02 etc) is used. The
larger this value is, the less the speed variation is.
93
3. Parameters
Jerk for machining [machine manufacturer]

Unit: ms
Value: 0~150.
Description: It refers to the variation of acceleration during machining. It is
usually set as 8, 16, 32, 64, or 100. The larger this value is,
the less the variation of acceleration is.
Positioning tolerance [machine manufacturer]

Unit: m or 0.001
Value: 0~255.
Description: It refers to the maximum offset when the axis is positioning.
servo, the performance of drive, and the capability. If this
parameter is too small, the system would be held. If it is too
large, the machining precision would be affected. The worse
the machine transmission and precision are, the larger this
value is. The worse the machining precision is, the less this
value is.
If the stepper motor is used, this value can be set as integral
times each steps pulses.
If the value of this parameter is less than the backlash, a halt
would occur during backlash. The reason is that clearing the
94
3. Parameters
backlash must within the range of the position tolerance.
3.3.3 Servo Parameters

In this section, servo parameters-Axis 0 is taken as an example.
Servo Type [CNC manufacturer]

Description: 45: Servo with position feedback.
46: Servo without position feedback, such as stepper motor.
Position-loop open-loop gain [CNC manufacturer] (not defined)

Position-loop feedforward coefficients [CNC manufacturer] (not defined)
Speed-loop ratio coefficient [Machine manufacturer] (not defined)
Speed-loop integration time constant [Machine manufacturer] (not defined)
Maximum torque [CNC manufacturer] (not defined)
Rated torque [CNC manufacturer] (not defined)
Maximum track error [CNC manufacturer]

Unit m or 0.001
Description: It refers to tracking error threshold. An alarm message will be
shown, if the number of actual tracking error is more than this
value. If the value is 0, it means that the alarm function is
deactivated.
Motor revolution [CNC manufacturer]

Unit: pulse
Description: It refers to the number of pulses which NC can get from each
revolution of the motor, i.e. It is the number of pulses sending
from servo drive or servo motor to NC device. Generally, it is
pulses from servo motor position encoder.
95
3. Parameters
Stepper motor pulses [CNC manufacturer]

Value: 0~65535.
Description: For example, the pulse of stepper motor with 2 phases is 4.
E-gear(NC)/E-gear(Servo) [CNC manufacturer]

Value: E-gear(NC) could be 0~65535. The default value is 1.
E-gear(Servo) could be 0~65535. The default value is -1.
Description: E - gear(NC) NC command pulse
=
E - gear(Servo) feedback pulse received from NC
REF point zero-pulse input [CNC manufacturer]

Description: 1: enabled; 0: disabled
Stepper motor [CNC manufacturer]

Description: 1: stepper motor; 0: no stepper motor
Note: It is recommended that do not change the setting of servo parameters

during the operation.
3.3.4 Axis Compensation Parameters

In this section, the axis compensation parameters axis 0 are taken as an example.
Reversed gap [machine manufacturer]
Unit m or 0.001
Description: This value is used for the measurement of machine operation
area. It should be set as 0, if the bi-directional pitch
compensation is used.
96
3. Parameters
Pitch compensation type [machine manufacturer]

Value: 0, 1, 2, 3, 4. The default value is 0.
Description: 0: no compensation
1: uni-directional, 2: bi-directional, 3: extended uni-directional,
4: extended bi-directional
Pitch comp point [machine manufacturer]

Value: 0~127/0~5000. The default value is 0.
Description: For uni-directional compensation, the maximum value is 128.
For bi-directional compensation, the maximum value is 64.
For the extended compensation, the maximum value is 5000.
Index of REF point [machine manufacturer]

Value: 0~127/0~5000. The default value is 0.
Description: The sequence number of the reference point in the offset
table. The rule is that the compensation points are ordered
increasingly and the index starts with 0.
For example, four points are ordered as follows: -180, -120,
-60, 0. Then, if the reference point is 0, the index number of
the reference point is 3.
If the four points are ordered as follows: 0, 60, 120, 180, and
the reference point is 0, the index number of the reference
point is 0.
Pitch comp point interval [machine manufacturer]

Unit: m or 0.001
Description: The distance between two adjacent compensation points.
Offset [machine manufacturer]

Unit m or 0.001
97
3. Parameters
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.
The following example is about the pitch compensation:

Given that: the reference point on X axis is 0, the direction of reference point return
is positive, the positive software limit is 2000m (2mm), the negative software limit is
-602000m (-602mm), the compensation interval within the limit is 40mm, and there
are 16 (600/40+1=16) points. The points are ordered as follows: -600, -560, -520,
-480, -440, -360, -320, -280, -240, -200, -160, -120, -80, -40, 0. Then, the index
number of the reference point is 15.
The following program is about measuring the pitch error:
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
M98 P2222 L15 ; call the subprogram (2222) fifteen times
ENDW ; end of the cycle
M30 ; stop
%1111 ; the subprogram name

G91 X-40 F1000 ; move the tool 40mm in the negative direction on X axis
M99 ; end of the subprogram
%2222 ; the subprogram name

G91 X40 F500 ; move the tool 40mm in the positive direction on X axis
M99 ; end of the subprogram
3.3.5 PMC User Parameters

P[0] ~ P[99]
Description: It is used in PLC programming.
PLC parameters can be modified by setting these PMC user
parameters instead of editing PLC source code. For example,
the time for lubricant on/off, the maximum spindle speed, the
spindle orientation speed etc.
3.3.6 DNC Parameters

COM [operator]
Description: It is the port used in DNC communication.
99
3. Parameters
Data length [operator]

Value: 5, 6, 7, 8. The default value is 8.
Description: It is the data length during DNC communication.
Stop bit [operator]

Description: It is the stop bit during DNC communication.
Parity check (operator)

Value: 0, 1, 2. The default value is 0.
Description: 0: without parity check
1: odd-parity check, 2: even-parity check
Baud rate [Operator]

300..,9600..,38400..,115200
Description: It should be same as the value on PC.
3.3.7 Quadrant Transition Parameters

In this section, the quadrant transition parameters axis 0 are taken as the example.
Compensation value (Quadrant error) [Operator]
Unit: m
Description: It is the compensation for the shaking error caused by the
mechanic installation at the reversed point, when the axis is
moving towards the reversed direction.
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.
Acceleration time (operator)

Unit: ms
Deceleration time (operator)
Unit: ms
Description The characteristics of acceleration/deceleration while setting
the compensation
101
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
4.1 Checking before Operation

4.1.1 Inspection of Wiring
Make sure that all cables are connected correctly, especially:
- The polarity of damper diodes for relays and solenoid valves (please refer to
Chapter 1).
- The phase sequence of strong current cables on motor.
- Position control cable and position feedback cable of feeding device and strong
current cable on motor shall be connected to the corresponding interface as
shown in Figure 4-1.
HNC--21/22
HNC Servo drive unit Servo
XS30
motor
Connect to the same

servo driver Connect to the same
servo driver
Figure 4 1 Correspondence of cables

- Ensure the type of analog voltage command received by spindle unit, and check
the wires to avoid damages to the related circuits. If it is 0~10V, AOUT2 (pin 14
and pin 15) of XS9 should be used. If it is -10V~+10V, AOUT1 (pin 6 and pin 7) of
XS9 should be used.
- Make sure that all grounding wires are reliable and correctly connected.
- Make sure that the emergency stop button and emergency stop circuit are
effective. Pressing the emergency stop button down or cutting off the emergency
stop circuit can cut out the power supply of moving units such as feed driver,
spindle motor with drive unit etc or enable signals. Please refer to Chapter 2.10
for the design of emergency stop circuit.
4.1.2 Inspection of Power

- Make sure that the voltage and the polarity of each part of the circuit are correct,
and the circuit of power supply shall not be short circuit.
103
4. Commissioning
- Make sure that the specification of each part of the power supply is correct.
- Make sure that the specification of each transformer in the circuit is correct, and
the directions of I/O wires are connected in correct direction.
4.1.3 Inspection of Device

- Make sure that each motor (spindle motor, feed motor) in the system is
separated from mechanical transmission part, and reliably set down and fixed.
- Make sure that each power supply switch, especially the power supply switch of
servo drive is off.
104
4. Commissioning
4.2 Trial Operation

4.2.1 Power On
Before the NC device is turned on or off, press E-stop button to avoid the
motor trembling instantly caused by the connection or disconnection
between the servo drive power supply and the servo control power
supply at the same time.
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.
4.2.2 Setting Parameters

After HNC-21/22 device is turned on, please ensure the setting of parameters is
suitable for the hardware. It is recommended to check and set parameters in the
following order. For detailed information, please refer to Chapter 3.
- Servo Parameters
Parameters Value
Servo Type (45: with feedback, 46: without feedback) * 45/46
Maximum track error (m) 12000
Stepper motor pulses * 0
E-gear(NC) 1
E-gear(Servo) -1
REF point zero-pulse input (1:enabled, 0:disabled) 0
Stepper motor (1: yes, 0:no) * 0/1
*: Those three parameters should be updated at the same time.
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.
- PMC User Parameters

Please follow the instruction of PLC programming to set PMC user parameters.
Do read the PLC programming manual and set the parameters
according to the hardware configuration.
Attention
Attention: In PLC programming, the parameter shall not be set as 0, if
one PMC user parameter is taken as denominator (such as spindle
speed gear ratio). Otherwise, the system would crash.
- Axis compensation parameters

All of the parameters are set as invalid.
- Quadrant transition parameters

All of the parameters are set as invalid.
- 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
4.2.3 Inspection of External Status

Do the following inspections before the servo power is on:
- Check each feed drive unit and spindle motor with drive unit, after power is on.
- Check the required status reply signal, such as feed drive, spindle motor with
drive unit etc.
4.2.3.1 PLC I/O Status

4.2.3.1PLC
The operator can check the status of I/O signal (register X, Y) by inspecting PLC
107
4. Commissioning
status. Moreover, the user can commission PLC program by inspecting the status of
the register G, F, P, B, R, which is used for PLC programming.
To monitor PLC status, the operator can press DGN function key on MCP of NC
device. For detailed information, please refer to the operation manual of HNC-21/22.
Figure 4-2 shows the PLC status on the screen of NC device.
Figure 4 2 PLC I/O Status

The values of register X and Y are shown in binary. One group is composed of eight
bits, and each bit represents one bit of external PLC input or output signal. For
example, X[00] includes 8 bits, which represents the inputs of X0.1~X0.7 from right
to left, respectively, and X[01] represents the inputs of X1.0~X1.7 etc. Y[00]
represents the outputs of Y0.0~Y0.7, and Y[01] represents the outputs of Y1.0~Y1.7.
If the status of the connected input component varies (such as 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.
4.2.3.2 PLC I/O Address

4.2.3.2PLC
PLC I/O addresses of HNC-21/22 device are defined as follows:
No. Register Interface Descriptions
PLC inputs
1 PLC inputs
X2.4X4.7 XS11, XS8
two interfaces of X4.0~X4.7 are connected in parallel.
108
4. Commissioning
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
PLC outputs
1 Y2.0Y3.7 XS21, XS8
two interface of Y3.4~Y3.7 are connected in parallel.
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
4.2.4 Servo Power On
4.2.4.1 Checking before Servo Power On

4.2.4.1Checking
If any parameter is modified, the operator shall keep the power supply of NC device
off for three minutes, and turn it on again. Then, do the following steps:
- If the spindle encoder is used, the operator can rotate the axis of encoder to
monitor the variation of spindle rotation, which can check the setting of spindle
encoder.
- When the servo unit is connected to the control power supply, the position
feedback control circuit is in the working mode. The operator can monitor the
actual position feedback by checking the actual position from NC device, such as
MCS (machine coordinate system), WCS (workpiece coordinate system), and
RCS (relative coordinate system). For more detailed information about viewing
the actual position from NC device, please refer to the operational manual of
HNC-21/22. Then, the setting of axis parameters and the connection between
servo and NC device can be checked.
4.2.4.2 Turn Servo Power On

4.2.4.2Turn
- Ensure PLC for the control logic of servo including the power supply, enabled,
and disabled function and the circuit are correct.
- Release the emergency stop button, and turn on the auxiliary relay on (chapter
2.10). Turn on the servo power supply or enable signal.
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4. Commissioning
- Ensure that the brake of motor is released. To check if the brake is released, the
operator can check the power supply of brake control (DC24V), or hear the
clatter when the brake is released at the instant of turning on the power supply.
- If the handwheel encoder is associated with the servo drive, this handwheel unit
can be used to directly control the motor operation and verify the connection
between servo unit and motor.
- The operator can turn on the enable signal of servo drive unit one by one, or
commission the axis of servo drive unit and the corresponding motor,
respectively.
- Check the reference point return on each axis, after the axis is commissioned.
For Stepper Motor Driver

- Ensure the type of pulse signal received by the stepper driver is the same as the
setting of the pulse type in HNC-21/22. For more detailed information, please
refer to Chapter 3.
- Ensure the correct number of beats of step motor is correct.
- Rotate the motor slowly and then quickly in jog or handwheel mode. If there is
abnormal sound or blocking during the motor rotation, please properly increase
the acceleration time for rapid traverse, jerk for rapid traverse, acceleration time
for machining, and jerk for machining.
- Related parameters
Servo parameters
Parameters Value
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
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4. Commissioning
Machine parameters
Parameters Value
For Servo Driver with pulse command

- Ensure the type of pulse signal received by the servo driver is the same as the
setting of the pulse type in HNC-21/22. For more detailed information, please
refer to Chapter 3.
- Ensure the correctness of the motor revolution in the setting of axis parameter. It
is usually feedback pulse from HNC-21/22 unit at each motor revolution. It is
usually the number of coil of motor encoder.
- Ensure the consistency of the variation between the feedback value during
motor rotation and NC device command value. The operator can control the
motor to move a short distance. Then, according to the variation of command
value and feedback value, set the sign of E-gear(NC) and E-gera(Servo) until the
variation of the feedback value is same as that of the command value.
- Control the motor to move a short distance (such as 0.1mm), and check if the
feedback value is same as the command value of the coordinate axis. If they are
not same, the operator shall set E-gear(NC) and E-gera(Servo). Then, the
command value and the feedback values of NC device are identical.
Thereafter, to fit with the variation of lead screw pitch and transmission ratio in
the machine connection, only two parameters i.e. External pulse of
equivalent(m)/External pulse of equivalent in axis parameter is required to
adjust. For more detailed information, please refer to chapter 3.
- Related parameters
Servo parameters
Parameters Value
Servo Type (45: with feedback, 46: without feedback) 45/46
E-gear(NC) and E-gear(Servo) 1
E-gear(NC) and E-gear(Servo) -1
111
4. Commissioning
Machine parameters
Parameters Value
112
4. Commissioning
4.3 PLC Commissioning

PLC function is offered in HNC-21/22. In aid of standard PLC application, the circuit
diagram of typical turning and milling system, the related parameters and PMC user
parameters, most NC turning machines and NC milling machines can be operated.
In addition, PLC programming package can be offered, if there are some special
requirements. Customers can edit PLC based on the standard PLC application.
4.3.1 Main Elements of PLC Commissioning

- Operate NC device to monitor PLC I/O status, and check the connection and
logic relationship of PLC inputs/outputs one by one against the circuit diagram of
machine tool.
- Check the overtravel limit switch of the machine tool and the alarm messages (a
normally open contact of the overtravel limit switch on each axis is connected to
the input interface).
4.3.2 Process of PLC Commissioning

- Check each button on the operation panel, the PLC input signals, the system
status and the action of the external logic circuit. For instance, if the coolant
button is pressed down, the button lamp should be on and AC contactor of
coolant motor should start to work. If it is pressed again, the lamp is turned off
and AC contactor of coolant motor should stop working.
- Set the input limit signal among the input signals to check if this signal can cause
the emergency stop and the alarm message can be shown. Usually, they are
X0.0~X0.7. For example, when X0.0 is connected, the alarm message about the
positive limit on axis X would be shown.
- Return the reference point on each axis. Set the reference point response signal,
and check whether each axis can implement the reference point return with the
correct direction or not.
- Connect the limit switch and the reference point return signal for each axis
correctly. Manually control the limit switch and the reference point switch, and
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4. Commissioning
repeat the above two commissioning steps to check these switches.
- Check the system alarm messages, the external alarm messages defined in
PLC program, and the corresponding system action, when each PLC input alarm
signal is inputted. For example, when the spindle alarm signal is valid, the
spindle and the machining program would stop.
4.3.3 Methods for PLC Commissioning

When PLC program cannot be executed in the expected procedure, the operator
can follow the following steps:
- Check PLC input status (register X) or system register (register G, F, P, B, R). If it
is not inputted correctly, check the external circuit. For the command M, S, T, the
operator should write a program including these commands, execute this
program in AUTO (automatic) or SBL (single block) mode, and monitor the
related registers during execution (PLC status cannot be got in MDI mode during
the execution).
- Check PLC output status (register Y) or system register (register G, F, P, B, R). If
it is not outputted correctly, check PLC program.
- Check if the electronic switch or the relay directly controlled by the PLC output
(register Y) can work. If not, check the wiring.
- Check if the contactor controlled by the relay or other switches (solenoid valve)
can work. If not, check the wiring.
- Check the execution unit, including motor, hydraulic circuit, pneumatic circuit etc.
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4. Commissioning
4.4 Machine Commissioning
4.4.1 Commissioning of Servo Parameters

Do check the effectiveness of the overtravel limit switch of the machine before
the machine commissioning.
- Check the PLC I/O status of NC device, and press the over-travel limit switch on
the machine to check the change of the corresponding PLC input status, and
check the connection of the over-travel limit switch.
- Rotate the motor slowly and then quickly in jog or handwheel mode.
- Set the acceleration time for rapid traverse, jerk for rapid traverse, acceleration
time for machining, and jerk for machining according to the running status. In
principle, the current of servo should not be too heavy during the start-up, the
shut-down, the acceleration and deceleration. The recommended current is not
more than three times rated current of servo.
- Check the consistency between the direction and distance of machine and the
corresponding commands from NC device. If not, the operator can modify the
value and sign of External pulse of equivalent(m) and External pulse of
equivalent in axis parameters.
- Move the axis slowly in jog or handwheel mode to verify the validity of over-travel
limit switch, the alarm messages, and the over-travel released button (please
refer to Chapter 2.10 for the operation of the over-travel released button).
- Depending on the condition of mechanical transmission and the requirement of
design, set the rapid traverse speed, the maximum federate, the rapid traverse
speed at REF, and the positioning speed at REF for each axis, correctly.
Note:
1) The rapid traverse speed is the maximum among these parameters.
2) The setting of speed should not lead to the over-rated revolution of
servo motor.
3) The rapid traverse speed at REF shall be higher than the positioning
speed at REF.
- According to the condition of mechanical transmission, set the acceleration time
for rapid traverse, the jerk for rapid traverse, the acceleration time for machining,
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4. Commissioning
and the jerk for machining for each axis to make each coordinate axis respond
quickly without too much impact on motor and mechanical transmission unit.
- Check the validity of over-travel switch for the reference point return.
Note 1: Do check the validity of over-travel limit switch before the
operation of reference point return.
1) Manually press the reference point switch during the movement of
machine tool to check the validity of the reference point return process.
2) Operate the machine tool and press the reference point switch by the
reference point block to check the validity of the process of reference
point return.
3) The recommended speed of reference point return is under
2000mm/min.
Note 2: The block of reference point shall be set within the certain
distance. The recommended length is above 30mm of the valid travel
distance. Otherwise, the block of reference point would be rushed over as the
high speed of reference point return.
Note 3: There shall be a certain amount of overlap between the reference
point block and the nearby over-travel limit switch to ensure that the
reference point return switch is not released, even if the over-travel limit switch
is pressed. The reference point return can be done correctly, when the
reference point switch just stops between the block of reference point and the
pressed over-travel limit switch. Figure 4-3 shows the installation of REF switch
and the over-travel limit switch. In the following figure, A means the block of
reference point, B means the over-travel limit block, a means the reference
point switch, and b means the over-travel limit switch. In these examples, the
block is fixed and the switch moves, when the machine tool moves.
REF direction REF direction
b B b B
A a A a
(a) Correct Installation-overlap (b) Incorrect Installation-without overlap
Figure 4 3 Installation of REF switch and over-travel limit switch

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4. Commissioning
- Check the effective travel range of each axis, and set the positive software limits,
the negative software limits in axis parameters (the software limit position is
usually set between the two over-travel limit switches). Check the software limit
protection after the reference point return.
- Check the direction and the speed of spindle rotation and set the related PLC
and D/A parameters (in general, they are set by PMC user parameters including
the transmission ratio of spindle transmission part, the initial voltage/slope/the
final voltage of D/A, the minimum speed, the maximum speed etc.), to reach the
running requirement of spindle.
Note: If the spindle is equipped with a brake, do release the brake unit before
running the spindle.
- Check other elements of PLC design, mainly including M, S and T commands,
the safety interlock relations etc.
4.4.2 Machine Error Compensation

Please read chapter 3 before setting the machine error.
Machine tool error compensation mainly includes the backlash and the pitch error
compensations, and these errors can be measured by the dial gauge, the block
gauge or the laser interferometer.
4.4.2.1 Backlash Error Compensation

4.4.2.1Backlash
For the small machine, the pitch error compensation is not usually done, while the
backlash is required to measure by using a dial gauge. The measurement is shown
as below:
G01command in MDI mode (not more than 1mm)
A same tool movement
B Reversed position
Reading data
Figure 4 4 Measurement of Backlash

Backlash error compensation (m) = |A B|; in which A is the value read from the
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4. Commissioning
dial gauge at position A, and B is the value read from the dial gauge at position B.
Example: A=3mm, B=2.75mm, then,

Backlash error compensation=3-2.75=0.25mm=25m
Note:
- Set the backlash error compensation to 0 before the measurement.
- Both backlash and pitch error compensation values can be measured by the
laser interferometer.
- If the bi-directional pitch error compensation is used, then the backlash can be
omitted, as it can be done through the bi-direction pitch error compensation.
4.4.2.2 Pitch Error Compensation

4.4.2.2Pitch
There are two kinds of pitch error compensation: unidirectional, and bi-directional.
The same offset for the positive and negative movement of feed axis is set in the
unidirectional compensation, while the different offset for the positive and negative
movement of feed axis is set in the bidirectional compensation. Generally, the
unidirectional pitch error compensation is used. The measurement is shown as
below:
A1~An+1: actual MCS position when the feed axis is moving in the positive direction;
B1~Bn+1: actual MCS position when the feed axis is moving in the negative direction;
Offset(m)=Programming coordinate value in MCSActual coordinate value in MCS;
Please refer to Chapter 3 for the program of measuring the pitch error.
Reading data
A1 A2 An An+1

B1 B2 Bn Bn+1
Clear backlash Clear backlash
Figure 4 5 Measurement of Pitch Error

In general, the offset interval is about 50mm.
Please set the offset parameters as 0 before the measurement of compensation.
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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.
Therefore, the compensation parameters for axis Y shall be set as below:

- Unidirectional pitch error compensation
Parameter Name Value Description
Backlash (m) 30 Take -200 as the coordinate value
Pitch compensation type 1 Unidirectional pitch error compensation
Pitch compensation point 9
Index of REF point 8
Pitch comp point interval (m) 50000 50mm
Offset (m) [0] 100 (-400)-(-400.10)
Offset (m) [1] 80 (-350)-(-350.08)
The data in the
Offset (m) [2] 50 (-300)-(-300.05) negative direction
Offset (m) [3] 60 (-250)-(-250.06) are used.
The offset for the
Offset (m) [4] 40 (-200)-(-200.04)
reference point is
Offset (m) [5] 20 (-150)-(-150.02) usually zero, as
Offset (m) [6] 10 (-100)-(-100.01) REF point is at the
initial position.
Offset (m) [7] 5 (-50)-(-50.005)
Offset (m) [8] 0 (0)-(0) (reference point)
- Bidirectional pitch error compensation

Parameter Name Value Description
Backlash (m) 0 It is usually set as 0.
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4. Commissioning
Pitch compensation type 2 Bidirectional pitch error compensation
Pitch compensation point 9
Index of REF point 8
Pitch comp point interval (m) 50000 50mm
Offset (m) [0] 150 (-400)-(-400.15)
Offset (m) [1] 120 (-350)-(-350.12)
Offset (m) [2] 100 (-300)-(-300.10)
Offset (m) [3] 100 (-250)-(-250.10)
the data in the
Offset (m) [4] 70 (-200)-(-200.07)
positive direction
Offset (m) [5] 60 (-150)-(-150.06)
Offset (m) [6] 40 (-100)-(-100.04)
Offset (m) [7] 50 (-50)-(-50.05)
Offset (m) [8] 30 (0)-(-0.03) (reference point)
Offset (m) [9] 100 (-400)-(-400.10)
Offset (m) [10] 80 (-350)-(-350.08)
Offset (m) [11] 50 (-300)-(-300.05)
Offset (m) [12] 60 (-250)-(-250.06)
the data in the
Offset (m) [13] 40 (-200)-(-200.04)
negative direction
Offset (m) [14] 20 (-150)-(-150.02)
Offset (m) [15] 10 (-100)-(-100.01)
Offset (m) [16] 5 (-50)-(-50.005)
Offset (m) [17] 0 (0)-(0) (reference point)
Note: When the laser interferometer is used to measure the pitch error, it is
necessary to measure more than once. And the measurement software 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.
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4. Commissioning
4.5 Commissioning of Spindle D/A Parameters

The output voltage of AOUT1 of spindle D/A is -10V~+10V. The output
voltage of interface AOUT2 of spindle D/A is 0V~+10V. In default,
AOUT1 is used.
- 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.
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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.
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5.2 Typical Design NC Milling System
5.2.1 Brief Introduction

- Machine tool: Milling machine with four axes;
- Structure of control cabinet: strong current control cabinet + suspension box
- Spindle: spindle servo driver, hydraulic drive shift (high, low gear).
The following table shows the main components in the design of NC milling system.
Table 5 1 Main components in the design of NC milling system
No. Name Specification Description
1 NC device HNC-21MD Control system
Handwheel
2 HWL-1001 Manual control
unit
Power supply for servo control and
AC380V/220V 300W
switch
Control Power supply for heat exchanger
3 /110V 250W
transformer and AC contactor
/24V 100W Power supply for spotlight
/24V 100W Power supply for HNC-21MD
Feeding servo
4 6KW Power supply for HSV-18D
reactor
Spindle servo
5 5.5KW Power supply for HSV-18S
reactor
Switching
6 AC220V/DC24V 50W Switch and auxiliary relay
power supply
Switching Driving shaft (axis Z) brake and
7 AC220V/DC24V 100W
power supply electromagnetic valve
8 Servo driver HSV-18D-025 Axis X/Y/Z/C motor drive unit
Spindle motor
9 HSV-18S-050 Spindle motor drive unit
with driver
10 Servo motor GK6073-6AC61-FE (11NM) Axis X/Y feed motor
GK6073-6AC61-FB
11 Servo motor Axis Z feed motor
(11NM, with brake)
12 Servo motor GK6061-6AC61-FE (6NM) Axis C feed motor
13 Servo motor GM7103-4SB61(5.5KW) Spindle AC servo motor
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5.2.2 Overall Diagram
HNC-21MD Encoder
XS9 HSV-18S Spindle motor

Front panel
PC keyboard
XS10,XS11 On-off inputs (Operational button,
XS2
machine tool inspection)
XS20 On-off outputs (servo, relay)
RS232 XS5
Encoder feedback on Axis X
USB XS7
XS30 HSV-18D servo X Servo motor X
Encoder feedback on Axis Y
Ethernet XS3
XS31
HSV-18D servo Y Servo motor Y
Encoder feedback on Axis Z

Handheld unit XS8 XS32
HSV-18D servo Z Servo motor Z
Encoder feedback on Axis C

XS33 HSV-18D servo C Servo motor C

Figure 5 1 Overall Diagram of Typical Design of NC Milling System
5.2.3 I/O Specification

This section would introduce I/O of typical NC milling system. Some inputs/outputs
in this example are not used, even though they are defined.
I/O signals from X4.0X4.7/Y3.4Y3.7 of XS8 are connected to the same signals
of XS11 and XS21 in parallel. They are reserved for the handwheel unit, and directly
connected from XS8.
XS12 (DB25/F), XS21, and XS22 (DB25/M) are not used.
The interface description of XS8 (DB25/F PIN) of handwheel unit
13 5VG
Power supply for manual pulse generator (MPG)
25 +5V
12 HB Phase B from MPG
24 HA Phase A from MPG
11 Y3.4 Undefined
23 Y3.5 Undefined
10 Y3.6 Pilot lamp on handwheel unit, low level valid
125
22 Y3.7 Undefined
Axis X selection input on the handwheel unit, normally
9 X4.0
open contact, close valid
Axis Y selection input on the handwheel unit, normally
21 X4.1
Axis Z selection input on the handwheel unit, normally
8 X4.2
4th axis selection input on the handwheel unit, normally
20 X4.3
Override input x1 on the handwheel unit, normally open
7 X4.4
contact, close valid
19 X4.5
6 X4.6
Handwheel unit enabled input, normally open contact,
18 X4.7
close valid
5 NC
17 ESTOP3 Emergency stop button on the handwheel unit is
connected in series to the terminal of emergency stop
4 ESTOP2
loop.
3,16 +24V
DC 24V power supply for I/O on the handwheel unit
1,2,14,15 24V GND
The inputs of XS10 (DB25/F): X0.0~X2.3

Overtravel positive-limit switch on axis X, normally open
13 X0.0
Overtravel negative-limit switch on axis X, normally open
25 X0.1
Overtravel positive-limit switch on axis Y, normally open
12 X0.2
Overtravel negative-limit switch on axis Y, normally open
24 X0.3
Overtravel positive-limit switch on axis Z, normally open
11 X0.4
Overtravel negative-limit switch on axis Z, normally open
23 X0.5
Overtravel positive-limit switch on 4th axis, normally open
10 X0.6
contact, close valid (not used)
Overtravel negative-limit switch on 4th axis, normally open
22 X0.7
Reference point return switch on axis X, normally open
9 X1.0
Reference point return switch on axis Y, normally open
21 X1.1
Reference point return switch on axis Z, normally open
8 X1.2
Reference point return switch on 4th axis, normally open
20 X1.3
7 X1.4 Coolant alarm, normally close contact, open valid (not used)
126
19 X1.5 Lubrication alarm, normally close contact, open valid
6 X1.6 Hydraulic alarm, normally close contact, open valid
18 X1.7 Undefined
1st spindle gear (low speed), normally close contact, open
5 X2.0
valid
2nd spindle gear (high speed), normally open contact, close
17 X2.1
valid
4 X2.2 Undefined
16 X2.3 Undefined
3 NC
1,2,14,15 24V GND External DC 24V Ground

13 X2.4 Operation enabled, normally open contact, close valid
25 X2.5 Servo power ready, normally open contact, close valid
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
23 X3.1 Spindle speed arrived, normally open contact, close valid
10 X3.2 Zero spindle speed, normally open contact, close valid
Spindle orientation, normally open contact, close valid (not
22 X3.3
used)
9 X3.4 Axis X ready, normally open contact, close valid
21 X3.5 Axis Y ready, normally open contact, close valid
8 X3.6 Axis Z ready, normally open contact, close valid
20 X3.7 4th axis ready, normally open contact, close valid
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
The interface of XS20 (DB25/F): Y0.0~Y1.7

13 Y0.0 Operation enable, low level valid
25 Y0.1 Reset, low level valid
12 Y0.2 Servo enable, low level valid
24 Y0.3 Spindle enable, low level valid
11 Y0.4 Driving shaft brake, low level valid
23 Y0.5 Coolant on, low level valid
10 Y0.6 Tool released, low level valid
22 Y0.7 Undefined
9 Y1.0 Spindle CW (spindle enable), low level valid
21 Y1.1 Spindle CCW (spindle enable), low level valid
Spindle mode switch/spindle brake, low level valid (not
8 Y1.2
used)
127
20 Y1.3 Spindle orientation, low level valid (not used)
7 Y1.4 1st spindle gear (low speed), low level valid
19 Y1.5 2nd spindle gear (high speed), low level valid (not used)
6 Y1.6 Undefined (reserved for 3rd spindle gear, low level valid)
18 Y1.7 Undefined (reserved for 4th spindle gear, low level valid)
5 NC
The output terminal of the emergency stop loop to control
17 ESTOP3
the power supply and drive auxiliary relay (Figure 2-54)
The input terminal where the emergency stop loop and the
4 ESTOP1
overtravel loop are connected in series (Figure 2-54)
16 OTBS2
The input terminal of overtravel limit switch (Figure2-xx)
3 OTPS1
1,2,14,15 24V GND External power supply DC 24V Ground
5.2.4 Circuit Diagram

The following section describes the main parts of the circuit diagram. As to the wire
number, only those appeared in different pages are given.
5.2.4.1 Connection to Power Supply

5.2.4.1Connection
In this example, the spotlight and HNC-21 use their respective power supply of
AC24V. The electromagnetic valve and the PLC outputs (such as relay, servo
control signal etc) use their own power supply of DC24V. In addition, a low pass filter
is set between them.
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.
: this part of signals would be used in the other circuit diagrams.
128
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
RC2 Spindle servo electric reactor

U11
QF2 KM2 Spindle servo
20A 25A
AC380/200 V11
5.5KW W11 drive unit
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
Suspension fan Low-pass filter

QF9
AC220V AC250V
3A
300W 6A
Switch power AC220V/ Switch power AC220V/

100W DC24V 50W DC24V
Control
Auto-lubricant
transformer QF11 QF10
6A 3A
24V1
24V 100 220A 220B

KA6 KA9 KA10 KA7 101
To:
2100 servo on Axis Z
To: To:
V1 V2 V3 VZ
YV1 YV2 YV3 YVZ Relay Servo drive unit
NC unit Spindle drive unit
Servo drive unit
Spindle drive unit
Spindle Tool Spindle Brake on

gear valve valve lubricant Axis Z
valve
Figure 5 2 Circuit diagram of typical milling system power supply
129
5.2.4.2 Connection to Relay and I/O

5.2.4.2Connection
KA1~KA10 are relays with DC24V, and are controlled by the PLC output signals.
The PLC input signals are mainly from the status and alarm messages of feeding
drive unit, spindle motor with driver, the electric part of machine tool etc.
Servo Spindle Spindle Spindle Brake Coolant Tool Spindle
Operation External
OK CW CCW gear Axis Z on released lubricant
enabled operation
Y0.0 enabled 100 440 Y1.0 Y1.1 Y1.4 Y0.4 Y0.6 Y0.5 Y0.7
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
Figure 5 3 Circuit diagram of typical milling system Relay
As it is shown in Figure 5-3,

SQX-1 and SQX-3 are the normally close contact of the overtravel limit switch
(positive, negative) on axis X.
SQY-1 and SQY-3 are the normally close contact of the overtravel limit switch
(positive, negative) on axis Y.
SQZ-1 and SQZ-3 are the normally close contact of the overtravel limit switch
(positive, negative) on axis Z.
The limit switch is not required on Axis C, since it is rational worktable with 360.
400 is from the fault chain of the servo drive unit.
100 is the ground for the switch power supply with DC24V 50W (Figure 5-2).
130
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
Figure 5 4 Circuit diagram of typical milling system I/O 1

In the Figure 5-4, 100 and 24V are the outputs of the switch power supply with
DC24V 50W (Figure 5-2).
131
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
+24V 3 OTBS1 3 100

24VG 15 24VG 15 (Relay DC24V Ground)
24VG 2 Handheld unit 24VG 2
24VG 14 24VG 14
24VG 1 24VG 1 100
(Relay DC24V Ground)
Figure 5 5 Circuit diagram of typical milling system I/O 2
132
5.2.4.3 Connection to Spindle

5.2.4.3Connection
Power supply for drive unit XS6 XT1

220A 1 AC220 P 1
220B
1 2 AC220 Brake resistance
Refer to Figure 5-2 Spindle drive unit 70 1000W
Refer to Figure 6-32 HSV-18S-050
XS4 BK 2
100 KA5 KA4
22 Spindle CW R 3 U11 Power supply
KA4 KA5
20 Spindle CCW S 4 V11
1 for spindle
HNC-21/MD 27
T 5 W11 drive unit
XS20 Refer to Figure 5-2
Y0.1 PE 9
25 24 Spindle reset
24 Y0.3 25 Spindle enabled
Spindle motor fan
XS11 X3.0
11 3 Spindle alarm U Encoder
X3.2 U 6
10 1 Spindle zero speed V
X3.1 V 7 5.5KW
23 4 Spindle speed arrived W XS
100 W 8
26
100 Spindle
27
XS9 motor
S pindle command cable
XS3
27
Spindle motor encoder cable
Figure 5 6 Circuit diagram of typical milling system Spindle
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
5.2.4.4 Connection to Servo Drive Unit

5.2.4.4Connection
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
Figure 5 8 Circuit diagram of typical milling system Servo Drive Unit
134
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
Figure 5 9 Circuit diagram of typical milling system Servo drive cables
135
5.3 Typical Design NC Turning System

5.3.1 Brief Introduction
- Machine: horizontal lathe with two axes and 4-position automatic cutter saddle;
- Structure of control cabinet: strong current control cabinet + operation station;
- Spindle: common AC induction motor, mechanic hand-gear;
The following table shows the main components in the design of NC turning system.
Table 5 3 Main components in the design of NC turning system
No. Name Specification Description
1 NC device HNC-21TD Control system
Power supply for servo control and
AC380V/220V 100W
switch
Control
2 /110V 100W Power supply for AC contactor
transformer
/24V 100W Power supply for spotlight
/24V 100W Power supply for HNC-21TD
Servo
3 3P AC380V/220V 2.5KW Power supply for servo drive unit
transformer
Switching
4 AC220V/DC24V 50W Switch and auxiliary relay
power supply
5 Servo driver HSV-160-030 (2 sets) Axis X/Z motor drive unit
6 Servo motor GK6071-6AC31-FE (6NM) Axis X feed motor
7 Servo motor GK6072-6AC31-FE (7.5NM) Axis Z feed motor
5.3.2 Overall Diagram
HNC-21TD
Front panel Spindle encoder
XS9
PC keyboard XS2 Spindle motor
RS232 XS5 On-off inputs (Operational button,

XS10,XS11
machine tool inspection)
USB XS7
XS20 On-off outputs (servo, relay)
Encoder feedback on Axis X

Ethernet XS3
XS30 HSV-160 servo X Servo motor X
Encoder feedback on Axis Z

Handheld unit XS8

XS32 HSV-160 servo Z Servo motor Z
Figure 5 10 Overall Diagram of Typical Design of NC Turning System
136
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.
13 X0.0
25 X0.1
12 X0.2
24 X0.3
Overtravel positive-limit switch on axis C, normally open
11 X0.4
Overtravel negative-limit switch on axis C, normally open
23 X0.5
Chuck clamped, normally open contact, close valid (not
10 X0.6
used)
Chuck released, normally open contact, close valid (not
22 X0.7
used)
9 X1.0
21 X1.1
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
5 X2.0
valid (not used)
17 X2.1
valid (not used)
4 X2.2 Undefined
16 X2.3 Undefined
3 NC
137
Servo power OK, normally open contact, close valid (not
25 X2.5
used)
24 X2.7
close 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
8 X3.6 Tool 5 OK, normally open contact, close valid (not used)
4-7, 16-19 X4.0-X4.7
to XS8.
3 NC
The interface of XS20 (DB25/F): Y0.0Y1.7

10 Y0.6 Turret CW, low level valid
22 Y0.7 Turret CCW, low level valid
8 Y1.2
used)
20 Y1.3 Chuck released, low level valid (not used)
7 Y1.4 1st spindle gear (low speed), low level valid (not used)
6 Y1.6 Undefined
18 Y1.7 Undefined
5 NC
17 ESTOP3
4 ESTOP1
16 OTBS2
The input terminal of overtravel limit switch (Figure 2-54)
3 OTPS1
138
5.3.4 Circuit Diagram
The following section describes the main parts of the circuit diagram. As to the wire
number, only those appeared in different pages are given.
5.3.4.1 Connection to Power Supply

5.3.4.1Connection
In this example, the spotlight and HNC-21 use their respective power supply of
AC24V. The electromagnetic valve is not used. Only one DC24V 50W switching
power supply is used with a low pass filter at the input side of the switching power
supply to isolate from the servo control power supply (AC220V).
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
AC380V 3-phase
QF0 Servo transformer

40A RC1
R
QF1 KM1 To:
AC380/220 S
10A 2.5KW
T Servo drive unit
KM2
RC2
QF2 KM3
20A 5.5KW Spindle motor
KM4
RC3
QF3 KM5
Turret motor
0.4A
RC4
QF4 KM6
1A Coolant motor
QF5 QF9 Low pass filter

AC220V A C250 V
3A 1A
100W 2A
QF7
AC24V Switch power AC220V/
6A
100W Pilot 50W DC24V
lamp
AC380V Spotlight
QF10
400W 3A
QF6
AC24V NC unit
6A
100W HNC-21TD 24V 1 00 220A 220B
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
Servo Spindle Spindle Turret Turret Coolant

power CW CCW motor CW motor CCW m otor
Figure 5 11 Circuit diagram of typical turning system Power supply
140
5.3.4.2 Connection to Relay and I/O

5.3.4.2Connection
KA1~KA8 are relays with DC24V, and are controlled by the PLC output signals. The
PLC input signals are mainly from the status and alarm messages of feeding drive
unit, spindle motor with driver, the electric part of machine tool etc.
Operation External Servo Spindle Spindle Turret Turret Coolant

operation OK CW CCW CW CCW on
enabled
enabl ed
Y0.0 100 420 Y1.0 Y1.1 Y0.6 Y0.7 Y0.5
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
Figure 5 12 Circuit diagram of typical turning system Relay
As it is shown in Figure 5-12,

SQX-1 and SQX-3 are the normally close contact of the overtravel limit switch
(positive, negative) on axis X.
SQZ-1 and SQZ-3 are the normally close contact of the overtravel limit switch
(positive, negative) on axis Z.
420 is from the fault chain of the servo drive unit.
100 is the ground for the switch power supply with DC24V 50W (Figure 5-11).
141
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
Figure 5 13 Circuit diagram of typical turning system I/O 1
In the Figure 5-13, 100 and 24V are the outputs of the switch power supply with
DC24V 50W (Figure 5-11).
142
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)
Figure 5 14 Circuit diagram of typical turning system I/O 2
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
5.3.4.3 Connection to Servo Drive Unit

5.3.4.3Connection
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
Figure 5 15 Circuit diagram of typical turning system Servo Drive Circuit
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
Axis control cables Encoder cables

Figure 5 16 Circuit diagram of typical turning system Servo Drive Cable
144
6 Appendix
This chapter would introduce the description of product type, the dimension and the
interfaces of HNC-21/22.
145
6. Appendix
6.1 Product Type
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
Type of feed axis Memory type:

D: pulse interface for pulse servo or stepper motor driver F: Flash RAM
H: IDE hard disk
Figure 6 1 Description of HNC-21/22
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
PgUp Shift Upper
Del
PgDn Alt 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
aHNC-21
bHNC-22
Figure 6 2 Dimension of HNC-21/22
15
100
15
Figure 6 3 Dimension of Installation
147
6. Appendix
6.2.2 DNC Unit
Figure 6 4 Dimension of DNC unit
6.2.3 Handwheel Unit
Figure 6 5 Dimension of Handwheel Unit
148
6. Appendix
Figure 6 6 Installation Dimension of Handwheel Unit
149
6. Appendix
6.3 Interface Description

6.3.1 NC Device

XS1: Power supply interface XS2: Keyboard interface
XS3: Ethernet interface XS5: RS232 interface
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
- XS1: power supply interface (PLT-167)

24VG 1:AC24V1
AC24V2 +24V 2:+24V
3:NC
4:24V GND
5:AC24V2
PE 6:PE
AC24V1 7 :
AC24V1
1, 5 AC24V, or DC24V (power supply for HNC-21)
AC24V2
+24V
2, 4 DC24V (PLC power supply)
24VG
6 PE Protection grounding
- XS2: Keyboard interface (6 PIN)
1DATA
6 5
2NC
4 3 3GND
4VCC
5CLOCK
2 1 6NC

1 DATA Data
3 GND Power GND
4 VCC Power
5 CLOCK Clock
- XS3: Ethernet interface (RJ45)
8BI_D4-
7BI_D4+
6RX_D2-
5BI_D3-
4BI_D3+
3RX_D2+
2TX_D1-
1TX_D1+
151
6. Appendix
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: RS232 interface (DB9 PIN)
XS5
5GND
3TXD
2: RXD

2 RXD Receive data
3 TXD Send data
5 GND Grounding
- XS8: Handwheel unit interface (DB25 PIN)
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
X4.0~X4.7 Inputs on the handwheel unit
Y3.4~Y3.7 Outputs on the handwheel unit
152
6. Appendix
- XS9: Spindle interface (DB15 PIN)
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
- XS10, XS11, XS12: PLC inputs (DB25 PIN)
XS10 DB25 PIN XS11 DB25 PIN XS12 DB25 PIN

1 :24VG 14:24VG 1 :24VG 1 :24VG
14:24VG 14:24VG
2 :24VG 2 :24VG 2 :24VG
15:24VG 15:24VG 15:24VG
3 :NC 1 14
16:X2.3 3 :NC 1 14 3 :NC 1 14
16:X4.7 16:X7.3
4 :X2.2 4 :X4.6 4 :X7.2
17:X2.1 17:X4.5 17:X7.1
5 :X2.0 18:X1.7 5 :X4.4 5 :X7.0
18:X4.3 18:X6.7
6 :X1.6 19:X1.5 6 :X4.2 6 :X6.6
19:X4.1 19:X6.5
7 :X1.4 20:X1.3 7 :X4.0 7 :X6.4
20:X3.7 20:X6.3
8 :X1.2 8 :X3.6 8 :X6.2
21:X1.1 21:X3.5 21:X6.1
9 :X1.0 9 :X3.4 9 :X6.0
22:X0.7 22:X3.3 22:X5.7
10:X0.6 23:X0.5 10:X3.2 10:X5.6
23:X3.1 23:X5.5
11:X0.4 13 25 24:X0.3 11:X3.0 13 25 24:X2.7 11:X5.4 13 25 24:X5.3
12:X0.2 25:X0.1 12:X2.6 25:X2.5 12:X5.2 25:X5.1
13:X0.0 13:X2.4 13:X5.0
Signal Description
X0.0~X7.3 PLC input (60 bit)
153
6. Appendix
- XS20, XS21, XS22: PLC outputs (DB25 PIN)
XS20DB25 PIN XS21DB25 PIN XS22DB25 PIN

13:Y0.0 13:Y2.0 13:Y4.0
25:Y0.1 25:Y2.1 25:Y4.1
12:Y0.2 12:Y2.2 12:Y4.2
24:Y0.3 24:Y2.3 24:Y4.3
11:Y0.4 11:Y2.4 11:Y4.4
23:Y0.5 23:Y2.5 23:Y4.5
10:Y0.6 22:Y0.7 10:Y2.6 22:Y2.7 10:Y4.6 22:Y4.7
9 :Y1.O 21:Y1.1 9 :Y3.O 21:Y3.1 9 :Y5.O 21:Y5.1
8 :Y1.2 20:Y1.3 8 :Y3.2 20:Y3.3 8 :Y5.2 20:Y5.3
7 :Y1.4 7 :Y3.4 7 :Y5.4
19:Y1.5 19:Y3.5 19:Y5.5
6 :Y1.6 6 :Y3.6 6 :Y5.6
18:Y1.7 18:Y3.7 18:Y5.7
5 :NC 5 :NC 5 :NC
17:NC 17:NC 17:NC
4 :NC 4 :NC 4 :NC
16:NC 16:NC 16:NC
3 :NC 15:24VG 3 :NC 15:24VG 3 :NC 15:24VG
2 :24VG 2 :24VG 2 :24VG
14:24VG 14:24VG 14:24VG
1 :24VG 1 :24VG 1 :24VG
Signal Description
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
6.3.2 DNC Unit (optional)
Ethernet Interface
Ethernet switcher RS232 Interface
Ethernet switcher
PC keyboard interface
RS232 switcher
RS232 switcher
Figure 6 9 Interface of DNC unit

The front interfaces are used to connect with PC or other devices, and the switchers
are used to connect with HNC-21/22 (Generally, DNC unit is not required for
HNC-21). The interfaces in Figure 6-9 are same as the interfaces mentioned in
section 6.3.1.
6.3.3 Handwheel Unit (optional)
DB25 PIN
Figure 6 10 Interface of Handwheel unit
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
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
156
6. Appendix
6.4 Standard PLC I/O in milling system

13 X0.0
25 X0.1
Overtravel positive-limit switch on axis Y, normally open
12 X0.2
Overtravel negative-limit switch on axis Y, normally open
24 X0.3
11 X0.4
23 X0.5
Overtravel positive-limit switch on 4th axis, normally open
10 X0.6
Overtravel negative-limit switch on 4th axis, normally open
22 X0.7
9 X1.0
Reference point return switch on axis Y, normally open
21 X1.1
8 X1.2
Reference point return switch on 4th axis, normally open
20 X1.3
7 X1.4 Coolant alarm, normally close contact, open valid (not used)
19 X1.5 Lubrication alarm, normally close contact, open valid
6 X1.6 Hydraulic alarm, normally close contact, open valid
18 X1.7 Undefined
5 X2.0
valid
17 X2.1
valid
4 X2.2 Undefined
16 X2.3 Undefined
3 NC

25 X2.5 Servo power ready, normally open contact, close valid
24 X2.7
close valid
157
6. Appendix
23 X3.1 Spindle speed arrived, normally open contact, close valid
10 X3.2 Zero spindle speed, normally open contact, close valid
Spindle orientation, normally open contact, close valid (not
22 X3.3
used)
9 X3.4 Axis X ready, normally open contact, close valid
21 X3.5 Axis Y ready, normally open contact, close valid
8 X3.6 Axis Z ready, normally open contact, close valid
20 X3.7 4th axis ready, normally open contact, close valid
4-7, 16-19 X4.0-X4.7
to XS8
3 NC

10 Y0.6 Tool released, low level valid
22 Y0.7 Undefined
8 Y1.2
used)
20 Y1.3 Spindle orientation, low level valid (not used)
7 Y1.4 1st spindle gear (low speed), low level valid
6 Y1.6 Undefined (reserved for 3rd spindle gear, low level valid)
18 Y1.7 Undefined (reserved for 4th spindle gear, low level valid)
5 NC
17 ESTOP3
4 ESTOP1
16 OTBS2
3 OTPS1
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
6.5 Standard PLC I/O in turning system

13 X0.0
25 X0.1
12 X0.2
24 X0.3
Overtravel positive-limit switch on axis C, normally open
11 X0.4
Overtravel negative-limit switch on axis C, normally open
23 X0.5
Chuck clamped, normally open contact, close valid (not
10 X0.6
used)
Chuck released, normally open contact, close valid (not
22 X0.7
used)
9 X1.0
21 X1.1
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
5 X2.0
valid (not used)
17 X2.1
valid (not used)
4 X2.2 Undefined
16 X2.3 Undefined
3 NC

Servo power OK, normally open contact, close valid (not
25 X2.5
used)
159
6. Appendix
24 X2.7
close valid
Spindle speed arrived, normally open contact, close valid
23 X3.1
(not used)
4-7, 16-19 X4.0-X4.7
to XS8.
3 NC

10 Y0.6 Turret CW, low level valid
22 Y0.7 Turret CCW, low level valid
8 Y1.2
used)
20 Y1.3 Chuck released, low level valid (not used)
7 Y1.4 1st spindle gear (low speed), low level valid (not used)
6 Y1.6 Undefined
18 Y1.7 Undefined
5 NC
17 ESTOP3
4 ESTOP1
16 OTBS2
3 OTPS1
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

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HNC-21/22 CNC Device

Wuhan Huazhong Numerical Control Co. Ltd

The organization of this manual:

2. DNC unit (optional)

3. Handwheel unit (optional)

4. I/O Terminal Board

: must do. : shall not be done.

; especially important : default, initial setting

: line or boundary : a set of cable

: signal direction : exchange

: point connected : terminal

: cable bunched/diverged : cable bunched/diverged

: shielding layer : grounding

: passive NO and NC : coil

: plug and socket : transducer

: pilot lamp : mechanical linkage

The product should be transported properly according to its weight.

Dragging its cable to move or lift the product is not allowed.

Keep damp-proof while storing and transporting.

Let us know in time if the product has been stored overtime.

Do not put the product near any inflammable or explosive matter.

Workers undertaking wiring or inspection must be qualified to do the jobs.

The NC device must be grounded reliably. The earth-resistance must be less

Wiring shall be correct and firm to avoid wrong operation.

Personnel to operate the device must be competent for their work.

Do not refit the device.

To prevent from or reduce the influence of electromagnetic interference on NC

1.1.7 Waste Treatment

Treat the wastes as ordinary industrial wastes.

1.1.8 General Instructions

1.2 Unpacking and Checking

1.2.2 Product Type

Type of feed axis Memory type:

Figure 1 2 Description of HNC-21

PgUp Shift Upper

PgDn Alt Enter

Figure 1 3 Dimension of HNC-21/22

Pgup Pgdn Alt Upper

Figure 1 5 Air flow direction in NC cabinet

effective steps shall be applied to dissipate the heat.

1.5 Environmental Requirement

- Ambient temperature: 0~40

- Relative humidity: 30%~95% (without dew)

1.5.3 Transportation and Storage

(-40~+55). The device can survive up to 70 in a short-term, less than 24

hours, transportation or storage. It is necessary to adopt moisture-proof, shockproof

1.5.4 Mechanical Environment

1.5.5 Environmental Pollution

2.1 Total Connection Diagram

Power supply XS1 XS30-XS35 Feed device

Keyboard XS2 XS8 Handheld unit

Ethernet XS3 XS9 Spindle unit

RS232 XS5 XS10-XS12 On-off input

USB XS7 XS20-XS22 On-off output

Figure 2 1 Total Connection Diagram of HNC-21/22

Figure 2 2 Interface of HNC-21

Figure 2 3 Interface of HNC-22

2.2.2 DNC unit (optional)

Ethernet switcher RS232 Interface

Figure 2 4 Interface of DNC unit

2.2.3 Handwheel unit (optional)

Figure 2 5 Interface of Handwheel unit

2.2.4 I/O Terminal Boards (optional)