HEIDENHAIN TNC 122 Technical Manual

Technical Manual

TNC 122

April 97

This Technical Manual for the HEIDENHAIN TNC 122 straight cut control applies for the NC software version 246 117 08 and is subject to change without notice.

Foreword

The HEIDENHAIN TNC 122 is a compact, three-axis straight cut control for machine tools with central drive. It has been developed as the successor model for the TNC 121, to which it is compatible for installation. The TNC 122 has an expanded range of functions.

This Technical Manual is intended for all machine tool builders and machine tool distributors, and for retrofitting companies who wish to replaced an installed TNC 121 with a TNC 122. It provides the information required for mounting, electrical connection and commissioning the control.

For information on the new and improved operating features, please refer to the User's Manual.

1 Specifications 4 2 Hardware 6 3 Software 6 4 EPROM Sockets 7 5 Power Supply 8 6 Grounding Diagram 9 7 Connections 10 8 Pin Layout 11

8.1 Data interface 15 9 Machine Integration 16

9.1 Encoders 16

9.2 Traverse ranges 17

9.3 Reference marks 18

9.4 Position feedback control of the NC axes 24

9.5 Monitoring functions 29

9.6 Display and operation 31

9.7 EMERGENCY STOP circuit 33 10 Exchanging the control 36 11 Machine Parameters 37

11.1 Entering and changing machine parameters 37

11.2 Machine parameter list 38 12 PLC Description 45

12.1 PLC-EPROM 45

12.2 PLC Commands 46

12.2.1 Load and store commands 46

12.2.2 Set commands 49

12.2.3 Logical connective operations 50

12.2.4 Arithmetic commands 52

12.2.5 Comparisons 54

12.2.6 Parenthetical expressions 55

12.2.7 Shift commands 56

12.2.8 Bit commands 57

12.2.9 Stack operations 57

12.2.10 Jump commands 59

12.3 Classes of markers and bytes 60

12.4 Marker list 61 13 Error Messages 65 14 Dimensions 66 15 Subject Index 69

4/97 TNC 122 Contents 3

1 Specifications

Type of control

Program memory

Design

Tool memory Modes of operation

Program input

Display step Programmable function

Languages Max. traverse Max. traversing speed Position encoders

PLC cycle time Control inputs

Control outputs

Data interface

Straight cut control for 3 axes and paraxial positioning

Memory for up to 500 NC blocks, 20 NC programs

Compact control for panel mounting 7-segment LED for actual position display LED dot matrix 5 x 7 for preset display

One tool for length and radius compensation Manual operation

Positioning with manual data input Program run single block Program run automatic Programming and editing

Manually through TNC keyboard Through RS-232-C/ V.24

1 µm or 5 µm (0.000 05 in., 0.000 2 in.) Nominal position in absolute or incremental dimensions

Subprograms, program section repeats Tool radius compensation R+/RBolt-hole circle, hole circle segment, linear hole pattern Feed rate / rapid traverse M functions

Dutch, English, French, German, Spanish ± 9999.999 mm 30 000 mm/min Incremental HEIDENHAIN position encoders, optionally

with distance-coded reference marks 16 µA

Grating Periods: 4, 10, 20, 40, 100, 200 µm 24 ms 3 position encoder inputs (sinusoidal inputs)

15 PLC inputs +1 PLC input for a control-is-ready acknowledgment

One analog output (for central drive) 15 PLC outputs + 1 PLC input for control-is-ready signal

RS-232-C/ V.24, up to 38 400 baud

/40 µAPP selectable

4 TNC 122 1 Specifications 4/97

Power supply Power consumption Ambient requirements

Weight

Primary-clocked power supply 100 V to 240 V 19 W Operation : 0° to +45° C

Storage : –30° to +70° C Relative humidity, mean annual: < 75%, for max. 30 days per annum, naturally distributed: < 95%

Approx. 3 kg

4/97 TNC 122 1 Specifications 5

2 Hardware

Id. Nr. 284 083 xx

3 Software

Software versions

The NC software 246 117 07, together with the PLC software 277 938 13 of the TNC 122 replaces the following software versions of the TNC 121:

Software Version of TNC 121

205 438 205 443 205 444 205 446 205 455 205 456 unipolar standard 205 457 bipolar standard 205 430

6 TNC 122 2 Hardware 4/97

4 EPROM Sockets

IC-P1 NC

IC-P2 PLC

The PLC EPROM is a 2 MB or 4 MB chip.

Danger of electrical shock!

Unplug the power cord before opening the housing.

Danger to internal components!

When handling components that can be damaged by electrostatic discharge (ESD), observe the safety recommendations in DIN EN 100 015. Use only antistatic packaging material. Be sure that the work station and the technician are properly grounded during installation.

4/97 TNC 122 4 EPROM Sockets 7

5 Power Supply

The voltage must comply with specifications:

Component Power supply Voltage range Max. power

Power consumption

consumption

NC Primary clocked

power supply

100 – 240 V (–15% to +10%)

— Approx. 19 W

48 – 62 Hz

PLC 24 V

(with basis insulation according to

Lower limit

20.4 V__....

Upper limit

31 V __....

Max. 10 mA per input Max. 100 mA per output

EN 50 178)

Voltage surges up to 36 V __.... for t < 100 ms are permissible.

All small contactors and relays must have a quenching diode.

PLC power supply

The PLC (PLC inputs and outputs) of the TNC 122 is powered from the 24 V machine control voltage supply.

Danger to internal components!

Connect inductive loads only with a quenching diode parallel to the inductance.

Superposed AC components as they arise from a three-phase bridge rectifier without smoothing (see DIN 40110/1075, Section 1.2) must not exceed 5%. This results at the upper limit in the absolute value 33.4 V and at the lower limit the absolute value of 18.5 V.

32.6 V 31 V

20.4 V

18.5 V

To increase the noise immunity, connect the ground terminal on the rear panel to the central ground point of the machine. (Minimum cross-section: 6 mm

The 0 V line of the PLC power supply must be grounded with an earth lead (∅ ≥ 6 mm

)

) to the main

frame ground of the machine.

8 TNC 122 5 Power Supply 4/97

4/97 TNC 122 6 Grounding Diagram 9

Machine-Encoders

321

6 Grounding Diagram

Line voltage 100 - 240V Line frequency 50 - 60 Hz

PLC supply voltage with basic insulation

X51

TNC 122

+24V-

X1 X2 X3

stab. power supply

X21

Adapter V.24

X41/23

Motor controller with nominal value

difference input

Pot. for feed rate

X41/9

X41/33

0V +24V-

15 outputs

0,1A EMERGENCY STOP

0,1A

16 inputs

X41

X41/10

X41

6mm

Optoc.

1 0

6mm 6mm

Test point 1 (Fault voltg. 0V/ housing)

X41/22

Test point 2 (Fault voltg. with grounded nominal value input)

X41/48 X41/24 X41/47

If nominal value input is grounded, a ground loop will result. Therefore be sure that 0 V and ground wire are short and configured for low noise.

7 Connections

X1 = Encoder 1 X2 = Encoder 2 X3 = Encoder 3

X51

NC xxx xxx xx

PLC xxx xxx xx

X21

3 4 5 6 7 8 9 101112 1314 151617 18192021222324

25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 434445 46 47 48

X41(EXT)

X21 = RS-232-C/V.24 data interface

X41 = PLC inputs/PLC outputs/analog output/feed rate override/24 V PLC X51 = Power supply

B = Signal ground

Danger to internal components!

Do not engage or disengage any connections while the unit is under power.

Interfaces X1, X2, X3, X21 comply with the recommendations in EN 50 178 for separation from line power.

The outputs at connection X41 are metallically isolated from the device electronics by means of optocouplers.

10 TNC 122 7 Connections 4/97

8 Pin Layout

X1, X2, X3 Pin number Assignment Encoder input

Flange socket with 5 I2+ 9-pin female insert 6 I2–

X21 Data interface Pin number Assignment RS-232-C/V.24

D-sub connector with 3 TXD 25-pin female insert 4 CTS

1I 2I

7I 8I

–

3+ 5 V 40 V 9 Internal shield Housing External shield

1 Housing 2RXD

5RTS 6DTR 7 GND signal ground 8 – 19 Do not use 20 DSR 21 – 25 Do not use

X51 Power connector Pin number Assignment

L1 Live (230 V, F2.5 A fuse)

Terminal board, 3-pole N Neutral

Protective ground

Power consumption: typically 10 W

4/97 TNC 122 8 Pin Layout 11

X41 TNC 122 Connection-assignment TNC 121

Contact Contact

PLC inputs PLC outputs Feed rate override PLC power supply

1 I8 High=M26/ Low=M27 2 I9 High=M24/ Low=M25 3 I10 High=M22/ Low=M23 or M09 4 I11 High=M20/ Low=M21 or M05

5 I12 M08 coolant ON/ M09 OFF Terminal board, 6 I13 M04 left spindle ON/ M05 OFF 48 contacts 7 I14 M03 right spindle ON/ M05 OFF

8 I15 acknowledgment M function

9 +24 V PLC

10 Control-is-ready output

11 O13 M04 left spindle ON/ M05 OFF or High=M18/

Low M19 12 O11 High=M20/ Low=M21 or M05 13 O9 High=M24/ Low=M25 14 O7 High=M28/ Low=M29 15 O5 Output for negative traverse direction (for one-

13 quadrant drives) Erosion (205430) M02,M30 switches the output = 0

16 O4 Output for rapid traverse

11 (erosion 205430 M02,M30 Stop-erosion output=0)

17 O3 Output for Z axis enable 18 18 O2 Output for Y axis enable 20 19 O1 Output for X axis enable 22 20 O0 Output for Manual operating mode 16 21 not assigned 22

0 V

Analog voltage 8 23 +/– 10 V Analog voltage (depending on MP 70) 9 24 Feed rate override (wiper

)

4 25 I0 Input NC start 1 26 I1 Input NC stop 2 27 I2 Input rapid traverse key (Erosion 205430 erosion

ended, acknowledge with M36) 28 I3 Input for control-is-ready acknowledgment 29 I4 not assigned 30 I5 not assigned 31 I6 High=M23/ Low=M33 32 I7 High=M28/ Low=M29 33 0 V PLC 6

12 TNC 122 8 Pin Layout 4/97

X41 TNC 122 Connection-assignment TNC 121

continued

The assignments are in accordance with the PLC Standard Program Id. Nr. 277 938 13!

Contact Contact

34 O14 M04 right spindle ON/ M05 OFF or High=M16/

Low=M17 35 O12 M08 coolant ON/ M09 OFF 36 O10 High=M22/ Low=M23 or M09 37 O8 High= M26/ Low=M27 38 O6 High=M32/ Low= M33 39 24 V for neg. traverse direction output 12 40 24 V for rapid traverse output 10 41 24 V for Z axis enable output 17 42 24 V for Y axis enable output 19 43 24 V for X axis enable output 21 44 24 V for “manual“ / “not manual“ output 15 45 “Not manual” output (inverted O0) 14 46 not assigned 47 Feed rate override 0 V 3 48 Feed rate override 15 V 5

The 24 Vdc power supply is monitored for reverse polarity and overvoltage. Reverse polarity blows a fuse (F 2.0 A). Overvoltage above 47 V destroys the damping diode and blows the fuse. Maximum current load is 300 mA.

PLC outputs: Inductive loads are permitted only with anti-surge diode!

Change of the I/O assignment only if Program 205 430 is active:

With the M functions M02 an M30 the output is switched to zero. Through the M function M36 the output O5 is switched to 1 and is used to start the erosion process. Through input I2 the function M36 is acknowledged and indicates that erosion has ended. In this case the feed-rate potentiometer is without function.

4/97 TNC 122 8 Pin Layout 13

Installation of the Potentiometer:

6OLGHU

Internal-source voltage for pot

External-source voltage for pot

TNC 122 8 Pin Layout 4/97

X21 Data Interface

The TNC 122 is equipped with an RS-232-C/V.24 data interface for operation in FE or EXT mode (see the User's Manual). Programs and a list of the machine parameters can be output though this interface. An RS-232-C adapter must be provided for a peripheral unit, such as a PC, FE 401, or printer, to be connected to the control panel. The following drawing illustrates how to connect the adapter block to X21.

HEIDENHAIN guarantees that, if properly connected, the RS-232-C/V.24 serial interface will reliably transmit data between the TNC and a peripheral unit up to a distance of 20 meters.

HEIDENHAIN provides a standard cable 3 meters in length (Id.-Nr. 274 545 01) for connecting peripheral units.

The data format in FE and EXT mode is fixed at 7 data bits, 2 stop bits and even parity. The FE mode operates with ACK/NAK handshake, the EXT mode with DC1/DC3 handshake and RTS/CTS. The data transfer rates are 9600 baud in FE mode and 2400 baud in EXT.

Peripheral

unit

GND TXD RXD RTS CTS DSR GND

DTR

3 m

Id.-Nr. 274 545 01

WH/BN WH/BN WH/BN

•

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18 19 20

2 3 4 5 6

•

7 8

9 10 11 12 13 14 15 16 17 18 19 20

•

WH/BN

GN YL GY PK BL RD

V.24-Adapter Block

Id.-Nr. 239 758 01

•

••

2 3 4 5 6 7 8 9

Id.-Nr. 239 760..

•

1 2 3 4 5 6 7 8 9

max. 17 m

YL GN PK GY BN RD

•

X21 RS-232-C/V.24

GND Chassis RXD Receive data TXD Transmit data CTS Clear to send RTS Request to send DTR Data terminal ready GND Signal ground

DSR Data set ready

The interface complies with the recommendations in EN 50 178 for separation from line power.

4/97 TNC 122 8 Pin Layout 15

9 Machine Integration

9.1 Encoders

You can continue to use the same incremental position feedback encoders on the TNC 122, as you used on the TNC 121.

Signal period

The signal period of the linear encoder is entered in machine parameter MP330.x (in µm). On linear encoders with sinusoidal output signals, the signal period is the same as the grating period:

Signal period (~) = Grating period

The standard linear encoders from HEIDENHAIN have a grating period of 20 µm. Older encoders have a grating period of 40 µm. If linear position feedback is carried out with a rotary encoder on the ballscrew, then to calculate the signal period you must consider not only the line count of the encoder (see the technical data for the encoder) but also the pitch of the ballscrew:

Signal period (~) =

MP330

MP330.0 Axis 1 MP330.1 Axis 2 MP330.2 Axis 3

Machine parameter MP7320 can set the encoder amplitude so that older encoder models (on machines with TNC 121) can be adapted to the TNC 122.

MP7320

Signal period Input values: 4, 10, 20, 40, 100, 200 [µm]

Switchover of encoder input amplitude Input values: 0 to 7

Bit 0 Axis X +0 = 16 µA

Bit 1 Axis Y +0 = 16 µA

Bit 2 Axis Z +0 = 16 µA

Screw pitch [mm] · 1000 [µm/mm]

Line count

+1 = 40 µA

+2 = 40 µA

+4 = 40 µA

16 TNC 122 9 Machine Integration 4/97

Traverse direction

Machine parameters MP210 and MP1040 define the axis traverse direction. The traverse directions for the axes on numerically controlled machine tools are specified in DIN.

MP210 defines the counting direction of the encoder signals. The counting direction depends on the mounting configuration of the encoders.

MP210

MP1040 defines the polarity of the nominal voltage for positive direction of traverse.

MP1040

Assignment of encoder inputs

The individual axes can be assigned to the encoder inputs X1 to X3 with machine parameter MP110.

MP110

Counting direction of encoder signals Input values: 0 to 7

Bit 0 Axis X +0 = positive

+1 = negative

Bit 1 Axis Y +0 = positive

+2 = negative

Bit 2 Axis Z +0 = positive

+4 = negative

Polarity of the nominal voltage with positive direction of traverse Input values: 0 to 7 (must be "0" if MP70 is on "1" or "2")

Bit 0 Axis X +0 = positive

+1 = negative

Bit 1 Axis Y +0 = positive

+2 = negative

Bit 2 Axis Z +0 = positive

+4 = negative

Assignment of axes to encoder inputs Input values: 0 to 2 0 = encoder input X1 1 = encoder input X2 2 = encoder input X3

MP110.0 Axis 1 MP110.1 Axis 2 MP110.2 Axis 3

9.2 Traverse Ranges

The traverse ranges are set with machine parameters. The traverse ranges are defined by software limit switches. The input values for the software limit switches are based on the scale datum.

If the machine moves to a software limit switch, the following error message appears:

LIMIT SWITCH <axis>...

and the corresponding marker is set (M2624 to M2629).

4/97 TNC 122 9 Machine Integration 17

MP 910

Entry range: –9999.999 to +9999.999 [mm]

MP910.0 Software limit switch axis X+ MP910.1 Software limit switch axis Y+ MP910.2 Software limit switch axis Z+

Positive traverse direction

MP 920

MP920.0 Software limit switch axis X– MP920.1 Software limit switch axis Y– MP920.2 Software limit switch axis Z–

M2624 M2625 M2626 M2627 M2628 M2629

Negative traverse direction Entry range: –9999.999 to +9999.999 [mm]

Set Reset Limit switch axis X+ NC NC Limit switch axis X– NC NC Limit switch axis Y+ NC NC Limit switch axis Y– NC NC Limit switch axis Z+ NC NC Limit switch axis Z– NC NC

9.3 Reference Marks

For workpiece machining, the datum setting procedure assigns a unique position value (coordinate) to each axis position. Since the actual position values are generated incrementally by the encoder, this relationship between axis positions and position values must be restored each time the power is interrupted.

HEIDENHAIN linear encoders are provided with one or more reference marks. When a reference mark is traversed, a signal is generated that identifies that position as a reference point. After a power interruption, crossing over the reference marks will restore the relationship between axis slide positions and position values that was last established through the datum setting procedure. Crossing over the reference marks also restores all machine-based references.

Since it is inconvenient to move the axes over large traverses to restore the reference point, HEIDENHAIN recommends position encoders with distance-coded reference marks. On these encoders the absolute position value is available after crossing two reference marks.

18 TNC 122 9 Machine Integration 4/97

9.3.1 Traversing the Reference Marks

The reference marks of the axes should be traversed after the control is switched on. Machines with the TNC 121 are usually equipped with scales that have a reference mark at each end. To prevent the software limit switch ranges from being shifted, always traverse the reference mark upon which the software limit switches are based.

If referencing is not desired, it can be deactivated with machine parameter MP1340.x or by pressing the NO ENT key.

To traverse the reference marks, press the machine axis direction buttons. The sequence of axes is determined by the user.

When the reference marks are crossed over,

the software limit switches are activated

•

the datum point last set is restored

•

If the position encoders have distance-coded reference marks, the machine datum is based on the scale reference point (on linear encoders the scale reference point is the first reference mark after the start of the measuring length; on angle encoders the scale reference point is marked).

Manual execution (standard process)

The reference mark is traversed with the axis-direction keys.

Automatic execution (not in TNC 122)

The direction of traverse and the speed when crossing over the reference marks is defined with machine parameters (MP1320.x, MP1330.x). The sequence of functions when crossing over the reference marks can be defined separately for each axis with MP1350.x.

A trip dog for the reference end position is necessary to prevent the traverse range from being exceeded when the reference marks are crossed over. Install the trip dog at the end of the traverse range. The trigger signal line from the trip dog is connected to a vacant PLC input. In the PLC program, this PLC input is combined with the markers for “Reference end position” (M2556 to M2558)

Encoders with distance-coded reference marks

Machine parameter MP1350.x=0

Reference marks

Trip dog

Closed Open

Traverse direction MP1320.x

4/97 TNC 122 9 Machine Integration 19

"Reference end position"

Sequence for “Automatic reference mark traverse” (pressing the machine START key). MP1350.x = 0

Press the external START key

No Yes

"Reference end position"

Machine moves

in direction from

MP1320.x

Trip dog

"Reference end position" is

closed before two successive

reference marks are

traversed

Two successive reference marks traversed

Trig dog

closed?

Ye s

Machine moves in inverted

traverse direction from

MP1320.x

Is the machine

outside the software

limit switch range?

Machine stops

software limit switch

Ye s

Machine moves to

20 TNC 122 9 Machine Integration 4/97

+ 49 hidden pages