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Hardinge Rotary Servo Control User Manual B-158B

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1. sees 37 6 2 3 Using a PC to Command the Servo Control sesessssseeeee nme 38 6 2 4 Multiple Controls using RS 232 Daisy Chaining eee 39 6 3 Remote Operation with a FANUC CNC Control sse eee 40 6 4 Infrared Sensor Capabilities eese e e heme mene meme meme eene 42 7 Control Parameters 7 Parameter Definitions and Settings esses memes eee 44 4 2 gt gt Gear Compensation 2 1 9 2 Hee as sired a Po D eb ERE bak tapi n aaa Teu Te Da eo ia 56 7 3 Default Parameter Settings for Hardinge Standard Rotary Products seeeeseess 57 7 4 Motors Approved for Use with the Hardinge Rotary Indexer Servo Control 58 8 Control Message Information 831 Errori Codes Ar 58 82 Servo OFF Godes ote saute ee totus ferte setts Deka ak pa p re b ERA NE qeu A MAT eer A ene al Que 59 8 3 Hardinge Informational Messages o oo sss Hm eme mememem emen 59 9 Hardware Supported by the Rotary Indexer Servo Control 9 Power and Encoder Cable oo cece cece ence ence nen n nee eese se ehe sisse en se sese sn 60 92 Remote CNG Cable oer kata ences a pisan ote date ea bean Suv ea ub ng de crei ese cured veh Pets 60 9 3 Home Switche pe ere oes oe ed Eee ry rre IRR an ences epis ate ve die ea beat Suv ea urere a oot ese aaa ruat Peleo 61 94 Pneumatic Clamp Valve scan kes koy aa ai ected Kata ye yota a dan ik
2. 1 1 c te deu loa na e ai bra Ma a da sap ices sone BR elan 16 3 6 Inserting a Step in a Program lllllleeoooooo ee ooo nesese nedsaetesostedeaetesosoeooaenenoooeuoooooooooonoooe 16 3 7 Deleting a Step ina Programmes cect eden eere de eer bla laj a L a pin d Sa Aaa DO D kan pl ka E ane 16 3 8 Selecting a Stored Program esses ehe ehem ehe seems esee eese l6 3 9 Clearing a Program Or 16 3 10 Software Limit Switch Function oo ete eototosouetettotoeotoseseseseoeoeoeoeoeososeueoeoeoos 17 4 Programming Examples 4 Example utilizing G91 G28 and G99 o oo cece cece cere eme e Hee meme esee eene 18 4 2 Example 2 utilizing G28 G91 and G99 with Loop Count csse 19 4 3 Example 3 utilizing G90 G99 and G88 o oo cece cece ee een e nee eme esee memes eene 19 44 Example 4 utilizing G98 and G99 oo ccc cence eee ee esee ee mememem esee memes ene 20 4 5 Example 5 utilizing G85 and G99 ssssssssssssssesssssssse eme eme ee ememes esee memes ene 20 4 6 Example 6 utilizing G83 G84 G94 and G99 sssssssssssssssssssee e e eme memes eee 20 4 7 Example 7 utilizing Spiral Milling eese m meme 22 4 8 Example 8 utilizing G95 G96 G97 G88 and G99 ssisssssssssssseee Hmmm 23 5 Features of the Enhanced Servo Control 5 1 L Glamp Circuit Schernatie d eerte ei recae e eror RO Roe E ERR QA RR been E nEPI TURO 24 5 2 Clamp theory Operation 3 2 i derer etica deae ERO rere e E
3. AIR FROM MACHINE 85 PSI Min 110 PSI Max 5 2 Clamp Theory of Operation CLAMP CYLINDER The clamp circuit is installed to work in the following way Air is supplied to the IN port of the clamp valve at a minimum of 85 psi and a maximum of 10 psi The air coming out of the valve through port B flows through a pressure switch and into the open port of the clamp Therefore if air is supplied to the unit and the power is off the unit is unclamped When power is turned on since the valve is in the de energized state the unit is un clamped In the unclamped state the pressure switch is high ON and sends an input to the control box verify ing the status of the clamp The valve is energized to cause the indexer to clamp When the valve is energized the output air is switched to port A which is plugged This removes the air from the open port and allows it to exhaust The pressure switch goes low OFF because of the lack of air pressure This removes the input to the control box and the software considers the unit clamped Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 Servo Control User Manual B 158B BAS HARDINSE Manual Switch Blue A B n m 2 A Msy51201 smoz sx BW i 1P 388 GSMC JAPAN 015 07MPa 5 3 Clamp Functionality of the Enhanced Servo Control The clamp circuit is d
4. There are several key items you need to consider to insure your program will run successfully First and foremost DPRNT must proceed every command sent to the Hardinge Control The commands are sent to the control in ASCII code and terminated by a carriage return CR All commands must be preceeded by an axis select code U V W X Y Z parameter 21 4 For this explanation X will represent the axis code Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 42 BS HARDINSE Servo Control User Manual B 158B RS 232 Command Blocks DPRNT Clear Reset receive buffer DPRNT XGnn Loads G code nn into Step DPRNT XSnn nnn Loads Step Size nnn nnn into Step DPRNT XFnn nnn Loads Feed Rate nnn nnn into Step DPRNT XLnnn Loads Loop Count into Step DPRNT XH Return home immediately without M FIN DPRNT XB Activates Remote Cycle Start without M FIN for X axis only DPRNT B Activates Remote Cycle Start without M FIN for all axes nitial settings Experiment with these settings only AFTER interface is functional Only one step can be programmed at a time over the RS 232 interface to the servo control If multiple commands are sent only the last sent codes are retained and executed when a start signal is received NOTES Use of X above assumes Hardinge Servo Control Parameter 21 4 2 Trailing 0 must be include
5. 150 000 degrees Set parameter 115 to a value of This will enable the use of the software limit function NOTE The software limit switch function is only used AFTER initial homing is done after power up They provide NO protection during the power up homing sequence The operator needs to use caution when operating the rotary indexer during this time to prevent damage to the unit or to the host machine tool Setting the positive travel limit Parameter 116 The positive travel limit has a value range of 0 to 180000 Units are 1000 degree So 120 000 degrees 120000 Jog the unit to the positive travel limit and record the value of the position Go into parameter mode and set the value for the high positive software limit Setting the negative travel limit Parameter 17 The negative travel limit has a value range of 0 to 180000 Units are 1000 I degree So 120 000 degrees 120000 Jog the unit to the negative travel limit and record the value of the position Go into parameter mode and set the value for the low negative software limit NOTE It is possible to program a movement larger than the travel limit The axis will rotate until it sees either the negative or positive software limit and will stop An error will be posted that the software limit has been reached This will require the operator to jog the axis in the opposite direction to reset the switch At this time the operator should fix the limit value or chan
6. FLT Clamp Pressure Low ERR Software limit exceeded HW Limit Jog Opp Direction Error Codes indicate an error with the rotary indexer Servo Control After the issue is evaluated and addressed push the cycle start button to clear the error The following messages may indicate a communication or opera tional error Definition Undefined command Drive needs to be inactive for the requested command or variable Variable value out of range Communication message syntax error G code feed rate step size accepted when current program running Remote cycle start accepted when current program running or there is no program at all The password entered by the user is incorrect The command or variable requested by the user is password protected To change protected parameters contact the Hardinge factory Clamp function is enabled but the air pressure switch is not satisfied A move was attempted which exceeded the limits of parameter for software limits Hardware Limit switch on jog indexer in the opposite direction Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 BAS HARDINSE Servo Control User Manual B 158B 8 2 Servo OFF Codes Servo OFF Codes are issues that occur which automatically disable the drive Once the issue is addressed the power must be cycled to re enable the drive At any time the servo is turned off one of the
7. be noted that while every attempt has been made to work with a number of different voltages the FIN contact circuitry is purposely designed to operate a 24 volt DC input Operating at a lower or higher voltage or interfacing to anAC circuit should be discussed with a manufacturer s representative The typical 4 wire interface is shown below RED GREEN 2 BLACK 3 k 12V WHITE 4 R206 180100 680 L SERVO CONTROL MACHINE PINOUT REMOTE INPUT NOTE On pin the circuit voltage 24V DC originates in the machine On pin 3 the 12V DC supply is provided by the servo control and is fused at amp The color codes given are typical If you hook the cable up and put any other voltage on pin 3 or pin 4 the internal fuse may be shorted out the opto isolated input could be damaged and the fuse may need to be replaced If your machine does not have relays for outputs a relay kit may be avail able It may also be possible to directly drive pin 4 with a sourcing DC output but this should be discussed with a manufacturer s representative The FIN relay is an Omron G2R 1 2vdc S P D T relay with silver alloy contacts rated at 5amps 30V DC It is de bounced with a 24V DC snubber circuit It is not suitable for loads less than 10 milliam peres at 5 F DC A pdf with more information is available on request Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge c
8. Control 11 1 282 umi n 9 6 244 a Direct Drive Servo Control 1 1 282 zm 9 6 244 A CAUTION A 2 4 Turning ON the Servo Control l 2 Verify that the power switch to the servo control is turned OFF and the power cord is unplugged Connect the encoder and power cables from the indexer to the servo control for the geared rotary indexer Connect the Direct Drive rotary table if equipped with quick connect style connector Check to verify that the red STOP button is pulled out Connect the power cord from the servo control to a 120V 15A or 230V 15A outlet Turn the power switch to the servo control ON The display will read Pressing any key will allow you to continue The panel now indicates that the axis is not homed The motor is now powered but the zero position is not yet defined PRAI POSITION 666 666 xis not homed Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 BAS HARDINSE Servo Control User Manual B 158B When the indexer homes after power up the control is looking to see the home switch and a marker pulse on the encoder of the motor This we will defi
9. Format XXX XXX programmable value range is 999 999 to 000 001 degrees second The maximum programmable speed is unit size and parameter settings dependent For the GD5C2 rotary indexer the maximum programmable speed is 360 000 degrees second For the GD16C2 the maximum programmable speed is 300 000 degrees second For the GD210LP and GDI60LP the maximum programmable speed is 240 000 degrees second Default settings are shown in Italics Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 BAS HARDINSE Servo Control User Manual B 158B Parameter 109 UNPROTECTED Position filter FILTDEPTH Param 109 Value 4 or l6 This parameter defines the filtration of the value of position which is displayed by the servo control The filtdepth variable can be set to a value of 4 or 16 The function of filtdepth is to stabilize the position value displayed on the 4 line display by averaging the axis position value over time Averaging them over the past 4 values gives a fast response but is also more responsive to axis dither when the axis is oscillating from an unsteady load Averaging the display over the last 16 position values gives a display which is slower to settle to a change in position but more stable while the axis is not moving Parameter 110 UNPROTECTED Clamp control CLAMPCTRL Param 110 Value 0 2 This parameter def
10. Pa EETA eese Zao EE sena da ki Pak 61 9 5 Clamp Pressure Switeh ross rotten iue peser Fee ee per Pepe Pa SO s sea de seal tal 62 9 6 Control Support Options i ete ettet E E E ELE EE OIR PER arabe b ee ab obi dina 63 9 7 Direct Drive Servo Control cci tbt eee eg PRA EE ERROR A SERE EE FPES IA 64 10 Troubleshooting 10 1 Testing the Remote CNC Cable and Cycle Start Finish Circuit cece cece ee ee cence ene ee eee 64 10 2 Inspecting Encoder Power Cable sess HH HH mememem esse memes eene 65 10 3 Checking the Pressure Switch sss e m mememem ese memes een 66 10 4 Pin Schematic for the Encoder Power Cable sss Henne 67 0 5 Checking the Clamp Valve 5 irre trn rer cian Depp dr eh dene rhet tar ite iea 68 lls Warranty iere E erbe reet ve eee eal Cen Dia Hee ede de TA pi sa Neu tee ae ee 68 G Code Reference Charts ic PERRA dit ae Gath E E pubis Dude ER ene E UTC a ae 68 Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 BAS HARDINSE Servo Control User Manual B 158B l Introduction The following information will be used to help you become familiar with the operation of the Hardinge Servo Control This information is written for the Standard and Enhanced Servo Controls utilizing software versions up to version 2 9 a Hardinge rotary products can be utilize
11. Part No BB 0009500 0158 BAS HARDINSE Servo Control User Manual B 158B 2 Servo Control Operation 2 1 Front Panel Controls and Display PROG NOGI LAZA 6891 AD 000 000 A Enclosure cover B CYCLE START button begins a step stops a continued operation inserts a step or turns the Servo on C STOP button turns off the Servo when on and aborts a step in progress D JOG causes the Servo to move in either the Forward or Backward direction at a rate defined by the last numeric key pressed 9 is the fastest and 0 is the slowest E Infrared sensor for receiving and transferring program data F ZERO RETURN causes the Servo to return to HOME position search for mechanical HOME delete a step or move forward to the mechanical offset WARNING In Parameter Mode ZERO RETURN resets the parameters to a set of default settings which may not be compatible with current unit G ZERO SET key clears the entered data or defines the present Servo position as HOME H MINUS KEY selects negative step values or Program Upload Download functions STEP SCAN scans step numbers from through 1000 J DISPLAY SCAN scans fields in PROGRAM mode MODE RUN PROG switches from RUN mode to PROGRAM mode L Data entry keys and jog speed selection M Four line display each having twenty characters a large amount of data can be viewed on one screen to reduce scrolling and simplify programming steps Hardinge Inc One Hardinge Drive El
12. THE EQUIPMENT with damaged or worn electrical cables VERIFY that the electrical cables are not restrained or pinched during full travel movement of the machine Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 RAS HARDINSE Servo Control User Manual B 158B Table of Contents Safety Recommendations 2 5 5 eerie rerit gage A RASA ORA APER ES SERRA BAR doub CAN cues SASA ea Aka 3 l Introduction I 1 Five Ways to Configure a Hardinge Rotary Product to your Machine eeeeeereerteeressrooes 7 1 2 Three Variations of the Hardinge Servo Control cceceeeee sence eee eeeneneeeeaeneneeeeaeaenens 7 2 Servo Control Operation 2 Front Panel Controls and Display e ce cece ce ee sence HH eme mem ememesee eee 9 2 2 Rear Panel ie e d RR UM Uer eue vi e ERR EI de E dk eae nebo Gees 10 2 3 DIMENSIONS rev ean LST es e ERE OA E eee betta A weed oad eat ee lines LI 24 Turning ON the Servo Control lllllllleeoeeoeoeeetetetoeteaoaeneseedeaooosesoeoeosoooeooeooooooooonone LI 2 5 Three Basic Servo Control Modes RUN PROGRAM and PARAMETER seem 13 3 Programming the Servo Control EMI E ET 15 DEESSET 15 3 3 Positlon P sce n eei rho ipee HIR REI dri qe sete in ER paudawedsqutsaee dda ETAN 15 34 G COAES CNET 15 3 5 rEoop Go nt LE
13. TOOL OR MACHINE MODIFICATION not obtained from Hardinge Inc must be reviewed by a qualified safety engineer before installation USE CAUTION around exposed mechanisms and tooling especially when setting up Be careful of sharp edges on tools DON T USE worn or defective hand tools Use the proper size and type for the job being performed USE ONLY a soft faced hammer on tooling and fixtures DON T USE worn or broken tooling on machine MAKE CERTAIN that all tool mounting surfaces are clean before mounting tools INSPECT ALL CHUCKING DEVICES daily to make certain that they are in good operating condition Replace any defective chuck before operating the machine USE MAXIMUM ALLOWABLE gripping pressure on the chuck Consider weight shape and balance of the workpiece DON T EXCEED the rated capacity of the equipment DON T LEAVE the equipment unattended while it is operating DON T CLEAN the equipment with an air hose KEEP TOTE PANS a safe distance from the machine Don t overfill the tote pans DON T LET STOCK project past the back end of the collet closer or equipment spindle without being adequately covered and properly supported UNLESS OTHERWISE NOTED all operating and maintenance procedures are to be performed by one person To avoid injury to yourself and others be sure that all personnel are clear of the equipment when opening or closing the coolant guard door and any access covers FORYOUR PROTECTION WORK SAFELY DON T OPERATE
14. ag SENA ia ge data EE E k eas 24 5 3 Clamp Functionality of the Enhanced Servo Control sese 25 5 4 Tipsfor GlampUse 5 6 ere eer e aer ITO D M Rate cue aa e ERROR EM REM REN P NS 26 5 5 General Purpose OUTPUT Functions cesses mme e eme memem esee eee een 26 5 6 General Purpose INPUT Functions ssssssssssee eme eme memem esee emen 28 5 7 Using the Inputs to Monitor Hardware Limit Switches esses 30 Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 BAS HARDINSE Servo Control User Manual B 158B 5 8 Using the Optional Hardinge Hardware Limit Switch Kit cese 30 59 Homing the Rotary Indexer using the Hardware Limit Switch Kit eese 30 5 10 Adjusting Hardware Limit Switches csse eme e eene 3l 5 Cooling Fan for the Enhanced Servo Control ssssssesee He 3l 5 12 External Stop Circuit Function of the Enhanced Servo Control ssesssssrsseseserersressrrsreseeese 3l 6 Interfacing to your Host Machine 6 Remote CNC Cable Connection and Use sisseesrn riri abenan VEELE Henne 32 6 27 amp RS 232 Capabilities 7 25 55 nen redes Oa o E cite eh hh oye e AERE ene nex Fuse eg A ka e sann 33 6 2 1 Configuring the PC using HyperTerminal cesses He 34 6 2 2 Uploading and Downloading Programs
15. an included angle of 180 degrees the program will read as follows 4 6 Example 6 Utilizing G83 G84 G94 and G99 The G codes G83 and G84 allow the unit to enter a continuous rotation For geared units the feed rate for this motion must be limited to insure that damage to the gear system does not occur The move should be tested and closely monitored so that the motion does not cause the indexer to heat up and bind the gears On direct drive units the movement should be monitored so that the motor does not see a significant heat rise In this case liquid cooling may have to be implemented Utilizing this feature is therefore greatly dependent on the duty cycle If assistance is required to aid in the use of this function please contact your Hardinge representative In this example we will program the G83 and G84 command using a feed rate of 10 degrees per second When programming using incremental motion the maximum programmable step is 9999 99 degrees In some cases where spiral milling or grinding is to be done a longer step may be required The G83 and G84 commands allow this to be done If a G83 command is given the unit will start a motion in the negative direction at the programmed feed rate G84 will cause the unit to rotate in the positive direction This motion will continue until the control receives a command to stop This will occur via pushing the CYCLE START button sending a start signal through the CNC cable or via RS 232 In ste
16. bits settings This parameter should be set to the value in the machine control or the computer settings to allow RS 232 communication l stop bits 2 2 stop bits Parameter 106 UNPROTECTED RS232 Data Bits DATABITS Param 106 Value 7 or 8 This parameter defines the RS 232 communication data bits settings This parameter should be set to the value in the machine control or the computer settings to allow RS 232 communication 7 7 data bits 8 8 data bits Parameter 107 UNPROTECTED RS232 Parity PARITY Param 107 Value 0 2 This parameter defines the RS 232 parity checking value for RS 232 communication This parameter should be set to the value in the machine control or the computer settings to allow RS 232 communication 0 no parity checking l odd parity 2 even parity Parameter 108 UNPROTECTED Speed Units SPDUNITS Param 108 Value 20r3 This parameter defines the programmability of the speed rate For Direct Drive rotary units the value should be set to 2 so that higher speeds can be programmed in the control For geared units the standard value of 3 should be used This value is measured in degrees second 2 Format XXXX XX programmable value range is 9999 99 to 0000 01 degrees second The maximum programmable speed is unit size and parameter settings dependent For the DD200 the maximum programmable speed is 1050 00 degrees second For the DD 100 the maximum programmable speed is 2700 00 degrees second 3
17. com Part No BB 0009500 0158 45 46 BS HARDINSE Servo Control User Manual B 158B Default settings are shown in Italics Parameter 5 UNPROTECTED Double remote trig REMTRIG Param 05 Value Oorl This parameter defines how the remote start trigger will operate The remote trigger is either the green cycle START button or the remote cable cycle start signal 0 One trigger to the remote input or one press of the cycle start button will activate the control to trigger a step The remote start must be triggered twice or the cycle start button must be pushed twice to activate the control to trigger a step Parameter 6 UNPROTECTED Disable panel start FRONTDIS Param 06 Value 0 or This parameter defines how the Cycle Start and Home Buttons function on the control panel 0 Front panel Cycle Start and Home buttons are enabled Front panel Cycle Start and Home buttons are disabled Control will only function through the remote input Parameter 7 UNPROTECTED Program protection MEMPROT Param 07 Value Oorl This parameter defines the protection level of stored programs in the servo control 0 Programs are unprotected and can be modified by the operator Programs are protected and cannot be altered until this parameter is changed to 0 Parameter 8 UNPROTECTED Disable remote start REMDIS Param 08 Value 0 or This parameter defines the operation of the start circuit of the remote cycle start functi
18. definitions for the various values are shown below 0 Digital inputs l 2 and 3 are general purpose inputs l Digital input is the positive hardware limit switch and input 2 and 3 are general purpose inputs 2 Digital input 2 is the negative hardware limit switch and input and 3 are general purpose inputs 3 Digital input is the positive hardware limit switch and digital input 2 is the negative hardware limit switch Digital input 3 is a general purpose input Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 BAS HARDINSE Servo Control User Manual B 158B Default settings are shown in Italics Parameter 114 UNPROTECTED En Dis by clamp CLAMPENDS Param 114 Value Oorl This parameter defines the motor behavior in conjunction with the clamp function By enabling this parameter the power of the motor is removed when the clamp is on This function utilizes the dwell time in parameter ILE before energizing or de energizing the motor Below are the permitted values of this parameter and their definition 0 Turns this function OFF Turns this function ON Example If parameter 110 2 111 350and 114 I When the rotary indexer stops after a commanded move a 350 millisecond dwell counts down and the clamp turns on Another 350 millisecond dwell counts down and the motor is de energized When a command to move is
19. following messages may be displayed Code FLT NVRAM Failure FLT Over Current FLT Over Voltage FLT Over Temp FLT Under Voltage FLT Not configured FLT LCD Fault FLT Following Error FLT Over Speed FLT Illegal Motor FLT Feedback Loss Description Non volatile memory cannot store data Power stage surge current clear by cycling power ON OFF Excessive decel rate Overload fan malfunction power stage failure Bus voltage is too low this will be displayed when the control power is turned off Incorrect parameters Bad LCD Position error larger than parameter 22 Velocity motor maximum speed The motor defined by parameter 100 does not suit the connected motor Failure in motor feedback wires FLT Over Load System overload 8 3 Hardinge Informational Messages These are messages that are displayed to describe the current status of the control Message Description Welcome Hardinge Indexer Welcome screen Stop Stop pressed RS232 Disable Drive was disabled through RS232 Servo OFF Servo is OFF Axis Not Homed Home needed C Clamp on 9 Hardware Supported by the Rotary Indexer Servo Control This portion of the manual will outline information of the various components powered by the indexer servo control These will include items which may have to be replaced over time The information is a guide for the customer If the function of any of the components described below is in question consult the Hardinge technical de
20. for alternate units The maximum feed rate programmable for a step is rotary indexer unit dependent The default on the display will always read 360 000 degrees second This is the standard maximum feed rate for the GD5C2 rotary indexer This will be required to be changed if using a rotary indexer with a smaller maximum feed rate The GD16C2 indexer for example has a maximum feed rate of 300 000 degrees per second thus the feed rate will have to be changed for every step that will be programmed If the indexer being used has a higher maximum feed rate than 360 000 degrees per second it will default to 360 000 For example the maximum feed rate programmable for a DD100 Rotary Table Indexer is 2700 00 degrees per second If a higher feed rate than 360 000 is desired with this indexer it will have to be programmed Maximum Feed Rates for Hardinge Rotary Table Indexers Model deg sec rev minute GD5C2 360 000 60 rpm GDI6C2 300 000 50 rpm GDI60LP 240 000 40 rpm GD210LP 240 000 40 rpm DD200 1050 00 175 rpm at 120V 2100 00 350 rpm at 230V DD100 2700 00 450 rpm at 120V 4200 00 700 rpm at 230V Step N The step number identifies each consecutive step in the program Each program can store up to 1 000 steps Two steps of the program are visible on the display at one time To move the cursor within a screen displaying two steps use the DISPLAY SCAN button To jump from screen to screen for more steps of the program use the
21. move 90 degrees and when finished the multi meter should beep verifying the function of the cable and also the cycle start finish circuit of the control box Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 BAS HARDINSE Servo Control User Manual B 158B 10 2 Inspecting Encoder Power Cable Check the rear panel of the servo control for loose or broken connectors for the power and encoder cable Check to make sure there are no bent loose or broken pins in cable connectors POWER CABLE ENCODER CABLE Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 65 66 BS HARDINSE Servo Control User Manual B 158B 10 3 Checking the Pressure Switch Insure that the air is connected and supplying 85 psi to the clamp valve When the clamp is in the unclamped state the pressure switch will be high the LED will be on kh m By actuating valve or by decreasing the air pressure below 75psi the pressure switch should go low LED will go off If the switch needs to be adjusted the adjustment screw is located above the LED Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 Servo Cont
22. recorded in the back of the manual 7 1 Parameter Definitions and Settings The parameters visible in parameter mode of the Servo Control are listed below NOTE Parameters that are UNDERLINED are only usable in the enhanced servo control The hardware to oper ate these functions do not exist in the standard servo control Default settings are shown in Italics Parameter UNPROTECTED Relay mode RELMODE Param OI Value 0 2 This parameter defines how the finish signal relay associated with the remote cable operates 0 relay active during indexer motion l relay pulsed for 25 second at end of motion 2 no relay action Parameter 2 UNPROTECTED Relay polarity RELPOLAR Param 02 Value Oorl This parameter defines how the relay associated with the remote cable finish signal operates 0 normally open the relay will close when the rotary indexer finishes the cycle l normally closed the relay will open when the rotary indexer finishes the cycle Parameter 3 PROTECTED Proportional gain GP Param 03 Value 1 7000 This parameter defines the proportional gain for the position loop The servo loop proportional gain increases current in inverse proportion to the proximity to the target position The farther from the target the greater the current up to the maximum value in parameter 40 Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge
23. sent through the RS 232 cable The rotary indexer servo control interprets these commands and executes them No programming is required in the rotary indexer servo control As an add on to a host machine using the RS 232 communication and remote CNC cable in conjunction This is the most reliable use of the rotary indexer with the servo control Programming is done in the host machine control and commands are communicated over the RS 232 cable The machine then uses an M code to send the start signal through the remote CNC cable and the rotary indexer servo control will execute the commanded motion The rotary indexer servo control then sends a finish signal to the host machine control to cancel the M code No programming in the rotary indexer servo control is required As a true 4th axis to the machine CNC control This configuration removes the rotary indexer servo control from the application and the rotary product is wired directly to the machine A rotary unit purchased with a servo control may not be convertible to a true 4th axis configuration A compatible motor to the host machine is required at time of purchase When using the rotary product wired directly to the machine consult the host machine manufacturer for information on 4th axis operation Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 BAS HARDINSE Servo Control User Man
24. the value in the Loop Count For step one enter G94 and for the Loop Count Step two will contain the G83 or G84 and the feed rate to be programmed The program should read as follows The machine will send a start signal to the rotary indexer servo control The servo control will issue an immediate finish signal to the machine and perform the next step as determined by the in the Loop Count The rotary indexer will begin a continuous rotation in the negative direction at 10 degrees per second The machine can then bring the tool in to do the desired operation When the machine is finished it will issue another start command via the M code which will cause the rotary indexer servo control to stop send a finish signal and set the program to the next step In this case step 3 is the G99 so the program will go back to step l If step 3 was another type of move or command step 3 would be loaded ready to go Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 22 BS HARDINSE Servo Control User Manual B 158B 4 7 Example 7 Utilizing spiral milling The simultaneous rotation and milling feature of the Hardinge Servo Control will permit machining of certain cam forms spiral and angular cuts Spiral milling is when the spindle rotates and an axis on your mill moves at the same time To spiral mill you will have to calculate the
25. www shophardinge com Part No BB 0009500 0158 19 20 BAS HARDINSE Servo Control User Manual B 158B 240 0808 G 98 368 666 L 1 8G 88 360 000 L 1 4 4 Example 4 Utilizing G98 and G99 The G code G98 can be used to do circle division to simplify programming The G98 command will divide 360 degrees by the value entered in the Loop Count It is important to note that 360 degrees is always used as the angle with the G98 command In this example we will program 6 moves of 60 degrees using the G98 command In step one the Position value can be skipped Regardless of what value is in the Position area 360 degrees will be used Enter G98 for the G code Set the feed rate to 75 000 degrees per second When executing step one the rotary indexer will index incrementally from the current position the number of degrees it calculates for each move For the Loop Count since we want 60 degree moves 360 60 6 therefore enter 6 in the Loop Count For step two make sure G99 is in the G code to end the program The program should read so so rara D hw E cw Ew E RW 4 5 Example 5 Utilizing G85 and G99 The G code G85 is used to do angle division to simplify programming Whereas G98 used an angle of 360 degrees exclusively G85 uses an operator entered angle for dividing the moves The control will start the moves incrementally from the current position To program positioning for a series of six holes which will lie in
26. www shophardinge com Part No BB 0009500 0158 Servo Control User Manual B 158B BAS HARDINSE FANUC control with custom macro enabled and parameter 6001 bits and 4 set to 6 3 Remote Operation with a FANUC CNC Control If you are only using one of the boxes in the chain it is necessary to power up all of the boxes between the data source and the box you are using Data is not passed through an unpowered box There are several requirements that must be met before a Hardinge Servo Control can be interfaced with a FANUC controlled mill 2 A serial port on the FANUC control must be available for exclusive use by the Hardinge Servo Control while DPRNT program is running 3 Hardinge Servo Control and rotary table indexer UNIT 4 RS 232 shielded cable 25 DB25M DB25M null modem not required 5 A shielded remote CNC interface cable Hardinge Part Number CI 301 I IC DB25 pinout l 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 20 20 1 RED 24V gt FINISH 2 SIGNAL M FINISH GREEN y E RELAY j BLACK CYCLE dmi START a RELAY P WHITE CYCLE A 2 680R p START CNC MILL HARDINGE 5C INDEXER CONTROLLER ja ae CYCLE FINISH START SIGNAL 5 AN PINOUT Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com 40 Part No BB 0009500 0158 RAS HARDINSE Servo Control User Manual B 158B HA
27. 0 0158 25 26 BAS HARDINSE Servo Control User Manual B 158B The clamp takes approximately 0 5 seconds to engage and 0 5 seconds to disengage Along with that time the dwell would be added to obtain a total cycle time for engaging and disengaging the clamp When programming the Enhanced Servo Control when a clamp is present there are no additional steps involved when parameter 10 0 or 2 Some machining processes may not require the use of the clamp If this is the case parameter 110 can be set to a value of This will reduce the cycle time of the process by only using the clamp for required machining If parameter 110 is equal to G80 is used to program the operation of the clamp circuit Using G80 will work as follows To engage the clamp G80 has to be used for the G code and the feed rate must be set to l 1 11 To disengage the clamp G80 is used and the feed rate must be set to 0 The two steps in the program would read as follows Step one of the program engages the clamp and step two disengages the clamp 5 4 Tips for Clamp Use If the error message FLT Clamp Pressure Low appears on the control display the clamp function is turned on but the pressure switch is not being satisfied If a clamp is installed on the unit insure that the shop air is at 85 psi and connected to the unit If it is determined that the shop air is connected properly and the air pressure is sufficient contact a Hardinge technician immed
28. 00 0158 RAS HARDINSE Servo Control User Manual B 158B The following are the RS 232 commands where x is the selected Axis and n is the Value Command Meaning xSn nnn Specifies a step size or absolute position Step size can be negative or positive xFn nnn Specifies the Feed Rate in units second xGnn Specifies the G code to be used xLnnn Specifies the Loop Count to be used xP Will show the rotary indexer s current position xB Begin the programmed step on the x axis only B Begin the programmed step on ALL axes at once xH Return to the Home position xC Clear the servo Position and set to zero xO Turn on the servo xE Turn off the servo xSTOP Stop the rotary indexer x Jog the indexer Units are encoder counts second Can be negative or positive There must be a space between the capital J and the number NOTE Above where an n decimal value is possible at least one digit to the right of the decimal point has to be entered For example xS90 will not work it must be xS90 0 Programming Example Program the rotary indexer Servo Control to make a 90 degree move at 30 degrees second incrementally using the PC and RS 232 communication The axis identifier will be A parameter 21 7 In HyperTerminal type AS90 000 Enter Programs an angle of 90 degrees AF30 000 Enter Programs a feed rate of 30 degrees second AG9 Enter Programs a G91 for incremental motion AB Enter Sends a start comm
29. 1 ISO GROUND INPUT 1 ISO GROUND Normally Open Circuit Normally Closed Circuit There are many different devices available that the operator may choose to use in the application These devices can be chosen to be normally open or normally closed devices Sometimes they are referred to as sourcing or sinking Therefore it is important to have the inputs correctly set by parameter 112 to work with the hardware device to be utilized Programming the Inputs To program the inputs G82 is used as the G code in the step of the part program The position value of the step will identify which input to be monitored The feedrate values for this function are ignored As with outputs G81 the step of a program which utilizes an input G82 function will not generate a finish signal from the control The program will not continue in the rotary table indexer control until the input is satisfied In this example make sure parameter 112 is set to 0 This means that all inputs are normally open Have a jumper ready to test the logic of the input circuit To begin the test no jumper is required In the position area when selecting which input to use the definitions are as follows Input 1 000 Input 2 2 000 Input 3 3 000 Programming Example of Input Function In the following photo the monitoring of input is demonstrated H gi P 98 88 F 68 68 N 62 P 1 606 F Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 150
30. 2 103 104 105 107 108 109 110 111 112 113 114 115 116 117 Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 57 58 BAS HARDINSE Servo Control User Manual B 158B 7 4 Motors approved for use with the Hardinge Rotary Indexer Servo Control Description GD5C2 GD16C2 GDI60LP GD16C2 Multi spindle GD210LP DD100 120V or 220V DD200 120V or 220V 5C Haas Brush Motor 5C Haas Single amp Dual 5C Haas Triple amp Quad Approved Motor Kollmorgen AKM41H CSSN2 02 Kollmorgen AKM42S CSSN2 02 Danaher BM 3035A Danaher BM 5802A Magmotor 93 5119 36 4175B Yaskawa SGMP 04A2HAI Yaskawa SGM 08U2HA 12 The following listed motors have been tested and approved with the Hardinge rotary indexer Servo Control Attempting to replace the original motor of the rotary indexer with a different motor will void the warranty If an issue occurs that may be motor related contact the Hardinge technical department immediately for assistance mechanical unit and servo control serial number will be required Hardinge P N Cl 0002412 Cl 00024 12M42 RTBOOO241202 RT 000241203 CI 0002412HBR Cl 0002412H Cl 0002412HM 8 Control Message Information 8 1 Error Codes Error Unknown Command Drive Active Val Out of Range Syntax Error Program Active Remote Ignored Incorrect password Password protected
31. 468 5946 www shophardinge com Part No BB 0009500 0158 35 BAS HARDINSE Servo Control User Manual B 158B 4 Define COM port properties Bit per second is an RS232 communication baud rate This field should be set according to rotary indexer parameter 26 E g if parameter 26 is 7 baud rate 9600 should be selected Data bits select 8 Parity select None Stop bits select Flow control select None Click OK comi Properties 21x Port Settings Bits per second 50 amp Data bits s 7 Parity None Y Stop bits ii m Elow control Restore Defaults Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com 36 Part No BB 0009500 0158 H HARDINSE Servo Control User Manual B 158B 5 In the HyperTerminal menu select File Properties Hardinge properties window will be open Select Settings tab and click on ASCII Setup In ASCII setup window set Line delay to 10 Character delay to Select Echo type characters locally Click OK Click OK to exit properties i e Hardinge HyperTerminal S lal xi File Edit View Cal Transfer Help Dll esl ola l Hardinge Properties 1 2 xl ConnectTo Settings Function arrow and ctri keys act as ASCII Setup zixj T 2 cC Teminalkeys Windows keys ASCI S Backspace key sends Send line ends with ine feeds f Cuh
32. 5 5 5 5 27 27 27 27 27 28 2048 2048 2048 2048 29 100 100 100 100 30 n a n a n a n a 31 0 0 0 0 36 546133 453290 91023 540672 39 7107 7107 7107 7107 40 500 500 500 500 43 10 10 10 10 100 0 0 0 0 101 n a n a n a n a 102 29 a 2 9 a 2 9 a 2 9 a 103 150 150 150 150 104 25 25 25 25 105 2 2 2 2 106 8 8 8 8 107 0 0 0 0 108 3 3 3 3 109 4 4 4 4 110 0 2 2 2 111 0 350 350 350 112 0 0 0 0 113 0 0 0 0 114 0 0 0 0 115 0 0 0 0 116 0 0 0 0 117 0 0 0 0 kw 3 e l e NJ gt o BS S P M Q Q Q Q o 1 1 1 1 1 0 0 0 0 0 700 5250 5250 4000 4000 P 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4096 16384 16384 16384 16384 0 0 0 0 0 0 0 0 0 0 6 6 6 6 6 n a n a n a n a n a 0 0 0 0 0 0 0 0 0 0 P 800000 40000000 40000000 10000000 20000000 P 741917 5242880 8716288 2031616 4128768 2 9 9 9 9 P 4 4 4 4 4 0 0 0 0 0 P 311 180 180 180 180 P 5 5 5 5 5 27 26 26 26 26 P 2048 163840 163840 163840 163840 P 100 50 50 50 50 P n a n a n a n a n a 0 0 0 0 0 494611 4947968 8224768 1933312 3866624 P 7107 0 0 0 0 P 500 800 800 800 800 10 12 12 24 24 0 0 0 0 0 P n a n a n a n a n a 2 9 a 29a 2 9 a 2 9 a 29 a 150 160 325 160 325 25 175 175 175 175 2 2 2 2 2 8 8 8 8 8 0 0 0 0 0 3 2 2 2 2 4 16 16 16 16 2 0 0 2 2 350 0 0 350 350 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 P PROTECTED PARAMETER Mechanical Unit S N ARAB Oto SBSBVSVYCSRRRBRRNYVsSsASasanzs 9gQoo oo oo oo oomnm2o ooouloonm2o 101 10
33. 7 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 29 30 BS HARDINSE Servo Control User Manual B 158B 5 7 5 8 5 9 Step two of the program will check for the status of input when executed The software will not allow the program to continue until the condition of input is satisfied true Once input is satisfied the program will advance to step three If the input is configured to be normally closed it will wait for the circuit to be closed If the input is configured to be normally open it will wait for the circuit to be open Run the program with no jumper in place for input the program should continue through step two Repeat the program with the jumper installed between pin 9 input and pin 3 ground on the I O connector When the program is executed it will hang on step two because the normally open input is now closed by the jumper Remove the jumper and the program will move to step three The use of the input function can be programmed and commanded using the RS 232 function Follow the pro gramming procedure outlined in the RS 232 section of the manual The G code will be G82 and the position value will be 1 000 2 000 or 3 000 Using the Inputs to Monitor Hardware Limit Switches By changing parameter 113 the function of the general purpose inputs can be modified so that they can be used to monitor hardware limit switches See the definitions of this option in
34. BAS HARDINSE Servo Control User Manual B 158B pH HARDINEE 18 800 G 91 B 369 888 L 28 N882 P P 63g 908 6 2 Setup and Operation for the Hardinge9 Standard Enhanced and Direct Drive Rotary Servo Controls Software Version 2 9 a Original U S A Instructions Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 BS HARDINSE Servo Control User Manual B 158B Safety Recommendations READ COMPLETE INSTRUCTIONS CAREFULLY BEFORE OPERATING THIS UNIT Note Equipment refers to the Hardinge Servo Control rotary table indexer and or machine it is used with When this instruction book was printed the information given was current However since we are constantly improving the design of our products it is possible that the illustrations and descriptions may vary from the system WARNING Occupational Safety and Health Administration OSHA Hazard Communication Standard 1910 1200 effective May 25 1986 and various state employee right to know laws require that information regarding chemicals used with this equipment be supplied to you Refer to the applicable section of the Material Safety Data Sheets supplied with your unit when handling storing or disposing of chemicals HARDINGE SAFETY RECOMMENDATIONS Your Hardinge Servo Control is designed and built for maximum ease and safety of operation Howev
35. Count of will be used in step one to start the rotary indexer and send a finish signal to the mill to start the x axis Thus both machine and rotary indexer will be moving simultaneously Step two will use the values calculated above to control the indexer to do the spiral The program will read as This procedure will be the starting point for developing a sound program to carry out the desired task Before machining of the actual part put an offset into the tooling of the machine so that it does not contact the part and perform a dry run to determine if the program is working as desired If possible test the actual process on a setup part to insure the depth of cut and speeds are not an issue Many times the process will involve a rough pass followed up by a finish pass with a much smaller depth of cut If additional spirals are to be added to the part items such as re orientation and dwells will have to be considered and worked into the program to work out the timing When the rotary indexer executes a G94 a 250 millisecond delay is required before executing the following step This may it usually doesn t cause your axis to move before the table rotates leaving a flat spot in the cut If this is a prob lem a solution is to insert a G04 dwell from 0 to 250 milliseconds in the CNC after the M function to prevent axis movement By selecting the right dwell the rotary indexer and the mill should start moving at the same instant I
36. Example 2 for a Hardinge GD210LP Rotary Table The brushless motor encoder has 2048 lines per revolution With quadrature 2048 x 4 this encoder has 8192 counts per revolution The mechanical unit has a 90 1 gear ratio Therefore one revolution of the motor results in 4 degrees of movement on the output shaft 360 90 4 To calculate counts per degree the equation would be 8192 counts rev x 1 rev 4 degrees 2048 encoder counts per degree 2048 is a whole integer and parameter 20 must be set to at least a value of 2 Therefore to calculate parameter 9 2048 x 2 4096 entered in parameter 9 At 2048 counts degree the system will have a total of 737280 counts revolution on the output shaft 2048 x 360 Parameter 10 UNPROTECTED Auto continue control MBMODE Param 10 Value 0 3 This parameter defines how the servo control executes the program in memory For normal operation this should be set to zero 0 Run one loop or if the loop count is one run one step l Continue all loops in a step and stop before the next step 2 Continue all steps in a program until end code 99 or 95 and stop 3 Repeat all steps until stopped manually Parameter UNPROTECTED Feedback direction MFBDIR Param l Value Oorl This parameter defines the positive direction of the rotary indexer when viewed looking at the spindle nose This is defined with the motor located in the standard position of the left side as viewed from the spindle nose Wh
37. H C Del C OH Space CilsH FM Echo typed characters locally Emulali Line delay fio milliseconds auto detect z Terminal Setup Character delay fi milliseconds Telnet terminal ID fansi ASCII Receiving Backscroll buffet lines 5o E Append line feeds to incoming fine ends Force incoming data to 7 bit ASCII Play sound when connecting or disconnecting IV Wrap lines that exceed terminal width Input Translation ASCII Setup Nui 6 2 2 Uploading and Downloading Programs using a PC UPLOADING Transfer programs from the Servo Control to the computer so oD nl oO YY FY M 10 Make sure HyperTerminal is open and communicating with the rotary indexer Servo Control Enter Program Mode on the rotary indexer Servo Control Activate the program to be uploaded Position the cursor on the G code of step one Press the button on the keypad Press the button again on the keypad Display should now read Send prog In HyperTerminal select Transfer Capture text A dialogue box will appear asking for the file to be named and saved Select location name file and press start Press the Cycle Start button on the rotary indexer Servo Control Program will start uploading A message sending program will appear Once the message disappears it is complete In HyperTerminal the program will be displayed on the computer screen In HyperTerminal select transfer capture text stop Hardi
38. OF THE WORKPIECE if the machine has been OFF for any length of time DRY CYCLE a new setup to check for programming errors MAKE CERTAIN that you are clear of any pinch point created by moving slides before starting the machine DON T OPERATE any equipment while any part of the body is in the proximity of a potentially hazardous area DON T REMOVE CHIPS with hands Use a hook or similar device and make certain that all machine movements have ceased BE CAREFUL of sharp edges when handling a newly machined workpiece DON T REMOVE OR LOAD a workpiece while any part of the equipment is in motion DON T OPERATE ANY EQUIPMENT while wearing rings watches jewelry loose clothing neckties or long hair not contained by a net or shop cap DON T ADJUST tooling or coolant hoses while the equipment is running DON T LEAVE tools work pieces or other loose items where they can come in contact with a moving component of the equipment DON T CHECK finishes or dimensions of workpiece near running spindle or moving slides DON T JOG SPINDLE in either direction when checking threads with a thread gage DON T ATTEMPT to brake or slow the equipment with hands or any makeshift device Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 BS HARDINSE Servo Control User Manual B 158B Safety Recommendations continued ANY ATTACHMENT
39. One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 BS HARDINSE Servo Control User Manual B 158B 3 Programming the Servo Control The servo control has the storage capacity for 50 programs which can contain 1 000 steps each Program 0 should be saved for RS 232 communication This will be covered later in the manual The following paragraphs will guide the operator through the programming sequence The indexer has two basic methods of positioning incremental and absolute as defined below Absolute Positioning Motion commands executed by the control to the indexer in absolute mode G90 will cause the indexer to move to the commanded or absolute position in degrees If you are at a position of 90 000 and the next step in the program is 90 000 with a G90 the rotary will not move The unit will rotate the shortest direction to get to the commanded position Incremental Positioning Motion commands executed by the control to the indexer in incremental mode G91 will cause the indexer to move an additional number of degrees from its current position If you are at a position of 90 000 and the next step in the program is 90 000 with a G91 the rotary will move an additional 90 degrees NOTE Because positive 90 000 was entered the indexer will move 90 degrees in the positive direction defined by parameter I 1 Programming is done through the s
40. RDINGE SERVO CONTROL Parameters for RS 232 Interface Once the previous requirements have been met you can revise the parameters of the Hardinge control Listed below are the parameters that will need to be changed Parameter Parameter 2 0 Parameter 5 0 Parameter 8 0 Parameter 10 0 Parameter 12 5 or 6 Parameter 21 4 see table I Parameter 26 5 see table 2 Parameter 31 0 Parameter 105 2 Parameter 106 8 Parameter 107 0 Table Table 2 0 upload download programs U 0 110 300 2 V 3 W 2 600 3 1200 4 X 5 Y 4 2400 5 4800 6 Z 7 A 6 7200 7 9600 8 B 9 C 8 19200 FANUC CNC CONTROL Parameters for RS 232 Interface The FANUC control parameters are usually set as follows to successfully communicate with the Hardinge Servo Control Baud Rate 4800 Parity Even Required setting do not experiment Data Bits 7 or ISO if CNC control defines Data bits as work length parity bit then set to 8 Stop bits 2 Required setting do not experiment Character Coding EIA ISO ISO Required setting EIA will not work DPRNT EOB LF CR CR CR is required LF is always ignored by Servo control DPRNT leading zeroes as blanks OFF nitial settings Experiment with these settings only AFTER interface is functional Be certain to set FANUC parameter related to actual serial port connected to Hardinge Servo Control The parameters have been set for remote operation You can now program or run an existing program
41. ROL E STOP GROUND E STOP SIGNAL Output is pin 15 Output 2 is pin 8 Output 3 is pin 7 Pins 6 13 and 14 are available 24V sources To program the outputs G81 is used in the step of the part program The position value of the step will identify which output to be used The feed rate value will determine whether the output is being turned on or off In the position area when selecting which output to use the definitions are as follows Output 1 1 000 Output 2 2 000 Output 3 3 000 In the feed rate area 1 111 will turn the output on and 0 will turn the output off Programming Example of Output Function To turn on output and to turn off output would appear as follows in program mode LJ C ani LJ C I im B8 1 A A Step one is turning on the output and step two is turning off the output NOTE When the output functions are used in the steps ofa program it is important to note that a finish signal will not be sent by the servo control when a G8 step is completed This means that when an output is turned ON or OFF a finish signal will not be sent to the machine host control To utilize this function when using an M code that requires a finish signal programming of these functions will have to utilize the G94 command to send back the finish signal to the machine control to allow the machine process to proceed If the machine host control does not require a finish signal the use of the outputs can be used as outl
42. STEP SCAN button The Display Scan button is used to navigate between fields The Up and Down Arrow buttons are used to navigate from screen to screen Position P The position identifies the angle in degrees to be used in the step The value can be 0 to 9999 99 depending on the setting of parameter 12 The position value is ignored with the use of certain G codes G codes G The G code in a step of a program identifies the type of command to be executed in that step G codes can command incremental or absolute positioning dwells jumps clamp commands continuous motion etc The following G codes are possible G28 return to home position same as G88 and G90 with step 0 G80 controls the clamp function when parameter 110 is set to in the enhanced control G81 controls the 3 general outputs of the enhanced control G82 controls the 3 general inputs of the enhanced control Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 BS HARDINSE Servo Control User Manual B 158B 3 5 3 6 3 7 3 8 3 9 G83 continuous rotation in negative direction G84 continuous rotation in positive direction G85 fractional circle division any value or 360 000 degrees can be divided equally G86 turn CNC relay ON G87 turn CNC relay OFF G88 return to HOME position same as G28 and G90 with step 0 G89 wait for remote input con
43. They can also be configured to use hardware limit switches for applica tions when the travel of the indexer is restricted because of clearance issues Parameter 13 defines the definition of the outputs when using them with hardware limit switches Refer to the diagram below for the input signal locations on the I O connector on the back panel of the Enhanced Servo Control AUX I O CONNECTOR ON BACK OF ENHANCED SERVO CONTROL E STOP GROUND E STOP SIGNAL GROUND Input is pin 9 Input 2 is pin 2 Input 3 is pin Pins 3 10 l and 12 are available grounds Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 BRS HARDINSE Servo Control User Manual B 158B The logic of the input software In the control box the input function can be used and programmed to monitor system devices When using the input commands in a part program the condition which the control is looking to be satisfied is a true condition to continue to the next program step If the input condition is false the program will hang on the input step until the condition is made to be true The condition for which the input is looking for is set by Parameter 12 see param eter section of manual for definitions In the parameter section a value of O identifies a normally open circuit and a value of identifies a normally closed circuit D LI l INPUT
44. alve with M5 Ports Part No CJ 00030485W SMC SY3120 5MOZ M5 RT 0003048CV Clamp Valve MAC 44B AAA GDAA IKT MAC valve with 10 32 Port WIXOM MI USA LIEGE BELGIUM TAIPEI TAIWAN WATTS 1 0 VACTO 100 PSI 9 5 Clamp Pressure Switch The clamp circuit in the Hardinge rotary indexer units includes a pressure switch to monitor the status of the clamp device The pressure switch is on high when the clamp is released A red LED on the sensor is illumi nated when the clamp is released This switch is set to go high with an air pressure of 75 psi When the pressure drops below 75 psi the LED turns off and the sensor is considered off low This will indicate a clamped state Set incoming air pressure for the clamp circuit to 85 psi minimum to insure a satisfactory working pressure For issues with the pressure switch contact a Hardinge service technician for assistance This switch has a maximum air pres sure of 110 psi Incoming air should be set to 85 100 psi Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 BAS HARDINSE Servo Control User Manual B 158B Pressure Switch Part No RT 000304805L Parker MPS P6N PC 9 6 Control Support Options Hardinge offers two styles of support options bracket shelves when trying to mount the servo control box to a host machine One type of support swivels
45. and tilts This support is recommended for machines for which placing the control on the roof is not practical as the machine is too tall The other type of support is the stationary which tilts only Swivel Control Support Part No Cl 0001990BCB Stationary Control Support Part No Cl 0001990CBSA Hoos alsiek nagg sa 6 anei Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 63 64 RS HARDINSE Servo Control User Manual B 158B 9 7 Direct Drive Servo Control The Enhanced Servo Control can be configured to operate the Hardinge DD100 and DD200 Direct Drive Rotary Table Indexers These controls are easily identifiable by the sheet metal junction box mounted to the top of the control box Located inside the junction box are the hardware for the clamp circuit and the interface box for the encoder system 10 Troubleshooting 10 1 Testing the Remote CNC Cable and Cycle Start Finish Circuit of the Servo Control l Make sure control is powered off Connect the CNC cable to the servo control box Attach a multi meter with the continuity function to the red and green wires of the cable Power on the indexer servo control and home the indexer Program a simple 90 degree move on the first line of the indexer program Touch the black wire on the CNC Cable to the white wire and release NO vo w om The indexer will
46. and to theA axis Once a command is sent to the rotary indexer Servo Control it will remember the command until it is changed Therefore to repeat a move simply send nB to the control again 6 2 4 Multiple controls utilizing RS 232 Daisy Chaining If a situation exists where more than one rotary indexer with servo control is placed on a machine tool it is possible to communicate with the rotary indexer Servo Controls and the machine tool control using RS 232 This is accomplished by connecting RS 232 cables from one control to the next To accomplish this a DB25 male to DB25 female cable is required One Servo Control which will serve as the master will connect to the machine tool host control as normal A second RS 232 cable will run from the master rotary indexer Servo Control DOWN port to the next indexer Servo Control UP port This is called daisy chaining Up to nine controls may be daisy chained together When programming the machine tool control it is important that the axis identifier preceding a command is properly addressed Each rotary indexer Servo Control should be set up as a different axis using parameter 21 See parameter 2 definition for the available labels It is also important to note that the axis identi fier be used before a B command i e XB AB etc If only B is programmed all axes will move at the same time Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946
47. cates that the zero position is established and the controller is ready to begin normal operations If a different position is to be used as zero jog the indexer to the new position and press the CLR key for three seconds The display will again indicate POSITION 000 000 If you had previously cleared a new home position for the indexer the display will show a nonzero position In this case press the ZERO RETURN button once more and the indexer will move forward to the predefined zero position Unless otherwise stated always press and immediately release buttons on the control Some buttons have more than one function depending upon which mode the servo control is in Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 BAS HARDINSE Servo Control User Manual B 158B 2 5 Three Basic Servo Control Modes RUN PROGRAM and PARAMETER RUN mode allows the operator to utilize the rotary indexer during machining The rotary indexer will execute the programmed steps residing in the servo control memory or will execute commands via RS 232 communi cation PROGRAM mode allows the operator to insert commands into the servo control for execution once returned to RUN mode PARAMETER mode is used to define system specific settings for the servo control Using PARAMETER mode allows the system to be customized for specific customer requir
48. conds Program a G88 to return home The program should read as 96 3 EF a8 Ba Gm koul sou cw i4 bed E e Loon La T kou NE kou kou Aw GED GOD kou Du kou Few ee ON n pk gn gn 9 o 0co05 L A 560 aaa Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 23 24 Servo Control User Manual B 158B BS HARDINSE 5 Features of the Enhanced Servo Control The Enhanced Servo Control has many additional features which can be utilized by the customer These features include the ability to operate a clamp circuit a cooling fan three outputs and inputs to control extra devices the ability to control hardware limit switches and the addition of an E stop circuit which can be tied to the host machine tool control This section will discuss in detail these added features All of the necessary hardware to allow the function of these additional features are located on the I O board The modes programming size and communication properties of the Enhanced Servo Control are identical to that of the Standard Servo Control The Enhanced Servo Control can be identified quickly by the presence of the I O connector on the back panel of the control 5 1 Clamp Circuit Schematic PRESSURE SWITCH CLAMP VALVE 85 P I IN REGULATOR SHOWN FO a FOR REFERENCE ONLY
49. d in various ways by the operator to perform simple to very complicated tasks LI Five Ways to Configure a Hardinge Rotary Product to your Machine l Asa stand alone unit with a control Programming is done in the rotary indexer servo control and executing the program is done through the cycle start button on the control 2 As an add on to a host machine via the remote CNC cable Programming is done in the indexer servo control and the program is executed through a start signal via the remote CNC cable This start signal can be provided by a mechanical switch the remote quill switch or by a relay contact from the host machine control using an M code 3 As an add on to a host machine utilizing RS 232 communication The servo control has the ability to communicate with a host machine capable of RS 232 programming commands Programming is done in the host machine control and commands are sent through the RS 232 cable The rotary table indexer servo control interprets these commands and executes them No programming is required in the rotary table indexer servo control 4 As an add on to a host machine using the RS 232 communication and remote CNC cable in conjunction This is the most reliable use of the rotary indexer with the servo control Programming is done in the host machine control and commands are communicated over the RS 232 cable The machine then uses an M code to send the start signal through the remote CNC cable and the rotary index
50. d when not using a decimal point If using a decimal point at least one numeric digit after the decimal point is required Correct S045 000 Wrong S45 3 When writing your program in the FANUC format it is important not to have blank spaces or carriage returns CR in your DPRNT statement The following is an Example of one way to program the FANUC POPEN OPEN FANUC SERIAL PORT DPRNT CLEAR RESET HARDINGE G04 P64 DWELL DPRNT XG91 LOAD AN INCREMENTAL MOVE COMMAND G04 P64 DWELL DPRNT XS90 0 LOADS STEP SIZE 90 0 INTO STEP G40 P64 DWELL DPRNT XF50 0 LOAD FEED RATE 50 DEGREES SEC INTO STEP G04 P64 DWELL Mnn REMOTE CYCLE START MOVES TO 90 0 SENDS M FIN G04 P250 DWELLS TO AVOID DPRNT WHILE M FIN IS STILL HIGH PCLOS CLOSE FANUC SERIAL PORT 6 4 Infrared Sensor Capabilities In the shop environment interfacing cable connections such as serial and USB can sometimes be affected by air borne contamination To alleviate this concern the Hardinge Servo Control has implemented the unique feature of infrared communication which has a lot of similarity to the systems used with TV remotes This method of communication occurs without wires cables or connectors The infrared send receive unit is conveniently located on the front panel of the control just above the ZERO Return button Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge co
51. date your jump to locations after a step is deleted Selecting a Stored Program There can be more than one stored program Selection of that program is done by pressing the minus key while the cursor is on the G code area of PROGRAM mode The display will change to Program N Press a number key to select a new program and then press the MODE key to return to RUN mode or the START key to continue with the PROGRAM mode There are fifty programs available numbered 0 to 49 Clearing a Program To initialize or clear a stored program not including parameters go to PROGRAM mode and press and hold the CLEAR ZERO SET button for five seconds The first step is set to G91 position value of 0 feed rate of 360 000 andaloop count of l Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 BAS HARDINSE Servo Control User Manual B 158B 3 10 Software Limit Switch Function The rotary indexer servo control has a feature called Software Limits These are programmable software limits to limit the travel in jog and run mode Whereas the hardware limit switches are physical limit switches software limits are only defined in the parameters of the control Software limits should generally be set 10 degrees less than the hardware limits For example if the hardware limits are set for 160 000 degrees the software limits should be set for
52. disconnect or other safety device DO NOT OPERATE EQUIPMENT if unusual or excessive heat noise smoke or vibration occurs Report any excessive or unusual vibration sounds smoke or heat as well as any damaged parts LIFTING AND HANDLING OF THE UNIT should be done with full knowledge of the unit weight and using proper procedures MAKE CERTAIN that the equipment is properly grounded Consult National Electric Code and all local codes REMOVE POWER from the unit by unplugging the power cord before attempting repair or maintenance Where Applicable DON T OPEN THE CONTROL BOX without consulting with Hardinge DON T TOUCH ELECTRICAL EQUIPMENT when hands are wet or when standing on a wet surface Where Applicable REPLACE BLOWN FUSES with fuses of the same size and type as originally furnished Where Applicable Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 BAS HARDINSE Servo Control User Manual B 158B Safety Recommendations continued ASCERTAIN AND CORRECT the cause of a shutdown caused by overload heaters before restarting the machine Where Applicable KEEP THE AREA AROUND THE EQUIPMENT well lit and dry KEEP CHEMICAL AND FLAMMABLE MATERIAL away from electrical or operating equipment HAVE THE CORRECT TYPE OF FIRE EXTINGUISHER handy when machining combustible material and keep chips clear of the work a
53. dividual magnetic poles of the motor not pole pairs Parameter 100 PROTECTED Motor type MOTORTYPE Param 100 Value Oorl This parameter defines the type of motor used in the system 0 brushless l brush Parameter 101 PROTECTED Serial number SERIALNO Param 101 Value value This parameter displays the serial number of the servo control This parameter along with parameter 30 is used for updating parameters in the field Parameter 102 PROTECTED Firmware revision REV Param 102 Value 0 2 9a This parameter displays the software revision of the Servo Control Parameter 103 UNPROTECTED Bus Voltage VIBUS Param 103 Value 10 325 This parameter defines the drive bus voltage of the system The value of this parameter is measured in volts Default settings are shown in Italics Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 51 52 BAS HARDINSE Servo Control User Manual B 158B Parameter 104 UNPROTECTED Encoder Init Current IENCSTART Param 104 Value 0 177 This parameter defines the maximum current applied to the motor during the encoder initialization procedure This is some percentage of the continuous current limit of the system Parameter 105 UNPROTECTED RS232 Stop Bits STOPBITS Param 105 Value or 2 This parameter defines the RS 232 communication stop
54. dwells jumps clamp commands continuous motion etc G CODE REFERENCE CHART G28 G80 G8 G82 G83 G84 G85 G86 G87 G88 G89 G90 G91 G92 G93 G94 G95 G96 G97 G98 G99 return to home position same as G88 and G90 with step 0 controls the clamp function when parameter 10 is set to in the enhanced control controls the 3 general outputs of the enhanced control controls the 3 general inputs of the enhanced control continuous rotation in negative direction continuous rotation in positive direction fractional circle division any value lt or 360 000 degrees can be divided equally turn CNC relay ON turn CNC relay OFF return to HOME position same as G28 and G90 with step 0 wait for remote input absolute position command incremental position command pulse CNC relay and wait for remote input pulse CNC relay pulse CNC relay and run next L steps automatically end of subroutine more steps follow subroutine call jump destination is a step number delay by L count 10 seconds down to 0 1 second circle division always assumes 360 000 degrees to be divided equally end of program return and end of steps Hardinge Inc One Hardinge Drive P O Box 1507 Elmira New York 14902 1507 USA USA 800 843 8801 Canada 800 468 5946 Fax 607 734 3886 To Order Online www shophardinge com Corporate Homepage www hardinge com E mail info shophardinge com Live Online Support www shophardinge com All specificat
55. e Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 31 32 Servo Control User Manual B 158B BAS HARDINSE AUX I O CONNECTOR ON BACK OF ENHANCED SERVO CONTROL Enhanced I O Connector DBI5 for top connect use 6 13 or 14 all 24 volts Machine E stop for bottom connect use 3 10 or II all O volts Enhanced I O Connector DBI5 for top connect use 6 13 or 14 all 24 volts Machine E stop for bottom connect use 3 lO or I all O volts 6 Interfacing to your Host Machine As mentioned earlier in this manual there are five ways to configure a Hardinge rotary product to your machine As a stand alone unit with a control Programming is done in the indexer servo control and executing the program is done through the cycle start button on the control As an add on to a host machine via the remote CNC cable Programming is done in the rotary indexer servo control and the program is executed through a start signal via the remote CNC cable This start signal can be provided by a mechanical switch the remote quill switch or by a relay contact from the host machine control using an M code As an add on to a host machine utilizing RS 232 communication The servo control has the ability to communicate with a host machine capable of RS 232 programming commands Programming is done in the host machine control and commands are
56. e any existing data in the current program Hold the pocket PC with the infrared port directed towards the infrared port on the control front panel Press the Xmit function on the pocket PC The range for the sensor is approximately 12 inches For best results make sure the infrared port on the pocket PC is lined up with the port on the control A program downloaded successfully screen will appear if the program downloaded correctly A timeout screen will appear if there was a problem with the download Repeat the process if this occurs Receiving a Program from the Hardinge Servo Control using Infrared To receive a program from the Hardinge Servo Control hold the pocket PC in front of the control infrared sensor and press the receive button The program received will appear on the screen of the pocket PC Installing the Software Follow these instructions to install the Hardinge Infralink software on the customer s pocket PC device l The customer will be provided with a WinZip file named Hardinge InfraLink 101 PPC2003 ARM 2 This file should be saved on a desktop or notebook computer in case a re installation is required Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 43 BS HARDINSE Servo Control User Manual B 158B 3 Connect a pocket PC to the computer which contains the WinZip file above 4 Sync the pocket PC and
57. e the way the control and servo loop operate To enter PARAMETER mode go to the PROGRAM mode by pressing the MODE button if not already in PROGRAM mode Then press the UP arrow and hold it for three seconds After three seconds the display will change to the PARAMETER mode The UP arrow key is used to select the next higher numbered parameter and the DOWN arrow key is used to select the next lower numbered parameter If a parameter value is changed pressing the UP arrow DOWN arrow or MODE keys will cause an entered parameter to be stored Parameters are one to ten digits in length and are decimal integers The Servo Loop must be OFF to change a parameter associated with the Servo Loop An error message of Drive Active will be displayed if a Servo Loop parameter change is attempted with the Servo Loop on Turn the Servo Loop off by pressing the red STOP button If a value is entered into a parameter that does not lie in its effective range a Value out of range will be displayed This will require a proper value to be re entered into the control To exit from PARAMETER mode either press the MODE button to go to RUN mode or push the DOWN arrow key until you return to step in PROGRAM mode Exiting PARAMETER mode in the latter way will enter the operator into PROGRAM mode Simply push the MODE button to return to RUN mode When in PARAMETER mode the display will read Parameter Description Param NNN Relay mode Value NNN Paramt Hardi
58. ectronic pressure switch installed in the circuit to monitor the clamp when it is disen gaged The clamp functionality will take place after initial homing after power up No clamp functionality is applied before that When the clamp is engaged a C will appear on the message line of the control display There are two Parameters which control the operation of the clamp circuit parameters 110 and 111 Parameter 110 defines the mode of the clamp circuit The possible values of this parameter and their definitions are 0 7 Clamp is ignored if a clamp is physically on the unit shop air still has to be supplied I G code commands the engage disengage of the clamp 2 7 Automatic clamp control clamp is automatically engaged when motion is stopped Parameter is a timer for the clamp function dwell It can have a value of 0 2000 The units of this value are in milliseconds If the value of parameter 110 is equal to 0 then parameter should be set to a value of 0 If the value of parameter 110 is equal to or 2 then the value of parameter should be set to 350 or greater The timer is utilized when the rotary indexer starts and stops Prior to motion the clamp will disengage and the timer will count down When motion stops the dwell will count down and the clamp will engage Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 000950
59. een steps If you can single block the control but it will not successfully run in the continuous mode then timing is off somewhere 4 8 Example 8 Utilizing G95 G96 G97 G88 and G99 Subroutines allow you to repeat a particular step sequence up to 999 times A subroutine is invoked by entering 96 into the G code After entering 96 you must DISPLAY SCAN to the Feed Rate location to enter the step you wish to jump to After executing a G96 step the control will jump to the step called out in the Feed Rate location execute that step and the ones following until it reaches G code 95 or 99 the end of subroutine call The program then jumps back to the step following the G96 A subroutine can be repeated a number of times by utilizing the loop count of the G96 step To end the subroutine insert a G code of 95 or 99 after the last sequence step A subroutine call is not consid ered a step by itself since it will always execute itself and the first step of the subroutine Nesting of subroutine calls is not permitted G97 is used to program a dwell or delay time into a program G97 does not pulse the CNC relay at step completion As an example programming a G97 and setting L 10 will produce a second dwell In this example we will program the rotary indexer to perform a subroutine which will index the unit 15 degrees with a feed rate of 300 000 then index 30 degrees with a feed rate of 25 000 Repeat the subroutine 3 times Program a dwell of 5 se
60. ements The operator can identify which mode the servo control is in by reading the display To change from RUN mode to PROGRAM mode press the MODE button To enter PARAMETER mode the servo control must first be in PROGRAM mode Next hold the UP STEP SCAN button for 5 seconds and the servo control will enter PARAMETER mode RUN mode display Line shows the PR program number or RS 232 N step L loop count and G G code Line 2 is empty Line 3 shows the current POSITION Line 4 shows the running status for example Stop PROI N l Laai GAYI POSITION 666 600 PROGRAM mode display Two steps of the program are visible on the display at one time To move the cursor within a screen displaying two steps use the DISPLAY SCAN button To jump from screen to screen for more steps of the program use the STEP SCAN button Lines and 2 show a N step indicating its P position G G code F feed rate and L loop count Lines 3 and 4 show the next step with its associated P G F and L The Display Scan button is used to navigate between fields The Up and Down Arrow buttons are used to navigate from screen to screen PARAMETER mode display Line shows the description of the parameter in logical English Line 2 shows the parameter number Line 3 shows the parameter value Line 4 shows an error message if occurred during parameter set Relay mode Param a1 1 Value Value out of ranse Hardinge Inc
61. en motor is located on the right the values below are reversed The drive must be disabled Servo OFF to change this parameter 0 Counterclockwise is positive direction l Clockwise is positive direction Parameter 12 UNPROTECTED Units UNITS Param 12 Value 5or6 This parameter defines the units utilized by the control and their precision The display position on the display screen can contain 7 characters including the decimal point The servo control can calculate distance in both angular and linear units The settings below describe the functionality 5 Angular in 1 100 degrees Example 0240 00 degrees 6 Angular in 1 1000 degrees Example 240 000 degrees Parameter 15 UNPROTECTED Backlash amount BACKLASH Param 15 Value 0 99 This parameter defines the electronic compensation for mechanical gear backlash It is measured in units of encoder counts This parameter CANNOT correct mechanical backlash Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 47 48 BS HARDINSE Servo Control User Manual B 158B Default settings are shown in Italics Parameter 16 UNPROTECTED Auto continue dwell DWELL Param l6 Value 0 99 This parameter defines the length of pause at the end of a step before performing the next step when the automatic continuation option parameter 10 is used The delay is in multip
62. er some previ ously accepted shop practices may not reflect current safety regulations and procedures and should be re examined to insure compliance with the current safety and health standards Hardinge Inc recommends that all shop supervisors maintenance personnel and machine tool operators be advised of the importance of safe maintenance setup and operation of Hardinge built equipment Our recommendations are described below READ THESE SAFETY RECOMMENDATIONS BEFORE PROCEEDING ANY FURTHER ANYONE HAVING ACTIVE IMPLANTS pacemakers or having any other ferromagnetic prosthesis is not qualified to work with these kinds of devices or to approach them Keep at a safe distance from the motor READ THE APPROPRIATE MANUAL OR INSTRUCTIONS before attempting operation or maintenance of the equipment Make certain that you understand all instructions DO NOT ALLOW the operation or repair of equipment by untrained personnel CONSULT YOUR SUPERVISOR when in doubt as to the correct way to do a job WEAR SAFETY GLASSES AND PROPER FOOT PROTECTION at all times When necessary wear respirator helmet gloves and ear muffs or plugs DON T OPERATE EQUIPMENT unless proper maintenance has been regularly performed and the equipment is known to be in good working order WARNING or INSTRUCTION TAGS are mounted on the unit for your safety and information Do not remove them or damage them DO NOT ALTER THE EQUIPMENT to bypass any interlock overload
63. er servo control will execute the commanded motion The rotary indexer servo control then sends a finish signal to the host machine control to cancel the M code No programming in the rotary indexer servo control is required 5 Asa true 4th axis to the machine CNC control This configuration removes the rotary indexer servo control from the application and the rotary product is wired directly to the machine A rotary unit purchased with a servo control may not be convertible to a true 4th axis configuration A compatible motor to the host machine is required at time of purchase When using the rotary product wired directly to the machine consult the host machine manufacturer for information on 4th axis operation This manual will outline in detail the operation and programming of the servo control configured in methods 1 4 1 2 Three Variations of the Servo Control The Standard Servo Control is compatible with the Hardinge GD5C2 Rotary Table Indexers This servo control is intended to be used with rotary products that do not utilize a clamping system The Enhanced Servo Control has all the features of the standard control plus it has the ability to control a clamp circuit for the rotary indexer as well as input and output features which can be beneficial for the customer The enhanced servo control is com patible with the Hardinge GD5C2 GD16C2 GD3J2 GD I 60LP GD210LP DD 100 and DD200 Rotary Table Indexers The Direct Drive Servo Contro
64. esigned for a normally open valve which allows the clamp on the rotary indexer to be in an unclamped state when air is supplied to the rotary indexer An air hose connector is provided either on the motor cover or the back of the Enhanced Servo Control to supply the air to the clamp circuit When the unit is shipped from the factory this connector is identified with a red tag An air hose is also supplied with the unit to be used to route the air supply from the rotary indexer to the outside air supply from the facility The installa tion of the air line is machine specific It should be routed so that it will not become tangled with any part of the machine during normal operation Hardinge will not be responsible for damage to any utilities which were not installed at the factory A minimum air supply of 85 psi is required for the clamp circuit to function properly The clamp circuit consists of three basic components These are the clamp pneumatic valve and pressure switch The clamp is a failsafe device meaning that if air is removed from the device it will cause the clamp to engage which will prevent the rotary indexer from motion This is why a verified presence of 85 psi of air must be supplied to the clamp prior to operation of the rotary indexer The pneumatic valve is a normally open 24V valve In this circuit the clamp is engaged when the solenoid of the valve is energized and disengaged when the solenoid is de ener gized Finally there is an el
65. executed the motor is energized and a 350 millisecond dwell counts down before the clamp is turned off Then another 350 millisecond dwell counts down before the indexer moves Parameter 115 UNPROTECTED SW limit mode SWLMTMODE Param 115 Value Oorl This parameter defines the status of the software limit switch function The Servo Control has the ability to set software limits for added crash protection when the work envelope becomes restricted It is important to understand that these limits do not take effect on control power up and initial homing of the indexer These limits only take effect after initial power up and the homing operation is performed 0 Software limit switch function OFF l Software limit switch function ON Parameter 116 UNPROTECTED SW limit high SWLMTHIGH Param 116 Value 0 to 180000 This parameter defines the POSITIVE software travel limit The units are degrees x 1 000 Example If the positive travel limit is 105 degrees the value in parameter 16 105 000 x 1 000 105000 Parameter 117 UNPROTECTED SW limit low SWLMTLOW Param 117 Value 0 to 180000 This parameter defines the NEGATIVE software travel limit The units are degrees x 1 000 Example If the negative travel limit is 73 degrees the value in parameter 17 73 000 x 1 000 73000 NOTE It is possible to program a movement larger than the travel limit The axis will rotate until it sees either the negative or positive sof
66. feed rate and angle of rotation for the Hardinge rotary indexer spindle so that the machine and rotary indexer will stop at the same instant to give the desired result To calculate the feed rate for the rotary indexer you will need to know l The angular rotation to be performed by the rotary indexer in degrees this should come from the print 2 The feed rate for the axis of the mill usually in inches per minute 3 The distance you wish to travel on the axis on the CNC machine this should come from the print For example we wish to mill a spiral that is 6 revolutions on a part which is 12 5 inches in length The part is oriented on the machine to utilize the movement of the x axis The desired feed rate for the x axis on the machine is 2 000 inches per minute To set up the rotary indexer we have to calculate the angle of rotation in degrees the cycle time in seconds and the feed rate in degrees second of the indexer The angle of rotation is calculated as follows 6 revolutions x 360 degrees revolution 2160 degrees NOTE Parameter 12 will have to be changed to 5 to accommodate the 2160 degree move The cycle time is 12 5 inches 2 000 inches minute 6 25 minutes Thus 6 25 minutes x 60 seconds minute 375 seconds The feed rate of the indexer is then calculated by dividing the angle by the cycle time 2160 degrees 375 seconds 5 760 degrees second We can now program the rotary indexer to perform the desired motion A G94 and Loop
67. ge the programmed position You can start your program on any step by using the UP DOWN scan keys 4 Programming Examples To begin verify that the servo control is powered ON and the rotary indexer is in the homed position Enter PROGRAM mode The cursor will be on the position area of step one x O EE E tant LAP so 4M RM R Ti a a ap n Ven mist 1 Push the DISPLAY SCAN button to move the cursor to the G code Push the MINUS button The current program number will be displayed Use the number pad to select a new program number between and 49 As the buttons are pushed the Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 BS HARDINSE Servo Control User Manual B 158B desired program number will appear Program 48 Press the CYCLE START button to begin programming the new selected program Pressing the MODE button will change the control to the new program but send you to RUN mode If this happens simply re enter PROGRAM mode by selecting the MODE button aad a aa hw Now you re ready to look at some examples 4 1 Example l Utilizing G91 G28 and G99 We will program the rotary indexer to perform four 90 degree moves in the positive direction one 60 degree move in the negative direction and return to home A feed rate of 300 degrees per second wil
68. his parameter defines the amount of time the CNC interface finish relay is held active at the end of a step If the value is set to zero the relay time defaults to 4 second All other values extend the hold time by 0 1 seconds Value is set to O from factory Parameter 36 PROTECTED Velocity limit VLIM Param 36 Value 10 8224768 VMAX This parameter defines the velocity limit of the system It is measured in counts per second This value must be less than or equal to parameter 18 Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 BAS HARDINSE Servo Control User Manual B 158B Default settings are shown in Italics Parameter 39 PROTECTED Motor encoder offset MENCOFF Param 39 Value 0 4X PARAMI 9 I This parameter defines the encoder index position of the encoder feedback system The maximum value of this parameter is counts per revolution after quadrature l Parameter 40 UNPROTECTED Torque limit ILIM Param 40 Value 1 999999 Motor dependent This parameter defines the current limit of the system This will limit the drive s peak current for motor and system protection Parameter 43 UNPROTECTED Motor poles MPOLES Param 43 Value 2 80 even This parameter defines the number of motor poles for the motor This variable is used for commutation control and represents the number of in
69. iately for help related to this issue If a clamp is not installed on the unit parameter 110 is set wrong Change parameter 110 to 0 2 When aligning a fixture with parameter 110 set to 2 it is difficult to jog the rotary indexer at low speeds to fine tune the alignment If this is the case change parameter 110 to 0 and align the fixture After the alignment is complete and the desired zero is set change parameter 110 back to 2 5 5 General Purpose OUTPUT Functions of the Enhanced Servo Control The Enhanced Servo Control is equipped with three digital outputs available for custom use by the operator These outputs function as a normally open set of contacts These outputs can be useful in running valves auto matically for items such as workholding for trunnions tailstocks and collet closers The I O connector has three 24V sources available to run the external devices Therefore the devices need to be 2 wire 24 volt devices Refer to the diagram below for the output signal locations on the I O connector on the back panel of the Enhanced Servo Control The connector on the control is DBI5 female A DBI5 male connector will be required to use this functionality Part No Cl 001024201 Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 BAS HARDINSE Servo Control User Manual B 158B AUX I O CONNECTOR ON BACK OF ENHANCED SERVO CONT
70. in step 6 to go home the control will reset itself to step because of the G99 command in step 7 This example was the long way to perform the motions required taking 7 steps to program With creative thinking and an understanding of the various G code capabilities programming complicated motion can be done with fewer steps in the program For instance the above program could have been written with just 4 steps a number of different ways We will refer to example one in the following program examples to show the capability of the G codes 4 2 Example 2 This example will use G28 G91 and G99 to simplify example by utilizing the loop count functionality Change the loop count value of step one from to 4 Delete steps 2 3 and 4 To delete a step make sure the cursor is on position area of the step to be deleted Press and hold the ZERO RETURN button for 3 seconds Utilizing the various capabilities of the control will simplify programming 4 3 Example 3 Utilizing G90 G99 and G88 In example we programmed four 90 degree moves using the incremental command of G91 Go to program mode and change the four 90 degree angles for the four positions to absolute positions and change the G codes to G90 Change the 60 degree move to 240 000 and make the G code G90 Finally change the G28 to G88 The program on the display should read Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946
71. ined above If the servo control is being started externally via an M code and the machine control requires a finish signal the following programming procedure can be used to turn the outputs on and off Part No BB 0009500 0158 Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com 28 BS HARDINSE Servo Control User Manual B 158B 5 6 In the above photographs step one and two will turn on output l Step one will send the machine host control the required finish signal When the next M code is sent to the rotary indexer servo control steps three and four will turn off output Step three will send the machine control the required finish signal The use of the outputs can be programmed and commanded using the RS 232 function Follow the programming procedure outlined in the RS 232 section of the manual The G code will be G81 the feed rate will be 1 111 or 0 and the position value will be 1 000 2 000 or 3 000 General Purpose INPUT Functions of the Enhanced Servo Control The enhanced servo control box is equipped with three digital inputs available for custom use by the operator The inputs can be configured to be normally open circuits or normally closed circuits See parameter 112 for the definition of the status of the inputs The inputs can be used to monitor safety switches used to check the status of devices using the control box outputs
72. ines the clamp functionality of the Enhanced Servo Control The clamp is a spring to close air to open actuator The clamp functionality will take place after power up and initial homing is performed No clamp functionality is applied before this If the rotary indexer is not equipped with a clamp the value of this parameter must be set to 0 Rotary indexers fitted with clamps can utilize values of 0 or 2 WARNING A minimum of 85 psi of filtered dry air is required for the clamp to open If the clamp is not going to be used the air MUST still be connected to allow the indexer to rotate 0 Clamp Ignored l G code commands the clamp to open close 2 Auto clamp when motion stops Auto unclamp when motion starts A minimum value of 350 must be in parameter 111 Parameter 111 UNPROTECTED Clamp Time Delay CLAMPTM Param III Value 0 2000 This parameter sets the time delay in milliseconds before opening closing the clamp when a rotary indexer move is to be performed When parameter 10 0 parameter should be set to 0 When Parameter 110 is equal to or 2 parameter must be set to a minimum of 350 and to a maximum of 2000 When the clamp function is turned on and a command to move is executed to the control the clamp will open and wait the time delay before the motion is started When the rotary indexer comes to a stop at the commanded position the time delay will be counted down before the clamp is engaged Hardinge I
73. ions are subject to change without notice due to ongoing continuous improvement All marks indicated by and are trademarks of Hardinge Inc Instruction Manual B 158B Litho in USA Hardinge Inc 2010
74. l be used to perform the moves Enter the data using the numbers on the keypad scrolling with the DISPLAY SCAN button for each screen and the STEP SCAN button to change screens The cursor should be on the position area of step one of the program Enter 90000 with the keypad and then use the DISPLAY SCAN button to forward to the feed rate If the wrong value is en tered push and immediately release the CLEAR ZERO SET button to reset and enter the correct value Enter 300000 for the feed rate and scroll to the position area of line two The display should read ag a T m Repeat the values in step for steps 2 3 and 4 in the program On step 5 enter 60000 for the position area and 300000 for the feed rate On step 6 enter G28 for the G code and 300 000 for the feed rate For step 7 enter G99 for the G code The program should read Dow Fac Fac kou En mie mom Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 BAS HARDINSE Servo Control User Manual B 158B To exit PROGRAM mode press and release the MODE RUN PROG button To run the program press and release the CYCLE START BUTTON The indexer will rotate to 90 000 degrees and move to step 2 Press the CYCLE START button on the control when the rotary indexer stops motion to continue through the program After the rotary indexer executes the G28 command
75. l has all of the features of the enhanced servo control Advanced G code programming supports hardware and software limit switches and clamping An additional input and output on the back of the unit support air intake and exhaust Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 BS HARDINSE Servo Control User Manual B 158B All Hardinge Servo Controls are CE certified The Enhanced Servo Controls for geared indexers are also offered in a CSA version for sale in Canada Part Number Hardinge Servo Control CIA 0003279CE Standard Hardinge Servo Control phasing out in 2010 substitute Cl 00032791 OL CIA 000327910 Enhanced Hardinge Servo Control CIA 00032791OCS Enhanced Hardinge Servo Control CSA Approved N A Direct Drive Servo Control IMPORTANT A servo control is configured and tuned to the mechanical rotary table indexer unit with which it ships Substituting controls with mechanical units is not recommended unless you are advised to do so by a Hardinge technician for troubleshooting purposes Prior to substituting any control with a different mechanical unit contact the Hardinge technical department for approval Failure to do so will void any and all warranties on all involved products Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com
76. le multiplier to work with Parameter 9 See Parameter 9 for examples Do NOT use Value Parameter 21 UNPROTECTED RS232 axis address AXIS Param 2l Value 0 10 This parameter defines the axis identifier in the servo control using the RS 232 function When this param eter is zero no remote RS 232 functions are available When using the RS 232 function to control the rotary indexer this identifier should match in the part program the set value of the parameter in the control see axis identifier listing on next page Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 BAS HARDINSE Servo Control User Manual B 158B Default settings are shown in Italics Value Axis Identifier 0 none U O ON BDU 4 00 N29 Oo NXXxX2 o Internal Hardinge Use Only Parameter 22 PROTECTED Maximum position err PEMAX Param 22 Value 0 2 147 483 647 This parameter defines the maximum allowed value of following error It is measured in motor counts When this parameter is set to O the function is disabled If set to non zero and the error exceeds the value the drive will become disabled and the message FOLLOWING ERROR will appear on the display Parameter 23 PROTECTED Sys cont current ICONT Param 23 Value 0 500 This parameter defines the system continuous current It is a percentage of the peak cu
77. le to rotate in the safe direction The hardware limit switches are located on the back of the indexer under a sheet metal cover They have been adjusted to have a travel of 160 000 degrees Depending on the workholding and part size these may have to be adjusted NOTE It is very important that the rotary indexer is homed prior to mounting any workholding on the system Once homed you can then jog the rotary indexer in the positive and negative directions to determine the available travel If needed re adjust the limit switches to safely operate the system Once adjusted correctly to the workholding limitation this will provide security when homing and running part programs Homing the Rotary Indexer Using the Hardware Limit Switch Kit With the hardware limit switch function turned on and the switches properly adjusted press ZERO return on the rotary indexer servo control If the axis encounters a hardware limit switch the control will stop the axis and require the operator to jog the axis in the opposite direction Hold the jog button until the axis homes If needed press the 5 key on the keypad to jog faster During the homing operation only the hardware limit switches are effective for protection against a crash The rotary indexer homes on power up in the positive direction The home position is when the B axis is vertical If the A axis is in a position in which the B axis is on the positive side Hardinge Inc One Hardinge D
78. les of 1 10 second Thus a value of 13 will give 1 3 seconds of delay During normal operation with parameter 10 0 this should be set to 0 Parameter 17 PROTECTED Integral gain GPI Param 17 Value 0 10000 This parameter defines the integral gain for the Proportional Integral Derivative PID compensator in the position loop Setting this value 10 000 means that GPI GPI expressed mathematically the internal PID gain used by the drive processor equals GP GPI 10000 Parameter 18 PROTECTED Acceleration ACC Param 18 Value 1298 54612570 This parameter defines how fast the motor is accelerated up to the desired speed The value used is measured in motor counts second second Parameter 19 UNPROTECTED Motor maximus speed MSPEED Param 19 Value 0 8716288 Unit dependent This parameter defines the maximum recommended speed of the motor This is only a reference and the velocity limit of the tuned system is used to calculate the system speed Parameter 20 PROTECTED Gear ratio divider GEARO Param 20 Value 2 100 This parameter defines the non integer multiplier to be used with Parameter 9 Parameter 20 must be set to a value of to 100 Parameter 9 is divided by Parameter 20 before it is used As an example if Parameter 9 4096 and Parameter 20 3 the number of steps per unit will be 4096 3 1365 333 thus compensating for fractional gear ratios Parameter 20 must be set to the lowest possib
79. m Part No BB 0009500 0158 BAS HARDINSE Servo Control User Manual B 158B To utilize the infrared feature the customer must provide a device that operates on a Pocket PC operating system The complete setup of the system will require software to be installed on the customer s pocket PC unit The software can be found on the CD that was included with the indexer unit This capability is termed the Hardinge Infralink This software will allow the user to send and receive programs from the customer s pocket PC device to the Hardinge Servo Control User Interface screen for the Hardinge Infralink software Typical Programming format RI N fg tedalrrdenee 4001 G91 180 000 F360 000 NO01 G91 180 000 F360 000 DOZ Gv9 NOD GID mo oen se J sem Jn Programs can be prepared on a desktop or laptop using notepad software Programs can also be written and modified using the Hardinge Infralink application by typing over or deleting and inserting the text in the conven tional method IMPORTANT Read NOTES section on the following page before sending or receiving programs from the Servo Control Sending a Program to the Hardinge Servo Control using Infrared To download a program to the Hardinge Servo Control stop the program if the indexer is running and make sure that you are in the Run Mode screen Make sure the proper program number is selected and active in the control as the download process will overwrit
80. med it is desired that for subsequent homing moves that the rotary indexer moves in the shortest direction to the zero posi tion Therefore 24 3 27 27 would be inserted for the value of this parameter Values available for customization l only table zero position switch available 2 only Z channel home available 3 home on both Z channel and table zero switch 4 home if inverted Z determined 8 home to the zero position in the negative direction 16 home to the zero position in the positive direction 24 home to the zero position in the shortest direction after power up and initial home 32 auto servo on at power on 64 auto search for home at power on have to have 32 enabled 128 used for inverted home switch 256 search for home in the positive direction Parameter 28 PROTECTED Encoder resolution MENCRES Param 28 Value 1 999999 This parameter defines the line count of the motor encoder per revolution before quadrature Parameter 29 PROTECTED BackEMF compensation MBEMFCOMP Param 29 Value 0 130 This parameter defines the back EMF compensation used by the system and is motor dependent The units of this parameter are 26 Parameter 30 UNPROTECTED Password protection PASSWORD Param 30 Value random This parameter is a random number which is used to unlock the control and alter parameters as required Parameter 31 UNPROTECTED Relay hold time RELTIME Param 3l Value 0 9 T
81. mira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 BAS HARDINSE Servo Control User Manual B 158B 2 2 Rear Panel REMOTE INPUT MODEL SERIAL NUMBER JOE AUX I O eye 15 AMP A CAUTION A H HARDINSE C rns ABLE SERV CONTROLLER IM FOR BRUSH AND BRUSHLESS SYSTEMS REMOVE POWER PLUG WHEN CONNECTING OR MADE I ISRAEL BY DABAHEN MOTION DISGONNECTING MOTOR LARI Nae ELM kaw USA 120 VOLTS AC TO AREVENT ELECTRICAL SHOCK DO NOT REMOVE 1 PHASE 50 60 HZ COVER NO USER SERICABLE PARTS MADE B FOR CONTINUED PROTECTION AGAINST FUSE HAPARD H REPLACE ONLY WITH SAME TYPE AUSE Motor Encoder Cable Connector Motor Power Cable Connector Remote CNC Cable Port RS 232 Up Connector RS 232 Down Connector Serial Number I O Connector Enhanced Servo Control only Power Cord 120 or 230 volt ro7 moO P gt Main Power Fuse Main Power Switch to Turn the Unit OFF ON Motor Cable Conduit Connection Direct Drive Servo Control only L Air Exhaust Direct Drive Servo Control only M Air Intake Direct Drive Servo Control only Part No BB 0009500 0158 Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com BAS HARDINSE Servo Control User Manual B 158B 2 3 Dimensions Standard and Enhanced Servo
82. n the same manner a problem may exist at the end of the spiral but this can be eliminated by slightly altering the feed rate on the mill Don t adjust the feed rate on the Hardinge servo control because the mill has a much finer feed rate adjustment than the Hardinge servo control If the undercut appears to be in the X axis direction then slightly speed up 0 1 change in feed rate the mill s feed rate If the undercut appears in the radial direction of the spindle of the rotary indexer slow down the mill s feed rate Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 BRAS HARDINSE Servo Control User Manual B 158B If the timing is off by several seconds such that the mill completes movement before the rotary indexer completes its movement and there are several spiral moves one right after another such as in retracing a spiral cut this may cause the CNC to stop for no reason The reason for this is that your CNC will send a cycle start signal for next cut to the Hardinge servo control before it has completed its first move thereby causing a timing hang up The Hardinge servo control will not accept another cycle start until it is finished with the first If doing multiple moves it is very important to check timing calculations A way to verify if this is actually the problem is to single block the control allowing five seconds betw
83. nc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 53 54 BS HARDINSE Servo Control User Manual B 158B Default settings are shown in Italics Parameter 112 UNPROTECTED Inverse Dig Inputs ININVX Param 112 Value 0 7 This parameter inverts the input condition to be satisfied between normally open and normally closed The 3 general inputs can be configured in the following manner 0 means NORMALLY OPEN operation identifies NORMALLY CLOSED operation Value Input Input2 Input 3 General Input Condition 0 0 0 0 Inputs 2 and 3 operate as normally open 0 0 Input is normally closed 2 and 3 normally open 2 0 0 Input 2 is normally closed and 3 normally open 3 0 Input and 2 normally closed 3 normally open 4 0 0 Input 3 normally closed and 2 normally open 5 0 Input and 3 normally closed 2 normally open 6 0 Input 2 and 3 normally closed normally open 7 Inputs 2 and 3 normally closed Visual Definition of Settings for Normally Open and Normally Closed circuites Input Value of 0 Input Value of rT ttl li INPUT 1 ISO GROUND INPUT 1 ISO GROUND Normally Open Circuit Normally Closed Circuit Parameter 113 UNPROTECTED Set Dig Inputs Mode INXMODE Param 113 Value 0 3 This parameter defines the functionality of the 3 general purpose inputs of the Enhanced Servo Control The
84. ne as absolute home A user defined home position can be set using the procedure in step 10 If a user defined home position has been put into the control the indexer will show the absolute home after power up as a value other than 000 000 At this point the zero return button must be pushed again for the indexer to position to the user defined home position If the previous user defined home position is no longer valid press the clear zero set button until the con trol re zeroes at the absolute home position Now a new offset home position can be defined Jogging of the rotary indexer can now be done with the front panel JOG button Jog the indexer in both directions using the JOG button The JOG button has a for positive and a for negative movement The positive and negative directions are derived from the setting of Parameter l The jog speed is se lected with the front panel number keys and is a fraction of the maximum feed rate set by the parameters JOG SPEEDS Number pressed Speed of maximum 0 0 008 0 015 0 031 0 062 0 125 0 25 default 0 5 1 0 4 0 16 0 o ON DBD U BR V N Press the ZERO RETURN button to move the rotary indexer back to the home ZERO position Offsetting the Zero Position Use the left right JOG switch to position the indexer to the position that you want to use as zero or home and then press and hold the CLR key for three seconds The display should now indicate POSITION 000 000 This indi
85. nge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 BAS HARDINSE Servo Control User Manual B 158B PROTECTED and UNPROTECTED Parameters PROTECTED parameters are set at the factory and are system specific These parameters deal with motor types gains and encoder characteristics These parameters require a password to change and can only be changed by a Hardinge authorized service technician If an attempt to change a PROTECTED parameter is made the following error message will be displayed Password protected These PROTECTED parameters are factory set and designed to work with the specific motor ordered and limitations of the particular unit If a protected parameter is in question contact Hardinge with the unit serial number to determine if the value is correct UNPROTECTED Parameters consist of settings which adapt the control to customer specific functions These include positive direction dwells automatic modes etc These can be changed by the customer at any time to gain a desired result NOTE Before any attempt is made to alter factory settings the value of all parameters should be recorded for future reference There is a section in the rear of the manual to record these values Standard default values for various systems can also be found in the back of the manual If custom tuning was done at the factory the settings will be
86. nge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 37 38 BS HARDINSE Servo Control User Manual B 158B Il The program has been uploaded and can be opened and edited with notepad I2 Close HyperTerminal 13 Exit Program Mode in the rotary indexer Servo Control DOWNLOADING Transfer programs from the computer to the servo control l Make sure HyperTerminal is open and communicating with the rotary indexer Servo Control Enter Program Mode on the rotary indexer Servo Control Activate the Program number where you wish to save the downloaded file Position the cursor on the G code of step one Press the button on the keypad Press the button again on the keypad Press the button a third time on the keypad The display should now read Receiving prog oN o VU gb ow oM In HyperTerminal select transfer send text file A dialogue box will appear to select the file Do not select yet Leave dialogue box active and move to the rotary indexer Servo Control 9 On the rotary indexer Servo Control press Cycle Start A message Receiving program will appear 10 In HyperTerminal select the program file using the dialogue box and press Open I1 The program will be downloaded and displayed on the rotary indexer Servo Control when complete 12 Check the steps of the program to insure that the transfer worked c
87. o control to the appropriate value Parameter 21 4 X axis Parameter 26 7 baud rate 9600 Parameter 105 stop bits l Parameter 106 8 data bits 8 Parameter 107 0 no parity checking 6 2 1 Configuring the PC using HyperTerminal l Use the HyperTerminal application for uploading downloading programs to the rotary indexer The Hyper Terminal application is available in every Windows operating system Launch HyperTerminal from the START menu Programs Accessories Communication Hyper Terminal Burn CD amp DVDs with Roxio My Bluetooth Places B New Office Document pi Open Office Document L Set Program Access and Defauks ke Windows Update di one CC es fa Communications F3 KMTG Motion Suite gt GA Notepad HyperTerminal gt gt f3 Microsoft visual Studo 6 0 gt MY Paint Y y T Adobe Reader 7 0 DS WordPad Per on x a Where are n W Microsoft Word Cic Ke to WWE EE TextPad To turn this off use Programs nal gl Windows 200 Pro e tTOSEU Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 BAS HARDINSE Servo Control User Manual B 158B 2 Enter connection name Hardinge for example and click enter Connection Description 3 Connect To Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800
88. of the switch the switch goes low sending a signal to the control to verify that the home position has been reached This switch is only active during the initial homing sequence after power up If the rotary indexer fails to home after power up contact a Hardinge service technician for assistance Home Switch Assembly Part No Cl 0010224A k 9 4 Pneumatic Clamp Valve The valve used to operate the clamp on the Hardinge rotary indexer is a two wire 24 volt device This valve is located inside the motor cover of geared indexer units and in the junction box on top of the rotary indexer servo control in Direct Drive rotary units The valve is configured so that an air supply is delivered to the clamp when the solenoid of the valve is de energized When the clamp is supplied air the clamp on the unit is in the un clamped state To clamp the spindle of the indexing table the solenoid of the valve is energized removing the air supplied to the clamp For issues with the clamp valve contact a Hardinge service technician for assistance Clamp Valve with 1 8 NPT Ports Part No CJ 0003048SCV SMC SY5120T 5MOZ O1T 4 Efn i 4 Msvsizor 5moz 01T 4a 1P 388 GSMC JAPAN D 5 07MPa fe Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 62 BAS HARDINSE Servo Control User Manual B 158B Clamp V
89. om Part No BB 0009500 0158 33 BAS HARDINSE Servo Control User Manual B 158B NOTE Make sure your CNC has the same number of M functions programmed as you have steps in the Hardinge servo control Do not program two M functions one directly after another in your CNC control to index the Hardinge servo control This may cause a timing hang up in your CNC Use a dwell between them in the CNC control See setting of parameter 31 and program the equivalent dwell 6 2 RS 232 Capabilities The Hardinge Servo control has the capability of RS 232 communication for running commands and uploading downloading programs There are two connectors on the back panel of the control for connecting RS 232 cables The top connector RS 232 UP is used for commanding and transferring programs The bottom connector RS 232 DOWN is used for connecting servo controls together This is called daisy chaining Up to nine controls can be daisy chained together To use a PC to communicate with the rotary indexer servo control an RS 232 cable is required This cable will require the DB 25 pin male connector on one end and either a USB or DB 9 connector for the PC The cable used must be wired DTE Data Terminal Equipment on the PC end Next the PC and rotary indexer control must be configured to perform the communication HyperTerminal is common on most PCs and will serve as the tool to accomplish the task The following parameters should be set in the serv
90. on 0 Remote Cycle Start circuit is enabled I Remote Cycle Start circuit is disabled In this mode only pushing the cycle start button on the rotary indexer servo control will start a step Parameter 9 UNPROTECTED Gear input GEARI Param 09 Value 1 32767 This Parameter defines the number of encoder steps counts required to complete one full unit degree inch millimeter etc Example For a Hardinge GD5C2 Rotary Indexer The brushless motor encoder has 2048 lines per revolution With quadrature 2048 x 4 this encoder has 8192 counts per revolution The mechanical unit has a 60 1 gear ratio Therefore one revolution of the motor results in 6 degrees of movement on the output shaft 360 60 6 To calculate encoder counts per degree the equation would be 8192 counts rev x 1 rev 6 degrees 1365 333 encoder counts per degree Since 1365 333 is not a whole integer it must be multiplied by some number to clear the decimal point Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 RAS HARDINSE Servo Control User Manual B 158B Default settings are shown in Italics Parameter 20 is used to accomplish this Set parameter 20 to 3 therefore 1365 333 x 3 4096 entered in parameter 9 At 1365 333 counts degree the system will have a total of 491520 counts revolution on the output shaft 1365 333 x 360
91. on to sense the limit switch reference dog Set the negative travel switch by jogging in the negative direction using the same technique 5 11 Cooling Fan for the Enhanced Servo Control The Enhanced Servo Control has a cooling fan installed to dissipate any extra heat generated by the I O board It is also responsible for cooling the control when the bigger motors are used for the larger geared units and direct drive units The operation of this feature is automatic and requires no input from the operator 5 12 External Stop Circuit Function of the Enhanced Servo Control The Enhanced Servo Control is capable of being disabled by the machine tool This capability will require a normally closed contact from the E stop relay in the machine tool When the machine E stop relay is energized on the machine side of the circuit the normally closed contact will open and allow the Enhanced Servo Control to operate the rotary indexer When the E stop relay is de energized the normally closed contact will disable the Enhanced Servo Control until corrective action re energizes the E stop contactor in the machine There are two possible hookups shown that will enable this function This interlock can be easily disabled for troubleshooting purposes by removing the I O plug temporarily NOTE Using this feature will prevent the user from operating the Enhanced Servo Control until the machine is out of its E stop condition Hardinge Inc One Hardinge Driv
92. ophardinge com Part No BB 0009500 0158 67 10 5 Checking the Clamp Valve Insure that 85 psi is supplied to the clamp valve in port This is the port located between the two exhaust ports on any of the three available valves for the clamp The air line to supply air to the open port of the clamp should be exiting the valve on port B There is a mechanical switch located on the valve to manually shift the spool to check operation When the valve is de energized the clamp should be unclamped At this time the LED on the valve should be off If the valve does not appear to be functioning correctly turn off the servo control and unplug the air supply at the quick disconnect either on the control box or the top of the indexer unit Next unplug the air line from port B of the valve Reconnect the air supply at the quick disconnect Air should exit port B in this state Activate the mechanical switch to shift the valve and the air should stop If it does not the valve is faulty and needs to be replaced ll One Year Limited Warranty The Hardinge Rotary Indexer Servo Control is provided with a one year warranty against any defects in material and workmanship Specific details of the warranty can be found in the Hardinge Terms and Conditions document associated with the purchase agreement The G code in a line of a program identifies the type of command to be executed in that line G codes can command incremental or absolute positioning
93. orrectly 13 Correct any errors manually that may have occurred in the program of the rotary indexer Servo Control 14 The program is now ready for use in the rotary indexer Servo Control 15 Close HyperTerminal l6 Exit Program Mode in the rotary indexer Servo Control Programming Format for Uploading Downloading Programs When downloading a program to the indexer servo control the first and last steps of the program should be the symbol When programs are uploaded from the control to the PC this is automatically completed For example 76 NOOI G91 S090 000 F080 000 LOO N002 G91 S 060 000 F100 000 LOO N003 G99 76 6 2 3 Using a PC to Send Commands to the rotary indexer Servo Control A PC can be used to send commands to the rotary indexer Servo Control via RS 232 The rotary indexer will translate these commands and execute the desired functions This is particularly helpful for custom applications utilizing a PC based control system When using this function of the rotary indexer Servo Control HyperTermi nal can be used for controlling the rotary indexer Other programs may apply but this manual will outline using HyperTerminal It is important that the HyperTerminal function be configured as described above Be sure caps lock is on when typing the commands in HyperTerminal Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 00095
94. p one enter G83 and a feed rate of 10 000 Step two should contain the G99 The program should read as follows Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 BAS HARDINSE Servo Control User Manual B 158B Press cycle START and the unit will rotate in the negative direction at 10 degrees per second until the cycle start button is pressed again to stop the motion If motion is desired in the positive direction enter a G84 The program should now read In most applications the servo control will be commanded to move through the host machine control via the CNC cable See section 6 1 for remote CNC cable use An M code will be executed in the machine control which will close a relay and send a start signal to the rotary indexer servo control This will start the movement of the next step programmed into the rotary indexer control Usually the machine control will wait for a finish signal to come back to the machine from the rotary indexer control to tell the machine the rotary indexer is finished and go ahead with the part program To use the G83 or G84 command in this fashion a G94 will also have to be used to allow the machine to continue The G94 command will cause the rotary indexer servo control to immediately send a finish signal to the machine host control and automatically execute the next number of steps determined by
95. partment prior to the ordering of parts The technician will help troubleshoot the issue and make sure the correct parts are ordered Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 59 60 BAS HARDINSE Servo Control User Manual B 158B 9 1 Power and Encoder Cable The cable which connects the servo control to the rotary indexer mechanical unit is responsible for controlling the communication of the motor encoder home switch and clamp circuit of the indexer system This cable in most applications is subject to the harsh machining environment The condition of this cable should be routinely checked for any signs of damage occurring from operation that may cause this communication to fail Check for any abrasions cuts or loose connectors If any damage to the cable is suspected contact the Hardinge technical depart ment for assistance This cable should immediately be replaced on the discovery of an issue Damage to the rotary indexer system resulting from the use of a defective cable will void the warranty It is the operator s responsibility to make sure that the cable is properly installed and routed in the machine to insure that the cable will not be damaged during motion of the machine s axes Encoder Cable Part No Cl 000301 11O 9 2 Remote CNC Cable One remote CNC Cable is supplied with all Hardinge rotar
96. quare 5 key keypad on the right side of the front panel The three buttons on the right column of the keypad are used for program control MODE RUN PROG button DISPLAY SCAN RIGHT ARROW button STEP SCAN UP DOWN ARROW S button The MODE button is the most important It selects between the RUN mode and PROGRAM mode To begin verify that the servo control is powered on and the rotary indexer is in the homed position PR 1 Hegi LAB Gadi POSITION aA AAR T Enter PROGRAM mode The cursor will be on the position area of step one HAAI P CA on e co kou r Qt Fr axr a Naa P Fo CA a t co co E kou F Feed Rate programmed in degrees second N Number of steps in program P Position programmed in degrees with possible minus sign Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 BAS HARDINSE Servo Control User Manual B 158B 3 1 3 2 3 3 3 4 G G code programmed using available G code commands L Loop Count programmed as number of times to repeat current program step Feed Rate F The default feed rate display is 360 000 preceded by an F This is the feed rate that will be used for the selected step The feed rate corresponds to degrees rotated per second A feed rate of 360 000 means the spindle will rotate 360 degrees in one second See parameter 108
97. rea DON T USE a toxic or flammable substance as a solvent cleaner or coolant MAKE CERTAIN THAT PROPER GUARDING is in place and that all doors to the primary machine are closed and secured DON T OPEN GUARD DOORS of the primary machine while any machine component is in motion MAKE SURE chucks closers fixture plates and all other spindle mounted workholding devices are properly mounted and secured before starting the unit or the machine MAKE CERTAIN all tools are securely clamped in position before starting the unit or the machine REMOVE ANY LOOSE PARTS OR TOOLS left on the unit or the machine or in the work area before operating the equipment Always check the machine and work area for loose tools and parts especially after work has been com pleted by maintenance personnel REMOVE CHUCK WRENCHES before starting the unit or the machine BEFORE PRESSING THE CYCLE START PUSH BUTTON make certain that proper functions are programmed and that all controls are set in the desired modes KNOW WHERE ALL stop push buttons are located in case of an emergency MAKE CERTAIN that all guards are in good condition and are functioning properly before operating the equipment INSPECT ALL SAFETY DEVICES AND GUARDS to make certain that they are in good condition and are functioning properly before the cycle is started CHECK THE POSITION of any load unload automation before pressing the Cycle Start push button CHECK SETUP TOOLING AND SECURITY
98. rive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 RAS HARDINSE Servo Control User Manual B 158B of home the A axis will trip the positive hardware limit switch when trying to home This will require the opera tor to jog back in the negative direction to find home If the B axis is on the negative side of home the A axis will home directly to the home position Once the home position is established on power up the rotary indexer will take the shortest path to home until power is shut off to the control After initial homing is done the software limit switches will become active and be used See the section of the manual defining the software limit switch function 5 10 Adjusting Hardware Limit Switches Hardware Limit Switches POSITIVE HARDWARE LIMIT SWITCH POSITIVE HARDWARE LIMIT SWITCH M5 ADJUSTING SCREWS POSITIVE TRAVEL NEGATIVE TRAVEL LIMIT SWITCH REFERENCE DOG The hardware limit switches are located on the rear of the unit A rear cover plate will need to be removed to observe and adjust the switches Make sure the rotary indexer is homed Install the workholding and a part piece Slowly jog the rotary indexer until the workholding and part piece are within approximately 10 degrees of their travel limit in the positive direction Adjust the positive travel switch by loosening the 2 M5 adjusting screws and sliding the bracket into positi
99. rol User Manual B 158B BAS HARDINSE 10 4 Pin Schematic for the Encoder Power Cable m Ug z N S Brown Bw Brown White oe Red N Red White Kj EO Ie T a Red Black Orange IU a Ow e Orange White a A Orange Black _ Yellow ou u Green EX Blue A Purple Nj Gray White QU ce A Black Drain oo Pink eo av a Light Green 5 A Pink Black 3 3 Wn NS Yellow Black w Green White Creen Black me vu A Ge Sa o 5 av D n BOU Du 5 uu 22 Red o 2 Red o a mN N ES A oo 22 Black O o UJ Black ws lt 2 2a 407 e A Yellow Green A z Blue White Bs ui Drain 5 Ki Purple White Ld STWNDIS TOULNOD OAYIS A TI Un o L d E IZ 8i aNd S 9c Oc LC vc EC ON Atc AO l N oo N oo NT zZ BA N No LNAWNDISSV Nid CU CU U DOD CU Co ON Ui BW N a aN w 2 29 oN n aoooooo eq caas EH gggooonodl TO C LT T w wh Fi 8d aJnjeuuy J030lN Y2UMS JPW p plouajos dwe 9JnssaJg duJe 5 Sd vd Ed Cd MS 30H epis Jexepu ajqej A1e10y d Ld J9MOd JOJOW Jopoouj sjeubis 9pis O11U0 J OAJAS Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www sh
100. rrent times 0 1 This variable is used in the feedback algorithm Parameter 26 UNPROTECTED RS232 baud rate BRAT Param 26 Value 0 10 This parameter defines the baud rate on the RS 232 interface This parameter should be set to match the baud rate of the computer or machine control that it is being interfaced with The parameter values and rates are 0 110 6 7200 300 7 9600 2 600 8 19200 3 1200 9 38400 4 2400 10 56000 5 4800 Parameter 27 PROTECTED Home type HOMETYPE Param 27 Value 1 999999 This parameter defines the homing routine for the rotary indexer and can be modified to customize the homing routine of the unit When the control is shut down and restarted it will give an axis not homed display requiring the user to press the zero return button When the zero return button is pressed the unit will follow a homing sequence defined by the value in parameter 27 Depending on the system one of the values from 1 3 must be used Any additional functions desired will be added to the initial required value Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 49 BS HARDINSE Servo Control User Manual B 158B Default settings are shown in Italics Example GD5C2 Rotary Indexer 3 must be chosen to use both the Z channel and table zero switch After initial power up and the unit is ho
101. the host computer 5 Copy the WinZip file Hardinge InfraLink 101 PPC2003 ARM to the pocket PC and place in the personal folder 6 Using the pocket PC find the Hardinge InfraLink 101 PPC2003 ARM file in the personal folder and double click it to run the installation program for Hardinge InfraLink 7 Hardinge InfraLink will be installed in the Program Folder on the pocket PC 8 Hardinge InfraLink is now installed and can be used to upload and download programs to the Hardinge Servo Control NOTES I Do not upload download programs using infrared while the rotary indexer is running a program Stop the Servo Control and reset the Program to Step 2 The Servo Control must be in the RUN Mode screen to upload or download programs After sending the data switch to PROGRAM Mode on the Servo Control to confirm that the transfer was successful 3 Before using the Hardinge InfraLink 101 PPC2003 ARM software you must go to Settings Con nections Beam and uncheck the box that indicates Receive all Incoming Beams on your Windows MobilPC 4 InfraLink cannot be used for parameter transfer or any data not within a part program 5 Contact the factory if you have trouble using the Hardinge InfraLink 7 Control Parameters There are 48 stored Parameters associated with the Servo Control There is nonvolatile memory in the control that will keep the parameters and the stored programs saved forever These parameters are used to chang
102. the parameter section of the manual Using these inputs for hardware limit switches can be valuable when there is a potential for damage to occur to the rotary indexer or machine tool when the travel of the rotary indexer should be limited This is especially helpful in the homing procedure after power up in preventing travel into a restricted area This is a backup to the software limits which are only valid after initial power up and homing With the optional Hardinge limit switch kit hardware limits are adjustable to meet most operator applications Procedure for Using the Optional Hardinge Hardware Limit Switch Kit Parameter 12 Inverse Dig Input This parameter inverts the input signal between normally open and normally closed To use the hardware limit switches this must be set to 3 or 7 This is because the limit switches utilized by the Hardinge Kit are normally open and use inputs and 2 Parameter 113 Set Dig Input Mode This parameter must be set to a value of 3 Input is positive hardware limit and input 2 is negative hardware limit When operating the system in jog or run mode if a hardware limit is encountered there will be an error message posted on the control display which reads HW LIMIT JOG OPP DIRECTION This will require the operator to press the green cycle start key one time to clear the error message Then the operator must jog the indexer in the opposite direction to the safe area The rotary indexer will only be ab
103. tinued G90 absolute position command G9 incremental position command G92 pulse CNC relay and wait for remote input G93 pulse CNC relay G94 pulse CNC relay and run next L steps automatically G95 end of subroutine more steps follow G96 subroutine call jump destination is a step number G97 delay by L count 10 seconds down to 0 1 second G98 circle division always assumes 360 000 degrees to be divided equally G99 end of program return and end of steps Loop Count L The loop count identifies how many times a step will be repeated before moving to the next step of the program The loop count display is three digits between and 999 If a G97 is used the loop count is transformed to a timer to be used as a dwell Inserting a Step in a Program In program mode put the cursor on the position area of the step which you would like to insert a step Hold the cycle START button for three seconds It will cause the present step and all following steps to be moved down and cause the new step to be initialized with default values You will need to check and update your jump to locations after an insertion The values can now be programmed for the inserted step Deleting a Step in a Program In program mode put the cursor on the position area of the step to be deleted Hold the Zero Return button for three seconds It deletes the current step and will cause the next step and all following steps to be moved up by one You will need to check and up
104. tware limit and will stop An error will be posted that the software limit has been reached This will require the operator to jog the axis in the opposite direction to reset the switch At this time the operator should fix the limit value or change the programmed position Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 55 56 BS HARDINSE Servo Control User Manual B 158B 7 2 Gear Compensation The Hardinge Servo Control can store a compensation table to correct for small errors in the gear The gear compensation tables are part of the parameters While in parameter mode press the DISPLAY SCAN button to select the gear compensation tables L m The gear compensation data is displayed as S a 1 2 ex S Qo POS Rotary indexer position in degrees CW Compensation value in encoder steps in the negative clockwise direction CCW Compensation value in the encoder steps in the positive direction counterclockwise There is a table entry every degree starting at 001 and going to 359 It is recommended that you do not change the values in the gear compensation tables When the gear compensation tables are displayed the up and down arrow button will select the next three degree entry and the minus and numeric buttons will enter a new value In addition to this the JOG button may be used to adj
105. ual B 158B 6 1 Remote CNC Cable Connection and Use Cycle Start Finish Circuit Definition The function of the remote CNC interface cable is to provide a hardware handshake between the main machine and the servo control While the control will function without this handshake feature as described elsewhere it is much safer to use this simple 4 wire connection between the machine and servo control to prevent the machine and servo control from operating independently To make this feature as universal as possible the interface imple mentation is made with relay contacts This allows the user to use an M code relay or a quill switch to operate the servo control and provides the capability of interfacing to many types of inputs with the servo control s FIN finished response It also helps prevent incompatibilities between equipment interface voltages The operation of the FIN signal relay can also be inverted to act as a machine feed permissive circuit by changing parameter 2 to a instead of a 0 The servo control expects to see a contact closure between pins 3 black wire and 4 white wire of the interface connector to cycle START the servo control when in RUN mode The control settings will determine if the cycle START executes a loop count step or an entire program When the servo control has executed what was desired the servo control closes a relay contact back to the machine on pins red wire and 2 green wire It should
106. ust the compensation value If the servo is on when changes are made the servo motor will move by the adjustment amount if the table is at the position corresponding to the entry changed This is valuable in that the JOG button can be used to move the motor to a desired position To exit the gear compensation display press the MODE button to return the control to RUN mode 7 3 Default Parameter Settings for Hardinge Standard Rotary Products The following table identifies the parameter value for standard rotary products shipped from Elmira New York The column on the right is provided to record any changes made to the original parameters Circle the unit for the product purchased and fill in the control and mechanical unit serial number for reference In the event of a service call have this information available for the technician to reference Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 Servo Control User Manual B 158B BAS HARDINSE Rotary Indexer Servo Control S N S e S e g o o o M P i 1 1 1 1 1 2 0 0 0 0 3 700 700 700 700 5 0 0 0 0 6 0 0 0 0 7 0 0 0 0 8 0 0 0 0 9 4096 4096 4096 4096 10 0 0 0 0 11 0 0 0 0 12 6 6 6 6 15 n a n a n a n a 16 0 0 0 0 17 0 0 0 0 18 6828032 5667266 1138005 4506501 19 819200 679936 136533 648806 20 3 3 3 2 21 4 4 4 4 22 0 0 0 0 23 311 311 311 311 26
107. y products This cable is used to remotely start the rotary indexer using a spare M code on a machine tool It can also be connected to a mechanical switch which can then be driven by a moving portion of a manually controlled machine This is called the remote quill switch This is a four wire cable with a connector on one end that will directly connect with the remote CNC cable port located on the back of the rotary indexer servo control The black and white wires control the start signal The red wire should be connected to a 24 volt supply and the green wire serves as the finish input signal if used Additional cables can be purchased and wired to machines making the movement of a rotary indexer from one machine to another more convenient Remote CNC Cable Part No Cl 000301 IIC Remote CNC Cable with Remote Quill Switch installed Part No Cl 0010224RSA shown Hardinge Inc One Hardinge Drive Elmira New York U S A 14902 1507 800 843 8801 Canada 800 468 5946 www shophardinge com Part No BB 0009500 0158 BRS HARDINSE Servo Control User Manual B 158B 9 3 Home Switch The home switch used with geared indexer units is a three wire hall effect switch This switch is a normally closed switch The switch is located inside of the motor cover and installed in the housing of the indexer Located on the gear of the mechanical unit is a magnet which is used as the reference dog for the switch When this magnet passes the sensor

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