HEIDENHAIN POSITIP 880 User manual

User’s Manual
POSITIP 880
English (en)
6/2005

Numeric input keys
Change negative/positive
value key
Select entry fields
Confirm entry
Parallel port
4 axis keys to select between X, Y
and Z axes
Soft keys - Row of keys under the screen
of the POSITIP whose functions vary
according to associated fields that appear
above them on the screen
Keys for selecting operating mode
(for detailed description of these key
functions, see Operating Modes in
chapter I-2)
Clear entry or
error messages
Incremental dimensions
Keypad and soft keys
POSITIP 880 Back View
Ground
Power button
Main power input
Serial
port
Axis ports
Edge finder Auxiliary
Machine
Interface
connector
Remote
console

POSITIP 880 3
General Notes
General Notes
Software version
The software version of your unit is shown on the initial power up
screen and on the prompt bar after pressing the Help soft key.
About this manual
This manual is divided into two parts:
Part I: Operating Instructions
Part II: Technical Information
Operating Instructions
When using the POSITIP 880 in your work, you need only refer to the
Operating Instructions (Part I).
If you're new to POSITIP 880, you can use the operating instructions
as a step-by-step workbook. This part begins with a short introduction
to the basics of coordinate systems and position feedback, and
provides an overview of the available features. Each feature is
explained in detail, using an example which you can immediately try
out on the machine — so you won't get "lost" in the theory. As a
beginner you should work through all the examples presented.
If you're already familiar with POSITIP 880, you can use the
Operating Instructions as a comprehensive review and reference
guide.
Technical Information
If you are interfacing the POSITIP 880 to a machine or wish to use the
data interfaces, refer to the technical information in Part II.
Dialog flowcharts
Dialog flowcharts are used for each example in this manual. They are
laid out as follows:
This User's Manual covers the functions of the POSITIP
880 for both milling and turning applications. Basic
POSITIP 880 functions are covered in the first 4 chapters
of this manual. The turning section deals only with the
functions specific to turning applications.

4
General Notes
This area explains the key function or work step. If
necessary, supplementary information will also be
included.
If there is an arrow at the end of the flowchart, this means that it
continues on the next page.
A perforated line indicates an alternative method of carrying out the
given function.
A prompt appears with some actions (not always) in the message bar
on the screen.
Important Notes in this Manual
Special green note boxes contain especially important information.
Please pay special attention to these notes. Neglecting this
information can result in e.g. functions not working in the desired way
or in causing damage to the workpiece or to the tool.
PROMPT
KEY

POSITIP 880 5
General Notes
Symbols within the notes
Every note is marked with a symbol on the left informing about the
meaning of the note.
General Information
e.g. on the behavior of the POSITIP 880.
Warning – Refer to accompanying documents
e.g. when a special tool is required for a function.
Caution - Risk of electric shock
e.g. when opening a housing.

POSITIP 880 7
I – 1 Fundamentals of Positioning ..... 12
Coordinate Systems ..... 12
Setting the Datum ..... 13
Nominal Position, Actual Position and Distance-To-Go ..... 14
Absolute Workpiece Positions ..... 15
Incremental Workpiece Positions ..... 15
Position Encoders ..... 17
Reference Marks ..... 17
Angle Reference Axis ..... 18
I – 2 Working with POSITIP 880 – First Steps ..... 19
Power Up ..... 19
Before You Start ..... 19
Operating Modes ..... 21
On-Screen Operating Instructions (HELP Mode) ..... 22
Confirming Your Changes ..... 22
Messages ..... 23
Error messages ..... 23
Selecting the Unit of Measure ..... 24
Selecting the Angle Format ..... 24
Tool Table ..... 24
Calling the Tool Data ..... 25
I – 3 Actual Value ..... 26
Datum Setting: Approaching Positions and Entering Actual Values ..... 26
Probing Functions for Datum Setting ..... 28
Datum Setting with a Tool ..... 34
I – 4 Distance-To-Go ..... 36
Displaying and Moving to Positions ..... 36
I – 5 Milling Patterns ..... 43
Circle Pattern ..... 43
Linear Pattern ..... 46
Milling a Rectangle Pocket ..... 49
I Operating Instructions ..... 11

8
I – 6 Programming POSITIP 880 ..... 53
Program Capabilities ..... 53
Editing and moving through a program ..... 53
Programming Features ..... 54
Tool Call ..... 56
Datum Call ..... 57
Presets ..... 58
Hole Patterns and Rectangle Patterns ..... 59
Subprograms ..... 59
Labels ..... 59
Label Number ..... 60
Label Call ..... 60
Position Drill ..... 62
Milling a Line ..... 63
Milling an Arc ..... 64
Blend ..... 66
Chamfer ..... 68
File Operation Soft Keys ..... 70
Loading, saving, deleting & clearing a program ..... 70
Directories ..... 71
Importing a Program ..... 73
Exporting a Program ..... 74
Block Function Soft Keys ..... 74
I – 7 Executing a Program ..... 78
Program views ..... 80
Contour View ..... 81
I – 8 INFO Screen ..... 83
JOB SETUP Menu ..... 83
Tool Table Usage ..... 85
Installation Menu ..... 92
Calculator ..... 92
Language ..... 95
Inch/MM ..... 95

POSITIP 880 9
I – 9 POSITIP 880 Turning Functions ..... 96
Power Up ..... 96
Fundamentals of Positioning ..... 97
Job Setup for Turning Applications ..... 98
Tool Table Usage ..... 99
Tool Offsetting ..... 102
NOTE/SET Function ..... 103
Datum Setting ..... 104
Taper Calculator ..... 104
Programming Turning Functions for POSITIP 880 ..... 106
Programming Features Soft Keys ..... 106
Multipass ..... 107
File Operation Soft Keys ..... 108
Block Function Soft Keys ..... 109

10
II – 1 Installation and Electrical Connection ..... 112
Items Supplied ..... 112
Mounting Location ..... 112
Installation ..... 112
Connecting the Encoders ..... 114
Connecting an Edge Finder ..... 115
II – 2 Installation Setup ..... 116
Initial switch-on ..... 116
General field/form navigation guide ..... 117
Axes Configuration ..... 117
Encoder Setup ..... 118
Error Compensation ..... 119
Linear Error Compensation ..... 120
Non-Linear Error Compensation ..... 121
Serial Port (X31) ..... 123
Parallel Port (X32) ..... 123
Protection ..... 124
Counter Settings ..... 124
Diagnostics ..... 125
AMI (Auxiliary Machine Interface)(X51) (Optional) ..... 126
Remote Console (X61) (Optional) ..... 127
II – 3 Encoders and Measured Value Display ..... 128
Setting the display step with rotary encoders ..... 129
II – 4 Data Interface ..... 130
II – 5 Measured Value Output ..... 135
Examples of character output at the data interface ..... 135
II – 6 Specifications for Milling ..... 139
II – 7 Specifications for Turning ..... 141
II – 8 Dimensions ..... 143
II – 9 Accessories ..... 144
Accessory ID Numbers ..... 144
POSITIP 880 Mounting Instructions
Universal Mounting Arm
ld. Nr. 382 929-01 ..... 145
POSITIP 880 Mounting Instructions
Mounting base
ld. Nr. 382 892-01 ..... 146
POSITIP 880 Mounting Instructions
Tilt/Swivel Mount
ld. Nr. 382 891-01 ..... 147
II Technical Information ..... 111

POSITIP 880 11
Operating Instructions

12 I Operating Instructions
I – 1 Fundamentals of Positioning
I – 1 Fundamentals of Positioning
Coordinate Systems
In order to define positions on a surface, a reference system is
required.
For example, positions on the earth's surface can be defined
absolutely by their geographic coordinates of longitude and latitude. In
contrast to the relative definition of a position that is referenced to a
known location, the network of horizontal and vertical lines on the
globe constitute an absolute reference system. See Fig. I.1.
On a milling machine, workpieces are normally machined according to
a workpiece-based Cartesian coordinate system (a rectangular
coordinate system named after the French mathematician and
philosopher Renatus Cartesius, who lived from 1596 to 1650). The
Cartesian coordinate system is based on three coordinate axes
designated X, Y and Z which are parallel to the machine guideways.
The figure to the right (Fig. I.2) illustrates the right-hand rule for
remembering the three axis directions: the middle finger is pointing in
the positive direction of the tool axis from the workpiece toward the
tool (the Z axis), the thumb is pointing in the positive X direction, and
the index finger in the positive Y direction.
You can skip over this chapter if you are familiar with the
concepts of coordinate systems, incremental and absolute
dimensions, nominal and actual positions, and distance-to-
go.
Fig. I.1 The geographic coordinate system is an
absolute reference system
Fig. I.2 Designations and directions of the axes on a
milling machine

POSITIP 880 13
I – 1 Fundamentals of Positioning
Setting the Datum
The workpiece drawing (Fig. I.3) identifies a certain point on the
workpiece (usually a corner) as the absolute datum and perhaps one
or more other points as relative datums.
The datum setting procedure establishes these points as the origin of
the absolute or relative coordinate systems: The workpiece, which is
aligned with the machine axes, is moved to a certain position relative
to the tool and the display is set either to zero or to another appropriate
value (e.g., to compensate the tool radius).
Example:
Drawing with several relative datums (ISO 129 or DIN 406 Part 11,
Fig. 171)
Fig. I.3 The workpiece datum represents the origin
of the Cartesian coordinate system

14 I Operating Instructions
I – 1 Fundamentals of Positioning
Example: Coordinates of hole 1:
X =10 mm
Y = 5 mm
Z = 0 mm (hole depth: Z = – 5 mm)
The datum of the Cartesian coordinate system is located 10 mm from
hole 1in the X axis and 5 mm from it in the Y axis. See Fig. I.4.
The KT Edge Finder from HEIDENHAIN, together with the
POSITIP 880's edge finding functions, facilitates finding and setting
datums.
Nominal Position, Actual Position and Distance-
To-Go
The position that the tool is to move to is called the nominal position
while the position of the tool at any given moment is called the actual
position. The distance from the nominal position to the actual position
is called the distance-to-go. See Fig. I.5.
Sign for distance-to-go
The distance-to go has a positive sign if the axis direction from the
actual towards the nominal position is negative.
The distance-to-go has a negative sign if the axis direction from the
actual towards the nominal position is positive.
Fig. I.4 Hole 1 defines the coordinatesystem
Fig. I.5 Nominal position S, actual position I and
distance-to-go R

POSITIP 880 15
I – 1 Fundamentals of Positioning
Absolute Workpiece Positions
Each position on the workpiece is uniquely identified by its absolute
coordinates. See Fig. I.6.
Example: Absolute coordinates of position 1:
X = 20 mm
Y = 10 mm
Z = 15 mm
If you are drilling or milling a workpiece according to a workpiece
drawing with absolute coordinates, you are moving the tool to the
value of the coordinates.
Incremental Workpiece Positions
A position can also be referenced to the preceding nominal position.
In this case the relative datum is always the last nominal position.
Such coordinates are referred to as incremental coordinates
(increment = increase). They are also called incremental or chain
dimensions (since the positions are defined as a chain of dimensions).
Incremental coordinates are designated with the prefix I.
Example: Incremental coordinates of position 3referenced to position
2. See Fig. I.7
Absolute coordinates of position 2:
X = 10 mm
Y = 5 mm
Z = 20 mm
Incremental coordinates of position 3:
IX = 10 mm
IY = 10 mm
IZ = –15 mm
If you are drilling or milling a workpiece according to a drawing with
incremental coordinates, you are moving the tool by the value of the
coordinates.
Fig. I.6 Position 1 definition through absolute
coordinates
Fig. I.7 Positions 2 and 3 through incremental
coordinates

16 I Operating Instructions
I – 1 Fundamentals of Positioning
A coordinate list corresponding to this example is useful when
working in the operating mode: PROGRAMMING. See Fig. I.8
Fig. I.8 Workpiece drawing with coordinate
dimensioning (ISO 129 or DIN 406 Part 11,
Fig. 179)
Coordinateorigin Dimensions in mm
Coordinates
Pos. X1 X2 Y1 Y2 r f d
1100 -
1 1.1 325 320 ø 120 H7
1 1.2 900 320 ø 120 H7
1 1.3 950 750 ø 200 H7
1 2 450 750 ø 200 H7
1 3 700 1225 ø 400 H8
2 2.1 -300 150 ø 50 H11
2 2.2 -300 0 ø 50 H11
2 2.3 -300 -150 ø 50 H11
3 3.1 250 0° ø 26
3 3.2 250 30° ø 26
3 3.3 250 60° ø 26
3 3.4 250 90° ø 26
3 3.5 250 120° ø 26
3 3.6 250 150° ø 26
3 3.7 250 180° ø 26
3 3.8 250 210° ø 26
3 3.9 250 240° ø 26
3 3.10 250 270° ø 26
3 3.11 250 300° ø 26
3 3.12 250 330° ø 26

POSITIP 880 17
I – 1 Fundamentals of Positioning
Position Encoders
The position feedback encoders convert the movement of the
machine axes into electrical signals. The POSITIP 880 constantly
evaluates these signals and calculates the actual positions of the
machine axes, which it displays as a numerical value on the screen.
See Fig. I.9.
If there is an interruption in power, the calculated position will no
longer correspond to the actual position. When power is restored, you
can re-establish this relationship with the aid of the reference marks
on the position encoders and the POSITIP 880's reference mark
evaluation feature (REF).
Reference Marks
The scales of the position encoders contain one or more reference
marks. When reference marks are crossed they can be used to define
an absolute position in an incremental system. If power is interrupted
this absolute position is lost and the relationship between the
reference mark and scale position is lost. The reference marks on the
position encoders and the POSITIP 880's reference mark evaluation
feature allows the unit to quickly re-establish this relationship again
when power is restored. See Fig. I.10.
When a reference mark is crossed over, it generates a signal which
identifies that position as the reference point. The POSITIP 880 uses
this reference point to restore the relationship between the scale
position and the display value which was last defined by setting the
datum.
If the position encoders feature distance-coded reference marks,
there are reference marks uniquely spaced along the length of the
scale. Crossing any two reference marks will restore the datum. Each
axis need only move a limited distance for linear encoders, and angle
for rotary encoders.
Fig. I.9 Linear position encoder, here for the X axis
Fig. I.10 Linear scales: with distance-coded
reference marks (upper illustration) and one
reference mark (lower illustration)
The datum setting cannot be restored from one power
cycle to the next if the reference marks were not crossed
before the datum was set.

18 I Operating Instructions
I – 1 Fundamentals of Positioning
Angle Reference Axis
For angular positions, the following reference axes are defined:
Positive direction of rotation is counterclockwise if the working plane
is viewed in negative tool axis direction. See Fig. I.11.
Example: Angle in the working plane X / Y
Fig. I.11 Angle and the angle reference axis, e.g. in
the X / Y plane
Plane Angle reference axis
XY +X
YZ +Y
ZX +Z
Angle Corresponds to the...
+ 45° ... bisecting line between +X and +Y
+/– 180° ... negative X axis
- 270° ... positive Y axis

POSITIP 880 19
I – 2 Working with POSITIP 880 – First Steps
I – 2 Working with POSITIP 880 –
First Steps
Power Up
Switch on the power (located on the back). It will take
approximately 25 - 30 seconds for system to start
after power up. The initial screen will appear (This
screen will only appear the first time you power
up). Select the language by pressing the LANGUAGE
soft key.
At this point you have the choice of MILL or TURN.
Select the MILL soft key to proceed with milling
functions the first time you power up. See Table of
Contents for turning functions section. See Fig. I.12.
You can change the application later in
INSTALLATION SETUP under COUNTER SETTINGS.
Your POSITIP 880 is now ready for operation and is in the operating
mode ACTUAL VALUE. Axis will show “NO REF”.
Before You Start
The POSITIP 880's reference mark evaluation feature automatically re-
establishes the relationship between axis slide positions and display
values that you last defined by setting the datum.
If the axis encoder has reference marks, the NO REF indicator will
flash. See Fig. I.13. After crossing over the reference marks, the
indicator will stop flashing and change to REF.
Working without reference mark evaluation
You can also use the POSITIP 880 without crossing over the reference
marks. Press the NO REF soft key to exit the reference mark evaluation
routine and continue in ACTUAL VALUE mode. The NO REF indicator
will indicate that reference marks were not crossed over for that axis.
You can still cross over reference marks at a later time. The ENABLE
REF soft key will be available from ACTUAL VALUE mode. Press this
soft key to activate the reference mark evaluation routine.
Fig. I.12 Initial screen
Fig. I.13 Display before choosing NO REF

20 I Operating Instructions
I – 2 Working with POSITIP 880 – First Steps
ENABLE REF function
The purpose of the ENABLE REF function, is to give the operator the
opportunity to either ignore the reference marks as they are crossed
over by disabling it, or finding reference marks when necessary by
enabling it. When the ENABLE REF soft key is pressed, the POSITIP 880
is ready to identify a reference mark. When the ENABLE REF soft key is
not depressed, POSITIP 880 will ignore all reference marks. When all
reference marks have been found, the ENABLE REF soft key will
disappear.
Once reference marks for all desired axes are established, press NO
REF soft key to cancel out of routine. You do not have to cross over the
reference marks of all the encoders, only those that you need.
Turn on power and press any key.
Cross over the reference marks (in any order).
Do not cross over the reference marks. Note: In this
case the relationship between axis slide position and
display value will be lost after a power interruption.
Press the NO REF soft key.
If an encoder is setup without reference marks, then the
REF indicator will not be displayed.
If you do not cross over the reference marks, POSITIP 880
does not store the datum points. This means that it is not
possible to re-establish the relationship between axis slide
positions and display values after a power interruption
(switch-off).