HEIDENHAIN ND 780 User manual
ND 780 Screen
Status Bar Symbols
Datum Tool Feed Rate Stopwatch Unit of
Measure Actual Value Distance-To-
Go Page
Indicator Set/Zero
Axis Label
Display Area
Ref symbol
Graphic
Positioning
Aid
Soft Key
Functions
Numeric input keys
3 axis keys to select between X, Y and Z axes
Soft keys - Row of keys under the screen of
the ND 780 whose functions vary according
to associated fields that appear above them
on the screen
Clear key Confirm entry and
select entry field
Up/Down arrow keys -
are also used to adjust
screen contrast
ND 780 5
Introduction
Software Version
The software version is shown on the initial power up screen.
Symbols within notes
Every note is marked with a symbol on the left indicating to the
operator the type and/or potential severity of the note.
ND 780 Fonts
The chart below shows how the different variables (soft keys, hard
keys, forms and form fields) are represented within the text of this
manual:
Soft keys - SETUP soft key
Hard keys - ENTER hard key
Forms - ANGULAR forms
Form Fields - RADIUS
Data in fields - ON, OFF
This User’s Manual covers the functions of the ND 780 for
both milling and turning applications. Operational
information is arranged in three sections: General
Operations, Mill Specific Operations and Turn Specific
Operations.
General Information
e.g. on the behavior of the ND 780.
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.
The ND 780 and the machine tool must be prepared by the
machine tool builder to perform this function.
ND 780 7
I – 1 Fundamentals of Positioning ..... 12
Datums ..... 12
Actual Position, Nominal Position and Distance-To-Go ..... 12
Absolute Workpiece Positions ..... 13
Incremental Workpiece Positions ..... 13
Zero Angle Reference Axis ..... 14
Position Encoders ..... 14
Encoder Reference Marks ..... 15
I – 2 General Operations for ND 780 ..... 16
Layout of Screen ..... 16
General Navigation ..... 17
Operating Modes ..... 17
Graphic Positioning Aid ..... 18
Help Screen ..... 18
Data Input Forms ..... 18
Error Messages ..... 19
Power Up ..... 20
Reference Mark Evaluation ..... 20
ENABLE/DISABLE REF function ..... 21
Setup ..... 22
Job Setup Parameters ..... 22
Units ..... 22
Scale Factor ..... 23
Mirror ..... 23
Edge Finder (milling applications only) ..... 23
Diameter Axes ..... 24
Measured Value Output ..... 24
Graphic Positioning Aid ..... 25
Status Bar Settings ..... 25
Stopwatch ..... 26
Remote Switch ..... 26
Console Adjustment ..... 27
Language ..... 27
Import/Export ..... 27
General Operation’s Soft Key Function Overview ..... 28
General Operation’s Soft Key Functions Detailed ..... 29
Set Zero Soft Key ..... 29
Calc Soft Key ..... 30
I Operating Instructions ..... 11
8
I – 3 Milling Specific Operations ..... 33
Soft Key Functions Detailed ..... 33
Tool Soft Key ..... 33
Tool Radius Compensation feature ..... 33
Tool Table ..... 33
Tool Table Usage ..... 35
Calling the Tool Table ..... 37
Tool call ..... 37
Datum Soft Key ..... 38
Probing Functions for Datum Setting ..... 40
Datum setting with the edge finder ..... 40
Probing with a Tool ..... 44
Preset Soft Key ..... 46
1/2 Soft Key ..... 52
Patterns Soft Key (Milling) ..... 53
Functions for milling patterns ..... 53
Circle Pattern Soft Key ..... 53
Linear Pattern ..... 56
I – 4 Turning Specific Operations ..... 59
Soft Keys Functions Detailed ..... 59
Tool Soft Key ..... 59
To access the Tool Table menu: ..... 59
Tool Table Usage ..... 60
Setting tool offsets using TOOL/SET ..... 60
Setting Tool Offset using NOTE/SET Function ..... 61
Datum Soft Key ..... 62
Preparation: ..... 62
Setting Datums using NOTE/SET Function ..... 64
Preset Soft Key ..... 65
RX(Radius/Diameter) Soft Key ..... 65
ND 780 9
II – 1 Installation and Electrical Connection ..... 68
Items Supplied ..... 68
Accessories ..... 68
ND 780 Display Unit ..... 68
Mounting Location ..... 68
Installation ..... 68
Electrical connection ..... 68
Electrical requirements ..... 69
Environmental ..... 69
Wiring the power connector, see Fig. II.1 ..... 69
Preventative maintenance ..... 69
Connecting the Encoders ..... 70
Pin layout for encoder inputs. ..... 70
Connecting Edge Finder Output and Input Signals ..... 72
Pin layout for Edge Finder and Measured Value Output input (see Fig. II.5 for pinout) ..... 72
II – 2 Installation Setup ..... 73
Installation Setup Parameters ..... 73
Encoder Setup ..... 74
Display Configuration ..... 74
Coupling ..... 74
Z Coupling (turning applications only) ..... 75
Enabling Z Coupling ..... 75
Disabling Z Coupling ..... 75
Error Compensation ..... 76
Linear Error Compensation ..... 76
Non-Linear Error Compensation ..... 77
Backlash Compensation ..... 78
Serial Port (X31) ..... 79
Counter Settings ..... 80
Diagnostics ..... 81
Keypad Test ..... 81
Encoder signal plot ..... 81
II – 3 Encoder Parameters ..... 82
Example settings for HEIDENHAIN linear encoders with 11-µAPP signals ..... 82
Example settings for HEIDENHAIN linear encoders with 1-VPP signals ..... 82
II – 4 Data Interface ..... 84
Serial port ..... 85
Wiring the connecting cable ..... 86
Signal ..... 86
External Operations via RS-232 Data Interface ..... 87
II Technical Information ..... 67
10
II – 5 Measured Value Output ..... 88
Data output using external signals ..... 88
Data output using Edge Finder ..... 90
II – 6 Specifications for Milling ..... 93
II – 7 Specifications for Turning ..... 95
II – 8 Dimensions ..... 96
II – 9 Accessories ..... 97
Accessory ID Numbers ..... 97
ND 780 Handle
Id. Nr. 520 012-01 ..... 97
ND 780 Mounting Instructions
Universal Mounting Arm
ld. Nr. 382 929-01 ..... 98
ND 780 Mounting Instructions
Tilting Base
ld. Nr. 281 619-01 ..... 99
ND 780 Mounting Instructions
Tilting Bracket
ld. Nr. 520011-01 ..... 100
ND 780 Mounting Instructions
Mounting Frame
ld. Nr. 532811-01 ..... 101
12 I Operating Instructions
I – 1 Fundamentals of Positioning
I – 1 Fundamentals of Positioning
Datums
The workpiece drawing 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 for tool radius).
Actual Position, Nominal Position and Distance-
To-Go
The position of the tool at any given moment is called the actual
position while the position that the tool is to move to is called the
nominal position. The distance from the nominal position to the
actual position is called the distance-to-go. See Fig. I.1
Fig. I.1 Nominal position S, actual position I and
distance-to-go R
ND 780 13
I – 1 Fundamentals of Positioning
Absolute Workpiece Positions
Each position on the workpiece is uniquely identified by its absolute
coordinates. See Fig. I.2.
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.3
.
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.2 Position 1 definition through absolute
coordinates
Fig. I.3 Position 3 using incremental coordinates
14 I Operating Instructions
I – 1 Fundamentals of Positioning
Zero Angle Reference Axis
The Zero Angle Reference Axis is the 0 degree position. It is defined
as one of the two axes in the plane of rotation. The following table
defines the Zero Angle where the position of the angle is zero for the
three possible planes of rotation.
For angular positions, the following reference axes are defined:
Positive direction of rotation is counterclockwise if the working plane
is viewed in the negative tool axis direction. See Fig. I.4.
Example: Angle in the working plane X / Y
Position Encoders
The position feedback encoders convert the movement of the
machine axes into electrical signals. The ND 780 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.5.
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 ND 780’s reference mark evaluation
feature (REF).
Fig. I.4 Angle and the angle reference axis, e.g. in
the X / Y plane
Plane Zero 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
Fig. I.5 Linear position encoder, here for the X axis
ND 780 15
I – 1 Fundamentals of Positioning
Encoder Reference Marks
Encoders normally contain one or more reference marks (see Fig. I.6)
which the ND 780’s Reference Mark Evaluation feature uses to re-
establish datum positions after a power interruption. There are two
main options available for reference marks; fixed and distance-coded.
Encoders with distance-coded reference marks have marks
separated by a specific encryption pattern that allows the ND 780 to
use any two pair of marks along the length of the encoder to re-
establish the prior datums. This configuration means that the operator
only has to travel a very short distance, any where along the encoder,
to re-establish the datums when the ND 780 is turned back on.
Encoders with fixed reference marks have one or more marks on
fixed intervals. To re-establish the datums correctly, it is necessary to
use the same exact reference mark, during the Reference Mark
Evaluation routine, that was used when the datum was first
established.
Fig. I.6 Linear scales: with distance-coded
reference marks (upper illustration) and one
reference mark (lower illustration)
The established datums’ cannot be restored from one
power cycle to the next if the reference marks were not
crossed before the datums were set.
16 I Operating Instructions
I – 2 General Operations for ND 780
I – 2 General Operations for ND 780
Layout of Screen
Status Bar - This displays the current datum, tool, feed rate, stop
watch time, unit of measure, actual value or distance-to-go status,
page indicator, and set/zero. See Job Setup for details on setting up
the Status Bar parameters.
Display Area - Indicates the current position of each axis. Also
shows forms, fields, instruction boxes, error messages and help
topics.
Axis Labels - Indicates axis for corresponding axis key.
Ref Symbols - Indicates current reference mark status.
Soft key Labels - Indicates the various milling or turning functions.
Status Bar Symbols
Datum Tool Feed Rate Stopwatch Unit of
Measure Actual Value Distance-
To-Go Page
Indicator Set/Zero
Axis Labels
Display Area Ref Symbols
Graphic
Positionin
Aid (In
Distance-
To-Go mode
only)
Soft key
Labels
ND 780 17
I – 2 General Operations for ND 780
General Navigation
Use keypad to enter numeric values within each field.
The ENTER key will confirm the entry within a field and return to the
previous screen.
Press the Ckey to clear entries and error messages or return back
to the previous screen.
SOFT KEY labels show the various milling or turning functions. These
functions are selected by pressing the corresponding soft key
directly below each soft key label. There are 3 page of selectable
soft key functions. These are accessed using the LEFT/RIGHT ARROW
keys as indicated below.
The LEFT/RIGHT ARROW keys move through pages 1-3 of soft key
selectable functions. The current page will be highlighted in the
Status bar at the top of screen.
Use the UP/DOWN ARROW keys to move between fields within a form
and list boxes within a menu. The orientation of the cursor is such
that it will return to the top once it has reached the bottom of the
menu.
Operating Modes
The ND 780 has two operating modes Actual Value and Distance-
To-Go. The Actual Value Operations mode always displays the current
actual position of the tool, relative to the active datum. In this mode,
all moves are done by traveling until the display matches the nominal
position that is required. The Distance-To-Go feature enables you to
approach nominal positions simply by traversing to display value zero.
When working within the Distance-To-Go mode you can enter nominal
coordinates as either absolute or incremental dimensions.
While in the Actual Value Mode, if the ND 780 is configured for Milling
applications, only the tool length offsets are active. Both the radius and
length offsets are used in the Distance-To-Go mode to calculate the
amount of “distance-to-go” required to get to the desired nominal
position relative to the edge of the tool that will be doing the cutting.
If the ND 780 is configured for a lathe, all tool offsets are used in both
the Actual Value and Distance-To-Go modes.
Press the ACTUAL VALUE/DISTANCE-TO-GO soft key to toggle between
these two modes. To view soft key functions in either Actual Value or
Distance-to-Go mode, use the LEFT/RIGHT ARROW keys.
The turning application provides a quick method for coupling the
Z axes position on a 3 axis system. See "Enabling Z Coupling" on page
75.
Fig. I.7 ACTUAL VALUE/DISTANCE-TO-GO soft key
18 I Operating Instructions
I – 2 General Operations for ND 780
Graphic Positioning Aid
When you are traversing to display value zero (in the Distance-To-Go
mode), ND 780 displays a graphic positioning aid. See Fig. I.8.
ND 780 displays the graphic positioning aid in a narrow rectangle
underneath the currently active axis. Two triangular marks in the
center of the rectangle symbolize the nominal position you want to
reach.
A small square symbolizes the axis slide. An arrow indicating the
direction appears in the square while the axis is moving. You can easily
tell whether you are moving towards or away from the nominal
position. Note that the square does not begin to move until the axis
slide is near the nominal position. For setting up the graphic
positioning aid. See "Graphic Positioning Aid" on page 25 under Job
Setup.
Help Screen
The integrated operating instructions provide information and
assistance in any situation. See Fig. I.9
To call the operating instructions:
8Press the HELP soft key.
8Information relevant to the current operation will be displayed.
8Use the UP/DOWN ARROW keys if the explanation is spread over more
than one screen page.
To view information on another topic:
8Press the LIST OF TOPICS soft key.
8Press the UP/DOWN ARROW keys to scroll through the index.
8Press the ENTER key to select the item you need.
To leave the operating instructions:
8Press the Ckey.
Data Input Forms
Information required for various operational functions and setup
parameters are entered through a data input form. These forms will
appear after selecting features that require any additional information.
Each form provides specific fields for entering the required
information.
You must confirm your changes by pressing the ENTER key for them
to become effective. If you do not want to save your changes, press
the Ckey to return to the previous screen without saving changes.
Fig. I.8 Graphic Positioning Aid in use (see arrows)
Fig. I.9 List of Topics under HELP mode
ND 780 19
I – 2 General Operations for ND 780
Instruction Box messages
Whenever a Menu, or Form is open an instruction box will also open
immediately to the right of it. This message box will provide
information to the operator on what the chosen function does and
present instructions on the available options.
Error Messages
If an error occurs while you are working with ND 780, the message will
appear on the display and provide an explanation of what caused the
error.
To clear the error message:
8Press the Ckey.
Fig. I.10 Example of Form and Instruction Box
20 I Operating Instructions
I – 2 General Operations for ND 780
Power Up
Switch on the power (located on the back). The initial
screen will appear. See Fig. I.11 (This screen will only
appear the very first time the unit is powered up. The
following steps may have already been completed by
the installer).
Select the proper language by pressing the
LANGUAGE soft key.
Choose your application of either MILL or TURN. The
APPLIC. [MILL/TURN] soft key toggles between
these two settings.
Next select the number of axes required. When
complete press the ENTER hard key.
If necessary, you can change the application later in
Installation Setup under Counter Settings.
Your ND 780 is now ready for operation and is in the operating mode
Actual Value. Each active axis will have a flashing“REF”sign next to it.
At this point the reference mark evaluation should be completed.
Reference Mark Evaluation
The ND 780'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 REF indicator will flash.
See Fig. I.12. After crossing over the reference marks, the indicator
will stop flashing and change to non-flashing REF.
Working without reference mark evaluation
You can also use the ND 780 without crossing over the reference
marks. Press the NO REF soft key to exit the reference mark evaluation
routine and continue.
You can still cross over reference marks at a later time, if it becomes
necessary to define datums that can be re-established after a power
interruption. Press the ENABLE REF soft key to activate the reference
mark evaluation routine.
Fig. I.11 Initial screen
Fig. I.12 Screen for establishing Ref Marks
If an encoder is setup without reference marks, then the
REF indicator will not be displayed, and datums will be lost
once power is turned off.
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