HEIDENHAIN IOB 49 User manual

User’s Manual
IOB 49
English (en)
3/2007

HEIDENHAIN IOB 49 3
I General Information ..... 6
Connecting the IOB 49 to X10 for executing switching functions (milling) or controlling the constant surface speed
CSS (turning) ..... 6
I – 1 Execution of Switching Functions ..... 7
Switching inputs ..... 7
Switching outputs ..... 7
I – 2 Controlling the Constant Surface Speed (CSS) ..... 10
Configuration of CSS ..... 11
CSS operating mode ..... 12
Activating the DAC output ..... 13
Connecting the IOB to the inverter of the lathe ..... 14
I – 3 Diagnostics ..... 15
Switching I/O functions ..... 15
CSS ..... 16
I Operating Instructions ..... 5

HEIDENHAIN IOB 49 5
Operating Instructions

6I Operating Instructions
General Information
General Information
Connecting the IOB 49 to X10 for executing
switching functions (milling) or controlling the
constant surface speed CSS (turning)
When the IOB 49 is connected to the ND 780, the functionalities
described above are available.
For information on the installation of the IOB 49 in an electrical cabinet,
the connection technology and the wiring, please refer to the
Operating Instructions. The Operating Instructions are included with
every position display unit, or can be requested from HEIDENHAIN.
The position display unit automatically recognizes when an IOB 49 is
connected and displays the CSS SETUP option or the SWITCHING
OUTPUTS option in the INSTALLATION SETUP menu. These options
can be used to configure all functions of the switching unit.

HEIDENHAIN IOB 49 7
I – 1 Execution of Switching Functions
I – 1 Execution of Switching
Functions
Switching functions can only be executed when the position display
unit is configured for milling applications.
If you want to use both the IOB 49 and the KT 130 edge finder at the
same time or if you want to transmit measured values via the external
switching output, the distribution cable with ID 532 909-01 is required.
Switching inputs
The IOB 49 provides three inputs that are used to zero the actual value
of the assigned axis. A low-to-high transition at the input causes the
value for that axis to be set to zero.
Switching outputs
The switching outputs consist of eight (integrated) relays that are
activated depending on the position. The relays can be configured to
activate when a position display reaches a specific value or within a
specified range of zero. The ninth output relay indicates readiness.
Select SWITCHING OUTPUTS from the INSTALLATION SETUP menu
to open the SWITCHING OUTPUTS table in which the configuration of
the eight outputs is stored. If you want to change the configuration of
an output, select it with the arrow keys and press ENTER to confirm
your selection. This opens the OUTPUT SETTINGS form in which you
define the switching conditions. To reset a relay, select the relay in the
table and press the CLEAR RELAY soft key.
Fig. I.1

8I Operating Instructions
I – 1 Execution of Switching Functions
The CONDITION field is used to assign an axis to the output and to
specify whether the axis position is an actual-value or distance-to-go
position. You also specify the position display value at which the
relay is activated, and the required condition.
The POINT/RANGE field is used to define whether the conditions
refers to a point on the axis or refers to a range about zero.
The OUTPUT field is used to specify the relay operation when the
switching condition is met. When the condition is met, the relay is
turned OFF or ON.
Fig. I.2 OUTPUT SETTINGS form
Fig. I.3 Possible switching states of the relays

HEIDENHAIN IOB 49 9
I – 1 Execution of Switching Functions
In PULSED mode, the relay is activated (ON or OFF) for a specific
period of time. After the period has timed out, the relay is deactivated.
The pulse time is 0.1 to 999 seconds.
Fig. I.4 CONTINUOUS mode
Fig. I.5 PULSED mode
The time period begins whenever the switching condition
transitions from FALSE to TRUE. If the switching
conditions transitions to TRUE before the period has timed
out, the timer will start over.
The switching functions cannot be used for coupled axes
or for axes with backlash compensation.
Relay
Condition
Relay
Condition

10 I Operating Instructions
I – 2 Controlling the Constant Surface Speed (CSS)
I – 2 Controlling the Constant
Surface Speed (CSS)
In CSS mode, a constant surface cutting speed can be maintained on
a lathe. The following functions are available:
CSS mode: The DAC output signal provides constant surface speed
by adjusting the spindle speed as the diameter (radius) of the
workpiece changes.
Direct entry of spindle speed: The DAC output signal sets the
spindle speed based on the value entered via the numeric keypad.
Speed limits: The user may set a safe operating range (minimum
and maximum speeds) for spindle speed.
Gear selection: Three different gears can be specified for varying the
relation between the actual speed and the DAC output signal.

HEIDENHAIN IOB 49 11
I – 2 Controlling the Constant Surface Speed (CSS)
Configuration of CSS
The spindle control configuration parameters are set up in the
INSTALLATION SETUP menu. Select the CSS SETTINGS parameter
to open the associated input form.
The CSS ON/OFF CONTROL field is used to specify whether the
CSS mode is operated by soft key or by an external hardware signal.
The current gear may be selected by local control (MANUAL via CSS
/ DIRECT RPM in the JOB SETUP menu) or remote control
(EXTERNAL; via switches in the machine gear). This is defined in the
CSS GEAR SELECT field.
The VOLTAGE OFFSET function is used to adjust for any inherent
offset in the DAC signal. Using a voltmeter, measure the actual
voltage at the DAC output. Press INCREASE or DECREASE to adjust
the offset until the output is 0 V. The offset range is limited to 0 to
50 (approximately 0 to 122 mV).
The VOLTAGE / RPM fields are used to establish the relationship
between the DAC output signal (0 to 10 V) and the spindle speed.
The minimum and maximum limits for each gear are entered.
If the position display of the third axis is configured to be used for the
spindle speed, the rpm in the SETTING field can be set to the current
spindle speed by pressing the TEACH soft key.
To set a specific spindle speed, the DAC output SOut uses this linear
relationship to determine the corresponding output voltage VOut:
VOut = 10 · (SOut - S0) / ( S10 - S0) + VOffset
Press ENTER to save the parameters and exit the input form. Press
the C key to exit without saving the changes you made.
Fig. I.6 CSS SETTINGS (1) form
Fig. I.7 CSS SETTINGS (2) form

12 I Operating Instructions
I – 2 Controlling the Constant Surface Speed (CSS)
CSS operating mode
The operating parameters are set in the CSS / DIRECT RPM form.
Press the CSS SETUP soft key to open the form or select the
parameter from the JOB SETUP menu.
The SETTINGS field is used to select the mode of operation and the
control settings. The spindle is controlled by selecting CSS or by
entering the spindle speed directly. The values to be entered
depend on the selected option.
If CSS was selected to maintain a constant surface speed, the surface
speed entered with the numeric keys is maintained. As the diameter
of the part changes, the spindle speed will be adjusted.
To set a specific spindle speed, select DIRECT / RPM and enter the
value with the numeric keypad.
If the position display of the third axis is configured to be used for the
spindle speed, the rpm in the SETTING field can be set to the current
spindle speed by pressing the TEACH soft key.
Select OFF when spindle control is not needed.
The GEAR SELECTION field is used to manually enter the operating
gear with the numeric keypad.
The LIMITS field is used to establish the minimum and maximum
limits of the controlled spindle speed. When operating in the CSS or
DIRECT RPM modes, the DAC output will not be set to a speed
above or below these limits.
If the position display of the third axis is configured to be used for the
spindle speed, the rpm in the SETTING field can be set to the current
spindle speed by pressing the TEACH soft key.
Press ENTER to save the parameters and exit the input form. Press
the C key to exit without saving the changes you made.
The settings will be lost when the ND 780 is switched off.
Fig. I.8 Form in which the speed limits are defined
If the gear control parameter in INSTALLATION SETUP is
set to EXTERNAL, the field will show the current gear
selection based on the external inputs. The field can then
not be selected and is skipped.

HEIDENHAIN IOB 49 13
I – 2 Controlling the Constant Surface Speed (CSS)
Activating the DAC output
After selecting the operating mode and entering its parameters, the
DAC output must be enabled to begin controlling the spindle.
The output to the spindle inverter drive is an open loop signal. The
system does not monitor the actual spindle speed. The output signal
is based solely on the inverter's speed input versus the input voltage
profile.
Depending on the operating mode selected, the RPM or CSS soft
key is displayed on the fourth page of the soft key menu. If the
current state indicated on the soft key is ON, the DAC output is
active. Press the soft key to OFF to disable the spindle control.
If CSS is active, the CSS icon appears next to the X-axis display. If the
entered surface speed or rpm cannot be maintained because the
speed is outside the range for the current gear or outside the limits
from the CSS/RPM SETTINGS form, an arrow will appear after the
CSS icon ( or ). The direction of the arrow indicates
whether the speed is at the upper or lower limit.
The SPEED + and SPEED – soft keys are used to increase or
decrease the current surface speed or spindle speed. The value is
increased or decreased by 5% each time the soft key is pressed.
The soft key to enable CSS or RPM control will not appear
if the operating mode is set to OFF.
If the CSS control parameter under INSTALLATION
SETUP is set to EXTERNAL, the CSS or RPM operation
cannot be controlled by soft key. The soft key will show
the current state, but pressing it will have no effect.

14 I Operating Instructions
I – 2 Controlling the Constant Surface Speed (CSS)
Connecting the IOB to the inverter of the lathe
Fig. I.9 Example of gear detection and switching to manual spindle
speed control
Fig. I.10 Example of switching to manual spindle speed control
X1039
X10310
X10311
X1021
X1022
X1023
X1024
X1025
X1026
X1027
X1028
X10211
X10212
MANUAL
RPM
+

1224 VDC
100 mA
OFF
FORWARD
REVERSE
ANALO SUPPLY
ANALO INPUT
ANALO COMMON
TURNIN APPLICATION 1Automatic CSS/Pot Control
CSS I/0 INVERTER
DAC OUT
COMMON
EAR 1
EAR 2
EAR 3
OUT 789
OUT 7
OUT 8
IN 0
IN 0+
IN 1
IN 1+
IN 2
IN 2+
IN 3
IN 3+
FWD
REV INPUT+COMMON
X1039
X10310
X10311
OUT 789
OUT 7
OUT 8
X1021
IN 0 X1022
IN 0+
X1023
IN 1 X1024
IN 1+
X1025
IN 2 X1026
IN 2+
X1027
IN 3 X1028
IN 3+
X10211
X10212
DAC OUT
COMMON
CSS/pot Selector
CSS I/0 INVERTER
FWD
REV
OFF
INPUT+COMMON
FORWARD
REVERSE
ANALO INPUT
ANALO COMMON
V ref.+
V ref.
Pot on machine
TURNIN APPLICATION 2Manual CSS/Pot Control

HEIDENHAIN IOB 49 15
I – 3 Diagnostics
I – 3 Diagnostics
When the IOB 49 is connected to the ND 780, the DIAGNOSTICS
menu under INSTALLATION SETUP provides further diagnostic
possibilities. The information available varies depending on the
configuration of the system (CSS or switching I/O functions).
Switching I/O functions
The SWITCHING I/O DIAGNOSTICS shows the status of the
communication via the CAN bus and the state of the switching inputs
and outputs to provide monitoring of the switching functions.
The CAN STATUS field shows the state of the bus communication
between the position display unit and the IOB 49.
The status information has the following meaning:
The SWITCHING I/O field shows the state of the inputs and the
switch position of the relays.
All currently active inputs (1 to 3) are shown in the ON field.
All currently active relay outputs (1 to 9) are shown in the OFF field.
The CALIBRATE soft key is used to re-synchronize the communication
with the IOB 49. This, however, is only required if the module is not
detected upon power on.
Information Meaning
NOT PRESENT No communication with hardware
NOR Communication – normal operation
CAL Communication – Hardware in calibration
mode
Wen Watchdog active
Wds Watchdog inactive
Wto Watchdog time-out
Tx Data is transmitted to hardware
Rx Data is received by hardware

16 I Operating Instructions
I – 3 Diagnostics
CSS
CSS DIAGNOSTICS shows the status of the communication via the
CAN bus and the state of the DAC output to provide monitoring of the
interfaces for operation with constant surface speed. The state of the
switching inputs and outputs is also shown.
The CAN STATUS field shows the state of the bus communication
between the position display unit and the IOB 49.
The status information has the following meaning:
The DAC OUTPUT field shows the current value of the transmitted
voltage. The value is between 0 and 4095, which corresponds to a
voltage of 0 to 10 V at X102-11. The corresponding CSS icon will be
displayed if the spindle speed is at the upper or lower limit ( or
).
The CSS INPUT/OUTPUT field shows the state of the switching
inputs and relay outputs.
Information Meaning
NOT PRESENT No communication with hardware
NOR Communication – normal operation
CAL Communication – Hardware in calibration
mode
Wen Watchdog active
Wds Watchdog inactive
Wto Watchdog time-out
Tx Data is transmitted to hardware
Rx Data is received by hardware

HEIDENHAIN IOB 49 17
I – 3 Diagnostics
The status information has the following meaning:
The CALIBRATE soft key is used to re-synchronize the communication
with the IOB 49. This, however, is only required if the module was not
detected at switch-on.
Information about
the inputs Meaning
EXT External switch is active (X102-12)
G1 Switch for gear 1 is active (X102-3,4)
G2 Switch for gear 2 is active (X102-5,6)
G3 Switch for gear 3 is active (X102-7,8)
Information about
the outputs Meaning
POT Potentiometer relay is active (X102-10)
DAC DAC output relay is active (X102-11)

HEIDENHAIN IOB 49 19
Index
A
Activating the DAC output ... 13
C
Configuration of CSS ... 11
Controlling the constant surface speed
(CSS) ... 10
CSS ... 16
CSS operating mode ... 12
D
Datums ... 6
Diagnostics ... 15
E
Execution of switching functions ... 7
R
Relay status ... 8
S
Switching I/O functions ... 15
Switching inputs ... 7
Switching outputs ... 7