896096-24 iTNC530 OEM HSCI

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iTNC 530 HSCI

The Versatile Contouring Control


for Milling, Drilling, Boring
Machines and Machining
Centers
Information for the Machine
Tool Builder

September 2013

TNC contouring control with drive system from HEIDENHAIN


General information

iTNC 530

 Contouring control for milling, drilling and boring machines,


and machining centers

 Up to 18 axes and closed-loop main spindle


 HEIDENHAIN inverter systems and motors recommended
 Uniformly digital with HSCI interface and EnDat interface
 TFT color flat-panel display, 19-inch or 15-inch
 Storage medium: HDR hard disk with 160 GB / SSDR solid state
disk with 32 GB

 Programming in HEIDENHAIN conversational format, with


smarT.NC or according to DIN/ISO

 Standard milling, drilling and boring cycles


 Touch probe cycles
 FK free contour programming
 Special functions for fast 3-D machining
 Short block processing time (0.5 ms)
 Automatic calculation of cutting data
 Pallet management

System test

Controls, motors and encoders from HEIDENHAIN are in most


cases integrated as components in larger systems. In these
cases, comprehensive tests of the complete system are required,
irrespective of the specifications of the individual devices.

Expendable parts

In particular the following parts in controls from HEIDENHAIN are


subject to wear:
 Hard disk
 Buffer battery
 Fan

Standards

Standards (ISO, EN, etc.) apply only where explicitly stated in the
catalog.

Note

Microsoft Windows, Windows 2000, Windows XP, Windows


Vista, Windows 7 and the Internet Explorer are registered
trademarks of Microsoft Corporation.

Validity

The features and specifications described here apply for the


following control and NC software versions:
iTNC 530 HSCI with NC software versions
606420-04 (export license required)
606421-04 (no export license required)
This catalog supersedes all previous editions, which thereby
become invalid. Subject to change without notice.

Prerequisites

Some of these specifications require particular machine


configurations. Please note also that, for some functions, a special
PLC program must be created by the manufacturer.

Functional safety

If no explicit distinction is made between standard and FS


components (FS = functional safety), then the data and other
information apply to both versions (e.g. TE 745, TE 745 FS).

Contents

TNC contouring control with drive system from HEIDENHAIN

Overview tables

HSCI control components

15

Accessories

32

Cable overview

45

Technical description

52

Data transfer and communication

79

Mounting information

82

Overall dimensions

84

General information

107

Other HEIDENHAIN controls

109

Subject index

110

Please refer to the page references in the tables with the


specifications.

Overview tables
Components

Control systems
Main computer

Storage medium

15 design

19 design

For operating panel MC 7422, MC 7522 (screen integrated) MC 6542


or MC 6542
For electrical
cabinet

MC 6441, MC 6541, MC 6542 or


MC 6641

MC 7x22;
MC 6x42

SSDR solid state disk

MC 6x41

HDR hard disk

Page
15

MC 6441, MC 6541, MC 6542 or


MC 6641
17

NC software license

On SIK component

Visual display unit

BF 750 (integrated in MC 7x22)

BF 760

27

Operating panel

TE 720 or TE 730 or TE 735

TE 740 or TE 745

27

Machine operating panel

MB 720 (integrated in TE 735)

Integrated in TE 745

27

Controller unit

PLB 6001 (HSCI adapter for OEM machine operating panel)

33

6 control loops

CC 6106

22

8 control loops

CC 6108

22

10 control loops

CC 6110

22

12 control loops

CC 6106 + CC 6106

22

14 control loops

CC 6108 + CC 6106

22

16 control loops

CC 6108 + CC 6108

22

18 control loops

CC 6106 + CC 6106 + CC 6106 or CC 6110 + CC 6108

22

20 control loops

CC 6110 + CC 6110

22

PSL 130 / PSL 135

32

PL 6000 consisting of PLB 62xx basic module (system PL) or PLB 61xx
(expansion PL) and I/O modules

29

On UEC

24

On UMC

26

Power supply1)
PLC inputs/
outputs1)

17

With HSCI
interface

Via CMD-H additional modules


With PROFIBUSDP interface
Additional module
Depending on the configuration

PL 550 consisting of PLB 550 basic module and I/O modules

31

CMA-H for analog axes/spindles in the HSCI system

34

CMA-H for PT 100 and analog inputs


CMD-H for fast PLC inputs/outputs
Module for PROFIBUS-DP
Compact inverters and modular inverters

*)

UEC 111

24

UMC 111

26

5 control loops

UEC 112

24

6 control loops

UEC 113

Inverter systems
Inverters with
integrated
controller unit

4 control loops

Connecting cable
*)
1)

For further information, refer to the Inverter Systems for HEIDENHAIN Controls brochure
PL 6000, UEC or UMC necessary, because the MC does not have any PLC inputs/outputs or touch probe connections

45

Accessories

Accessories

iTNC 530

Page

Electronic handwheels

38

Workpiece touch probes

Tool touch probes

HR 410 portable handwheel or


HR 520 portable handwheel with display or
HR 550 FS portable wireless handwheel with display or
HR 130 panel-mounted handwheel or
Up to three HR 150 panel-mounted handwheels via HRA 110 handwheel adapter

 TS 230 touch trigger probe with cable connection or


 TS 440 touch trigger probe with infrared transmission or
 TS 444 touch trigger probe with infrared transmission or
 TS 640 touch trigger probe with infrared transmission or
 TS 740 touch trigger probe with infrared transmission
 TT 140 touch trigger probe with cable connection or
 TT 449 touch trigger probe with infrared transmission or
 TL Nano laser system for contact-free workpiece measurement or
 TL Micro laser system for contact-free workpiece measurement

36

37

USB hub

80

Programming station

Control software for PCs for programming, archiving, and training


 Single-station license with original control keyboard
 Single-station license with virtual keyboard
 Network license with virtual keyboard
 Demo version with virtual keyboard or PC keyboardfree of charge

*)

Industrial PC

IPC 6110/IPC 6120Remote operation of the control and data transfer


IPC 6641Industrial PC for Windows

41

Snap-on keys

For the control


For the handwheel

43
42

*)

For more information, refer to the Programming Station TNC brochure.

Accessories / Software

iTNC 530

Page

PLCdesign1)

PLC development software

76

KinematicsDesign1)

Software for creating kinematics and initializing DCM

66

TNCremo2)

Data transfer software

80

TNCremoPlus2)

Data transfer software with live screen

80

CycleDesign1)

Software for creating cycle structures

78

Software Key Generator1)

Software for enabling SIK options for a limited time

17

TNCscope1)

Software for data recording

73

DriveDiag1)

Software for diagnosis of digital control loops

72

TNCopt1)

Software for putting digital control loops into service

72

IOconfig1)

Software for configuring PLC I/O and PROFIBUS-DP components

30

Software for remote diagnostics, monitoring, and operation

73

Function library for developing customized applications for communication with


HEIDENHAIN controls

81

Control component for virtual machines

81

TeleService1)
RemoTools

SDK1)

virtualTNC1)
1)
2)

Available to registered customers for downloading from the Internet


Available to all customers (without registration) for downloading from the Internet

Specifications

Specifications

iTNC 530

Page

Axes1)

Max. 18

56

Rotary axes

Max. 3

Synchronized axes

PLC axes

Spindle

max. 2; second spindle can be controlled alternately with the first

59

Spindle speed2)

Max. 60 000 min1

59

Operating mode switchover

59

Position-controlled spindle

59

Oriented spindle stop

59

Gear shifting

59

Milling-head change

Programmable via PLC

59

NC program memory

MC 6x41: Approx. 144 GB on HDR hard disk


MC 6542, MC 7x22: Approx. 21 GB on SSDR solid state disk

15

Input resolution and display step

56

Linear axes

0.1 m

Rotary axes

0.0001

Functional safety

With FS components, SPLC and SKERN

For applications up to

 SIL 2 according to EN 61 508


 Category 3, PL d according to EN ISO 13 849-1: 2008

Interpolation

MC

Straight line

In 5 axes

Circle

In 3 axes

Helix

Spline

63

Axis feedback control

61

With following error

With feedforward

Axis clamping

Maximum feed rate

56
60000 min1
No. of motor pole pairs

at fPWM = 5000 Hz

53

56
Screw pitch [mm]

Specifications

iTNC 530

Page

Cycle times of main computer

MC

62

Block processing

0.5 ms

63

Cycle times of controller unit

CC/UEC/UMC

62

Path interpolation

3 ms

62

Fine interpolation

Single speed: 0.2 ms


Double speed: 0.1 ms (option 49)

Position controller

Single speed: 0.2 ms


Double speed: 0.1 ms (option 49)

Speed controller

Single speed: 0.2 ms


Double speed: 0.1 ms (option 49)

Current controller

fPWM
3333 Hz
4000 Hz
5000 Hz
6666 Hz
8000 Hz
10 000 Hz

Permissible temperature range

Operation:
In electrical cabinet: 5 C to 40 C
In operating panel: 0 C to 50 C
Storage: 20 C to 60 C

*)
1)
2)

TINT
150 s
125 s
100 s
75 s with option 49
60 s with option 49
50 s with option 49

For further information, refer to the iTNC 530 brochure (ID 892921-xx)
As ordered
On motors with two pole pairs

Machine interfacing

Machine interfacing

iTNC 530

Page

Feature Content Level (FCL)

17

Error compensation

67

Linear axis error

67

Nonlinear axis error

67

Backlash

67

Reversal spikes with circular


movement

67

Hysteresis

67

Thermal expansion

67

Stick-slip

67

Sliding friction

67

Integrated PLC

74

Program format

Statement list

74

Program input at the control

74

Program input by PC

74

PLC memory

At least 1 GB

74

PLC cycle time

Typically 21 ms, adjustable

74

A PLC system can consist of max. seven PLB 61xx and max. two MB 7xx, TE 7x5 or
PLB 6001. A total maximum of 1000 inputs/outputs is supported.

29,
24

CMD-H, CMA-H additional modules

34

PLC inputs, 24 V DC1)

Via PL, UEC, UMC, CMD-H additional module

29

PLC outputs, 24 V DC1)

Via PL, UEC, UMC, CMD-H additional module

29

Analog inputs  10 V

Via PL, CMA-H additional module

29

Inputs for PT 100 thermistors

Via PL, CMA-H additional module

29

Analog outputs 10 V

Via PL

29

PLC functions

74

Small PLC window

75

Large PLC window

75

PLC soft keys

75

PLC positioning

75

PLC basic program

77

PLC

inputs/outputs1)

Integration of applications

76

High-level language programming Python programming language used in combination with the PLC (option 46)

76

User interfaces can be customdesigned

76

1)

Inclusion of specific user interfaces from the machine tool builder (option 46)

Further PLC inputs/outputs via PL 550 for connection to MC with PROFIBUS-DP additional module

Machine interfacing

iTNC 530

Page

Commissioning and diagnostic


aids

72

DriveDiag

Software for diagnosis of digital drive systems

72

TNCopt

Software for putting digital control loops into service

72

KinematicsDesign

Software for creating the machine kinematics, initialization of DCM

66

Integrated oscilloscope

73

Trace function

73

Logic diagram

73

Table function

73

Log

73

Bus diagnostics

73

Data interfaces

Ethernet (1000BASE-T)

79

USB 3.0

79

RS-232-C/V.24

79

Protocols

79

Standard data transfer

79

Blockwise data transfer

79

Blockwise data transfer and


simultaneous program run

With programming memory on the hard disk

LSV2

1)

79

Further PLC inputs/outputs via PL 550 for connection to MC with PROFIBUS-DP additional module

Encoder inputs

CC 6106

CC 6108

CC 6110

UEC 111

UMC 111

UEC 112

UEC 113

60

Position

10

60

Incremental

1 VPP

60

Absolute

EnDat 2.2

60

Shaft speed

10

60

Incremental

1 VPP

60

Absolute

EnDat 2.2

60

Nominal-value outputs

CC 6106

CC 6108

CC 6110

UEC 111

UMC 111

UEC 112

UEC 113

60

PWM

10

21

Motor connections

21

Brief description

iTNC 530
Option

User function

Standard

User functions

Basic version: 3 axes plus spindle


0-7 A total of 14 additional NC axes or 13 additional NC axes plus second spindle
77
78
Digital current and speed control

Program entry





Program
optimization

Point filter for smoothing externally created NC programs

Position entry






Nominal positions for lines and arcs in Cartesian coordinates or polar coordinates
Incremental or absolute dimensions
Display and entry in mm or inches
Display of the handwheel path during machining with handwheel superimpositioning

Tool compensation




Tool radius in the working plane and tool length


Radius-compensated contour look-ahead for up to 99 blocks (M120)
Three-dimensional tool-radius compensation for changing tool data without having to recalculate an
existing program

HEIDENHAIN conversational
With smarT.NC
According to ISO
42 Direct loading of contours or machining positions from DXF files and saving as smarT.NC or
conversational contouring programs, or as point tables

9
Tool tables

Multiple tool tables with any number of tools

Cutting data





Cutting data tables for automatic calculation of spindle speeds and feed rates from tool-specific data
(cutting speed, feed per tooth)
Entry of cutting speed as alternative to the spindle shaft speed
Feed rate can also be entered as FZ (feed per tooth) or FU (feed per revolution)

Constant contour
speed




Relative to the path of the tool center


Relative to the tools cutting edge

Parallel operation

Creating a program with graphical support while another program is being run

3-D machining

Motion control with smoothed jerk


3-D tool compensation through surface normal vectors
Tool center point management (TCPM): Using the electronic handwheel to change the angle of the
swivel head during program run without affecting the position of the tool point
9 Keeping the tool normal to the contour
9 Tool radius compensation normal to the tool direction
9 Manual traverse in the active tool-axis system
92 Compensating form errors of tools with 3D-ToolComp
9 Spline interpolation
9
9

Rotary table
machining

8
8

Programming of cylindrical contours as if in two axes


Feed rate in distance per minute

Contour elements









Straight line
Chamfer
Circular path
Circle center
Circle radius
Tangentially connecting circular arc
Corner rounding

Approaching and
departing the
contour




Via straight line: tangential or perpendicular


Via circular arc

10

iTNC 530
Option

Standard

User function

Adaptive feed
control

45 AFC: Adaptive feed control adjusts the contouring feed rate to the current spindle power

Collision monitoring

40
40
40
40
40

Dynamic Collision Monitoring (DCM)


Graphic depiction of the active collision objects (FCL 04)
Fixture monitoring
Tool holder monitoring
DCM in the Test Run mode

FK free contour
programming

FK free contour programming in HEIDENHAIN conversational format with graphic support for
workpiece drawings not dimensioned for NC

Program jumps





Subprograms
Program-section repeat
Calling any program as a subprogram

Fixed cycles











Drilling, tapping with a floating tap holder, rigid tapping


Peck drilling, reaming, boring, counterboring, centering
Milling internal and external threads
Clearing level and oblique surfaces
Multioperation machining of straight and circular slots
Multi-operation machining of rectangular and circular pockets, rectangular and circular studs
Cartesian and polar point patterns
Contour train (also 3-D), contour pocketalso with contour-parallel machining
Contour slot with trochoidal milling
Interpolation turning
OEM cycles (special cycles developed by the machine tool builder) can be integrated
Engraving cycle: Engrave text or numbers in a straight line or on an arc

96


Coordinate
transformation

Q parameters
Programming with
variables

Programming aids






8
44







Datum shift, rotation, mirror image, scaling factor (axis-specific)


Tilting the working plane, PLANE function
Manually definable: Global program settings make it possible to manually define shifts, rotations, and
handwheel superimpositioning
Mathematical functions =, +, , *, /, sin , cos , tan , arc sin, arc cos, arc tan, an, en, In, log, square
root of a, square root of (a2 + b2)
Logical operations (=, = /, <, >)
Calculating with parentheses
Absolute value of a number, constant , negation, truncation of digits before/after decimal point
Functions for calculation of circles
Functions for text processing




Calculator
Complete list of all current error messages
Context-sensitive help function for error messages
TNCguide: The integrated help system. User information available directly on the iTNC 530; contextsensitive (FCL 03)
Graphic support for programming cycles
Comment and structure blocks in the NC program

Teach-In

Actual positions can be transferred directly into the NC program

Test graphics
Display modes





Graphic simulation before a program run, even while another program is running
Plan view / projection in 3 planes / 3-D view, also in tilted working plane
Magnification of details

3-D line graphics

For verification of programs created offline (FCL 02)

Programming
graphics

In the Programming and Editing mode, the contour of the NC blocks is drawn on screen while they
are being entered (2-D pencil-trace graphics), even while another program is running

11

Standard

Program-run
graphics
Display modes




Graphic simulation during real-time machining


Plan view / projection in 3 planes / 3-D view

Machining time




Calculation of machining time in the Test Run operating mode


Display of the current machining time in the Program Run operating modes

Returning to the
contour




Mid-program startup in any block in the program, returning the tool to the calculated nominal position
to continue machining; the graphic support in smarT.NC also lets you return to a point pattern
Program interruption, contour departure and return

Datum
management

One table per traverse range for storing reference points

Datum tables

Several datum tables for storing workpiece-related datums

Pallet tables

Pallet tables (with as many entries as desired for the selection of pallets, NC programs and datums)
can be machined workpiece by workpiece

Touch probe cycles








Touch probe calibration


Compensation of workpiece misalignment, manual or automatic
Datum setting, manual or automatic
Automatic tool and workpiece measurement
Global setting of touch-probe parameters (FCL 02)
Probing cycle for three-dimensional measurements. Toggle between showing the measurement
results in the coordinate system of the workpiece or the machine (FCL 03)
48 Automatic measurement and optimization of machine kinematics

Conversational
languages

English, German, Chinese (traditional, simplified), Czech, Danish, Dutch, Finnish, French, Hungarian,
Italian, Polish, Portuguese, Russian (Cyrillic), Spanish, Swedish
41 For more conversational languages, see Options, Page 13

12

iTNC 530
Option

User function

Options

Option
number

Option

As of NC
software
60642x-

ID

Comment

Additional axis

01

ID 354540-01

Additional control loop 1

Additional axis

01

ID 353904-01

Additional control loop 2

Additional axis

01

ID 353905-01

Additional control loop 3

Additional axis

01

ID 367867-01

Additional control loop 4

Additional axis

01

ID 367868-01

Additional control loop 5

Additional axis

01

ID 370291-01

Additional control loop 6

Additional axis

01

ID 370292-01

Additional control loop 7

Additional axis

01

ID 370293-01

Additional control loop 8

Software option 1

01

ID 367591-01

Rotary table machining


 Programming of cylindrical contours as if in two axes
 Feed rate in distance per minute
Coordinate transformation
 Tilting the working plane, PLANE function
Interpolation
 Circular in 3 axes with tilted working plane

Software option 2

01

ID 367590-01

3-D machining
 3-D tool compensation through surface normal vectors
 Tool center point management (TCPM): Using the electronic
handwheel to change the angle of the swivel head during
program run without affecting the position of the tool point
 Keeping the tool normal to the contour
 Tool radius compensation normal to the tool direction
 Manual traverse in the active tool-axis system
Interpolation
 Linear in 5 axes (export license required)
 Spline: execution of splines (3rd degree polynomial)

18

HEIDENHAIN DNC

01

ID 526451-01

Communication with external PC applications over COM


component

40

DCM collision

01

ID 526452-01

Dynamic Collision Monitoring (DCM)

41

Additional language
01

ID 530184-01
ID 530184-02
ID 530184-04
ID 530184-06
ID 530184-08
ID 530184-09

Additional conversational language:


Slovenian
Slovak
Norwegian
Korean
Turkish
Romanian

42

DXF converter

01

ID 526450-01

Load and convert DXF contours

44

Global PGM
settings

01

ID 576057-01

Global program settings

45

Adaptive feed
control (AFC)

01

ID 579648-01

Adaptive feed control

46

Python OEM
process

01

ID 579650-01

Python application on the iTNC

48

KinematicsOpt

01

ID 630916-01

Touch probe cycles for automatic measurement of rotary axes

49

Double-speed axis

01

ID 632223-01

Short control-loop cycle times for direct drives

13

Option
number

Option

As of NC
software
60642x-

ID

Comment

52

KinematicsComp

01

ID 661879-01

Spatial compensation of error in rotary and linear axes

77

4 additional axes

01

ID 634613-01

4 additional control loops

78

8 additional axes

01

ID 634614-01

8 additional control loops

92

3D-ToolComp

01

ID 679678-01

Compensating tool form error (only with software option 2)

93

Extended tool
management

01

ID 676938-01

Extended tool management

96

Adv. spindle interp.

02

ID 751653-01

Advanced functions for an interpolated spindle

98

CAD viewer

02

ID 800553-01

Opening CAD files directly on the TNC

101 - 130

OEM option

01

ID 579651-01 to
ID 579651-30

Options of the machine tool builder

133

Remote desk.
manager

02

ID 894423-01

Display and remote operation of external computer units (e.g. a


Windows PC)

141

Cross talk comp.

02

ID 800542-01

CTC: Compensation of axis couplings

142

Pos. adapt. control

02

ID 800544-01

PAC: Position-dependent adaptation of control parameters

143

Load adapt. control

02

ID 800545-01

LAC: Load-dependent adaptation of control parameters

144

Motion adaptive
control

03

ID 800546-01

MAC: Motion-dependent adaptation of control parameters

145

Active chatter
control

03

ID 800547-01

ACC: Active suppression of chatter

146

Active vibration
damping

04

ID 800548-01

AVD: Active vibration damping

14

HSCI control components


Main computer

Main computer

The MC main computers feature:

 Processor
 RAM memory
 HSCI interface to the CC 6xxx or UEC/UMC and to other control
components

 HDL interface to the BF 7xx visual display unit (BF integrated in


MC 7x22)

 USB 3.0 interface to the TE 7xx operating panel


To be ordered separately, and installed in the main computer by
the OEM:
 HDR or SSDR storage medium with the NC software
 SIK component (System Identification Key) for enabling the
control loops and software options
The following HSCI components are necessary for operation of
the iTNC 530:
 MC main computer
 Controller unit
 PLB 62xx PLC input/output unit (system PL; integrated in UEC/
UMC)
 MB 720 machine operating panel (integrated in TE 7x5) or
PLB 6001 HSCI adapter for connection of an OEM machine
operating panel
Interfaces

The standard MC main computers feature USB 3.0, RS-232-C/V.24


and Ethernet interfaces for use by the end user. Connection to
PROFIBUS-DP is possible via an additional module.

Power supply

24 V DC of power are supplied to the main computer and other


HSCI components by the PSL 13x supply unit. For the entire
HSCI system, the 24 V DC NC supply voltage for the control
components is required to be safely separated voltage (PELV).
It must not be connected to the 24 V DC supply voltage for PLC
components (e.g. holding brakes).

Export version

Because the entire NC software is saved on the memory card


(HDR or SSDR), no export version is required for the main
computer itself. Export versions are available only for the easily
replaceable storage medium and the SIK component.

15

Versions

Various versions of the MC main computer are available:

 For installation in the operating panel




The MC 7x22 and the BF visual display unit (15) form one unit,
and are installed directly in the operating panel.
Advantage: except for the power supply line, only one HSCI
connecting cable to the electrical cabinet is necessary.
For installation in the electrical cabinet
The MC 6x41 is installed in the electrical cabinet. HSCI, USB
and HDL cables to the operating panel are required as control
lines.
For installation in the operating panel or electrical cabinet
Because the SSDR solid state disk is used as a storage
medium, the MC 6542 can be universally integrated. HSCI, USB
and HDL cables to the operating panel are required as control
lines.

The main computers listed are supported as of NC software


60642x-04. These MC main computers cannot be run on earlier
software versions.

MC 6542

MC 7x22 with main computer installed on the back


MC 6x41

16

To be
installed in

Storage
medium

Processor

MC 7422

Operating
panel

SSDR

MC 7522

Operating
panel

MC 6542

RAM
memory

Power
loss

Weight

Intel Celeron 1047 2 GB


1.4 GHz2 cores

52 W

7.5 kg

ID 1039537-01

SSDR

Intel Core i7-3


1.7 GHz2 cores

2 GB

60 W

7.5 kg

ID 1071597-01

Operating
panel or
electrical
cabinet

SSDR

Intel Core i7-3


1.7 GHz2 cores

2 GB

48 W

4.0 kg

ID 1081188-01

MC 6441

Electrical
cabinet

HDR

Intel Celeron 1047 2 GB


1.4 GHz2 cores

40 W

4.0 kg

ID 1054739-01

MC 6541

Electrical
cabinet

HDR

Intel Core i7-3


1.7 GHz2 cores

2 GB

48 W

4.0 kg

ID 1081185-01

MC 6641

Electrical
cabinet

HDR

Intel Core i7-3


2.1 GHz4 cores

2 GB

75 W

4.0 kg

ID 811550-01

Options

The capabilities of the iTNC 530 can also be adapted retroactively


with options to meet new requirements. These options are
described on page 13. They are enabled by entering keywords
based on the SIK number, and are saved in the SIK component.
Please indicate your SIK number when ordering new options.

Storage medium

The storage medium is removable and must be ordered separately


from the main computer. It contains the NC software 60642x-04.
Depending on the main computer, the HDR hard disk or the SSDR
solid state disk is used as a storage medium. The NC software is
based on the HEIDENHAIN HEROS 5 operating system.
HDR hard disk
Free capacity
For main computer
Export license required
No export license required
SSDR solid state disk
Free capacity
For main computer
Export license required
No export license required

144 GB
MC 6441, MC 6541,
MC 6641
ID 682272-04
ID 682272-54
21 GB
MC 6542, MC 7422,
MC 7522
ID 736591-04
ID 736591-54

HDR hard disk

SSDR solid state disk

SIK component

The SIK component contains the NC software license for


enabling control loops and software options. It gives the main
computer an unambiguous ID codethe SIK number. The SIK
component is ordered and shipped separately. It must be inserted
in a special slot in the MC main computer.
The SIK component with the NC software license is available in
various versions, depending on the enabled control loops and
options. Further control loops up to the maximum number
available (see Controller Unit) can be enabled later by entering a
keyword. HEIDENHAIN provides the keyword, which is based on
the SIK number.

SIK component

When ordering, please indicate the SIK number of your control.


When the keywords are entered in the control, they are saved
in the SIK component. This enables and activates the options.
Should service become necessary, the SIK component must be
inserted in the replacement control to enable all required options.
Master keyword
(general key)

There is a master keyword (general key) for putting the iTNC 530
into service that will unlock all options for a duration of 90 days.
After this period, only those options with the correct keywords will
be active. The general key is activated via a soft key.

17

Software Key Generator (accessory)

The PC software makes it possible to generate an activation code


for software options on HEIDENHAIN controls. The selected
option is enabled for a limited time (10 to 90 days). It can only
be enabled once. You generate the desired activation code by
entering the SIK number, the option to be enabled, the duration
and a manufacturer-specific password. Option enabling is
independent of the general key.

Feature Content
Level (FCL)

On the iTNC 530, error fixes and software improvements were


separated from each other as of NC software 34049x-02. Error
fixes are usually free of charge and contained in updates of the
NC software. In contrast, software improvements are available
for a fee. They are offered as feature upgrades and are enabled
via the Feature Content Level (FCL) option (ID 529969-01). The
features in a feature content level are listed in User functions. For
the current NC software 60642x-xx, there are not yet any FCL
software improvements that are subject to a fee.

18

NC software license
2 x CC 6108

CC 6106 +
CC 6108

2 x CC 6106

CC 6110

CC 6108

CC 6106

Recommended combinations
Active
control loops

NC software
license and
enabling of
control loops
depending on the
CC

Without
software
option

Incl. option 8

Incl. options 8
and 9

SIK

SIK

SIK

Included
options

ID 586084-20
ID 586084-70

ID 586084-09
ID 586084-59

ID 586084-01
ID 586084-51

ID 586084-24
ID 586084-74

ID 586084-17
ID 586084-67

ID 586084-02
ID 586084-52

ID 586084-25
ID 586084-75

ID 586084-18
ID 586084-68

ID 586084-03
ID 586084-53

0, 1

ID 586084-26
ID 586084-76

ID 586084-19
ID 586084-69

ID 586084-04
ID 586084-54

0, 1, 2

ID 586084-27
ID 586084-77

ID 586084-23
ID 586084-73

ID 586084-05
ID 586084-55

77

ID 586084-06
ID 586084-56

77, 0

10

ID 586084-07
ID 586084-57

77, 0, 1
77, 0 ,1 ,2

11

ID 586084-10
ID 586084-60

12

ID 586084-11
Only through subsequent enabling ID 586084-61
of control loops (additional axes)
ID 586084-12
ID 586084-62

13

14

78
78, 0

ID 586084-13
ID 586084-63

78, 0, 1

15

ID 586084-14
ID 586084-64

78, 0, 1, 2

16

ID 586084-15
ID 586084-65

77, 78

Only through subsequent enabling of control loops


(additional axes)

77, 78,
0...3

17 20
(Italics: Export version)

19

Enabling further
control loops

20

Further control loops can be enabled either as groups or


individually. The combination of control-loop groups and individual
control loops makes it possible to enable any number of control
loops. Up to 20 control loops are possible.
Control-loop groups

Option

4 additional control loops

77

ID 634613-01

8 additional control loops

78

ID 634614-01

Individual control loops

Option

1st additional control loop

ID 354540-01

2nd additional control loop

ID 353904-01

3rd additional control loop

ID 353905-01

4th additional control loop

ID 367867-01

5th additional control loop

ID 367868-01

6th additional control loop

ID 370291-01

7th additional control loop

ID 370292-01

8th additional control loop

ID 370293-01

Controller unit

Controller unit

Due to the very short cycle times of the position, speed and
current controllers, the controller units from HEIDENHAIN are
equally suited for conventional drives, for direct drives (linear
motors, torque motors) and for HSC spindles. They permit a high
loop gain and short reaction times to changing machining forces,
and so make the high contour accuracy and surface quality of the
workpiece possible.

Single speed
Double speed

Single-speed control loops are usually sufficient for linear or


torque motors and for conventional axes. Double-speed control
loops (option 49) are preferred for HSC spindles and axes that are
difficult to control. In the default setting, all axes are set to single
speed. Each axis that is switched from single speed to double
speed can reduce the number of available control loops by one.
PWM frequencies greater than 5 kHz require double-speed control
loops, for which option 49 must be enabled.

Cycle times

With fPWM

Position controller

Single-speed

Double-speed

150 s

300 s

150 s

4000 Hz

125 s

250 s

125 s

5000 Hz

100 s

200 s

100 s

6666 Hz1)

75 s

150 s

150 s

Hz1)

60 s

125 s

125 s

50 s

100 s

100 s

10000 Hz1)
1)

Versions

Speed controller

3333 Hz

8000

Number of control
loops

Current controller

Same as speed
controller

Possible only with option 49

The number of enabled control loops depends on the SIK (see


Main computer), or on additionally enabled control loops, which
can also be ordered as needed later.

 Modular CC 61xx controller units with PWM interface to the


inverters

 Compact UEC/UMC inverters with integrated controller unit


Controller units, main computers and inverters operate in any
desired combination.

21

CC 61xx

The CC 61xx controller units feature:

 Position controller, speed controller, current controller


 HSCI interfaces
 PWM interfaces to the UM, UR, UE power modules
 Interfaces to the speed and position encoders
 Interfaces for power supply (via inverter or PSL 135)
 SPI interfaces for expansion modules (e.g. CMA-H)

CC 6110

CC 6106

CC 6108

CC 6110

Digital control loops

Max. 6 (single speed)

Max. 8 (single speed)

Max. 10 (single speed)

Speed inputs

6 x 1 VPP or EnDat 2.2

8 x 1 VPP or EnDat 2.2

10 x 1 VPP or EnDat 2.2

Position inputs

6 x 1 VPP or EnDat 2.2

8 x 1 VPP or EnDat 2.2

10 x 1 VPP or EnDat 2.2

PWM outputs

10

Weight

4.1 kg

4.7 kg

4.8 kg

ID 662636-xx

ID 662637-xx

ID 662638-xx

For more than 10 control loops, an HSCI line is used to combine


the controller units. For example:
CC 6106 + CC 6106 for up to 12 control loops
CC 6106 + CC 6108 for up to 14 control loops
CC 6110 + CC 6108 for up to 18 control loops
Constraints:

 Max. 20 control loops for max. 18 axes + 2 spindles can be




22

activated (second spindle can be controlled alternately with the


first spindle).
Up to four drive-control motherboards are permissible in the
HSCI system (CC 6106 has one motherboard, CC 6108/CC 6110
each has two motherboards).

Ribbon cable for


supply voltage

Additional ribbon cables are necessary if multiple CC 6xxx units


are combined.
Combination

Length

Dimension
c

2 x CC 6108, or
2 x CC 6110, or
CC 6108 and
CC 6110

300 mm1)

26.5 mm

ID 325816-22

2 x CC 6106

100 mm

31.5 mm

ID 325816-24

1)

In order to reduce the voltage drop, the long ribbon cable is led
doubled.

The short ribbon cables included in delivery are not necessary


for combinations with CC 6108 and/or CC 6110. They are only
necessary for connecting sockets X69 A and X69 B if the CC units
are used separately.
For more information about connecting a CC 6xxx to a supply unit
via ribbon cables, see the Inverter Systems brochure.

23

UEC 11x

The UEC 11x compact inverters not only include the inverter, but
also a controller with PLC inputs and outputs and an integrated
braking resistor. They offer a complete solution for machines with
a limited number of axes and low power demands.
Controller

 Position controller, speed controller, current controller


 HSCI interface
 Interfaces to the speed and position encoders
Inverter
 Power electronics
 Connections for axis motors and spindle motor
 Braking resistor
 Connections for motor holding brakes
System PL
 Interfaces for one workpiece touch probe and one tool touch
probe
 Integrated PLC (expandable with PL 61xx)
UEC 11x: 38 free inputs, 23 free outputs (7 of which can be
switched off)
UEC 11x FS: 38 free inputs, 28 free outputs (7 of which can be
switched off), 8 free FS inputs, 8 free FS outputs
 Configuration with IOconfig PC software

UEC 111

DC-link connections
The UEC 111 and UEC 112 do not have any DC-link connection.
On the UEC 111 FS, UEC 112 FS and UEC 113 (FS) an additional
DC-link connection is located on the front panel for connection
of a PSL 130.

UEC 113

24

UEC 111/UEC 112/UEC 113


Controller

4/5/6 digital control loops

Speed inputs

4/5/6 x 1 VPP or EnDat 2.2

Position inputs

4/5/6 x 1 VPP or EnDat 2.2

Inverter

2/3/4 axes

1 axis

Spindle

3333 Hz

6.0/12.0 A

9.0/18.0 A

24.0/36.0 A

4000 Hz

5.5/11.0 A

8.3/16.5 A

22.0/33.0 A

5000 Hz

5.0/10.0 A

7.5/15.0 A

20.0/30.0 A

6666 Hz

4.2/8.4 A

6.3/12.6 A

16.8/25.2 A

8000 Hz

3.6/7.3 A

5.5/11.0 A

14.6/21.9 A

10000 Hz

3.0/6.0 A

4.6/9.2 A

12.2/18.3 A

Rated current IN/


maximum current Imax1)
at a PWM frequency of

Supply

voltage2)

3 x 400 V AC ( 10 %); 50 Hz

Rated power of DC link

14 kW

Peak power3) of DC link

18 kW / 25 kW

Power loss at IN

 450 W

DC-link voltage

565 V DC

Integral braking resistance4)

2.1 kW / 27 kW

Power pack for HSCI components

24 V DC / 3.5 A

Module width

150 mm

Weight

 20 kg

Functional safety

UEC 111
UEC 112
UEC 113

ID 625777-xx
ID 625779-xx
ID 828471-xx

ID 1075825-xx
ID 1075826-xx
ID 1038694-xx

1)

2)
3)

4)

Axes: 0.2 s cyclic duration factor for duty cycle time of 10 s with 70 % rated current preload
Spindle: 10 s cyclic duration factor for duty cycle time of 60 s with 70 % rated current preload
For UL certification: 3 x 480 V AC (+6%/-10%); 60 Hz
1st value: 40 % cyclic duration factor for 10 minutes duty cycle time (S6-40 %)
2nd value: 4 s cyclic duration factor for 20 seconds duty cycle time.
1st value: Continuous duty
2nd value: Peak power (1.5 % cyclic duration factor for 120 seconds duty cycle time).

25

UMC 11x

The UMC 111 is a compact inverter with integrated controller


unit and PLC inputs/outputs. As opposed to the UEC, it is used
exclusively for controlling axis motors and is powered by an
external DC link. The UMC automatically enables the control loops
needed for auxiliary axes. No additional options are required.
Please note: The UMC does not increase the number of possible
axes. Interpolation with NC axes is not possible.
Controller

 Position controller, speed controller, current controller


 HSCI interface
 Interfaces to the speed encoders
Inverter
 Power electronics
 Connections for axis motors
 Connections for motor holding brakes
System PL
 Interfaces for one workpiece touch probe and one tool touch
probe with signal transmission by cable
 Integrated PLC, expandable with PL 61xx
UMC 111: 38 free inputs, 23 free outputs (7 of which can be
switched off)
UMC 111 FS: 38 free inputs, 28 free outputs (7 of which can be
switched off)
8 FS inputs, 8 FS outputs
 Configuration with IOconfig PC software

UMC 111

UMC 111
Controller

4 digital control loops

Speed inputs

4 x 1 VPP or EnDat 2.2

Inverter

4 axes

Rated current IN/


maximum current
Imax1) at a PWM
frequency of

9.0/18.0 A

4000 Hz

8.3/16.5 A

5000 Hz

7.5/15.0 A

6666 Hz

6.3/12.6 A

8000 Hz

5.5/11.0 A

10000 Hz

4.6/9.2 A

Power loss at IN

Approx. 300 W

DC-link voltage

565 V DC

24 V PLC current consumption

24 V DC / 2 A

Module width

150 mm

Weight

Approx. 11 kg

UMC 111
UMC 111 FS

ID 736435-xx
ID 664231-xx

1)

26

3333 Hz

Axes: 0.2 s cyclic duration factor for duty cycle time of 10 s with 70 % rated current preload
Spindle: 10 s cyclic duration factor for duty cycle time of 60 s with 70 % rated current preload

15" screen and keyboard

BF 750 color flatpanel display

 Power supply: 24 V DC / approx. 50 W


 15.1-inch; 1024 x 768 pixels
 HDL interface to the MC 6xxx
 8 horizontal soft keys, 6 vertical soft keys for PLC
 Soft-key row switchover
 Screen layout
 Operating mode switchover
 USB port with cover cap on front
 Integrated USB hub with four USB interfaces on the rear
BF 750
Weight

TE 730 keyboard

TE 730

ID 805489-01
Approx. 4.2 kg

Same features as TE 730 but without touchpad


TE 720

TE 735 keyboard
unit with
integrated
machine
operating panel

BF 750

 For BF 750, MC 7422 or MC 7522


 Axis keys
 The keys for axes IV and V are exchangeable snap-on keys.
 Contouring keys
 Operating mode keys
 ASCII keyboard
 Spindle-speed and feed-rate override potentiometers
 USB interface to the MC
 Touchpad
TE 730
Weight

TE 720 keyboard

ID 785080-01
Approx. 4 kg

ID 805488-01

 For BF 750, MC 7422 or MC 7522


 NC keyboard same as TE 730
 USB interface to the MC main computer
 Machine operating panel (same as MB 720)
 HSCI interface
TE 735
TE 735 FS
Weight

ID 771898-01
ID 805493-01
Approx. 3.4 kg

TE 735

MB 720 machine
operating panel

 Power supply 24 V DC / approx. 4 W


 Suitable for BF 750
 36 exchangeable snap-on keys with status LEDs, freely
definable via PLC

 Operating elements: 12 axis keys, 24 function keys, NC start ,


1)




1)

MB 720

NC stop1), spindle start, spindle stop (all snap-on keys),


emergency stop button, control voltage on1); 2 holes for
additional keys or keylock switches
HSCI interface
MB 720: 7 free PLC inputs and 5 free PLC outputs
MB 720 FS: 4 free FS inputs and 5 free PLC outputs; and dualchannel FS inputs for emergency stop and permissive buttons of
the handwheel.
Keys illuminated, addressable via PLC

MB 720
ID 784803-01
MB 720 FS ID 805474-01
Weight
Approx. 1 kg

27

19" screen and keyboard

BF 760 color flatpanel display

 Power supply: 24 V DC/approx. 65 W


 19-inch; 1280 x 1024 pixels
 HDL interface to the MC 6xxx
 10 horizontal NC soft keys, 8 + 10 vertical soft keys for PLC
 Soft-key row switchover
 Screen layout
 Operating mode switchover
 Integrated USB hub with six USB interfaces on the rear
BF 760
Weight

ID 732589-01
Approx. 7.8 kg

BF 760

TE 740 keyboard

 Suitable for BF 760 (19 design)


 Axis keys
 The keys for axes IV and V are exchangeable snap-on keys.
 Contouring keys
 Operating mode keys
 ASCII keyboard
 Spindle-speed, feed-rate and rapid-traverse override
potentiometers

 USB interface to the MC main computer


 Touchpad
 USB port with cover cap on front

TE 740

A PLB 6001 is required for connection of an OEM-specific


machine operating panel.
TE 740
Weight
TE 745 keyboard
unit with
integrated
machine
operating panel

ID 886546-01
Approx. 3.2 kg

Same as TE 740, but with integrated machine operating panel

 Power supply 24 V DC / approx. 4 W


 36 exchangeable snap-on keys with status LEDs, freely
definable via PLC

 Operating elements: 12 axis keys, 24 function keys, NC start ,


1)

1)





1)

NC stop , spindle start, spindle stop, emergency stop button,


control voltage on1); 3 holes for additional keys or keylock
switches
Connection for HR handwheel
HSCI interface
TE 745: 7 free PLC inputs and 5 free PLC outputs
TE 745 FS: 4 free FS inputs and 5 free PLC outputs; and dualchannel FS inputs for emergency stop and permissive buttons of
the handwheel.
Keys illuminated, addressable via PLC

TE 745
TE 745 FS
Weight

28

ID 679817-01
ID 805482-01
Approx. 4.3 kg

TE 745

PL 6000 PLC input/output systems with HSCI

PL 6000

The PLC inputs and outputs are available via external modular
PL 6000 PLC input/output systems. They consist of a basic
module and one or more input/output modules. A total maximum
of 1000 inputs/outputs is supported. The PL 6000 units are
connected to the MC main computer via the HSCI interface. The
PL 6000 units are configured with the IOconfig PC software.

PLB 62xx

Basic modules

There are basic modules with HSCI interface available for 4,


6 or 8 I/O modules. They are mounted on standard NS 35 rails
(DIN 46 227 or EN 50 022).
Supply voltage
Power consumption1)
Weight
1)

System PL

24 V DC
Approx. 48 W at 24 V DC NC
Approx. 21 W at 24 V DC PLC
0.36 kg (bare)

PLB 6xxx completely filled, incl. TS, TT. For more details
regarding power supply for 24 V DC NC, see Power supply for
HSCI components.

 Necessary once for each control system (except with UEC)


 Includes connections for TS and TT touch probes, as well as TL
 Safety-relevant inputs/outputs
 Without FS: 12 free inputs, 7 free outputs
With FS: 6 free FS inputs, 2 free FS outputs
PLB 6204
PLB 6204 FS
PLB 6206
PLB 6206 FS
PLB 6208
PLB 6208 FS

Expansion PL

for 4 I/O modules


for 4 I/O modules
for 6 I/O modules
for 6 I/O modules
for 8 I/O modules
for 8 I/O modules

ID 591832-03
ID 586789-03
ID 630054-03
ID 622721-03
ID 630055-03
ID 620927-03

For connection to the system PL to increase the number of


PLC inputs/outputs
PLB 6104
PLB 6104 FS
PLB 6106
PLB 6106 FS
PLB 6108
PLB 6108 FS

for 4 I/O modules


for 4 I/O modules
for 6 I/O modules
for 6 I/O modules
for 8 I/O modules
for 8 I/O modules

ID 591828-03
ID 590479-03
ID 630058-03
ID 804755-01
ID 630059-03
ID 804756-01

Up to seven PLB 6xxx can be connected to the control. The


maximum cable length results from the maximum permissible
length of the HSCI chain of 70 m.

29

I/O modules for


HSCI

There are I/O modules with digital and analog inputs and outputs.
For partially occupied basic modules, the unused slots must be
occupied by an empty housing.
PLD-H 16-08-00
PLD-H 08-16-00
PLD-H 08-04-00 FS
PLD-H 04-08-00 FS

I/O module with 16 digital inputs and


8 digital outputs
I/O module with 8 digital inputs and
16 digital outputs
I/O module with 8 digital FS inputs and
4 digital FS outputs
I/O module with 4 digital FS inputs and
8 digital FS outputs

ID 650891-02
ID 598905-02
ID 727219-02

Total current
Power output
Weight

Outputs 1 to 7:  2 A per output (8 A simultaneously)


Max. 200 W
0.2 kg

PLA-H 08-04-04

Analog module for PL 6xxx with


 8 analog inputs, 10 V
 4 analog outputs, 10 V
 4 analog inputs for PT 100 thermistors
0.2 kg

Weight
Empty housing

For unused slots

IOconfig
(accessory)

PC software for configuring HSCI and PROFIBUS components

30

ID 594243-02

ID 383022-11

ID 675572-01

PL 550 PLC input/output system for PROFIBUS-DP

PL 550

PLC inputs and outputs are also available via the external modular
PL 550 PLC input/output system. It consists of a basic module
and one or more I/O modules, and is connected to the MC main
computer via the PROFIBUS-DP interface. The PLC I/O modules
are configured with the PC software IOconfig. The additional
module for PROFIBUS-DP (Page 35) must be installed in the
MC before the PLB 550 is connected to the control.

PL 550

Basic module

Basic module with PROFIBUS-DP interface


The PLB 550 has slots for four I/O modules. It serves as a
PROFIBUS slave. A total of 32 slaves can be connected to the
MC with integrated PROFIBUS interface board (PROFIBUS single
master). They are mounted on standard NS 35 rails (DIN 46 227 or
EN 50 022).
PLB 550
Supply voltage
Power consumption
Weight

I/O modules

ID 507872-01
24 V DC
Approx. 20 W
0.36 kg (bare)

The I/O modules consist of one module with digital inputs/outputs


and one analog module. For partially occupied basic modules, the
unused slots must be occupied by an empty housing.
PLD 16-8
ID 360916-11
I/O module for PL 5x0 with
16 digital inputs and
8 digital outputs.
The maximum power output per module is 200 W. A load of up to
2 A can be placed on each output. No more than four outputs may
be loaded with 2 A at any given time.
Weight
0.2 kg
PLA 4-4
ID 366423-01
Analog module for PL 5x0 with
4 analog inputs for PT 100 thermistors
4 analog inputs for 10 V
Weight
0.2 kg

Empty housing

For unused slots

IOconfig
(accessory)

PC software for configuring HSCI and PROFIBUS components

ID 383022-11

31

Accessories
Power supply for HSCI components

PSL 13x

To power the HSCI components, HEIDENHAIN offers the PSL 13x


power supply unit. Either line voltage and DC-link voltage or only
line voltage is provided to the PSL 13x. The PSL 13x provides
the safely separated 24 V DC NC power supply required for the
HSCI components by EN 61 800-5-1. The NC supply voltage and
the PLC supply voltage are separated from each other by basic
insulation.
Supply
voltage
Outputs

Line voltage 400 V AC 10% 50 Hz and


DC-link voltage 400 V DC to 750 V DC
Power consumption max. 1000 W
NC:
24 V DC / 20 A
(double insulation from line power)
5 V DC / 16 A (only for PSL 135)
electrically connected with 24 V DC NC
PLC:
24 V DC / 20 A (basic insulation from line
power)
Total:
Max. 32 A / 750 W

PSL 130

The PSL 130 serves as a 24 V DC power supply unit for supplying


the HSCI components. If a UEC controller unit is used, then the
PSL 130 is not necessary if the total current consumption of the
connected HSCI components does not exceed 3.5 A.
HSCI components

Current consumption 24 V DC NC

Main computer

MC 6441
MC 6541, MC 6542
MC 6641
MC 7422
MC 7522

1.7 A
2.0 A
3.2 A
2.2 A
2.5 A

Machine operating panel

PLB 6001
MB 7x0

0.2 A (without handwheel)


0.2 A (without handwheel)

Keyboard unit

TE 7x5 (MB integrated)

0.2 A (without handwheel)

PLC inputs/outputs

PLB 62xx
PLB 61xx
PLD
PLA

0.3 A (without touch probe)


0.2 A
0.05 A
0.1 A

Visual display unit

BF 750
BF 760

2.1 A
2.5 A

Handwheels

HR 520
HRA 551 FS + HR 550 FS
HR 410
HR 130
HRA 110 + 3 x HR 150

0.05 A
0.5 A (during charging)
0.05 A
0.05 A
0.2 A

Touch probes

See specifications of the touch probes

The PSL 135 has an additional 5 V DC output and is therefore


suited for supplying the CC controller unit and the MC main
computer. It may be necessary for a double-row configuration.

32

Module width

Degree of
protection

Weight

PSL 130

50 mm

IP 20

2.1 kg

ID 575047-04

PSL 135

50 mm

IP 20

2.5 kg

ID 627032-03

HSCI adapter for OEM machine operating panel

PLB 6001

The PLB 6001 HSCI adapter is required in order to connect an


OEM-specific machine operating panel to the iTNC 530. The
spindle-speed and feed-rate override potentiometers of the TE 7xx
and the HR handwheel are also connected to this adapter.

 HSCI interface
 Connection for HR handwheel
 Inputs/outputs for keys/key illumination




Without FS: Terminals for 72 inputs and 40 outputs


With FS: Terminals for 36 FS inputs and 40 outputs
Connection for spindle-speed, feed-rate and rapid-traverse
overrides
Screw fastening or top-hat-rail mounting
Configuration of the PLC inputs/outputs with the IOconfig
computer software

PLB 6001
PLB 6001 FS
Weight

PLB 6001

ID 668792-01
ID 722083-01
Approx. 1.2 kg

33

Additional modules

Overview

The additional modules are directly connected to the HSCI control


system through a slot on the MC main computer, CC controller
unit or UEC/UMC inverter.

Module for analog


axes

Digital drive designs sometimes also require analog axes or


spindles. The additional module CMA-H 04-04-00 (Controller
Module AnalogHSCI) makes it possible to integrate analog servo
drives in an HSCI system.
The CMA-H is connected to the HSCI control system through
a slot on the underside of the CC or UEC. Every controller unit
has slots for two boards. The CMA-H does not increase the total
number of available axes: every analog axis used reduces the
number of available digital control loops by one. Analog control
loops also need to be enabled on the SIK. The analog control-loop
outputs can only be accessed via the NC, and not via the PLC.
Additional module for analog axes/spindles

 Expansion board for CC 61xx or UEC controller units


 4 analog outputs, 10 V for axes/spindle
 Spring-type plug-in terminals
CMA-H 04-04-00

CMA-H 04-04-00
Module for fast
digital PLC inputs/
outputs

ID 688721-01

The CMD-H 24-12-00 additional module features 24 PLC inputs


and 12 PLC outputs. The CMD-H is directly connected to the MC
main computer through a slot. This eliminates the propagation
times for HSCI transmission during the exchange of data, and
makes fast PLC inputs/outputs possible without a propagation
delay. The IOconfig 3.0 software (available as of the end of 2013) is
required for configuration.
Additional module for digital PLC inputs/outputs

 Digital expansion board for the MC main computer


 24 digital inputs, 24 V
 8 digital outputs, 24 V, 150 mA
 4 digital outputs, 24 V, 2 A
 Connection via 44-pin D-sub connector, triple-row
CMD-H 24-12-00

ID 810900-01

Accessories

Cable for CMD-H


ID 620320-xx
For connection to a terminal block; with
one 44-pin D-sub connector, triple-row

Module for analog


PLC inputs

The CMA-H 02-00-04 additional module makes it possible to


directly connect PT 100 thermistors to the MC main computer
and can be used as an alternative to the PLA-H I/O module. The
module also provides two analog  10 V inputs for the PLC. The
IOconfig 3.0 software (available as of the end of 2013) is required
for configuration.
Additional module for PT 100 and analog inputs
 Analog expansion board for the MC main computer
 4 analog inputs for PT 100 thermistors
 2 analog inputs  10 V
 Spring-type plug-in terminals
CMA-H 02-00-04

34

ID 743095-01

Module for
PROFIBUS-DP

An expansion board can be used to provide the iTNC 530 with a


PROFIBUS interface at any time. This makes the connection to a
PROFIBUS-DP field bus system possible.
The PROFIBUS module is integrated in the control system by
using a slot in the MC. The interface is configured with IOconfig.
Additional module for PROFIBUS-DP

 Expansion board for the MC main computer


 Connection for D-sub connector (female) 9-pin
PROFIBUS-DP additional module

Module for PROFIBUS-DP

ID 828539-01

35

Touch probes

Overview

Touch probes for tool and workpiece measurement are connected


via the system PL 62xx or the UEC/UMC. These touch probes
generate a trigger signal that saves the current position value to
the NC. For more information on the touch probes, ask for our
brochure titled Touch Probes.

Workpiece
measurement

The TS touch trigger probes have a stylus for probing workpieces.


The HEIDENHAIN controls provide standard routines for datum
setting and workpiece measurement and alignment. The touch
probes are available with various taper shanks. Assorted styli are
available as accessories.
Touch probe with cable connection for signal transmission for
machines with manual tool change:

TS 230

Touch probe for NC machines

TS 230

Touch probe with infrared transmission for machines with


automatic tool change:
TS 440

Compact dimensions

TS 440

TS 444

Compact dimensions, battery-freepower supply through


integrated air turbine generator over central compressed air supply

TS 640

Standard touch probe with wide-range infrared transmission and


long operating time

TS 740

High probing accuracy and reproducibility, low probing force

SE transmitter-receiver unit

The infrared transmission is established between the TS touch


probe and the SE transceiver unit. The following SE units can be
combined with the TS touch probes:
SE 640 for installation in the machines working space
SE 642 common SE for TS and TT 449; otherwise same as SE
640
SE 540 for infrared transmission; for installation in the spindle
head

36

SE 640

Tool
measurement

The touch probes for tool measurement from HEIDENHAIN


are suited for probing stationary or rotating tools directly on the
machine. The iTNC 530 has standard routines for measuring
length and diameter of the tool as well as the individual teeth. The
iTNC 530 automatically saves the results of measurement in a
tool table. It is also possible to measure tool wear between two
machining steps. The iTNC 530 compensates the changed tool
dimensions automatically for subsequent machining or replaces
the tool after a certain limitas for example after tool breakage.
With the triggering TT touch probes, the disk-shaped contact
plate is deflected from its rest position upon contact with a
stationary or rotating tool, sending a trigger signal to the iTNC 530
control.

TT 140

Signal transmission to the control over connecting cable

TT 140

TT 449

Signal transmission over infrared beam to SE 642 transmitter/


receiver unit

TL Micro/TL Nano

The TL laser systems operate without any contact. A laser


beam probes the length, diameter or contour of the tool. Special
measuring cycles in the iTNC 530 evaluate the information.

37

Electronic handwheels

Overview

The standard iTNC 530 supports the use of electronic


handwheels.
 HR 550 FS wireless handwheel, or
 HR 410 or HR 520 portable handwheel, or
 HR 130 panel-mounted handwheel
 Up to three HR 150 panel-mounted handwheels via HRA 110
Two handwheels or HRA handwheel adapters, one of which
can be a HR 550 FS, can be connected to the MB machine
operating panel, the MC main computer or the PLB 6001 adapter
for HSCI.Handwheels with functional safety are cross-circuit proof
thanks to the special permissive key logic.

HR 410

Portable electronic handwheel with


 Keys for actual-position capture and the selection of 5 axes
 Keys for traverse direction and three preset feed rates
 Three keys with machine functions (see below)
 Emergency stop button and two permissive buttons (24 V)
 Magnetic holding pads
All keys are designed as snap-on keys and can be replaced by keys
with other symbols (see Snap-on keys).

HR 410

HR 410 FS

Keys

Without
detent

With detent

FCT A, FCT B,
FCT C

ID 296469-53

Spindle right/left/
stop

ID 296469-54

NC start/stop,
ID 296469-55
spindle start (for
PLC basic program)

ID 535220-05

FCT A, FCT B,
FCT C

ID 337159-11

ID 578114-01

NC start/stop,
ID 337159-21
spindle start (for
PLC basic program)

ID 578114-11

HR 410

Weight approx. 1 kg
HR 520

Portable electronic handwheel with

 Display for operating mode, actual position value, programmed


feed rate and spindle speed, error messages

 Override potentiometer for feed rate and spindle speed


 Selection of axes via keys or soft keys
 Actual position capture
 NC start/stop
 Spindle on/off
 Keys for continuous traverse of the axes
 Soft keys for machine functions of the machine manufacturer
 Emergency stop button
Without
detent

With detent

HR 520

ID 670302-01

ID 670303-01

HR 520 FS

ID 670304-01

ID 670305-01

Weight approx. 1 kg
Mount for HR 520

38

For fastening on machine

ID 591065-02

HR 520

HR 550 FS

Electronic handwheel with wireless transmission. Display,


operating elements and functions same as HR 520.
In addition:

 Functional safety
 Wireless transmission range up to 20 m (depending on
environment)
HR 550 FS

Without detent
With detent

ID 598515-03
ID 606622-03

Replacement
battery

for HR 550 FS

ID 623166-xx

HR 550 FS with HRA 551 FS

HRA 551 FS

Handwheel mount for HR 550 FS

 For docking the HR 550 FS on the machine


 Integrated charger for HR 550 FS
 Connections to the control and the machine
 Integrated transmitter/receiver unit
HRA 551 FS
Weight

ID 731928-02
Approx. 1.0 kg

For more information, see the HR 550 FS Product Information


sheet.
Connecting cable

For HR 410/
HR 520

For
HR 410 FS/
HR 520 FS

For HR 550 FS
with
HRA 551 FS

Connecting cable (spiral cable) to HR


(3 m)

ID 312879-01

Connecting cable with metal armor

ID 296687-xx

Connecting cable without metal armor 

ID 296467-xx

Adapter cable for HR/HRA to MC

1)

ID 296466-xx

Extension cable to adapter cable

1)

ID 281429-xx

Adapter cable for HRA to MC

2)

ID 749368-xx

Extension cable to adapter cable

2)

ID 749369-xx

Dummy plug for standard handwheels 

ID 271958-03

Dummy plug for handwheels with FS

ID 271958-05

1)
2)

For cable lengths up to 20 m between MB and HRA 551 FS


For cable lengths up to 50 m between MB and HRA 551 FS

See also Cable overview on Page 45.

39

HR 130

Panel-mounted handwheel with ergonomic control knob.


It is attached to the MB 7x0 or the TE 7x5 either directly or via an
extension cable.
HR 130
Weight

Without detent
With detent
Approx. 0.7 kg

ID 540940-03
ID 540940-01

HR 130

HR 150

Panel-mounted handwheel with ergonomic control knob for


connection to the HRA 110 handwheel adapter.
HR 150
Weight

Without detent
With detent
Approx. 0.7 kg

ID 540940-07
ID 540940-06

HR 150

HRA 110

Handwheel adapter for connection of up to three HR 150 panelmounted handwheels and two switches for axis selection and
for selecting the interpolation factor. The first two handwheels
are permanently assigned to axes 1 and 2. The third handwheel
is assigned to the axes over a selection switch (accessory) or by
machine parameters. The position of the second selection switch
(accessory) is evaluated by the PLC, for example to set the proper
interpolation.
HRA 110
Weight

Approx. 1.5 kg

ID 261097-04

Step switch

With turning knob and cable ID 270908-xx

HRA 110

Step switch

40

Industrial PC

IPC 6110
IPC 6120

The IPC 6110 and IPC 6120 industrial PCs from HEIDENHAIN are
convenient solutions for an additional, remote station for operating
the machine or machine units, such as tool-changing stations. The
remote operation, which was designed for the iTNC 530 (singleprocessor version), permits very simple connection of the IPC via
a standard Ethernet connection with a cable of up to 100 meters.
The IPC 6110 is designed as a compact version and provides the
most important function keys of the iTNC in addition to the ASCII
keyboard. The IPC 6120 is used in conjunction with the complete
TE 630 or TE 620 keyboard unit (without touchpad).
The control automatically detects when remote operation by the
IPC is active. The IPC is shut down automatically when the control
is switched off.
Here the TNCterminal software included with the IPC ensures
simple connection and convenient operation of the IPC on the
iTNC 530. During remote operation, the controls screen is
displayed identically on the IPC, and the most important functions
of the control can be operated from the integrated keyboard.

IPC 6110

Windows XP Embedded is installed as operating system, and the


TNCremo file-transmission software is also installed. This means
that the transfer of programs and files from the IPC 6110 to the
control is very easy via the USB port located next to the screen.
The machine manufacturer also has the option of installing special
additional software on the IPC.
You can find more information in the IPC 6110/IPC 6120 Product
Information sheet.
IPC 6641
for Windows

With the IPC 6641 industrial PC you can start and remotely
operate Windows-based applications via the TNCs user interface.
The user interface is displayed on the control screen. Option 133 is
required.
Since Windows runs on the industrial PC, it does not influence
the NC machining process. The IPC is connected to the NC main
computer via Ethernet. No second screen is necessary, since
the Windows applications are displayed on the TNCs screen via
remote accesses.
In addition to the IPC 6641 industrial PC, a separately ordered hard
disk is required for operation. The operating systems Windows 7
or 8 can be installed on this empty data medium.
IPC 6641
To be installed in
Processor
RAM memory
Weight

ID 1039543-01
Electrical cabinet
Intel Core i7-3
2.1 GHz4 cores
4 GB
4.0 kg
IPC 6641

HDR hard disk

ID 1074770-51
Empty data carrier for Windows operating
system
Free capacity
Approx. 160 GB

41

Snap-on keys for HR

Overview
The snap-on keys make it easy to replace the key symbols. In this way, the HR handwheel can be adapted to different requirements. The
snap-on keys are available in packs of 5 keys.

Axis keys




Machine
functions

Spindle
functions

Other keys

42

Snap-on keys for control

Overview
The snap-on keys make it easy to replace the key symbols. In this way, the keyboard can be adapted to different requirements. The snapon keys are available in packs of 5 keys.

Keys




Machine
functions

43

Spindle
functions

Other keys

44

722414-xx

HSCI

PL 610x

PL 620x

1 VPP

HSCI

Axes + spindle: 60m

X500

X502

X500

X502

HSCI

HSCI

X502

ribbon cable for sk *)

X1

2x USB

X502

X500

40 inputs
24 outputs

Axes: 60m

340302-xx

EnDat 2.1 interface

VL
336847-xx

X502B*)

X500B*)

X502A

X500A

PWM
out

336376-xx

289440-xx

PLC I/0

X15...X18

1)

X51B...X56B*

HSCI

X201A ... X204A


X201B ... X206B*)

X502

2) only

289440-xx

VL
323897-xx

KTY

KTY
Voltage controller 5 V
383951-01

Voltage controller 5 V
368210-01
2)

509667-xx

for connection of the KTY

336376-xx

4)

368330-xx

4)

3)

1m

30m

LC x83

max. 9m

4)

3)

1 VPP

60m
LB/LS

1 VPP

1 VPP

60m

30.07.2013

LC x83

RCN 729
RCN 226
RCN 228

60m

LC x83

RCN 729
RCN 226
RCN 228

60m

Pure serial EnDat 2.2

EnDat with incremental signals

533631-xx max. 9m

1m

533661-xx max. 16m

4)

533631-xx max. 9m

673459-xx max. 20m

4)

558714-xx max. 30m

3)

309783-xx

310199-xx

1 VPP

**) included with the MB (0,5m)

*) included with the MC (1,5m)

HSCI total length 70 m

VL: Extension cable


for separation points with connecting cable
for extending existing connecting cable

360974-xx (LS x87)


max. 20m
298429-xx (LB, LF 183) max. 12m
298430-xx (LF 481)
max. 12m

MC 7xxx

VL
3)
323897-xx

X500

X501

3)

533627-xx

332115-xx

Position inputs

connector 544703-01
for spindle (if necessary)

1) Adapter

X15A ... X18A


X15B ... X20B*)

*) CCs with 2nd controller board

CC 6xxx

688144-xx

MB 720

250479-55

X3

max. 20m

USB 1.1 624775-xx


ribbon cable for sk *)

max. 5m

USB 2.0 354770-xx

X1

ribbon cable for pots **)


X10

UMC 11x

X51A...X54A

M12

Cabinet

250479-60

X60

TE 720/TE 730

Speed inputs

TE 735/TE 745

Cable overview
Control systems with CC; MC in operating panel

45

46

X500

HSCI

X502

X500

X502

HSCI
618893-xx

X502

Axes + spindle: 60m

1 VPP

PL 610x

PL 620x

722414-xx

HSCI

HSCI
618893-xx

ribbon cable for pots *)

X1

2xUSB

X500

X502

336376-xx

289440-xx

PLC I/0

X15...X18

UMC 11x

1)

X51B...X56B*
PWM
out

X500B***)

40 inputs
24 outputs

Axes: 60m

CC 6xxx

625 901-xx
max. 20m

X249

X201A ... X204A


X201B ... X206B*)

MC 6xxx

X141
X142

USB

289440-xx
KTY

3)

1m

30m

LC x83

max. 9m

4)

3)

1 VPP

LB/LS

60m

60m

29.07.2013

LC x83

RCN 729
RCN 226
RCN 228

60m

LC x83

RCN 729
RCN 226
RCN 228

60m

Pure serial EnDat 2.2

EnDat with incremental signals

1 VPP

1 VPP

1 VPP

533631-xx max. 6m

1m

533661-xx max. 16m

4)

533631-xx max. 9m

673459-xx max. 20m

4)

558714-xx max. 30m

3)

309783-xx

310199-xx

max. 20m
max. 12m
max. 12m

**) included with the MB (0,5m)

*) included with the BF (1m)

HSCI total length 70 m

VL: Extension cable


for separation points with connecting cable
for extending existing connecting cable

360974-xx (LS x87)


298429-xx (LB, LF 183)
298430-xx (LF 481)

VL
323897-xx

KTY
Voltage controller 5 V
383951-01

Voltage controller 5 V
368210-01
2)

509667-xx

Adapter connector 544703-01


for spindle (if necessary)
only for connection of the KTY

2)

336376-xx

4)

4)

368330-xx

VL
3)
323897-xx

3)

533627-xx

332115-xx

Position inputs

BF 760
BF 750

1)

X15A ... X18A


X15B ... X20B*)

X502B***) ***) CCs with 2nd controller board

X500A

X502A

X500

X51A...X54A

340302-xx

250479-55

X3

max. 5m
max. 20m

ribbon cable for sk *)

USB 2.0 354770-xx max. 5m


USB 1.1 624775-xx max. 20m

688 144-xx

X502

MB 720

X10

cabinet

EnDat 2.1 interface

VL
336847-xx

HSCI

M12

X1

USB 2.0 354770-xx


USB 1.1 624775-xx

250479-60 ribbon cable for pots **)

X60

TE 720/TE 730

Speed inputs

TE 735 /TE 745

Control systems with CC; MC in electrical cabinet

HSCI

722414-xx

PL 610x

1 VPP

HSCI

Axes + spindle: 60m

X500

X502

HSCI

HSCI

X502

ribbon cable for sk *)

X1

2x USB

Axes: 60m

340302-xx

X500

X502

X502

X15 ... X18 (UEC 111)


X15 ... X19 (UEC 112)
X15 ... X20 (UEC 113)

X201 ... X204 (UEC 111)


X201 ... X205 (UEC 112)
X201 ... X206 (UEC 113)

336376-xx

1)

X80 ... X85

289440-xx

24 outputs

40 inputs

MB 720

UEC 11x

688144-xx

PLC I/O

EnDat 2.1 interface

VL
336847-xx

M12

Cabinet

X10

289440-xx

4)

only for connection of the KTY

2)

VL
323897-xx

KTY

KTY
Voltage controller 5 V
383951-01

Voltage controller 5 V
368210-01
2)

509667-xx

Adapter connector 544703-01


for spindle (if necessary)

1)

368330-xx

4)

3)

1m

30m

LC x83

max. 9m

4)

3)

1 VPP

60m
LB/LS

12m

60m

29.07.2013

LC x83

RCN 729
RCN 226
RCN 228

60m

LC x83

RCN 729
RCN 226
RCN 228

60m

Pure serial EnDat 2.2

EnDat with incremental signals

1 VPP

1 VPP

533631-xx max. 6m

1m

533661-xx max. 16m

4)

533631-xx max. 9m

673459-xx max. 20m

4)

558714-xx max. 30m

3)

309783-xx

310199-xx

1 VPP

**) included with the MB (0,5m)

*) included with the MC (1,5m)

HSCI total length 70 m

VL: Extension cable


for separation points with connecting cable
for extending existing connecting cable

360974-xx (LS x87)


max. 20m
298429-xx (LB, LF 183) max. 12m
298430-xx (LF 481)
max. 12m

MC 7xxx

VL
3)
323897-xx

X500

X501

3)

533627-xx

332115-xx

Position inputs

336376-xx

250479-55

X3

max. 20m

USB 1.1 624775-xx


ribbon cable for sk *)

max. 5m

USB 2.0 354770-xx

HSCI

X1

ribbon cable for pots **)

X60

TE 720/TE 730

Speed inputs

TE 735 /TE 745

Control systems with UEC; MC in operating panel

47

48

X502

X500

HSCI

HSCI
618893-xx

X502

1 VPP

Axes + spindle: 60m

PL 610x

722414-xx

HSCI

HSCI
618893-xx

ribbon cable for sk *)

X1

2x USB

Axes: 60m

340302-xx

250479-55

X15 ... X18 (UEC 111)


X15 ... X19 (UEC 112)
X15 ... X20 (UEC 113)

336376-xx

1)

X80 ... X85

289440-xx

24 outputs

40 inputs

X249

X201 ... X204 (UEC 111)


X201 ... X205 (UEC 112)
X201 ... X206 (UEC 113)

UEC 11x

MC 6xxx

PLC I/O

X500

X502

X500

X141
X142

USB

289440-xx

4)

Only for connection of the KTY

2)

KTY

3)

1m

30m

LC x83

max. 9m

4)

3)

1 VPP

LB/LS

60m

12m

60m

29.07.2013

LC x83

RCN 729
RCN 226
RCN 228

60m

LC x83

RCN 729
RCN 226
RCN 228

60m

Pure serial EnDat 2.2

EnDat with incremental signals

1 VPP

1 VPP

533631-xx max. 6m

1m

533661-xx max. 16m

4)

533631-xx max. 9m

673459-xx max. 20m

4)

558714-xx max. 30m

3)

309783-xx

310199-xx

1 VPP

**) included with the MB (0,5m)

*) included with the BF (1m)

HSCI total length 70 m

VL: Extension cable


for separation points with connecting cable
for extending existing connecting cable

360974-xx (LS x87)


max. 20m
298429-xx (LB, LF 183) max. 12m
298430-xx (LF 481)
max. 12m

VL
323897-xx

4)

KTY
Voltage controller 5 V
383951-01

Voltage controller 5 V
368210-01
2)

509667-xx

Adapter connector 544703-01


for spindle (if necessary)

368330-xx

VL
3)
323897-xx

1)

533627-xx

332115-xx

3)

BF 760
BF 750

Position inputs

336376-xx

625901-xx
max. 20m

X3

max. 5m
max. 20m

ribbon cable for sk *)

USB 2.0 354770-xx max. 5m


USB 1.1 624775-xx max. 20m

688144-xx

X502

MB 720

X10

cabinet

EnDat 2.1 interface

VL
336847-xx

HSCI

M12

X1

USB 2.0 354770-xx


USB 1.1 624775-xx

250479-60 ribbon cable for pots **)

X60

TE 720/TE 730

Speed inputs

TE 735 /TE 745

Control systems with UEC; MC in electrical cabinet

max. 55m

max. 20m

Voltage controller 5 V
368210-02

643450-xx max. 20m

735961-xx

679671-xx max. 6m

509667-xx

641926-xx

509667-xx

332115-xx

533627-xx

332115-xx

533627-xx

309783-xx

310199-xx

LC 211
LC x15 / EnDat 22

LC 281
LC x83 / EnDat 02

643450-xx max. 20m

727658-xx

max. 55m

max. 30m

max. 55m

max. 55m

max. 25m

max. 55m

max. 20m

RCN xx80 / EnDat 02

679671-xx max. 6m

max. 9m

55m

max. 25m

RCN xx10 / EnDat 22

533631-xx max. 9m

558714-xx

1 VPP

1 VPP

310128-xx (LB, LF 183)


310123-xx (LF 481)
360645-xx (LS x87)

1 VPP

533661-xx max. 6m

673459-xx

max. 20m
max. 12m
max. 12m

735994-xx

360974-xx (LS x87)


298429-xx (LB, LF 183)
298430-xx (LF 481)

X201A ... X204A


X201B ... X206B*)

*) CCs with 2nd controller board

X15A ... X18A


X15B ... X20B*)

533661-xx max. 6m

558727-xx

735994-xx

Voltage controller 5 V
368210-02

RCN xx80 / EnDat 02

max. 55m

max. 25m

641926-xx

533631-xx max. 9m

RCN xx10 / EnDat 22

max. 55m

max. 20m

LC x8/3 / EnDat 02

max. 55m

LC x15 / EnDat 22

X500B*)

X502B*)

UEC 1xx
UMC 1xx
CC 6xxx

Speed inputs

X502A

Position inputs

X500A

29.07.2013

Measuring devices

49

Inverter system

50

X121
(Option)

516670-01

516670-01

PL 620x
UEC 11x
UMC 11x

X113

X141
X142

X27

X26

X112

PLC

CC 6xxx
UEC 11x
UMC 11x

MC 6x41
MC 7222

515845-01

PL 550

100m

USB hub
582884-01

Adapter 25 pin
310085-01

Adapter 9 pin
363987-02

X23

274545-xx

PUR protective armor

Steel braiding

560040-xx

50m
TT 140

633608-xx

633611-xx

683259-xx

TL Nano
TL Micro 150
TL Micro 200
TL Micro 300

30m

TS 230

V.24/RS-232-C

VL
281429-xx

366964-xx

30m
20m with connection of a USB hub

560041-xx

826269-01

633613-xx

633616-xx

624775-xx

5m

365725-xx

355484-xx

354770-xx

CMA-H 04-04-00
analog axis
688721-xx

Ethernet

CMD-H 24-12-00
for fast PLC I/Os
810900-01

CMA-H 02-00-04
analog inputs + PT 100
743095-01

MB 720
TE 735
TE 745
PLB 6001

749369-xx

PC

20m

296466-xx

296466-xx

749368-xx

20m

50m

50m

SE x40
TS

296687-xx

296467-xx

312879-01

3 inputs

663631-xx

SE 540
626001-xx

517375-xx

0.5m

HRA 110
261097-xx

50m

296467-xx

max. 2m

HR 520 FS
670304-xx
670305-xx
HR 410 FS
337159-xx
578114-xx

HR 520
670302-xx
670303-xx
HR 410
296469-xx
535220-xx
HR 130
540940-01
-03
HR 150
540940-06
-07

50m

HR 550 FS
598515-xx
606622-xx

SE 642

TT

TS

With SE 642:
TT 449 and TS 740, TS 640, TS 440, TS 444
TS 460 or TS 642

With SE x40:
TS 740, TS 640, TS 440, TS 444
TS 460 or TS 642

30.07.2013

Connector housing must be mounted

VL: Extension cable


for separation points with connecting cable
for extending existing connecting cable

max. 20 m

3m

HRA 551 FS
731928-xx

Accessories

51

Technical description
Digital control design

Uniformly digital

In the uniformly digital control design from HEIDENHAIN, all


components are connected to each other via purely digital
interfaces: The control components are connected via HSCI
(HEIDENHAIN Serial Controller Interface), the new real-time
protocol from HEIDENHAIN for Fast Ethernet, and the encoders
are connected via EnDat 2.2, the bidirectional interface from
HEIDENHAIN. This achieves a high degree of availability for the
entire system. It can be diagnosed and is immune to noisefrom
the main computer to the encoder. These outstanding properties
of the uniformly digital design from HEIDENHAIN guarantee not
only very high accuracy and surface quality, but rapid traverse
speeds as well. Please refer to the Uniformly Digital Technical
Information sheet for more detailed information.

HSCI

HSCI, the HEIDENHAIN Serial Controller Interface, connects the


main computer, controller(s) and other control components. HSCI
is based on 100BaseT Ethernet hardware. A special interface
component developed by HEIDENHAIN makes short cycle times
for data transfer possible.
Main advantages of the control design with HSCI:

 Hardware platform for flexible and scalable control system (e.g.


local axis systems)

 High noise immunity due to digital communication between


components

 Hardware basis for the implementation of functional safety


 Simpler wiring (initial operation, configuration)
 Inverters remain connected via proven PWM interface
 Greater cable lengths in the entire system (HSCI up to 70 m)
 Number of control loops can be increased (up to 18 axes and
alternatively two spindles)

 More PLC inputs and outputs


 Controller units can be installed elsewhere
CC or UEC controller units, up to nine PL 6000 PLC input/output
modules, and machine operating panels (such as the MB 720 from
HEIDENHAIN) can be connected to the serial HSCI bus of the MC
main computer. The HR handwheel is connected directly to the
machine operating panel. The combination of visual display unit
and main computer is especially advantageous if the computer
is housed in the operating panel. All that is required then is the
power supply and an HSCI line to the controller in the electrical
cabinet.
The maximum permissible number of individual HSCI participants
is listed below.
HSCI components

52

Maximum number

MC

HSCI master

1 in the system

CC, UEC, UMC

HSCI slave

4 drive-control motherboards (distributed to CC, UEC, UMC


as desired)

MB, PLB 6001

HSCI slave

2 in the system

PLB 61xx, PLB 62xx

HSCI slave

7 in the system

HR

On MB or
PLB 6001

2 in the system (of which only one HR 550 FS)

PLD-H-xx-xx FS

In PLB 6xxx FS

10 in the system

PLD-H-xx-xx, PLA-H-xx-xx

In PLB 6xxx

25 in the system

Total maximum of
1000 inputs/outputs

Functional safety

Basic principle

Controls from HEIDENHAIN with functional safety meet


safety integrity level 2 (SIL 2) as per the EN 61 508 standard, as
well as performance level d, category 3, as per EN ISO 13 849-1
(which replaced EN 954-1). These standards describe the
assessment of safety-related systems, for example based on the
failure probabilities of integrated components and subsystems.
This modular approach helps the manufacturers of safety-related
systems to implement their systems, because they can begin
with subsystems that have already been qualified. Safety-related
position encoders, the iTNC 530 control and functional safety
accommodate this concept. Two redundant safety channels that
work independently of each other are the foundation for controls
with functional safety. All safety-relevant signals are captured,
processed and output via two channels. Errors are detected by
mutual comparison of the states and data in the two channels. In
this way, the occurrence of just one fault in the control does not
lead to the safety functions being incapacitated.

Structure

The safety-related controls from HEIDENHAIN have a dual-channel


design with mutual monitoring. The SPLC (safety-related PLC
program) and SKERN (safe core software) processes are the basis
of the two redundant systems. The two software processes run
on the MC main computer (CPU) and CC controller unit (DSP)
components. The dual-channel structure of the MC and CC is
also used in the PLB 6xxx FS input/output systems and the
MB 7xx FS machine operating panel. This means that all safetyrelevant signals (e.g. permissive buttons and keys, door contacts,
emergency stop button) are captured via two channels, and are
evaluated independently of each other by the MC and CC. The
MC and CC use separate channels to also address the power
modules, and to stop the drives in case of an error.

Components

In systems with functional safety, certain hardware components


assume safety-relevant tasks. Systems with FS may consist of
only those safety-relevant components, including their variants,
which HEIDENHAIN has approved for use!
Control components with functional safety are recognizable by the
suffix FS after the model designation, e.g. MB 720 FS.

MB and TE

An MB machine operating panel with FS is indispensable for


systems with functional safety. Only on such a machine operating
panel do all keys have a dual-channel design. Axes can be moved
without additional permissive keys.

PLB

In systems with functional safety, a combination of hardware (FS


and standard) is possible, but a PLB 62xx FS is essential.

HR

FS handwheels are required in systems with functional safety


because only they have the required cross-circuit-proof permissive
buttons.
For a current list of components approved for FS, see the
Functional Safety FS Technical Manual.

53

Safety functions

The following safety functions are integrated in the hardware and


software:
 Safe stop reactions (SS0, SS1, SS2)
 Safe torque off (STO)
 Safe operating stop (SOS)
 Safely limited speed (SLS)
 Safely limited position (SLP)
 Safe brake control (SBC)
 Safe operating modes in accordance with EN 12 417
Operating mode 1: Automated or production mode
Operating mode 2: Set-up mode
Operating mode 3: Manual intervention
Operating mode 4: Advanced manual intervention, process
monitoring
Please note:
The complete feature content is not yet available for all machine
types with functional safety. Before planning a machine with
functional safety, please inform yourself of whether the current
scope of features suffices for your machine design.

Activation of
functional safety

If the control identifies a PLB 62xx FS in the system during


booting, functional safety is activated.
In this case, it is essential that the following prerequisites be
fulfilled:
 Functional safety versions of safety-related control components
(e.g. MB 720 FS, TE 735 FS, HR 550 FS)
 Safety-related SPLC program
 Configuration of safe machine parameters
 Wiring of the machine for systems with functional safety
Functional safety cannot be activated or deactivated by parameter.

More information

54

For more information on the topic of functional safety, refer to


the Technical Information documents Safety-Related Control
Technology for Machine Tools and Safety-Related Position
Encoders.
For details, see the Functional Safety FS Technical Manual. Your
contact person at HEIDENHAIN will be glad to answer any
questions concerning controls with functional safety.

Operating system

HEROS 5

The iTNC 530 works with the real-time operating system


HEROS 5 (HEIDENHAIN Real-time Operating System). This futureoriented operating system features powerful functions:
 Display of PDF files. Drawings, work instructions, etc. can be
opened directly on the control.
 Direct Internet access from the iTNC 530 thanks to the
integrated browser.
 You can open various file formats directly on the iTNC 530 and
also edit some of them with the appropriate editors:
Text files (.txt, .ini)
Graphic files (.gif, .bmp, .jpg, .png)
Tables (.xls, .csv)
Internet files (.html)
 Standardized display format for operating system dialogs

55

Axes

Linear axes

The iTNC 530 can control the linear axes X, Y, Z as well as U, V, W,


depending on the version.

Display and
programming

99 999.9999 to +99 999.9999 [mm]


Feed rate in mm/min relative to the workpiece contour, or mm per
spindle revolution
Feed rate override: 0% to 150%
Maximum feed rate:
60000 min 1
No. of motor pole pairs

Traverse range

Screw pitch [mm]

99 999.9999 to +99 999.9999 [mm]


The machine tool builder defines the traverse range. The user can
set additional limits to the traverse range if he wishes to reduce
the working space. Three different traverse ranges can be defined
(selection by PLC).

Rotary axes

The iTNC 530 can control the rotary axes A, B and C. Special PLC
functions are available for rotary axes with Hirth coupling.

Display and
programming

0 to 360 or
99 999.9999 to +99 999.9999 []
Feed rate in degrees per minute [/min]

Traverse range

99 999.9999 to +99 999.9999 []


The machine tool builder defines the traverse range. The user can
set additional limits to the traverse range if he wishes to reduce
the working space. Three different traverse ranges can be defined
(selection by PLC).

Free rotation

For milling-turning operations, the rotary axis can be started via


the PLC with a defined feed rate. For functions specific to milling/
turning machines, see Turning operations.

Cylindrical surface
interpolation
(option 8)

A contour defined in the working plane is machined on a cylindrical


surface.

56

Tilting the
working plane
(option 8)

The iTNC 530 has special coordinate transformation cycles for


controlling swivel heads and tilting tables. The offset of the tilting
axes and the tool lengths are compensated by the TNC.
The TNC can manage more than one machine configuration (e.g.
different swivel heads). The machine configurations are switched
via the PLC. The change in the dimensions of the swivel head or
tilting table caused by a rise in temperature can be compensated
by the iTNC 530.

Tilting table
Swivel head

5-axis machining
(option 9)

Tool Center Point Management (TCPM)


The offset of the tilting axes is compensated so that the tool
tip remains on the contour. Handwheel commands can also be
superimposed during machining without moving the tool tip from
the programmed contour.

Synchronized
axes

Synchronized axes move in synchronism


and are programmed with the same axis
designation.
With HEIDENHAIN controls, parallel
axis systems (gantry axes) such as on
portal-type machines or tilting tables
can be moved synchronously to each
other through high-accuracy and dynamic
position control.
With gantry axes more than one slave axis
can be assigned to one master gantry axis.
They may also be distributed to several
controller units.

57

Torque control

Torque control is used on machines with


mechanically coupled motors for which
 a defined distribution of drive torque is
desired,
or
 parts of the controlled system show a
backlash effect that can be eliminated
by "tensioning" the servo drives. (e.g.
toothed racks)
For torque control, the master and slave
must be on the same motherboard
(DSP). Depending on the controller unit
being used, up to five slave axes can be
configured for each master in this manner.

PLC axes

58

Axes can be controlled by the PLC. They


are programmed through M functions or
OEM cycles. The PLC axes are positioned
independently of the NC axes and are
therefore designated as asynchronous
axes.

Spindle

Overview

The iTNC 530 contouring control is used in connection with the


HEIDENHAIN inverter systems with field-oriented control. As an
alternative, an analog nominal speed value can be output.

Controller unit

With the CC controller units and the UEC/UMC inverters, a PWM


basic frequency can be set for each controller assembly (e.g.
4 kHz). Possible basic frequencies are 3.33 kHz, 4 kHz or 5 kHz.
The Double Speed option (option 49) can double this frequency
for high-speed spindles (e.g. 8 kHz for HF spindles). See Technical
Manual.

Controller groups

For example with CC 6106


1: X51 + X52
2: X53 + X54
3: X55 + X56

Maximum spindle
speed

The maximum spindle speed is calculated as follows:


nmax =
fPWM =
NPP =



 

 
 

PWM frequency in Hz
No. of pole pairs

Operating mode
switchover

For controlling the spindle (e.g. for wye/delta connection), two


parameter sets can be stored. You can switch between the two
parameter sets in the PLC.

Positioncontrolled spindle

The position of the spindle is monitored by the control.

Encoder

HEIDENHAIN rotary encoder with sinusoidal voltage signals (1 VPP)


or EnDat interface.

Tapping

There are special cycles for tapping with or without floating tap
holder. For tapping without floating tap holder, the spindle must be
operated under position control.

Oriented spindle
stop

With a position-controlled spindle, the spindle can be positioned


exactly to 0.1.

Spindle override

0 to 150%

Gear ranges

A specific nominal speed can be defined for each of the eight gear
ranges. The gear code is output via the PLC.

Second spindle

Up to two spindles can be alternately controlled. You can switch


from spindle 1 to spindle 2 through the PLC. Because the second
spindle is controlled instead of an axis, the number of available
axes is reduced by one.

Milling-head
change

The iTNC 530 can manage various milling-head descriptions. You


program the milling-head change in the integrated PLC.

59

Encoders

Overview

For speed and position control of the axes and spindle,


HEIDENHAIN offers both incremental and absolute encoders.

Incremental
encoders

Incremental encoders have as measuring standard a grating


consisting of alternate lines and spaces. Relative movement
between the scanning head and the scale causes output of
sinusoidal scanning signals. The measured value is calculated from
these signals.

Reference mark

When the machine is switched on, the machine axes need to


traverse a reference mark to establish an accurate connection
between measured value and machine position. For encoders
with distance-coded reference marks, the maximum travel until
automatic reference mark evaluation for linear encoders is only
20 mm or 80 mm, depending on the model, or 10 or 20 for angle
encoders.

Reference mark
evaluation

The routine for traversing the reference marks can also be started
for specific axes via the PLC during operation (reactivation of
parked axes).

Output signals

Incremental encoders with sinusoidal output signals with levels


1 VPP are suitable for connection to HEIDENHAIN numerical
controls.

Absolute
encoders

With absolute encoders, the position information is contained


in several coded tracks. Thus, an absolute reference is available
immediately after switch-on. Reference-mark traverse is not
necessary. Additional incremental signals are output for highly
dynamic control loops.

EnDat interface

The iTNC 530 features the serial EnDat 2.2 interface (includes
EnDat 2.1) for the connection of absolute encoders.
Note: The EnDat interface on HEIDENHAIN encoders differs in
its pin assignment from the interface on Siemens motors with
integrated absolute ECN/EQN rotary encoders. Special adapter
cables are available.

Encoder inputs

Incremental and absolute linear, angle or rotary encoders from


HEIDENHAIN can be connected to all position encoder inputs of
the controller unit.
Incremental and absolute rotary encoders from HEIDENHAIN can
be connected to all speed encoder inputs of the controller unit.
Signal level/
Interface1)

Input frequency1)
Position

Shaft speed

Incremental signals

1 VPP

33 kHz/350 kHz

350 kHz

Absolute position values


Incremental signals

EnDat 2.22)/02
1 VPP

33 kHz/350 kHz

350 kHz

Absolute position values

EnDat 2.22)/22

Inputs

1)
2)

60

Switchable
Includes EnDat 2.1

Digital servo control

Integrated inverter

Position controllers, speed controllers, current controllers


and inverters are integrated in the iTNC 530. HEIDENHAIN
synchronous or asynchronous motors are connected to the
iTNC 530.

Axis feedback
control

The iTNC 530 can be operated with following error or feedforward


control. During roughing operations at high speeds, for example,
you can switch to velocity semi-feedforward control via an OEM
cycle in order to machine faster at reduced accuracy.

Servo control
with following
error

The term following error denotes the distance between the


momentary nominal position and the actual position of the axis.
The velocity is calculated as follows:
v = kv sa

v
kv
sa

= velocity
= position loop gain
= following error

Servo control
with feedforward

Feedforward means that the speed and the acceleration are


adjusted to fit the machine. Together with the values calculated
from the following error, it forms the nominal value. This greatly
reduces the following error (to within a few m).

Compensation of
torque ripples

The torque of synchronous, torque and linear motors is subject


to periodic oscillations, one cause of which can be permanent
magnets. The amplitude of this torque ripple depends on the
motor design, and under certain circumstances can have an
effect on the workpiece surface. After the axes have been
commissioned with the TNCopt software, the Torque Ripple
Compensation (TRC) of the CC 61xx or UEC 11x can be used to
compensate it.

61

The cycle time for path interpolation is defined as the time


interval during which interpolation points on the path are
calculated. The cycle time for fine interpolation is defined as
the time interval during which interpolation points are calculated
that lie between the interpolation points calculated for path
interpolation. The cycle time for the position controller is defined
as the time interval during which the actual position value is
compared to the calculated nominal position value. The speed
controller cycle time is the time interval in which the actual
speed value is compared to the calculated nominal speed value.
The cycle time for the current controller is defined as the time
interval during which the actual current value is compared to the
calculated nominal current value.
CC/UEC/UMC
Path interpolation

3 ms

Fine interpolation

0.2 ms/0.1 ms1)

Position controller

0.2 ms/0.1 ms2)

Speed controller

0.2 ms/0.1 ms1)

Current controller

0.1 ms at fPWM = 5000 Hz

1)
2)

Double-speed (with option 49) without position encoder


Single-speed/double-speed (with option 49)

Axis clamping

The control loop can be opened through the PLC in order to clamp
specific axes.

Double-speed
control loops
(option 49)

Double-speed control loops permit higher PWM frequencies as


well as shorter cycle times of the speed controller. This makes
improved current control for spindles possible, and also higher
control performance for linear and torque motors.

Jerk

The derivative of acceleration is referred to as jerk. A linear change


in acceleration causes a jerk step. Such motion sequences may
cause the machine to oscillate.

Jerk limiting

To prevent machine oscillations, the jerk is limited to attain


optimum path control.

Jerk smoothing

The jerk is smoothed by nominal position value filters. The


iTNC 530 therefore mills smooth surfaces at the highest possible
feed rate and yet keeps the contour accurate. The operator
programs the permissible tolerance in a cycle. Special filters for
HSC machining (HSC filters) can specifically suppress the natural
frequencies of an individual machine. The desired accuracy and a
very high surface quality are attained.

62

Position

Control loop cycle


times

Time

Fast contour milling

Short block
processing time

The iTNC 530 provides the following important features for fast
contour machining:
The block processing time of the MC 6xxx/MC 7222 is 0.5 ms.
This means that the iTNC 530 is able to run long programs from
the hard disk, even with contours approximated with linear
segments as small as 0.2 mm, at a feed rate of up to 24 m/min

Look-ahead

The iTNC 530 calculates the geometry ahead of time in order to


adjust the feed rate (max. 1024 blocks). In this way directional
changes are detected in time to accelerate or decelerate the
appropriate NC axes.

Spline
interpolation
(option 9)

If your CAD system describes contours as splines, you can


transfer them directly to the iTNC 530. The iTNC 530 features a
spline interpolator, with which third-degree polynomials can be
processed.

Dynamic
Efficiency

With the concept of Dynamic Efficiency, HEIDENHAIN offers


innovative TNC functions that help the user to make heavy
machining and roughing more efficient while also enhancing its
process reliability. Dynamic Efficiency permits higher removal
rates and therefore increases productivity without making the
user resort to special tools. At the same time, it prevents any tool
overloading and the concomitant premature cutter wear. Dynamic
Efficiency comprises three software TNC functions:

 Active Chatter Control (ACC): This option reduces chatter


tendencies and permits greater infeeds

 Adaptive Feed Control (AFC): This option controls the feed rate
depending on the machining situation

 Trochoidal milling: A function for the roughing of slots and


pockets that eases the load on the tool
Each solution in itself offers decisive advantages in the machining
process. But the combination of these TNC features, in particular,
exploits the potential of the machine and tool and at the same
time reduces the mechanical load.

63

Adaptive Feed
Control (AFC)
(option 45)

With Adaptive Feed Control (AFC), the contouring feed rate is


regulated depending on the respective spindle power in percent.
Benefits of adaptive feed control:

 Optimization and reduction of machining time


 Tool monitoring
 Protection of the machine mechanics
 Documentation by capturing and saving the learning and

100%

process data

 Integrated NC function, and therefore an alternative to external


software solutions

 Already existing NC programs can be used


Restrictions:
AFC cannot be used for analog spindles or in volts-per-hertz control
mode.
Active Chatter
Control (ACC)
(option 145)

Strong milling forces come into play during heavy machining


roughing at high cutting speed. Depending on the tool spindle
speed, the resonances in the machine tool and the chip volume
(metal-removal rate during milling), the tool can sometimes begin
to chatter. This chattering places heavy strain on the machine,
and causes ugly marks on the workpiece surface. The tool, too,
is subject to heavy and irregular wear from chattering. In extreme
cases it can result in tool breakage. To reduce the inclination to
chattering, HEIDENHAIN now offers an effective antidote with
the Active Chatter Control (ACC) option. The use of this option
is particularly advantageous during heavy cutting. ACC makes
substantially higher metal removal rates possibledepending
on the machine model the metal removal rate increases by 25%
and more. You reduce the mechanical load on the machine and
increase the life of your tools at the same time.

Top: Part milled with ACC


Bottom: Part milled without ACC

64

Monitoring functions

Description

During operation the control monitors:

 Amplitude of the encoder signals


 Edge separation of the encoder signals
 Absolute position for encoders with distance-coded reference
marks

 Current position (following error monitoring)


 Actual path traversed (movement monitoring)
 Position deviation at standstill
 Nominal speed value
 Checksum of safety-related functions
 Supply voltage
 Buffer battery voltage
 Operating temperature of the MC and CPU
 Run time of the PLC program
 Motor current and temperature
 Temperature of power module
 DC-link voltage
With EnDat 2.2 encoders:
 CRC checksum of the position value
 EnDat alarm Error1 EnDat status alarm register (0xEE)
 EnDat alarm Error2
 Edge speed of 5 s
 Transmission of the absolute position value on the time grid
In the case of hazardous errors, an EMERGENCY STOP message
is sent to the external electronics via the control-is-ready output,
and the axes are brought to a stop. The correct connection of the
iTNC 530 in the machines EMERGENCY STOP loop is checked
when the control system is switched on. In the event of an error,
the control displays a message in plain language.
Dynamic Collision
Monitoring (DCM)
(option 40)

The TNC features a Dynamic Collision Monitoring (DCM) software


option for cyclically monitoring the working space of the machine
for possible collisions with machine components. The machine
manufacturer must define three-dimensional collision objects
within the working space of the machine that are to be monitored
by the TNC during all machine motions, including those made
by swivel heads and tilting tables. If two objects monitored
for collision come within a defined distance of each other, the
TNC outputs an error message. At the same time, the machine
components concerned are shown in red color in the machine
display. Dynamic collision monitoring is active in both the manual
operating modes as well as the machine operating modes, and is
indicated by a symbol in the operating mode display.
Please note:
 Only the machine manufacturer can define collision objects
(including clamping fixtures).
 Collisions between machine components (such as swivel heads)
and the workpiece cannot be detected.
 In servo-lag operation (no feedforward), an oversize must be
taken into account for the collision objects.
 Checking for collision is not possible in the Test Run mode.
Collision monitoring also protects fixtures and tool carriers from
collisions. These can be selected from a library, adapted and
inserted in the machines kinematics model.
The 3-D collision objects are configured with the commissioning
software KinematicsDesign.

65

Context-sensitive
help

The HELP and ERR keys provide the user with context-sensitive
help. This means that in the event of an error message, the control
displays information on the cause of the error and proposes
solutions. The machine tool builder can also use this function for
PLC error messages.

KinematicsDesign
(accessory)

KinematicsDesign is a PC program for creating adaptable


kinematic configurations. It supports:
 Complete kinematic configurations
 Transfer of configuration files between control and PC
When used with the iTNC 530, KinematicsDesign provides further
conveniences:
 Assignment table
 Kinematics description table
 Kinematics subfile description table
 Tool-carrier kinematics description table
 Definition table for collision-monitored objects (CMO)
 Initial and subsequent configuration of Dynamic Collision
Monitoring (DCM; option 40)
If KinematicsDesign is connected with a control online (operation
is also possible with the programming station software), then
machine movements can be simulated graphically along with axis
traverse. With the iTNC 530, when DCM is active the working
space is also simulated and any collisions or collision-endangered
components of defined objects are displayed in a definable color.
Depending on the control involved, the visualization capabilities
range from the pure depiction of the transformation sequence to
wire models or, on the iTNC, to a complete representation of the
working envelope.

66

Error compensation

Overview

The iTNC 530 automatically compensates mechanical errors on


the machine.

Linear error

Linear error can be compensated over the entire travel range for
each axis.

Nonlinear error

The iTNC 530 can compensate for ball-screw pitch errors and sag
errors simultaneously. The compensation values are stored in a
table.

Backlash

The play between table movement and rotary encoder


movement on direction changes can be compensated in length
measurements by spindle and rotary encoder. This backlash is
outside the controlled system.

Hysteresis

The hysteresis between table movement and motor movement is


also compensated in direct length measurements. In this case the
hysteresis is within the controlled system.

Reversal spikes

In circular movements, reversal spikes can occur at quadrant


transitions due to mechanical influences. The iTNC 530 can
compensate for these reversal spikes.

Stick-slip

At very low feed rates, high static friction can cause the slide to
stop and start repeatedly for short periods. This is commonly
known as stick-slip. The iTNC 530 can compensate for this
problem condition.

Sliding friction

Sliding friction is compensated by the speed controller of the


iTNC 530.

Thermal
expansion

To compensate thermal expansion, the machines expansion


behavior must be known.
The temperature can be recorded via thermistors connected to the
analog inputs of the iTNC 530. The PLC evaluates the temperature
information and transfers the compensation value to the NC.

KinematicsOpt
(option 48)

Using the KinematicsOpt function, machine tool builders or


end users can check the accuracy of rotary or swivel axes, and
compensate for possible displacements of the center of rotation
of these axes. The deviations are automatically transferred to
the kinematics description and can be taken into account in the
kinematics calculation.
In order to measure the rotary axes, you must attach a calibration
sphere (e.g. KKH 100 or KKH 250 from HEIDENHAIN) at any
position on the machine table. A HEIDENHAIN touch probe uses
a special cycle to probe this calibration sphere, and measures the
rotary axes of the machine fully automatically. But first you define
the resolution of the measurement and define for each rotary axis
the range that you want to measure. The results of measurement
are the same regardless of whether the axis is a rotary table, a
tilting table or a swivel head.

67

Calibration
sphere
(accessory)

HEIDENHAIN offers calibration spheres as accessories


for the measurement of rotary axes with KinematicsOpt:
KKH 100
KKH 250

KinematicsComp
(option 52)

Height 100 mm
Height 250 mm

ID 655475-02
ID 655475-01

Narrow workpiece tolerances require high machine accuracy.


However, machine tools inevitably have errors resulting from their
assembly or the design.
The more axes a machine has, the more sources of errors
there are. For example, according to ISO 230-1, a linear axis can
have six types of error, and a rotary axis can have eleven. The
use of mechanical means to cope with these errors requires
considerable effort. These errors become particularly evident on 5axis machines or very large machines. Thermal expansion that can
cause highly complex geometry changes of machine components
cannot be disregarded either.
The KinematicsComp function (option 52) enables the machine
tool builder to improve machine accuracy considerably.
The machines degrees of freedom and the positions of the
centers of rotation of the rotary axes are described in the standard
kinematics of the iTNC 530. The expanded kinematics description
of KinematicsComp permits the import of compensationvalue tables. Most of the geometry errors of a machine can be
described in compensation-value tables. They are compensated
in such a way that the tool center point follows exactly the ideal
nominal contour. Thermally induced errors are also measured and
compensated via sensors and the PLC.

Fault characteristics according to ISO 230-1: EBA

For example, the spatial errors of the tool tip are measured with a
laser tracer or laser interferometer.
The KinematicsComp option cannot be enabled for the export
versions.

Fault characteristics according to ISO 230-1: EXA

68

Dynamic Precision

The hypernym Dynamic Precision stands for a number of


HEIDENHAIN solutions for milling that dramatically improve the
dynamic accuracy of a machine tool. The dynamic accuracy of
machine tools can be seen in position errors at the Tool Center
Point (TCP), which depend on the motion quantities such as
velocity and acceleration (also jerk) and result from vibrations
of machine components and other causes. All the deviations
are together responsible for dimensional errors and faults in the
workpiece surface. They therefore have a decisive influence
on quality and, when poor-quality parts are scrapped, also on
productivity.
Because the stiffness of machine tools is limited for reasons of
design and economy, problems such as compliance and vibration
within the machine design are very difficult to avoid. Dynamic
Precision counteracts these problems with intelligent control
technology to enable designers to further improve the quality
and dynamic performance of machine tools. That saves time and
money in production.
The machine tool builder can use the options comprised by
Dynamic Precision either individually or in combination:

 CTC Compensates acceleration-dependent position errors at






Cross Talk
Compensation
(CTC)
(option 141)

the tool center point, thereby increasing accuracy in acceleration


phases
AVD Active vibration damping improves surfaces
PAC Position-dependent adaptation of control parameters
LAC Load-dependent adaptation of control parameters
enhances accuracy regardless of load and aging
MAC Motion-dependent adaptation of control parameters

CTC (option 141) makes it possible to compensate dynamic


position deviations that can occur with the use of coupled axes.
To increase productivity, machine tool users are asking for ever
higher feed rates and acceleration values, while at the same time
they need to maintain the highest possible surface quality and
accuracy, placing very special requirements on path control.
Highly dynamic acceleration processes introduce forces to the
structure of a machine tool. They can deform parts of the machine
and thereby lead to deviations at the tool center point (TCP).
Besides deformation in axis direction, the dynamic acceleration
of an axis due to mechanical axis coupling can also result in
deformation of axes that are perpendicular to the direction of
acceleration. The resulting position error at the TCP in the direction
of the accelerated axis and lateral axes is proportional to the
amount of acceleration.
If the dynamic position error as a function of the axis acceleration
is known, this acceleration-dependent error can be compensated
with the CTC option (Cross Talk Compensation) in order to
prevent negative effects on the surface quality and accuracy of
the workpiece. Often, the resulting error at the TCP depends not
only on the acceleration but also on the position of the axes in
the working space. This can also be compensated by the control
option CTC.

69

Active Vibration
Damping (AVD)
(option 146)

The high dynamics of modern machine tools lead to deformations


in the machine base, frame and drive train during acceleration and
deceleration of the feed drives. This results in vibrations, such as
machine setup vibrations, that may reduce the attainable accuracy
and surface quality of the workpieces. The Active Vibration
Damping (AVD) controller function dampens the especially critical
low-frequency oscillations and optimizes the control behavior
of the affected axis at the same time so that high-accuracy
workpieces with increased surface quality can also be produced
at high feed rates. The improved rigidity attained can be used to
increase the dynamic limit values (e.g. jerk), and therefore makes
reduced machining times possible.

Position Adaptive
Control (PAC)
(option 142)

Option 142, PAC, permits dynamic and position-dependent


adaptation of controller parameters depending on the position of
the tool in space.
The specifics of a machines kinematics cause a unique position
of the axes center of gravity in the working space. This results in
a variable dynamic behavior of the machine, which can negatively
influence the controls stability depending on the axis positions.
To exploit the machines dynamic possibilities, you can use
the PAC option (Position Adaptive Control) to change machine
parameters depending on position. This makes it possible to
assign the respectively optimal loop gain to defined support
points. Additional position-dependent filter parameters can be
defined in order to further increase control loop stability.

Load Adaptive
Control (LAC )
(option 143)

LAC (option 143) enables you to adapt controller parameters


dynamically depending on the load or friction.
The dynamic behavior of machines with rotary tables can vary
depending on the mass moment of inertia of the fixed workpiece.
The LAC option (Load Adaptive Control) enables the control to
automatically ascertain the workpieces current mass moment of
inertia and the friction forces.
In order to optimize changed control behavior at differing loads,
adaptive feedforward controls can exploit data on acceleration,
holding torque, static friction and friction at high shaft speeds.

70

Motion Adaptive
Control (MAC)
(option 144)

In addition to the position-dependent adjustment of machine


parameters by the PAC option, the MAC option (Motion Adaptive
Control) also provides a way to change machine parameter values
depending on other input quantities such as velocity, following
error or acceleration of a drive. Through this motion-dependent
adaptation of the control parameters it is possible, for example,
to realize a velocity-dependent adaptation of the control loop gain
on motors whose stability changes through the various traversing
velocities.

Crossover Position
Filter (CPF)

To increase the stability of the position control loop in systems


with resonances, the position signal from the position encoder,
which is filtered through a low-pass filter, is combined with the
position signal from the motor speed encoder, which is filtered
through a high-pass filter. This signal combination is made available
to the position controller as actual position value. This results in
a significant increase in the possible position controller gain (kV
factor). The filter separation frequency is set specifically for each
axis via machine parameters. The CPF can be used only in dualencoder systems, i.e. on drive motors with speed encoder and
position encoder.

71

Commissioning and diagnostic aids

Overview

The iTNC 530 provides comprehensive internal commissioning


and diagnostic aids. It also includes highly effective PC software
for diagnosis, optimization and remote control.

Diagnostic
function

The integral diagnostic function permits:


 Display and evaluation of internal control statuses
 Display and evaluation of status signals of the inverter
components

Electronic ID label

Various HEIDENHAIN components feature an electronic ID label


to simplify commissioning and diagnostics. The information, such
as model designation, ID number or serial number, stored in this
ID label can be read by the iTNC 530, or the DriveDiag or TNCopt
software for PCs.
The diagnostic function of the iTNC 530 is especially user friendly.
It automatically recognizes the motor type and, if required,
updates the machine parameter entry every time it is switched on.

DriveDiag

DriveDiag permits quick and easy troubleshooting of the drives.


The following diagnostic functions are available:
 Reading and displaying the electronic ID labels of QSY motors
with EQN 13xx or ECN 13xx as well as the inverter modules
UVR 1xxD and UM 1xxD
 Displaying and evaluating the internal control conditions and the
status signals of the inverter components
 Displaying the analog values available to the drive controller
 Automatic test for proper function of motors and inverters, of
position encoders and speed encoders
DriveDiag can be called directly from the control via the Diagnosis
soft key. It is also available for downloading as PC software
(accessory) from the HESIS Web Including FileBase on the
Internet. End users have read-access, whereas the code number
for the machine tool builder gives access to comprehensive
testing possibilities with DriveDiag.

TNCopt
(accessory)

Requirements

72

PC software for commissioning digital control loops


Functions:
 Commissioning the current controller
 (Automatic) commissioning of the speed controller
 (Automatic) optimization of sliding-friction compensation
 (Automatic) optimization of the reversal-spike compensation
 (Automatic) optimization of kV factor
 Circular interpolation test, contour test

DriveDiag and TNCopt place the following demands on the PC:

 Windows 2000/XP/Vista/7 operating system


 At least 15 MB of free hard-disk space
 Serial or Ethernet interface

Oscilloscope

The iTNC 530 features an integrated oscilloscope. Both X/t and


X/Y graphs are possible. The following characteristic curves can be
recorded and stored in six channels:
 Actual value and nominal value of the axis feed rate
 Contouring feed rate
 Nominal and actual position
 Following error of the position controller
 Nominal values for speed, acceleration and jerk
 Content of PLC operands
 Encoder signal (0 A) and (90 B)
 Difference between position and speed encoder
 Nominal velocity value
 Integral-action component of the nominal current value
 Torque-determining nominal current value

Logic signals

Simultaneous graphic representation of the logic states of up to


16 operands (markers, words, inputs, outputs, counters, timers)
 Marker (M)
(I)
 Input
 Output (O)
 Timer (T)
 Counter (C)
 IpoLogik (X)

TNCscope
(accessory)

PC software for transferring the oscilloscope files to a PC.


With TNCscope you can record and save up to 16 channels
simultaneously.

Logic diagram

Simultaneous graphic representation of the logic states of up to


16 operands (markers, words, inputs, outputs, counters, timers)

Table function

The current conditions of the markers, words, inputs, outputs,


counters and timers are displayed in tables. The conditions can be
changed through the keyboard.

Trace function

The current content of the operands and the accumulators is


shown in the statement list in each line in HEX or decimal code.
The active lines of the statement list are marked.

Log

For the purposes of error diagnostics, all error messages and


keystrokes are recorded in a log. The entries can be read using the
PLCdesign or TNCremo software for PCs.

TeleService
(accessory)

PC software for remote diagnostics, remote monitoring and


remote operation of the control. For more information, please ask
for the Remote Diagnosis with TeleService Technical Information
sheet.

Bus diagnosis

In Diagnosis mode, the structure of the HSCI/PROFIBUS system


as well as the details of the HSCI/PROFIBUS components can be
displayed in a clearly laid out screen. For HSCI components this is
possible even to the level of individual terminals.

73

Integrated PLC

Overview

The PLC program is created by the machine manufacturer either


at the control or with the PLC development software PLCdesign
(accessory). Machine-specific functions are activated and
monitored via the PLC inputs/outputs. The number of PLC inputs/
outputs required depends on the complexity of the machine.

PLC inputs/
outputs

PLC inputs and outputs are available via the external PL 6000 PLC
input/output systems or the UEC 11x. The PLC inputs/outputs and
the PROFIBUS-DP-capable I/O system must be configured with
the IOconfig PC software.

PLC programming

Format

Statement list

Memory

1 GB

Cycle time

Typically 21 ms, adjustable

Command
set

Encryption of
PLC data

 Bit, byte and word commands


 Logical operations
 Arithmetic commands
 Comparisons
 Nested calculations (parentheses)
 Jump commands
 Subprograms
 Stack operations
 Submit programs
 952 timers
 48 counters
 Comments
 PLC modules
 100 strings

Encrypting the PLC partition (PLCE:) is an effective tool for the


machine tool builder to prevent third parties from viewing or
changing files.
The files on the PLCE partition can only be read by the TNC or by
using the correct OEM keyword.
This ensures that OEM-specific know-how and special customdesigned solutions cannot be copied or changed.
The machine tool builder can also determine the size of the
encrypted partition. The size is defined by the machine tool builder
when the PLCE partition is created. Another advantage is that the
data can be backed up from the control to a separate data carrier
(USB drive, network e.g. via TNCremo) in spite of the encryption,
and can later be uploaded again. You need not enter the password,
but the data cannot be read until the keyword is supplied.

74

PLC window

PLC error messages can be displayed by the TNC in the dialog line
during operation.

Small PLC window

The TNC can show additional PLC messages and bar diagrams in
the small PLC window.

Small PLC window

Large PLC window

A complete PLC page can be shown as a window. PLC messages


and graphics can be displayed.

PLC soft keys

With the BF 750, the machine tool builder can define his own
soft keys on the screen, instead of the horizontal NC soft keys. In
addition, he can define his own PLC soft keys in the vertical softkey row.
The BF 760 also features soft keys on the left of the screen. Selfdefined soft keys can be shown there as required.

PLC positioning

All closed-loop axes can be also positioned


via the PLC. PLC positioning of the NC
axes cannot be superimposed on NC
positioning.

PLC axes

Axes can be controlled by the PLC. They are programmed


by M functions or OEM cycles. The PLC axes are positioned
independently of the NC axes.

75

PLCdesign
(accessory)

PC software for PLC program development.


The PC program PLCdesign can be used for easy creation of
PLC programs. Comprehensive examples of PLC programs are
included with the product.
Functions:

 Easy-to-use text editor


 Menu-guided operation
 Programming of symbolic operands
 Modular programming method
 Compiling and linking of PLC source files
 Operand commenting, creation of the documentation file
 Comprehensive help system
 Data transfer between the PC and control
 Creation of PLC soft keys
PC requirements:

 Windows 2000/XP/Vista/7 operating system


 At least 20 MB free memory on the hard disk
 Serial interface; Ethernet interface recommended
 Internet Explorer
Python OEM
Process
(option 46)

The Python OEM Process option is an effective tool for the


machine tool builder to use an object-oriented high-level
programming language in the control (PLC). Python is an easy-tolearn script language that supports the use of all necessary highlevel language elements.
Python OEM Process can be universally used for machine
functions and complex calculations, as well as to display special
user interfaces. User-specific or machine-specific solutions can be
efficiently implemented. Numerous libraries on the basis of Python
and GTK are available, regardless of whether you want to create
special algorithms for special functions, or separate solutions such
as an interface for machine maintenance software.
The applications created can be included via the PLC in the familiar
PLC windows, or they can be displayed in separate free windows
that can be expanded to the controls full screen size.

76

PLC basic
program

The PLC basic program serves as a basis for adapting the


control to the requirements of the respective machine. It can be
downloaded from the Internet.
These essential functions are covered by the PLC basic program:

 Controlling all axes


 Clamped axes
 Homing the axes; reference end positions
 Positioning the axes after reference run
 Compensating the axis temperature
 Switching the traverse ranges
 Alternating table operation
 Feed rate control
 Controlling and orienting the spindle
 Activating tool-specific torque monitoring
 Tool changer
 Pallet changer (translational, rotatory, setup functions)
 Vertical PLC soft-key row
 Support for 19 screens
 Displaying and managing PLC error messages
 Status display in the small PLC window
 Hydraulic control
 Control of the coolant system (internal, external, air)
 M functions
 Lubrication
 Chip conveyor
 Operation of the second spindle alternately with the first
 Wye/delta connection switchover (static, dynamic)
 S-coded spindle
 3-D head with C-axis operation
 3-D head change
 Positioning the spindle as an axis
 Operation with clamped axes
 Axes with central drive
 Axes with Hirth grid
 Indexing fixture
 PLC log
 Touch probes
 PLC support for handwheels
 Control of doors
 Support for IPC 61xx

77

Interfacing to the machine

OEM cycles

The machine tool builder can create and store his own cycles for
recurring machining tasks. These OEM cycles are used in the
same way as standard HEIDENHAIN cycles.

CycleDesign
(accessory)

The soft-key structure for the cycles is managed using the


CycleDesign PC program. In addition, CycleDesign can be used to
store help graphics and soft keys in BMP format in the TNC.

OEM options
(options 101 to 130)

The machine tool builder can enable his own developments by


using the HEIDENHAIN option management in the SIK menu of
the control. Thirty OEM options are available that can be enabled
separately with a HEIDENHAIN keyword just as any normal
option.
These options are requested, for example, by OEM cycles or PLC
modules that are ideally stored on the encrypted PLCE partition of
the control.
Another advantage is that options can be enabled with the
Software Key Generator for a limited time for testing.

Tool management

With integral PLC, the tool changer is moved either via proximity
switch or as a controlled axis. Tool management including tool life
monitoring and replacement tool monitoring is carried out by the
iTNC 530.

Tool measurement

Tools can be measured and checked using the TT or TL tool


touch probes (accessory). The control features standard cycles for
automatic tool measurement. The control calculates the probing
feed rate and the optimal spindle speed. The measured data is
stored in a tool table.

Cutting data calculation

The user selects the material used and the tool. The optimal
values for feed rate and spindle speed are then calculated by the
iTNC 530. All of this data is stored in cutting data tables and can
be adapted by the user as he wishes.

Pallet
management

Pallet movement can be controlled via PLC


axes. The order of movement, as well as
pallet and workpiece datums, must be
defined in the pallet table by the user. The
pallet tables are freely configurable, which
means that any information can be stored
in the tables and called up later by the
PLC. The execution of pallet tables can be
oriented to the workpiece or the tool.

78

Data transfer and communication


Data interfaces

Overview

The iTNC 530 is connected to PCs, networks and other data


storage devices via data interfaces.

Ethernet

The iTNC 530 can be interconnected via the Ethernet interface.


The control features a 1000BASE-T (Twisted Pair Ethernet)
connection to the data network.
Maximum transmission distance:
Unshielded 100 m
Shielded 400 m

Protocol

The iTNC 530 communicates using the TCP/IP protocol.

Network connection

 NFS file server


 Windows networks (SMB)

Data transfer rate

Approx. 400 to 800 Mbit/s (depending on file type and network


utilization)

RS-232-C/V.24

Data interface according to DIN 66 020 or EIA standard RS-232-C.


Maximum transmission distance: 20 m

Data transfer rate

115 200; 57 600; 38 400; 19 200; 9600; 4800; 2400; 1200; 600;
300; 150; 110 Bit/s

Protocols

The iTNC 530 can transfer data using various protocols.

Standard data
transfer

The data is transferred character by character. The number of data


bits, stop bits, the handshake and character parity must be set by
the user.

Blockwise data
transfer

The data is transferred blockwise. A block check character (BCC) is


used to ensure data integrity. This method improves data security.

LSV2

Bidirectional transfer of commands and data as per DIN 66 019.


Before being transferred the data are split into telegrams (blocks).

Adapter block

For connecting the interface to the electrical cabinet or operating


panel
RS-232-C/V.24 adapter

9-pin
25-pin

ID 363987-02
ID 310085-01

USB

The MC 7xxx features two USB 3.0 ports for the connection
of standard USB devices, such as the mouse, drives, etc. One
of them is led to the BF or TE. There the user has an easily
accessible USB interface. The integrated USB hub on the rear of
the screen has further USB ports. The USB ports are rated for a
maximum of 0.5 A.

USB cable

Cable length up to 5 m
Cable length 6 m to 30 m with integrated
amplifier; USB 1.1.

ID 354770-xx
ID 624775-xx

79

USB hub

If you need further USB ports or if the supply current is not


sufficient, a USB hub is required. The USB hub from HEIDENHAIN
offers four free USB ports.
USB hub
Power supply 24 V DC / max. 300 mA

Cover

ID 582884-02

The USB hub can be installed in the operating panel in such a


way that two USB ports can be accessed from the outside. An
optionally available cover cap can be used to protect the ports
from contamination.
Cover

ID 508921-01

Software for data


transfer

To transfer files between the iTNC 530 and PC, we recommend


using HEIDENHAIN software.

TNCremo
(accessory)

This PC software package helps the user to transfer data from


the PC to the control. The software transfers data blockwise with
block check characters (BCC).
Functions:

 Data transfer (also blockwise)


 Remote control (only serial)
 File management and data backup of the control
 Reading out the log
 Print-out of screen contents
 Text editor
 Managing more than one machine
Requirements:
 Windows 2000/XP/Vista/7 operating system
 At least 10 MB free hard-disk space
 Serial or Ethernet interface
TNCremoPlus
(accessory)

In addition to the features you are already familiar with from


TNCremo, TNCremoPlus can also transfer the current content
of the controls screen to the PC (live screen). This makes it very
simple to monitor the machine.
TNCremoPlus

Remote Desktop
Manager
(option 133)

Remote operation and display of external computer units via


Ethernet connection (e.g. to a Windows PC). The information is
displayed on the controls screen.
Remote desktop manager

80

ID 340447-xx

ID 894423-01

DNC applications

Overview

The development environments on Windows operating systems


are particularly well suited as flexible platforms for application
development in order to come to terms with the increasingly
complex requirements of the machines environment. The
flexibility of the PC software and the large selection of ready-touse software components and standard tools in the development
environment enable you to develop PC applications of great use to
your customers in a very short time, for example:

 Error reporting systems that, for example, send the customer






a text message to his cell phone reporting problems on the


currently running machining process
Standard or customer-specific PC software that decidedly
increases process security and equipment availability
Software solutions controlling the processes of manufacturing
systems
Information exchange with job management software

HEIDENHAIN
DNC
(option 18)

The HEIDENHAIN DNC software interface is an attractive


communication platform for this purpose. It provides all the data
and configuration capabilities needed for these processes so that
an external PC application can evaluate data from the control and,
if required, influence the manufacturing process.

RemoTools SDK
(accessory)

To enable you to use HEIDENHAIN DNC effectively, HEIDENHAIN


offers the RemoTools SDK development package. It contains the
COM components and the ActiveX control for integration of the
DNC functions in development environments.
RemoTools SDK

ID 340442-xx

For more information, refer to the HEIDENHAIN DNC brochure.


virtualTNC
(accessory)

The virtualTNC control software is a control component for


virtual machines for machine simulations, and is available via the
HEIDENHAIN DNC interface.
Single station license
Network license For 14 workstations
For 20 workstations

ID 584421-01
ID 643492-01
ID 643494-01

For more information, refer to the HEIDENHAIN DNC brochure.

81

Mounting information
Clearances and mounting

Proper minimum
clearance

When mounting the control components,


please observe proper minimum
clearances, space requirements, length
and position of the connecting cables.





Leave space for air circulation and servicing

Mounting
and electrical
installation

82

Remember the following during mounting and electrical


installation:
 National regulations for power installations
 Interference and noise immunity
 Operating conditions
 Mounting attitude

Degrees of
protection

The following components fulfill the requirements for IP 54 (dust


protection and splash-proof protection):
 Visual display unit (when properly installed)
 Keyboard unit (when properly installed)
 Machine operating panel (when properly installed)
 Handwheel
All electric and electronic control components must be installed
in an environment (e.g. electrical cabinet, housing) that fulfills
the requirements of protection class IP 54 (dust and splash-proof
protection) in order to fulfill the requirements of contamination
level 2. All components of the OEM operating panel must also
comply with protection class IP 54, just like the HEIDENHAIN
operating panel components.

Electromagnetic
compatibility

Protect your equipment from interference by observing the rules


and recommendations specified in the Technical Manual.

Intended place of
operation

This unit fulfills the requirements for EN 50370-1 and is intended


for operation in industrially zoned areas.

Likely sources of
interference

Interference is produced by capacitive and inductive coupling into


electrical conductors or into device connections, caused by e.g.:
 Strong magnetic fields from transformers or electric motors
 Relays, contactors and solenoid valves
 High-frequency equipment, pulse equipment and stray magnetic
fields from switch-mode power supplies
 Power lines and leads to the above equipment

Protective measures

 Keep a minimum distance of 20 cm from the MC, CC and its


leads to devices that carry interference signals

 Keep a minimum distance of 10 cm from the MC, CC and its






leads to cables that carry interference signals. For cables in


metallic ducting, adequate decoupling can be achieved by using
a grounded separation shield.
Shielding according to EN 50 178
Use equipotential bonding conductors with a cross section of
6 mm2
Use only genuine HEIDENHAIN cables and connecting
elements

83

Overall dimensions
Main computer

MC 6441, MC 6541, MC 6641, IPC 6641

84

MC 6542

85

MC 7422, MC 7522

 

 
    



 
    

86

Controller unit

CC 6106

87

CC 6108, CC 6110

 










88

UEC 111, UEC 112, UEC 113

89

UMC 111

90

Monitor and keyboards

BF 760

 

 
    



 
    

91

TE 740


  
  

92

TE 745


  
  

93

BF 750

 

 
    



 
    

94

TE 720, TE 730
   
   

    
    

95

TE 735


  
  

96

MB 720

 

 
    

PLB 6001

97

PLC inputs and outputs

PL 6000 (PLB 62xx, PLB 61xx)

 

 


PL 550

 

 


98

Power supply units

PSL 130

PSL 135

99

Electronic handwheels

HR 410

Adapter cable for HR 410 and HR 520

 
  

 
   
 


100

HR 520

Mount for HR 520

101

HR 550 FS

HRA 551 FS

Tolerancing ISO 8015


ISO 2768 - m H
< 6 mm: 0.2 mm

102

HR 130, HR 150 with control knob

103

HRA 110

Step switch

104

Interface accessories

Line-drop compensator for encoders with EnDat interface



RS-232-C adapter

  


105

USB hub
 
 

  

USB extension cable with hubs

 

106

General information
Documentation

Technical
documentation

User
documentation

Other
documentation

 iTNC 530 HSCI Technical Manual


 Inverter Systems and Motors Technical Manual
 Functional Safety Technical Manual
 TS 230 Mounting Instructions
 TS 440 Mounting Instructions
 TS 444 Mounting Instructions
 TS 640 Mounting Instructions
 TS 740 Mounting Instructions
 TT 140 Mounting Instructions
 TT 449 Mounting Instructions
iTNC 530

ID 801739-xx; in PDF format on HESIS-Web


including Filebase
ID 208962-xx
ID 749363-xx
ID 312821-91
ID 632756-9x
ID 632757-9x
ID 632760-9x
ID 632761-9x
ID 297510-xx
ID 664914-xx

 Conversational Programming Users Manual


 Cycle Programming Users Manual
 DIN/ISO Users Manual
 smarT.NC Pilot

For NC software 34049x-xx


ID 670387-xx
ID 670388-xx
ID 670391-xx
ID 533191-xx

Miscellaneous
 TNCremo Users Manual
 TNCremoPlus Users Manual
 PLCdesign Users Manual
 CycleDesign Users Manual
 IOconfig Users Manual
 KinematicsDesign Users Manual

As integrated help
As integrated help
As integrated help
As integrated help
As integrated help
As integrated help

 iTNC 530 brochure


 Touch Probes brochure

Inverter Systems brochure


 Motors brochure
 IPC Product Information
 HEIDENHAIN DNC brochure
 Remote Diagnosis with TeleService Product Overview
 Touch Probes CD-ROM
 iTNC 530 Presentation CD-ROM
 iTNC Programming Station Demo Version CD-ROM
 HR 550FS Product Information
 Technical Information:
Safety-Related Control Technology
 Technical Information:
Safety-Related Position Measuring Systems
 Technical Information:
Uniformly Digital

ID 892921-xx
ID 208951-xx
ID 622420-xx
ID 208893-xx
ID 630601-xx
ID 628968-xx
ID 348236-xx
ID 344353-xx
ID 373080-xx
ID 384565-xx
PDF
PDF
PDF
PDF

107

Service and training

Technical support

HEIDENHAIN offers the machine manufacturer technical support


to optimize the adaptation of the TNC to the machine, including
on-site support.

Replacement
control system

In the event of a fault, HEIDENHAIN guarantees the rapid supply


of a replacement control system (usually within 24 hours in
Europe).

Hotline

Our service engineers are naturally at your disposal by telephone


if you have any questions on the interfacing of the control or in the
event of faults.
TNC support
PLC programming
NC programming
Measuring systems
Lathe controls

+49 8669 31-3101


E-mail: [email protected]
+49 8669 31-3102
E-mail: [email protected]
+49 8669 31-3103
E-mail: [email protected]
+49 8669 31-3104
E-mail: [email protected]
+49 8669 31-3105
E-mail: [email protected]

Machine
calibration

On request, HEIDENHAIN engineers will calibrate your machines


geometry, e.g. with a KGM grid encoder.

Seminars

HEIDENHAIN provides technical customer training in the following


subjects:
 NC programming
 PLC programming
 TNC optimization
 TNC service
 Encoder service
 Special training for specific customers
For more information on dates, registration, etc. call in Germany:
+49 8669 31-2293 or 31-1695
+49 8669 31-1999
E-mail: [email protected]
www.heidenhain.de

108

Other HEIDENHAIN controls


Examples

TNC 128

Information:
TNC 128 brochure

 Straight-cut control for milling machines


 Up to 5 axes and open-loop main spindle
 Analog command interface to the drives ( 10 V)
 Compact design: Screen, keyboard and computer all in one unit
 Dimensions: 400 mm x 450 mm x 91 mm
 Integral 12.1-inch TFT color flat-panel display
 Storage medium for NC programs: CompactFlash memory card
 Programming in HEIDENHAIN conversational format
 Standard milling, drilling and boring cycles
 Touch probe cycles
 Short block processing time
TNC 620

Information:
TNC 620 brochure

 Contouring control for milling machines


 Up to 5 axes and closed-loop main spindle
 HEIDENHAIN inverter systems and motors recommended
 Uniformly digital with HSCI interface and EnDat interface
 Compact design:








TNC 640

Screen, keyboard and main computer housed in one unit


(MC 7410)
Screen and main computer housed in one unit (MC 7420) and
separate keyboard with integrated ASCII keys
Dimensions: 400 mm x 470 mm x 100 mm (MC 7410)
Integrated 15-inch TFT color flat-panel display
Storage medium for NC programs: CompactFlash memory card
Programming in HEIDENHAIN conversational format or
according to DIN/ISO
Standard milling, drilling and boring cycles
Touch probe cycles
Short block processing time (1.5 ms)

Information:
TNC 640 brochure

 Contouring control for milling and milling/turning machines


 Up to 18 axes and closed-loop main spindle
 HEIDENHAIN inverter systems and motors recommended
 Uniformly digital with HSCI interface and EnDat interface
 TFT color flat-panel display, 19-inch or 15-inch
 Storage medium: HDR hard disk with 160 GB or SSDR solid
state disk with 32 GB

 Programming in HEIDENHAIN conversational format or


according to DIN/ISO

 Comprehensive cycle package for milling and turning operations


 Constant surface speed
 Tool-tip radius compensation
 Touch probe cycles
 FK free contour programming
 Special function for fast 3-D machining
 Short block processing time (0.5 ms)

109

Subject index

Dynamic Precision............................... 69

Jerk smoothing................................... 62

5-axis machining.................................. 57

Electromagnetic compatibility.............. 83
Electronic handwheels........................ 38
Empty housing.............................. 30, 31
Encoder inputs.................................... 60
Encryption of PLC data........................ 74
EnDat 2.2............................................ 52
Error compensation............................. 67
Ethernet.............................................. 79
Expansion PL...................................... 29
Export version..................................... 15

KinematicsComp................................. 68
KinematicsDesign................................ 66

Absolute encoders..............................
Accessories..................................... 5,
Active Chatter Control.........................
Active Vibration Damping.....................
Adaptive Feed Control (AFC)................
Additional modules..............................
Axes...................................................
Axis clamping......................................
Axis feedback control..........................

60
51
64
70
64
34
56
62
61

L
Linear axes..........................................
Linear error.........................................
Load Adaptive Control (LAC)................
Log.....................................................
Logic diagram......................................
Look-ahead..........................................

56
67
70
73
73
63

F
B
Backlash..............................................
Basic modules.....................................
BF 750.......................................... 27,
BF 760.......................................... 28,
Bus diagnosis......................................

67
29
94
91
73

C
Cable overview................................... 45
Calibration sphere................................ 68
CC 6106........................................ 22, 87
CC 6108.............................................. 22
CC 6108, CC 6110............................... 88
CC 6110.............................................. 22
CC 61xx.............................................. 22
CMA-H 02-00-04................................. 34
CMA-H 04-04-00................................. 34
CMD-H 24-12-00................................. 34
Commissioning and diagnostic aids...... 72
Compensation of torque ripples........... 61
Components......................................... 4
Connecting cable................................. 39
Context-sensitive help......................... 66
Controller unit..................................... 21
Control loop cycle times...................... 62
Crossover Position Filter (CPF)............. 71
Cross Talk Compensation (CTC)........... 69
Cycle times......................................... 21
Cylindrical surface interpolation............ 56

D
Data interfaces.................................... 79
Degrees of protection......................... 83
Diagnostic function.............................. 72
Digital control design........................... 52
Digital servo control............................ 61
Display step.......................................... 6
DNC applications................................. 81
Double speed...................................... 21
Double-speed control loops................. 62
DriveDiag............................................ 72
Dynamic Collision Monitoring.............. 65
Dynamic Efficiency.............................. 63

110

Fast contour milling.............................


Feature Content Level (FCL)................
Flat-panel display.................................
Functional safety.................................

63
18
27
53

G
Gantry axes......................................... 57
Gear ranges........................................ 59

H
HEROS 5............................................ 55
HR 130....................................... 40, 103
HR 150....................................... 40, 103
HR 410....................................... 38, 100
HR 410 FS.......................................... 38
HR 520....................................... 38, 101
HR 520 FS.......................................... 38
HR 550 FS.................................. 39, 102
HRA 110...................................... 40, 104
HRA 551 FS................................ 39, 102
HSCI................................................... 52
HSCI adapter....................................... 33
HSCI control components.................... 15
Hysteresis........................................... 67

I
I/O modules.................................. 30, 31
Incremental encoders.......................... 60
Industrial PC........................................ 41
Input resolution..................................... 6
Integrated inverter............................... 61
Integrated PLC.................................... 74
Inverter system................................... 50
IOconfig........................................ 30, 31
IPC 6110............................................. 41
IPC 6120............................................. 41
IPC 6641....................................... 41, 84

J
Jerk..................................................... 62
Jerk limiting........................................ 62

M
Machine interfacing............................... 8
Machine operating panel..................... 27
Main computer................................... 15
Master keyword.................................. 17
Maximum spindle speed..................... 59
MB 720........................................ 27, 97
MB 720 FS......................................... 27
MC 6441...................................... 16, 84
MC 6541...................................... 16, 84
MC 6542...................................... 16, 85
MC 6641...................................... 16, 84
MC 7422....................................... 16, 86
MC 7522...................................... 16, 86
Milling-head change............................. 59
Module for analog axes....................... 34
Module for PROFIBUS-DP................... 35
Monitoring functions........................... 65
Motion Adaptive Control (MAC)........... 71
Mounting and electrical installation....... 82

N
NC software license............................ 19
Nonlinear error.................................... 67

O
Operating system................................
Options...............................................
Oriented spindle stop..........................
Oscilloscope........................................

55
13
59
73

P
PL 550................................................
PL 6000........................................ 29,
PLA 4-4...............................................
PLA-H 08-04-04...................................
PLB 550..............................................
PLB 6001...................................... 33,
PLB 6104............................................
PLB 6104 FS.......................................
PLB 6106............................................
PLB 6106 FS.......................................

31
98
31
30
31
97
29
29
29
29

PLB 6108............................................
PLB 6108 FS.......................................
PLB 6204............................................
PLB 6204 FS.......................................
PLB 6206............................................
PLB 6206 FS.......................................
PLB 6208............................................
PLB 6208 FS.......................................
PLC axes...................................... 58,
PLC basic program..............................
PLCdesign...........................................
PLC inputs/outputs..............................
PLC positioning...................................
PLC programming...............................
PLC soft keys......................................
PLC window.......................................
PLD 16-8.............................................
PLD-H 04-08-00 FS..............................
PLD-H 08-04-00 FS..............................
PLD-H 08-16-00...................................
PLD-H 16-08-00...................................
Position Adaptive Control (PAC)............
Position-controlled spindle...................
Power supply................................ 15,
Proper minimum clearance..................
PSL 130........................................ 32,
PSL 135........................................ 32,
Python OEM Process..........................

29
29
29
29
29
29
29
29
75
77
76
74
75
74
75
75
31
30
30
30
30
70
59
32
82
99
99
76

R
Remote Desktop Manager.................. 80
RemoTools SDK.................................. 81
Reversal spikes................................... 67
Ribbon cable....................................... 23
Rotary axes......................................... 56
RS-232-C/V.24..................................... 79
RS-232-C adapter.............................. 105

S
Screen................................................ 27
Second spindle.................................... 59
Servo control with feedforward............ 61
Servo control with following error........ 61
SIK component................................... 17
Single speed....................................... 21
Sliding friction..................................... 67
Snap-on keys................................. 42, 43
Software............................................... 5
Software Key Generator...................... 18
Specifications........................................ 6
Spindle................................................ 59
Spindle override.................................. 59
Spline interpolation.............................. 63
Step switch......................................... 40
Stick-slip.............................................. 67
Storage medium................................. 17
Synchronized axes............................... 57
System PL.......................................... 29

T
Table function...................................... 73
Tapping............................................... 59
TE 720................................................ 27
TE 730.......................................... 27, 27
TE 735.......................................... 27, 96
TE 735 FS........................................... 27
TE 740.......................................... 28, 92
TE 745.......................................... 28, 93
TE 745 FS........................................... 28
TeleService.......................................... 73
Tilting the working plane...................... 57
TNCopt............................................... 72
TNCremo............................................ 80
TNCremoPlus...................................... 80
TNCscope........................................... 73
Tool measurement.............................. 37
Torque................................................. 58
Torque control..................................... 58
Touch probes....................................... 36
Trace function...................................... 73

U
UEC 111........................................ 25, 89
UEC 112........................................ 25, 89
UEC 113........................................ 25, 89
UEC 11x.............................................. 24
UMC 111....................................... 26, 90
UMC 11x............................................. 26
USB.................................................... 79
USB hub..................................... 80, 106

V
virtualTNC........................................... 81

W
Workpiece measurement.................... 36

111

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DE

HEIDENHAIN Vertrieb Deutschland


83301 Traunreut, Deutschland
08669 31-3132
08669 32-3132
E-Mail: [email protected]

ES

FARRESA ELECTRONICA S.A.


08028 Barcelona, Spain
www.farresa.es

PL

APS
02-384 Warszawa, Poland
www.heidenhain.pl

FI

PT

HEIDENHAIN Technisches Bro Nord


12681 Berlin, Deutschland
030 54705-240

HEIDENHAIN Scandinavia AB
02770 Espoo, Finland
www.heidenhain.

FARRESA ELECTRNICA, LDA.


4470 - 177 Maia, Portugal
www.farresa.pt

FR

RO

HEIDENHAIN Technisches Bro Mitte


07751 Jena, Deutschland
03641 4728-250

HEIDENHAIN FRANCE sarl


92310 Svres, France
www.heidenhain.fr

HEIDENHAIN Reprezentanta Romania


Brasov, 500407, Romania
www.heidenhain.ro

GB

HEIDENHAIN (G.B.) Limited


Burgess Hill RH15 9RD, United Kingdom
www.heidenhain.co.uk

RS

Serbia BG

RU

MB Milionis Vassilis
17341 Athens, Greece
www.heidenhain.gr

OOO HEIDENHAIN
125315 Moscow, Russia
www.heidenhain.ru

SE

HEIDENHAIN LTD
Kowloon, Hong Kong
E-mail: [email protected]

HEIDENHAIN Scandinavia AB
12739 Skrholmen, Sweden
www.heidenhain.se

SG

HEIDENHAIN PACIFIC PTE LTD.


Singapore 408593
www.heidenhain.com.sg

HEIDENHAIN Technisches Bro West


44379 Dortmund, Deutschland
0231 618083-0
HEIDENHAIN Technisches Bro Sdwest
70771 Leinfelden-Echterdingen, Deutschland
0711 993395-0
HEIDENHAIN Technisches Bro Sdost
83301 Traunreut, Deutschland
08669 31-1345

AR

AT

AU

BE

BG

BR

BY

CA

CH

CN

CZ

DK

GR

HK

HR

Croatia SL

HU

SK

NAKASE SRL.
B1653AOX Villa Ballester, Argentina
www.heidenhain.com.ar

HEIDENHAIN Kereskedelmi Kpviselet


1239 Budapest, Hungary
www.heidenhain.hu

KOPRETINA TN s.r.o.
91101 Trencin, Slovakia
www.kopretina.sk

ID

SL

HEIDENHAIN Techn. Bro sterreich


83301 Traunreut, Germany
www.heidenhain.de

PT Servitama Era Toolsindo


Jakarta 13930, Indonesia
E-mail: [email protected]

NAVO d.o.o.
2000 Maribor, Slovenia
www.heidenhain.si

IL

TH

FCR Motion Technology Pty. Ltd


Laverton North 3026, Australia
E-mail: [email protected]

NEUMO VARGUS MARKETING LTD.


Tel Aviv 61570, Israel
E-mail: [email protected]

HEIDENHAIN (THAILAND) LTD


Bangkok 10250, Thailand
www.heidenhain.co.th

IN

HEIDENHAIN Optics & Electronics


India Private Limited
Chetpet, Chennai 600 031, India
www.heidenhain.in

TR

IT

HEIDENHAIN ITALIANA S.r.l.


20128 Milano, Italy
www.heidenhain.it

JP

HEIDENHAIN K.K.
Tokyo 102-0083, Japan
www.heidenhain.co.jp

KR

HEIDENHAIN Korea LTD.


Gasan-Dong, Seoul, Korea 153-782
www.heidenhain.co.kr

MX

HEIDENHAIN CORPORATION MEXICO


20235 Aguascalientes, Ags., Mexico
E-mail: [email protected]

MY

ISOSERVE SDN. BHD.


43200 Balakong, Selangor
E-mail: [email protected]

NL
DR. JOHANNES HEIDENHAIN
(CHINA) Co., Ltd.
Beijing 101312, China
www.heidenhain.com.cn

HEIDENHAIN NEDERLAND B.V.


6716 BM Ede, Netherlands
www.heidenhain.nl

NO

HEIDENHAIN s.r.o.
102 00 Praha 10, Czech Republic
www.heidenhain.cz

HEIDENHAIN Scandinavia AB
7300 Orkanger, Norway
www.heidenhain.no

PH

Machinebanks` Corporation
Quezon City, Philippines 1113
E-mail: [email protected]

HEIDENHAIN NV/SA
1760 Roosdaal, Belgium
www.heidenhain.be
ESD Bulgaria Ltd.
Soa 1172, Bulgaria
www.esd.bg
DIADUR Indstria e Comrcio Ltda.
04763-070 So Paulo SP, Brazil
www.heidenhain.com.br
GERTNER Service GmbH
220026 Minsk, Belarus
www.heidenhain.by
HEIDENHAIN CORPORATION
Mississauga, OntarioL5T2N2, Canada
www.heidenhain.com
HEIDENHAIN (SCHWEIZ) AG
8603 Schwerzenbach, Switzerland
www.heidenhain.ch

TP TEKNIK A/S
2670 Greve, Denmark
www.tp-gruppen.dk

896096-24 5 9/2013 H Printed in Germany

T&M Mhendislik San. ve Tic. LTD. STI.


34728 mraniye-Istanbul, Turkey
www.heidenhain.com.tr

TW

HEIDENHAIN Co., Ltd.


Taichung 40768, Taiwan R.O.C.
www.heidenhain.com.tw

UA

Gertner Service GmbH Bro Kiev


01133 Kiev, Ukraine
www.heidenhain.ua

US

HEIDENHAIN CORPORATION
Schaumburg, IL 60173-5337, USA
www.heidenhain.com

VE

Maquinaria Diekmann S.A.


Caracas, 1040-A, Venezuela
E-mail: [email protected]

VN

AMS Co. Ltd


HCM City, Vietnam
E-mail: [email protected]

ZA

MAFEMA SALES SERVICES C.C.


Midrand 1685, South Africa
www.heidenhain.co.za

Zum Abheften hier falzen! / Fold here for ling!

Vollstndige und weitere Adressen siehe www.heidenhain.de


For complete and further addresses see www.heidenhain.de

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