iTNC 530 Information for the Machine Tool · PDF fileInformation for the Machine Tool Builder August 2011. 2 ... † HEIDENHAIN inverter systems recommended ... TS 640 or TS 740 workpiece

iTNC 530The Versatile Contouring Control for Milling, Drilling, Boring Machines and Machining Centers

Information for the

Machine Tool Builder

August 2011

2

iTNC 530

Contouring control for machines with up to 13 axes and • controlled spindleHEIDENHAIN inverter systems recommended• TFT color fl at-panel display• Hard disk with at least 121 GB• Programming in HEIDENHAIN conversational format, with • smarT.NC or according to DIN/ISOStandard 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, with option 9)• Automatic calculation of cutting data• Pallet management• Option: Windows XP on MC 422 C dual-processor computer•

TNC Contouring Control with Inverter System

from HEIDENHAIN

BF 150 color fl at-panel display with TE 530 B keyboard

System tests 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 specifi cations 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.

Main computer and controller unit

with modular inverter system

3

Contents

This catalog supersedes all previous editions, which thereby become invalid.

Subject to change without notice

Windows and Windows XP are registered trademarks of Microsoft Corporation.

The features and specifi cations described here apply for the following control and NC software versions:

iTNC 530 with NC software versions

606 420-01 SP 5 (export license required)606 421-01 SP 5 (no export license required)340 492-06 (with Windows XP, export license required)340 493-06 (with Windows XP, no export license required)

Some of these specifi cations require particular machine confi gurations. Please note also that, for some functions, a special PLC program must be created by the manufacturer.

Page

Tables with Specifi cations, Machine Interfacing, User Functions and Accessories

4

Control Systems 14

Cable Overviews 30

Technical Description 33

Overall Dimensions 60

Documentation 75

Service 76

Subject Index 78

Please refer to the page references in the tables with the specifi cations.

4

Specifi cations

Specifi cations iTNC 530 Page

Control systems 14

Main computer MC 422 D orMC 422 C with Windows XP

16, 60 – 62

Controller unit CC 422 orCC 424 B

20, 60 – 62

Screen BF 150 color fl at-panel TFT display 22, 63

Operating panel TE 530 B orTE 535 Q orTE 520 B

22, 64

Inverter systems **

Compact inverters ✔ **

Modular inverters ✔ **

Axes1)

Max. 13 33

Rotary axes Max. 3 33

Synchronized axes ✔ 35

PLC axes ✔ 35, 50

Spindle Max. 2; second spindle can be controlled alternately with the fi rst spindle 45

Shaft speed2) Max. 60 000 min–1 45

Operating-mode switchover ✔ 46

Position-controlled spindle ✔ 46

Oriented spindle stop ✔ 46

Gear shifting ✔ 46

Milling-head change Programmable via PLC 46

NC program memory MC 422 D: approx. 121 GB on hard diskMC 422 C with 2 processors: approx. 13 GB on hard disk

Input resolution and display step

Linear axes 0.1 µm 33

Rotary axes 0.000 1° 33

1) As ordered2) On motors with two pole pairs** For further information, refer to the Inverter Systems brochure (ID 622 420-xx)

5

Specifi cations iTNC 530 Page

Interpolation MC 422 D

MC 422 C with Windows XP

Straight line In 4 axes;With option 9: in 5 axes

*

Circle In 2 axes;With option 8: in 3 axes

*

Helix ✔ *

Spline With option 9 39 *

Axis feedback control 36

With following error ✔ 36

With feedforward ✔ 36

Axis clamping ✔ 33

Maximum feed rate · screw pitch [mm]

33

Cycle times of main computer MC 422 D


37

Block processing 3.6 ms0.5 ms with option 9

39

Cycle times of controller unit CC 424 B CC 422 37

Position controller 0.2 ms/0.1 ms1) 1.8 ms 37

Speed controller 0.2 ms/0.1 ms2) 0.6 ms 37

Current controller fPWM TINT 3 333 Hz 150 µs 4 000 Hz 125 µs 5 000 Hz 100 µs 6 666 Hz 150 µs/75 µs2)

8 000 Hz 125 µs/60 µs2)

10 000 Hz 100 µs/50 µs2)

fPWM TINT 3 333 Hz 150 µs 4 166 Hz 120 µs 5 000 Hz 100 µs 6 666 Hz 75 µs 8 333 Hz 60 µs10 000 Hz 50 µs

37

Permissible temperature range Operation 0 °C to +40 °CStorage –35 °C to +65 °C

–

1) Double-speed without position encoder (e.g. for direct drives)2) Single-speed/double-speed* For further information, refer to the iTNC 530 brochure (ID 363 807-xx)

60 000 min–1

No. of pole pairs in motor

6

Machine Interfacing

Machine interfacing iTNC 530 Page

Feature Content Level (FCL) ✔ 18

Error compensation ✔ 41

Linear axis error ✔ 41

Nonlinear axis error ✔ 41

Backlash ✔ 41

Reversal peaks with circular movement ✔ 41

Hysteresis ✔ 41

Thermal expansion ✔ 41

Stick-slip friction ✔ 41

Sliding friction ✔ 41

Integral PLC 49

Program format Statement list 49

Program input on the TNC ✔ 49

Program input via PC ✔ 49

PLC encryption ✔ 49

PLC memory At least 948 MB on hard disk 49

Process memory (RAM) 512 KB 49

PLC cycle time 10.8 ms 49

PLC inputs/outputs ✔ 49, 23

PLC inputs, DC 24 V 56 (expandable by PL) 49, 23

PLC outputs, DC 24 V 31 (expandable by PL) 49, 23

Analog inputs, ±10 V 3 (expandable by PL) 23

Inputs for thermistors 3 (expandable by PL) 23

Analog outputs, ±10 V MC 422 D: 12 outputsMC 422 C with Windows XP: 6 outputs

–

PLC functions ✔ 50

Small PLC window ✔ 50

Large PLC window ✔ 50

PLC soft keys ✔ 50

PLC positioning ✔ 50

PLC basic program ✔ 52

7

Machine interfacing iTNC 530 Page

Integration of applications 51

High-level language programming Python programming language used in combination with the PLC 51

User interface can be custom-designed Inclusion of specifi c user interfaces from the machine tool builder 51

Commissioning and diagnostic aids 47

DriveDiag Software for diagnosis of digital drive systems 47

TNCopt Software for putting digital control loops into service 47

KinematicsDesign Software for creating the machine kinematics, initialization of DCM 44

Integrated oscilloscope ✔ 48

Trace function ✔ 48

Logic diagram ✔ 48

Table function ✔ 48

Log ✔ 48

Data interfaces 54

Ethernet (100 BaseT) ✔ 54

USB 2 54

RS-232-C/V.24 ✔ 54

RS-422/V.11 ✔ 54

Protocols 54

Standard data transfer ✔ 54

Blockwise data transfer ✔ 54

Blockwise data transfer and simultaneous program run

With program memory on the hard disk 54

LSV2 ✔ 54

Encoder inputs 40

Position None, 5 or 101) 40

Incremental/absolute 1 VPP/EnDat 40

Shaft speed CC 422: 6, 10 or 121); CC 424 B: 6, 8, 10, 12 or 141) 40

Incremental/absolute 1 VPP/EnDat 40

Monitoring functions 43

DCM dynamic collision monitoring With option 40 43

1) As ordered

8

Accessories iTNC 530 Page

Electronic handwheels One HR 410, HR 550 FS, HR 520, HR 130, or up to three HR 150 via HRA 110 24 – 26

Touch probes One TS 220, TS 440, TS 444, TS 640 or TS 740 workpiece touch probeOne TT 140, TT 449 or TL tool touch probe

29

PLC input/output systems Modular external input/output systems PL 510 or PL 550 consisting ofBasic module with HEIDENHAIN PLC interface• PLB 510: for 4 I/O modulesPLB 511: for 6 I/O modulesPLB 512: for 8 I/O modulesor Basic module with PROFIBUS-DP interfacePLB 550: for 4 I/O modulesPLD 16-8:• I/O module with 16 digital inputs and 8 digital outputsPLA 4-4:• Analog module with 4 analog inputs for ±10 V and 4 inputs for PT 100 thermistors

23

USB hub ✔ 54

PLC basic program1)

✔ 52

iTNC programming station Control software for PCs for programming, archiving, and training *

Industrial PC IPC 6110/IPC 6120 – remote operation of the control and data transfer 28

Software

PLCdesign1) PLC development software 51

KinematicsDesign1) Software for creating kinematics and initializing DCM 44

TNCremo Data transfer software 55

TNCremoPlus Data transfer software with live-screen function 55

CycleDesign1) Software for creating cycle structures 53

Software Key Generator1) Software for enabling SIK options for a limited time 18

TNCscope1) Software for data recording 48

DriveDiag1) Software for diagnosis of digital drive systems 47

TNCopt1) Software for putting digital control loops into service 47

IOconfi g1) Software for confi guring PROFIBUS-DP components 23

TeleService1) Software for remote diagnostics, monitoring, and operation 48

RemoTools SDK 1.21) Function library for developing customized applications for communication

with HEIDENHAIN controls56

virtualTNC Control component for virtual machines 56

* For further information, refer to the iTNC 530 brochure (ID 363 807-xx)1) Registered customers can download these software products from the Internet

Accessories

9

User Functions

User functions

Sta

nd

ard

Op

tio

n

FC

L

Program entry • 42

With smarT.NC, in HEIDENHAIN conversational format and according to DIN/ISODirect loading of contours or machining positions from DXF fi les and saving as smarT.NC or

conversational contouring programs, or as point tables

Program optimization 02 Point fi lter for smoothing externally created NC programs

Position data ••••

Nominal positions for lines and arcs in Cartesian coordinates or polar coordinatesIncremental or absolute dimensionsDisplay and entry in mm or inchesDisplay of the handwheel path during machining with handwheel superimpositioning

Tool compensation •••

Tool radius in the working plane and tool lengthRadius-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

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-specifi c data (cutting speed, feed per tooth)

Entry of cutting speed as alternative to the spindle shaft speedFeed 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 centerRelative to the tool’s cutting edge

Parallel operation • Creating a program with graphical support while another program is being run

3-D machining 999

9999 02

Particularly jerk-free path control3-D tool compensation through surface normal vectorsTool 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 pointKeeping the tool normal to the contourTool radius compensation normal to the tool directionSpline interpolationManual traverse in the active tool-axis system

Rotary table machining 88

Programming of cylindrical contours as if in two axesFeed rate in mm/min

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

Collision monitoring 4040404040

04Dynamic Collision Monitoring (DCM)Graphic depiction of the active collision objectsFixture monitoringTool holder monitoringDCM in the Test Run mode

10

User functions

Sta

nd

ard

Op

tio

n

FC

L

Contour elements •••••••

Straight lineChamferCircular pathCircle centerCircle radiusTangentially connecting circular arcCorner rounding

Approaching and

departing the contour

••

Via straight line: tangential or perpendicularVia circular arc

FK free contour

programming

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

Program jumps •••

SubroutinesProgram-section repeatCalling any program as a subroutine

Fixed cycles ••••••••••

Cycles for drilling, and conventional and rigid tappingDrilling cycles for pecking, reaming, boring, counterboring, centeringCycles for milling internal and external threadsMulti-operation machining of rectangular and circular pockets, rectangular and circular studsCycles for clearing level and inclined surfacesMultioperation machining of straight and circular slotsLinear and circular point patternsContour train, contour pocket—also with contour-parallel machiningContour slot with trochoidal millingOEM cycles (special cycles developed by the machine tool builder) can be integrated

Coordinate transformation

•8

44

Programmable:Datum shift, rotation, mirror image, scaling factor (axis-specifi c)Tilting the working plane, PLANE function

Manually defi nable:Global program settings make it possible to manually defi ne shifts, rotations, and handwheel

superimpositioning

Q parameters

Programming with variables•

•••

••

Mathematical functions =, +, –, *, /, sin Þ, cos Þ, tan Þ, arc sin, arc cos, arc tan, an, en, In, log, √a, √a2 + b2

Logical operations (=, = /, <, >)Calculating with parentheses Absolute value of a number, constant þ, negation, truncation of digits before or after the

decimal pointFunctions for calculation of circlesFunctions for text processing

Programming aids ••••

••

03

CalculatorComplete list of all current error messagesContext-sensitive help function for error messagesTNCguide: The integrated help system. User information available directly on the iTNC 530;

context-sensitiveGraphical support for programming cyclesComment and structure blocks in the NC program

Actual position capture • Actual positions can be transferred directly into the NC program

User Functions

11

User functions

Sta

nd

ard

Op

tio

n

FC

L

Test run graphics

Display modes•••

Graphic simulation before a program run, even while another program is runningPlan view / projection in 3 planes / 3-D view, also in tilted working planeMagnifi cation of details

3-D line graphics 02 For verifi cation of programs created offl ine

Interactive programming

graphics

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

Program-run graphics

Display modes••

Graphic simulation during real-time machiningPlan view / projection in 3 planes / 3-D view

Machining time ••

Calculation of machining time in the Test Run operating modeDisplay 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

Preset tables • One preset 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 or tool by tool

Touch probe cycles ••••

48

0203

Touch probe calibrationCompensation of workpiece misalignment, manual or automaticDatum setting, manual or automaticAutomatic tool and workpiece measurementGlobal setting of touch-probe parametersProbing cycle for three-dimensional measurements. Toggle between showing the

measurement results in the coordinate system of the workpiece or the machineAutomatic measurement and optimization of machine kinematics

Conversational languages •

41

English, German, Chinese (traditional, simplifi ed), Czech, Danish, Dutch, Finnish, French, Hungarian, Italian, Polish, Portuguese, Russian (Cyrillic), Spanish, Swedish

For more conversational languages, see Options

12

Options

Option

number

Option As of NC software ID Comment

606 42x- 340 49x-

0

1

2

3

4

5

6

7

Additional axis 01 01 354 540-01353 904-01353 905-01367 867-01367 868-01370 291-01370 292-01370 293-01

Additional control loops 1 to 8

8 Software option 1 01 01 367 591-01 Rotary table machining

Programming of cylindrical contours as if in two axes• Feed rate in mm/min•

Coordinate transformation

Tilting the working plane, PLANE function• Interpolation

Circle in 3 axes with tilted working plane•

9 Software option 2 01 01 367 590-01 3-D machining

Particularly jerk-free path control• 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 pointKeeping 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 (subject to export permit)• Spline: execution of splines (3rd degree polynomial)•

Block processing time 0.5 ms

18 HEIDENHAIN DNC 01 01 526 451-01 Communication with external PC applications over COM component

13

Option

number

Option As of NC software ID Comment

606 42x- 340 49x-

40 DCM Collision 01 02 526 452-01 Dynamic Collision Monitoring (DCM)

41 Additional language010101010101010101

020303030303040405

530 184-01530 184-02530 184-03530 184-04530 184-06530 184-07530 184-08530 184-09530 184-10

Additional conversational language:SloveneSlovakLatvianNorwegianKoreanEstonianTurkishRomanianLithuanian

42 DXF Converter 01 02 526 450-01 Load and convert DXF contours

44 Global PGM Settings 01 03 576 057-01 Global program settings

45 Adaptive Feed Control (AFC)

01 03 579 648-01 Adaptive feed control

46 Python OEM Process 01 04 579 650-01 Python application on the iTNC

48 KinematicsOpt 01 04 630 916-01 Touch probe cycles for automatic measurement of rotary axes

52 KinematicsComp 01 05 661 879-01 Three-dimensional compensation

53 Feature content level 01 02 529 969-01 –

77 4 Additional Axes 01 06 634 613-01 4 additional control loops

78 8 Additional Axes 01 06 634 614-01 8 additional control loops

92 3D-ToolComp 01 06 679 678-01 3-D tool radius compensation depending on the tool’s contact angle

93 Extended Tool Management

01 06 679 938-01 Extended tool management(only with software option 2)

101..

130

OEM option 01 04 579 651-01..579 651-30

Options of the machine tool builder

14

HEIDENHAIN Control Systems

Overview

Model Page

iTNC 530 Main computer MC 422 D or MC 422 C with

two processors

16

Controller unit CC 422 orCC 424 B

20

Keyboard unit TE 530 B orTE 520 B orTE 535 Q

22

Screen BF 150 22

Connecting cables 30 – 32

Accessories Machine operating panel

MB 420 orMB 520 (integrated in TE 535 Q)

22

PLC inputs/outputs PL 510 orPL 550 (together with PROFIBUS option)

23

Electronic handwheels

HR 410 orHR 520 orHR 550 FS (with HRA 551) orHR 130 orHR 150

24

25

26

Touch probes TS 220 orTS 440 orTS 444 orTS 640 orTS 740

29

TT 140 orTT 449 orTL

Industrial PC IPC 6110 orIPC 6120

28

The iTNC 530 contouring control from HEIDENHAIN includes various components, which can be selected and combined to fi t the application.

15


with compact inverter and additional power module


with modular inverter system

16

Main Computer

Main computer The main computers feature:Processor• RAM memory• PLC• Interface to CC 4xx controller unit• Interface to operating panels and screen• Interface to handwheel and touch probes• Further interfaces (PLC expansion, Ethernet, USB, • RS-232-C/V.24, RS-422/V.11)

To be ordered separately:HDR• hard disk with the NC softwareSIK component• (System Identifi cation Key) for enabling the control loops and software options

Power supply The main computers are powered by the supply unit over the CC 42x controller unit.

Export version Because the entire NC software is saved on the hard disk, no export version is required for the main computer itself. Export versions are available only for the easily replaceable HDR hard disk and the SIK component.

Versions The MC 422 D main computer and MC 422 C with Windows XP main computer are available in versions with 10, 5 or no position encoder inputs. The version without position encoder inputs is intended for the CC 424 B controller. It offers up to 15 control

loops.

The MC 422 C is only available as a dual-processor computer with Windows XP.

Please note:

NC software 606 420-01 or 606 421-01, or higher, each with service pack SP5, is required in order to operate the MC 422 D.NC software 340 492-04 or 340 493-04, or higher, is required in order to operate the MC 422 C.

Main computer

with 10 position encoder inputs

17

MC 422 D

Single-processor version

Position inputs Without 5 x 1 VPP or EnDat 2.1 10 x 1 VPP or EnDat 2.1

Recommended

controller unit

CC 424 B CC 422 with 6 speed inputs

CC 422 with 10/12 speed inputs

Processor HEROS 5 1 GHz Celeron

RAM memory 1 GB

Power loss 40 W

Weight 4.3 kg 4.5 kg 4.7 kg

ID 747 624-xx 747 628-xx 747 630-xx

MC 422 C

Dual-processor version with Windows XP

Position inputs Without 5 x 1 VPP or EnDat 2.1 10 x 1 VPP or EnDat 2.1

Recommended

controller unit

CC 424 B CC 422 with 6 speed inputs

CC 422 with 10/12 speed inputs

Processor HEROS 4 Windows XP

800 MHz Pentium III1.8 GHz Pentium M

RAM memory

HEROS 4 Windows XP

512 MB1 GB

Power loss † 36 W


ID 631 209-xx 631 215-xx 631 217-xx

ID with integrated PROFIBUS interface

631 212-xx 631 216-xx 631 201-xx

Software options The capabilities of the iTNC 530 can also be adapted retroactively with options to meet new requirements. These options are described on page 12. 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.

The MC 422 D can be delivered with a selectable scope of software functions activated (see NC software license). Software options can also be enabled retroactively.

18

Main Computer—HDR Hard Disk, SIK Component

HDR hard disk The HDR hard disk is removable. It contains the current NC software and a slot for the SIK component.

HDR for MC 422 D1 processor

MC 422 C2 processors with

Windows XP

iTNC 530

with smarT.NC

HDR: ID 682 272-02with SW 606 420-xx

HDR: ID 617 969-01with SW 340 492-xx

iTNC 530

with smarT.NC

Export version

HDR: ID 682 272-52with SW 606 421-xx

HDR: ID 617 969-51with SW 340 493-xx

HDR hard disk

SIK component

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 code—the SIK number. The SIK component is ordered and shipped separately. It must be inserted in a special slot in the HDR.

The SIK component with the NC software license is available in various versions, depending on the main computer and the enabled control loops. 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.

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 using a soft key.

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-specifi c password. The enabling is independent of the General Key.

Feature content level

(FCL)

Until now, each NC software update contained error fi xes and software improvements. As of NC software 340 49x-02, error fi xes and software improvements are separated from each other. This is done to avoid customers taking advantage of improvements even though they are only receiving the software update to correct errors. The corrected NC software is free of charge. The software improvements can be enabled via the Feature Content Level option (ID 529 969-01) for a fee.

19

NC software license

and enabling of

control loops

depending on CC and MC

Co

ntr

ol lo

op

s CC 422 CC 424 B NC software license for

Max. 6

Max. 10

Max. 12

Max. 6

Max. 8

Max. 10

Max. 12

Max. 14 MC 422 D

1 processorMC 422 C

2 processorsSIK ID SIK ID

2)SIK ID

3)SIK ID

41) 389 764-01389 764-51

389 764-15389 764-65

389 764-28389 764-78

389 769-01389 769-51

5 389 764-02389 764-52

389 764-16389 764-66

389 764-29389 764-79

389 769-02389 769-52

6 389 764-03389 764-53

389 764-17389 764-67

389 764-30389 764-80

389 769-03389 769-53

7 389 764-04389 764-54

389 764-18389 764-68

– 389 769-04389 769-54

71) 389 764-01389 764-51

389 764-15389 764-65

389 764-28389 764-78

389 769-01389 769-51

8 389 764-05389 764-55

389 764-19389 764-69

– 389 769-05389 769-55

8 389 764-02389 764-52

389 764-16389 764-66

389 764-29389 764-79

389 769-02389 769-52

9 389 764-03389 764-53

389 764-17389 764-67

389 764-30389 764-80

389 769-03389 769-53

10 389 764-04389 764-54

389 764-18389 764-68

– 389 769-04389 769-54

11 389 764-05389 764-55

389 764-19389 764-69

– 389 769-05389 769-55

12

Only through subsequent enabling of control loops (additional axes)

–

13 –

14 –

In italics: Export version (no export license required)1) Basic version 2) Reduced scope of functions, without software option 23) Reduced scope of functions, without software options 1 and 2 Useful combinations

If additional control loops are required for retrofi tted options, the CC must make it possible to enable further control loops.

Retroactive enabling

of control loopsControl loop Corresponds on basic version of CC to MC 422 D


4 control loops 7 control loops ID

1st additional axis 5th control loop 8th control loop 354 540-01

2nd additional axis 6th control loop 9th control loop 353 904-01

3rd additional axis 7th control loop 10th control loop 353 905-01

4th additional axis 8th control loop 11th control loop 367 867-01

5th additional axis – 12th control loop 367 868-01




The additional axes are always numbered starting from the basic version.For example: for 13 control loops, the SIK for 11 control loops (= basic version with 7 control loops including 4 additional axes) plus the 5th and 6th additional axes must be ordered.

20

Controller Unit

Controller unit HEIDENHAIN offers the CC 422 and CC 424 B controller units in various versions. Controller units and main computers operate in any desired combination.

Components of the CC 422 and CC 424 B controller units:Position controller (only with CC 424 B)• Speed controller• Current controller• Interfaces to the UM 1xx, UR 2xx, UE 2xx power modules • (PWM outputs)Interfaces to the speed encoders• Interfaces to the position encoders (only CC 424 B)• Interfaces for power supply for controller unit and main • computer (supply via UVR 1xx D, UE 2xx D, UR 2xx or UV 105)

Conventional axes The CC 422 und CC 424 B controller units are suited for conventional digital axes.

Direct drives Direct drives (linear motors, torque motors) require very high quality controllers and very short cycle times. HEIDENHAIN has developed the CC 424 B controller unit specifi cally for these applications.

Number of axes 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 at a later date.

CC 422 The CC 422 is available with up to 6, 10 or 12 digital control loops.Because the CC 422 controller unit does not have its own position controllers, it must be combined with main computers with position encoder inputs. The associated position controllers are located on the main computer (version with 5 or 10 position encoder inputs).

CC 422 – 6 CC 422 – 10 CC 422 – 12

Digital control loops Max. 6 Max. 10 Max. 12

Speed inputs 6 x 1 VPP or EnDat 2.1 10 x 1 VPP or EnDat 2.1 12 x 1 VPP or EnDat 2.1

PWM outputs 6 10 12

Power loss † 9 W † 18 W † 22 W


ID 359 651-xx 359 652-xx 359 653-xx

CC 422

with up to 6 control loops

21

CC 424 B

with up to 6 control loops

CC 424 B – 6 CC 424 B – 8 CC 424 B – 10 CC 424 B – 12 CC 424 B – 14

Digital control loops Max. 6 Max. 8 Max. 10 Max. 12 Max. 14

Speed inputs 6 x 1 VPPor EnDat 2.1

8 x 1 VPPor EnDat 2.1




Position inputs 6 x 1 VPPor EnDat 2.1





PWM outputs 6 8 10 12 14

Control loops1)

for

Double-speed

Single-speed

24

–8

64

48

212

Power loss † 15 W † 15 W † 28 W † 28 W † 28 W

Weight 4.1 kg 4.7 kg 4.8 kg 5.6 kg 5.8 kg

ID 580 501-xx 580 510-xx 580 503-xx 580 511-xx 580 512-xx

1) Factory default setting; adjustable by machine parameters

CC 424 B Besides the inputs for rotational speed measurement, the CC 424 B also includes inputs for position measurement. It is available with up to 6, 8, 10, 12 or 14 digital control loops and correspondingly provides 6, 8, 10, 12 or 14 shaft-speed inputs and up to 12 position encoder inputs. Together with the CC 424 B, the main computer without position encoder inputs is to be used.

Special characteristics of the CC 424 B:

Suitability for digital control of direct-drive and conventional • motorsPosition, speed, and current controllers together in one • assemblyVery short cycle times for position, speed and current control • (see Digital Control)Very short delay times within the controller (no external • interfaces)High control loop gain• High contour accuracy and surface quality• Short reaction time to changing cutting forces•

Double-speed control loops are used primarily for high-speed spindles as well as linear motors and torque motors.

Single-speed control loops are intended for conventional drives and torque motors.

When switching from single speed to double speed, the number of available control loops is reduced by one each.

22

Keyboard and Screen

BF 150 with strips

MB 520

TE 535 Q

TE 530 B

BTS 150

Keyboard unit

TE 530 B

ID 519 441-11• Weight approx. 2.4 kg•

Axis keys (keys for axes IV and V are replaceable, see • Snap-On Keys)Path-function keys, operating mode keys, ASCII keyboard• Touchpad and command keys for Windows• Spindle-speed and feed-rate override potentiometers•

Keyboard unit

TE 520 B

ID 535 835-01• Same features as TE 530 B, but without touchpad•

Keyboard unit

TE 535 Q

with integrated

machine operating

panel

ID 547 577-03• Weight approx. 3 kg•

NC keyboard same as TE 530 B• Machine operating panel same as MB 520•

Machine operating

panel MB 520

ID 628 040-01• Weight approx. 0.9 kg•

Operating elements: 12 axis keys, 16 function keys, NC start• 1), NC stop1), spindle start, spindle stop (all are snap-on keys; see Snap-On Keys); emergency stop button, control voltage on1); 2 holes for additional keys or detachable-key switch

1) Keys illuminated

Machine operating

panel MB 420

ID 293 757-45• Weight 0.9 kg•

21 snap-on keys, freely defi nable via PLC• Operating elements (assigned according to PLC basic program):• Control voltage on; Emergency stop; NC start; NC stop; 5 axis keys; Rapid traverse; Retract axis; Tool change; Unclamp tool; Menu selection; Unlock door; Spindle start; Spindle stop; Coolant; Rinse-water jet; Chip removal. All are snap-on keys, see Snap-On Keys.Additional connections• Terminals for 3 PLC inputs and 8 PLC outputs

BF 150 color fl at-

panel display

ID 353 522-03• Weight approx. 4 kg•

Power supply 24 V–/approx. 45 W• 15.1-inch; 1 024 x 768 pixels• 8 horizontal soft keys, 6 vertical soft keys for PLC• Soft-key row switchover• Screen layout• Operating-mode switchover•

Screen accessories Attachable strips to adapt the design• ID 339 516-02 (bottom)• ID 339 516-04 (top)•

BTS 150 screen-

and-keyboard

switch

For extending the monitor cable and connecting two keyboards and two screens to one MC. They are mounted on standard NS 35 rails (DIN 46 227 or EN 50 022).

Connections for 2 x BF 150; 2 x TE 530 B/520 B/535 Q• Power supply DC 24 V/approx. 0.6 W• Weight Approx. 1 kg• ID 353 544-01•

23

PL 510

PL 550

PLC Inputs/Outputs

If the PLC inputs/outputs of the MC are insuffi cient, additional PL 510 or PL 550 PLC input/output units can be connected. These external modular I/O systems consist of a basic module and one or more input/output modules.

Basic modules Basic modules are available for HEIDENHAIN PLC interface (PL 510) or for PROFIBUS-DP (PL 550). They are mounted on standard NS 35 rails (DIN 46 227 or EN 50 022)

Supply voltage DC 24 VPower consumption approx. 20 WWeight 0.36 kg (bare)

PLB 510

PLB 511

PLB 512

Basic modules with HEIDENHAIN PLC interfaceSlots for 4 I/O modules ID 358 849-01Slots for 6 I/O modules ID 556 941-01Slots for 8 I/O modules ID 557 125-01Up to four PLB 510, and up to two PLB 511 or PLB 512 can be connected to the control. The maximum cable length to the last PLB 51x is 30 meters.

PLB 550 Basic module with PROFIBUS-DP interfaceSlots for 4 I/O modulesThe PLB 550 serves as a PROFIBUS slave. A total of 32 slaves can be connected to the PROFIBUS interface board (accessory) of the MC 422 C (PROFIBUS single master). The PROFIBUS components are confi gured with the PC software IOconfi g.

ID 507 872-01

PROFIBUS interface PCB

The PROFIBUS-DP interface board must be installed in the MC before the PLB 550 is connected to the control.PROFIBUS-DP interface PCB for MC 422 C/MC 420

ID 352 517-51

IOconfi g software for PCsfor confi guring PROFIBUS-DP components

ID de: 520 942-01 en: 520 943-01

I/O modules 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 I/O module 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 kgID 360 916-11

PLA 4-4 Analog module with4 analog inputs for PT 100 thermistors4 analog inputs, ±10 V

Weight 0.2 kgID 366 423-01

Empty housing For unused slotsID 383 022-01

24

HR 410

HR 520

Electronic Handwheels

The iTNC 530 supports the use of electronic handwheels.

The following handwheels can be installed:

One • HR 550 FS wireless handwheel, orOne • HR 410 or HR 520 portable handwheel, orOne • HR 130 panel-mounted handwheel, orUp to three • HR 150 panel-mounted handwheels via the HRA 110 handwheel adapter

HR 410 Portable electronic handwheel withKeys for the selection of 5 axes• Traverse direction keys• Keys for three preset feed rates• Actual-position-capture key• Three keys with machine functions (see below)• Two permissive buttons (24 V)• Emergency stop button (24 V)• Magnetic holding pads•

All keys are designed as snap-on keys and can be replaced by keys with other symbols. (For key symbols, see Snap-On Keys.)

Weight Approx. 1 kg

HR 410 model Mechanical detent

With Without

Standard assignment with the FCT A, FCT B, FCT C function keys

– 296 469-53

For PLC basic program with NC start/stop, spindle start

535 220-05 296 469-55

With spindle right/left/stop – 296 469-54

HR 520 with

display

Portable electronic handwheel withDisplay for operating mode, actual position value, programmed • feed rate and spindle speed, error messagesOverride 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 defi ned by the machine tool • builderEmergency stop button•

Weight Approx. 1 kg

HR 520 (without detent) ID 670 302-01HR 520 (with detent) ID 670 303-01

Mount For HR 520, for fastening on the machine ID 591 065-02

25

HR 550 FS Electronic handwheel with wireless transmissionDisplay, operating elements and functions same as HR 520

In addition:Functional safety (short-circuit-proof due to specifi c logic behind • the permissive buttons)Wireless transmission range• Up to 20 m (depending on environment)

HR 550 FS (without mechanical detent) ID 598 515-xxHR 550 FS (with mechanical detent) ID 606 622-xx

HRA 551 FS Handwheel mount for HR 550 FSFor docking the HR 550 FS on the machine• Integrated charger for the HR 550 FS• Connections to the control and the machine• Integrated transceiver unit•

Weight Approx. 1 kg

ID 731 928-xx

You can fi nd more information in the HR 550 FS Product Information brochure.

Connecting cables ID For HR 410/HR 520 For HR 550 FS with HRA 551 FS

Connecting cable (spiral)to HR (3 m)

312 879-01 ✔ –

Connecting cablein metal armor

296 687-xx ✔ –

Connecting cablewithout metal armor

296 467-xx ✔ ✔

Adapter cable for HR/HRA to MC 296 466-xx ✔ ✔2)

Extension cable to adapter cable 281 429-xx ✔ ✔2)

Adapter cable for HRA to MC1) 749 368-xx – ✔

Extension cable to adapter cable1) 749 369-xx – ✔

Dummy plug for EMERGENCY STOP circuit

271 958-03 ✔ ✔

1) For cable lengths up to 50 m between MC and HRA 551 FS2) For cable lengths up to 20 m between MC and HRA 551 FS (See also Cable Overviews)

HR 550 FS with

HRA 551 FS

26

HR 130 Panel-mounted handwheel with ergonomic control knob.It is connected directly or via extension cable.

Weight Approx. 0.7 kg

HR 130 without mechanical detent ID 540 940-03HR 130 with mechanical detent ID 540 940-01

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

HRA 110

ID 261 097-xxWeight Approx. 1.5 kg

Handwheel step switch with knob and cableID 270 908-xx

HR 150 Panel-mounted handwheel with ergonomic control knob for connection to the HRA 110 handwheel adapter.

Weight Approx. 0.7 kgHR 150 without mechanical detent ID 540 940-07HR 150 with mechanical detent ID 540 940-06

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27

Snap-On Keys

The snap-on keys make it easy to replace the key symbols. In this way, the MB 420 machine operating panel, TE 535 and the HR 410 handwheel can be adapted to different requirements.The snap-on keys are available in packs of 5 keys.

Axis keys

Orange

Spindle functions

Other keys

Gray

(green)

(red)

(red)

(green)

Machine functions

28

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 a machine unit, such as a tool-changing station. The remote concept, which was designed with the single-processor version of the iTNC 530 in mind, permits very simple connection of the IPC, via an Ethernet connection with a cable up to 100 meters long.

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. The TNCterminal software included with the IPC ensures simple connection and convenient operation of the IPC on the iTNC 530. During remote operation, the IPC screen displays exactly the screen contents of the control, and the most important functions of the control can be operated from the integrated keyboard.

Windows XP Embedded is installed as operating system, and the TNCremo fi le-transmission software is also installed. This means that the transfer of programs and fi les from the IPC 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 fi nd more information in the IPC 6110/IPC 6120 Product Information brochure.

29

Touch Probes

Before the iTNC 530 leaves the factory, it is already prepared for the use of touch probes for workpiece or tool measurement. 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 or CD ROM entitled Touch Probes.

Workpiece

measurement

The TS touch trigger probe has a stylus with which it probes workpieces. The TNC provides 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 220 TTL version

Touch probe with infrared signal transmission for machines with automatic tool change

TS 440 Compact dimensions

TS 444 Compact dimensions, battery-free power 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 repeatability, low probing force

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 integration in the machine’s workspaceSE 642 common SE for TS and TT 449, otherwise same features as SE 640SE 540 for integration in the spindle head

Tool measurement The touch probes for tool measurement from HEIDENHAIN are suited for probing stationary or rotating tools directly on the machine. The TNC has standard routines for measuring length and diameter of the tool as well as the individual teeth. The TNC automatically saves the results of measurement in a tool table. It is also possible to measure tool wear between two machining steps. The TNC compensates the changed tool dimensions automatically for subsequent machining or replaces the tool after a certain limit—as for example after tool breakage.

With the triggering TT touch probes the disk-shaped contact plate is defl ected from its rest position upon contact with a stationary or rotating tool, sending a trigger signal to the NC control.

TT 140TT 449

Signal transmission to the TNC over connecting cableSignal 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 TNC evaluate the information.

TS 220

TT 140

TS 640 with SE 640

TL Micro 150,

TL Micro 300

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33

Technical Description

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 inmm/min relative to the workpiece contour, or mm per spindle revolution

Feed rate override: 0 to 150%

Maximum feed rate: · screw pitch [mm]

Traverse range –99 999.9999 to +99 999.9999 [mm]

The machine tool builder defi nes 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 defi ned (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 defi nes 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 defi ned (selection by PLC).

Free rotation For milling-turning operations, the rotary axis can be started via the PLC with a defi ned feed rate.

Cylindrical surface

interpolation (option 8)

A contour defi ned in the working plane is machined on a cylindrical surface.

Axis clamping The control loop can be opened through the PLC in order to clamp specifi c axes.

60 000 min–1

No. of pole pairs

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34

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 iTNC 530 can manage more than one machine confi guration (e.g. different swivel heads). The machine confi gurations 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.

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.

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Synchronized axes Synchronous axes are moved simultaneously and are programmed with the same axis designation, e.g. gantry axes or tandem tables. A maximum of 4 x 2 axes can be defi ned as synchronous axes.

Torque control Torque control is used on machines with mechanically coupled motors for which

a defi ned distribution of drive torque is • desired,

orparts of the controlled system show a • backlash effect that can be eliminated by "tensioning" the servo drives, (e.g. toothed racks).

PLC axes Axes can be controlled by the PLC. They are programmed over M functions or OEM cycles.

The PLC axes are positioned independently of the NC axes and are therefore designated as asynchronous axes.

36

Digital Control

Integrated inverters Position controllers, speed controllers, current controllers and inverters are integrated in the iTNC 530. HEIDENHAIN synchronous and asynchronous motors are connected to the iTNC 530.

Axis feedback

control

The iTNC 530 can be operated with lag 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 = velocity kv = position loop gain sa = following error

Servo control with

feedforward

Feedforward means that the speed and the acceleration are adjusted to fi t 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 µm).

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 these oscillations 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 424 B can be used to compensate for this torque ripple.

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Control-loop

cycle times

The cycle time for path interpolation is defi ned as the time interval during which interpolation points on the path are calculated. The cycle time for fi ne interpolation is defi ned 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 defi ned as the time interval during which the actual position value is compared to the calculated nominal position value. The cycle time for the speed controller is defi ned as the time interval during which the actual speed value is compared to the calculated nominal speed value. The cycle time for the current controller is defi ned as the time interval during which the actual current value is compared to the calculated nominal current value.

CC 422 CC 424 B

Path interpolation 1.8 ms 3 ms

Fine interpolation – 0.2 ms/0.1 ms1)

Position controller 1.8 ms 0.2 ms/0.1 ms2)

Speed controller 0.6 ms 0.2 ms/0.1 ms1)

Current controller 0.1 ms 0.1 ms

1) Double-speed without position encoder2) Single-speed/double-speed

Time

TimePo

sitio

nPo

sitio

n

Jerk The derivative of acceleration is referred to as jerk.A linear change in acceleration causes a jerk step. However, such motion sequences may cause the machine to oscillate.

Jerk limiting To prevent machine oscillations, the jerk is limited to attain optimum path control.

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Contour path deviation due to acceleration and

deceleration with jerk

Smoother jerk reduces contour path deviation

Smoother jerk The jerk is smoothed by nominal position value fi lters. 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.Nominal position value fi lters for HSC machining (HSC fi lter) with selectable fi lter characteristics for fi nishing and roughing (with option 9 for MC 420).

39

Short block

processing times

The iTNC 530 provides the following important features for the fast machining of contours:

The block processing time of the MC 422 C/D 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. 1 024 blocks). In this way directional changes are detected in time to accelerate or decelerate the appropriate NC axes.

Spline interpolation 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. Spline interpolation is also available on the MC 420 with software option 9.

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.

Benefi ts 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 • process dataIntegrated NC function, and therefore an alternative to external • software solutionsAlready existing NC programs can be used•

Constraints:AFC cannot be used for analog spindles or in volts-per-hertz control mode.

Fast Contour Milling

40

Encoders

For speed and position control of the axes and spindle, HEIDENHAIN offers both incremental as well as 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 for an accurate reference to be established 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 specifi c axes via the PLC during operation (reactivation of parked axes).

Output signals Incremental encoders with sinusoidal output signals with » 1 VPP levels 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 is fi tted with the serial EnDat 2.1 interface 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, angular or rotary encoders from HEIDENHAIN can be connected to all position encoder inputs of the MC und CC 424 B.

Incremental and absolute rotary encoders from HEIDENHAIN can be connected to all speed encoder inputs of the CC 42x.

Inputs Signal level/

Interface1)

Input frequency1)

Position Shaft speed

Incremental » 1 VPP 33 kHz/350 kHz 350 kHz

absolute EnDat 2.1» 1 VPP

–33 kHz/350 kHz

–350 kHz

1) Switchable

41

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 ballscrew pitch errors and sag 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 length measurements. In this case the hysteresis is within the controlled system.

Reversal spikes In circular movements, reversal peaks can occur at quadrant transitions due to mechanical infl uences. The iTNC 530 can compensate for these reversal peaks.

Static friction 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 this problem condition.

Sliding friction Sliding friction is compensated by the speed controller of the iTNC 530.

Thermal expansion To compensate thermal expansion, the machine’s expansion behavior must be known.

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

Error Compensation

42

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 fi rst you defi ne the resolution of the measurement and defi ne 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.

Calibration sphere

(accessory)HEIDENHAIN offers calibration spheres as accessories for the measurement of rotary axes with KinematicsOpt:KKH 100 Height 100 mm ID 655 475-02KKH 250 Height 250 mm ID 655 475-01

KinematicsComp

(option 52)Narrow workpiece tolerances require high machine accuracy. However, machine tools inevitably have errors due to mounting or 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 5-axis 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 machine's 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 compensation-value 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.

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 as per ISO 230-1: EBA

Fault characteristics as per ISO 230-1: EXA

43

Monitoring Functions

During operation, the iTNC 530 monitors:

Amplitude of the encoder signals• Edge separation of the encoder signals• Absolute position for encoders with distance-coded reference • marksCurrent 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• Running time of the PLC program• Motor current• Motor temperature• Temperature of power module• DC-link voltage•

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 into the machine’s EMERGENCY STOP loop is checked when the control system is switched on.

In the event of an error, the iTNC 530 displays a message in plain language.

DCM –

Dynamic Collision

Monitoring

option 40 (only on MC 422 D)

The iTNC 530 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 defi ne three-dimensional collision objects within the working space of the machine that are to be monitored by the iTNC during all machine motions, including those made by swivel heads and tilting tables. If two objects monitored for collision come within a defi ned 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 defi ne collision objects • (including clamping fi xtures).Collisions between machine components (such as swivel heads) • and the workpiece cannot be detected.Collisions during motions with handwheel superimpositioning • with M118 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 fi xtures and tool carriers from collisions. These can be selected from a library, adapted and inserted in the machine’s kinematics model.

The 3-D collision objects are confi gured with the commissioning software KinematicsDesign.

44

KinematicsDesign

(accessory)KinematicsDesign is a PC program for creating adaptable kinematic confi gurations. KinematicsDesign also provides a convenient way to confi gure the DCM 3-D collision monitoring function (option 40) and to put it into service.

The software makes complete generation possible of theAssignment table• Kinematics description table• Kinematics subfi le description table• Tool-carrier kinematics description table• Defi nition table for collision-monitored objects (CMO)•

and the transfer of confi guration fi les between control and PC.

If KinematicsDesign is connected to a control online (operation is also possible with the programming station software of the iTNC 530), then machine movements or the working space can be simulated when the axes are moved and DCM is active.Collisions that occur between defi ned machine objects, or machine components in danger of collision, are displayed in a color that you defi ne.

The comprehensive possibilities for displaying range from a pure listing of the transformation chain to a wire model to the depiction of the entire working envelope.

45

The iTNC 530 contouring control is used in connection with the HEIDENHAIN inverter systems with fi eld-oriented control. As an alternative, an analog nominal speed value can be output.

CC 422

controller unit

The individual control loops of the CC 422 controller unit are divided into several controller groups. A separate DSP is assigned to each of these controller groups and a separate PWM frequency can be set for each group (max. 10 kHz).

Normally the iTNC 530 and the HEIDENHAIN inverter system operate with a PWM frequency of 5 000 Hz. For high-speed spindles, higher PWM frequencies are required. If a frequency higher than 5 000 Hz is set for a controller group, only one control loop remains available in this group (see Technical Manual for the iTNC 530). The increased PWM frequency also reduces the permissible rated current values of the inverters (see Inverters).

CC 424 B

controller unit

With the CC 424 B controller unit, the PWM basic frequency can be set for each controller assembly (e.g. 4 kHz). The CC 424 B with up to 6 or 8 control loops consists of one controller assembly, the version with up to 10, 12 or 14 control loops consists of two controller assemblies. Possible basic frequencies are 3.33 kHz, 4 kHz or 5 kHz. For high-speed spindles, this frequency may be doubled (e.g. 8 kHz for HF spindles). (see the Technical Manual for the iTNC 530).

Maximum

spindle speed

The maximum spindle speed is calculated as follows:

nmax =

fPWM = PWM frequency in HzNPP = number of pole pairs

fPWM · 60 000 min–1

NPP · 5000 Hz

Spindle

46

Operating-mode

switchover

Two parameter blocks can be stored for controlling the spindle (e.g. for wye/delta connection). You can switch between wye and delta connection in the PLC.

Analog nominal

speed value

Up to 100 000 min–1

Position-controlled

spindle

The position of the spindle is monitored by the iTNC 530.

Encoder HEIDENHAIN rotary encoder with sinusoidal voltage signals (1 VPP) or EnDat interface.

Tapping There are special cycles for tapping with or without fl oating tap holder. For tapping without fl oating 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 specifi c nominal speed can be defi ned 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. Since the second spindle is controlled in place 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.

47

Commissioning and Diagnostic Aids

The iTNC 530 provides comprehensive, internal commissioning and diagnostic aids. In addition, highly effective PC software for diagnosis, optimization and remote control is available.

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 (accessory) The DriveDiag software for PCs enables the service technician to make a simple and fast diagnosis of the drives. It also makes it possible to display and evaluate the electronic ID labels.

The following diagnostic functions are available:Reading and displaying the electronic ID labels of QSY motors • with EQN 1325 or ECN 1313Reading and displaying the electronic ID labels of the UVR 1xx D • and UM 1xx D inverter modulesDisplaying and evaluating the internal control conditions and the • status signals of the inverter componentsDisplaying the analog values available to the drive controller• Automatic test for proper function of motors and inverters• Automatic test of position and speed encoders•

TNCopt (accessory) PC software for commissioning digital control loops

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

Requirements DriveDiag and TNCopt place the following demands on the PC:Windows 2000/XP/Vista operating system• At least 15 MB of free hard-disk space• Serial or Ethernet interface•

Context-sensitive

help

A HELP key provides the user with context-sensitive help. This means that in the event of an error message, the iTNC 530 displays information on the cause of the error and proposes solutions. The machine manufacturer can also use this function for PLC error messages.

48

Oscilloscope The iTNC 530 features an integrated oscilloscope. Both X/t and X/Y graphs are possible. The following characteristic curves of six channels can be recorded and saved:

Actual value of axis feed rate• Nominal value of axis feed rate• Contouring feed rate• Actual position• Nominal position• Nominal position after nominal position value fi lter• Following error of the position controller• Actual values for torque, speed, acceleration and jerk• Nominal values for voltage, speed, acceleration and jerk• Analog nominal speed value• Integral-action component of the nominal current value• Torque-determining nominal current value• Utilization of drive• Current value of I• 2t monitoring of motor and power moduleMechanical and electrical power• Block number of the NC program• Content of PLC operands• Measuring signals from the position encoder• Difference between position and speed encoder• Difference between synchronized axes• Circular interpolation test•

TNCscope

(accessory)PC software for transferring the oscilloscope fi les to a PC

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 instruction list in each line in HEX or decimal code. The active lines of the instruction 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 diagnosis, remote monitoring, and remote control of the iTNC 530. For further information, ask for the Remote Diagnosis with TeleService Technical Information sheet.

Logic diagram

Nominal and actual position

49

Integral PLC

The PLC program is created by the machine manufacturer either at the control or using the PLC development software PLCdesign (accessory).

Machine-specifi c 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 expansion If the PLC inputs/outputs of the MC 422 C/D are insuffi cient, the additional input/output units PL 510, PL 511, PL 512 or PL 550 can be connected.

The PROFIBUS-DP compatible PLC input/output system must be confi gured with the PC software IOconfi g.

Rated operating

current per output

Logic unit: 0.15 A(For PL 5xx, see PLC Inputs/Outputs)

PLC programming Format Statement list

Memory Approx. 16 000 logic commandsSingle-processor version: At least 948 MB on hard diskDual-processor version: At least 957 MB on hard disk

Process memory 512 KB RAM

Cycle time † 10.8 ms

Instruction set • Bit, byte und word commands• Logical operations• Arithmetic commands• Comparisons• Terms in parentheses• Jump commands• Subprograms• Stack operations• Submit programs• 952 timers• 48 counters• Comments• PLC modules• 100 strings

Encryption of

PLC data

Encrypting the PLC partition (PLCE:) is an effective tool for the machine tool builder to prevent third parties from viewing or changing fi les. The fi les on the PLCE partition can only be read by the TNC or by using the correct OEM keyword.This ensures that OEM-specifi c know-how and special custom-designed solutions cannot be copied or changed.

The machine tool builder can also determine the size of the encrypted partition. The size is defi ned 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.

50

PLC window PLC error messages can be displayed by the iTNC 530 in the dialog line during operation.

Small PLC window The iTNC 530 can show additional PLC messages and bar diagrams in the small PLC window.

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.

PLC soft keys With the BF 150, the machine tool builder can defi ne his own soft keys on the screen, instead of the horizontal NC soft keys. In addition, he can defi ne his own PLC soft keys in the vertical soft-key row.

Large PLC window A complete PLC page can be shown as a window. PLC messages and graphics can be displayed.

Large PLC window .......................................

Small PLC window ........

51

PLCdesign

(accessory)PC software for PLC program developmentPLCdesign can be used to easily create PLC programs. Comprehensive examples of PLC programs are included.

Functions:Easy-to-use text editor• Menu-guided operation• Programming of symbolic operands• Modular programming method• “Compiling” and “linking” of PLC source fi les• Operand commenting, creation of a documentation fi le• Comprehensive help system• Data transfer between the iTNC 530 and the PC• Creation of PLC soft keys• Testing of the PLC program of the TNC 426/TNC 430 for symbol • confl icts on the iTNC 530

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-to-learn script language that supports the use of all necessary high-level language elements.

Python OEM Process can be universally used for machine functions and complex calculations, as well as to display special user interfaces.User-specifi c or machine-specifi c solutions can be effi ciently 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 TNC's full screen size.

52

Description of PLC

basic program

The PLC basic program serves as a basis for adapting the iTNC 530 to the requirements of the respective machine. It can be downloaded from the Internet.

The PLC basic program provides the following functions:Controlling all axes• Positioning the axes to 0 after the reference run• Axes with only one position encoder• Clamped axes• Homing the axes, reference end positions• Compensating the axis temperature• Axes with Hirth coupling• Feed rate control• Axes operated as C axes (moving the axes with the aid of • the spindle motor)Indexing fi xture• Gear stages for the spindle• Controlling and orienting the spindle• Activating tool-specifi c torque monitoring• Alternate operation (machining a workpiece alternately on • the left/right side of the machine)Manual or automatic tool change (pick-up device; single gripper • or dual gripper). There is, of course, a larger range of defi nitions to choose from; the respective type of tool changer must be adapted by the PLC programmer to the exact requirements of the specifi c machine.Help functions to confi gure the tool changer• Type of tool magazine (controlled by pulses or as an • asynchronous axis)PLC soft keys• Diagnosis of axes, spindle, tool changer and tool magazine• Displaying and managing PLC error messages• Displaying functions in the small PLC window• Hydraulic control• Electronic handwheel• Controlling the coolant system• Handling M functions• Lubrication• Chip conveyor• Touch Probes• Controlling the doors•

53

Original Equipment Manufacturer’s (OEM) Cycles

The machine manufacturer 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 OEM cycles is managed using the CycleDesign PC program. In addition, CycleDesign can be used to store help graphics and soft keys in BMP format on the hard disk of the iTNC 530.

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

Pallet 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 140, TL Micro or TL Nano tool touch probes (accessories). The iTNC 530 provides standard cycles for automatic tool measurement. It 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 movement can be controlled via PLC axes. The order of movement, as well as pallet and workpiece datums, must be defi ned in the pallet table by the user. The pallet table is freely confi gurable, 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.

54

Data Interfaces

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 100 BaseT Ethernet (Twisted Pair Ethernet) for connection to the data network.

Protocol The iTNC 530 communicates using the TCP/IP protocol.

Network connection NFS fi le server• Windows networks•

Data transfer rate Approx. 40 to 80 Mbps (depending on fi le 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

RS-422/V.11 Data interface according to EIA standard RS-422.Maximum transmission distance: 1 km

Data transfer rate 115 200; 57 600; 38 400; 19 200;9 600; 4 800; 2 400; 1 200; 600; 300; 150; 110 bps

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 for data security, which is improved as a result.

Blockwise data transfer and simultaneous program run

It is possible to run a program while it is being downloaded via the RS-232-C/V.24 or RS-422/V.11 interface and stored on the hard disk.

LSV2 Bidirectional transfer of commands and data according to DIN 66 019. The data is divided into blocks and transferred.

Adapter block For connecting the interface to the electrical cabinet or operating panel.RS-232-C/V.24 adapter 9-pin ID 363 987-02 25-pin ID 310 085-01RS-422 / V.11 adapter 9-pin ID 363 987-01

USB The MC 4xx features two USB 1.1 interfaces. One of them is permanently assigned to the touchpad of the TE 530 B keyboard unit. The other one is available for the connection of standard USB devices, such as the mouse, drives, etc. The USB interface is rated for a maximum supply current of 0.5 A.

USB cable Cable length up to 5 m ID 354 770-xxCable length 6 m to 30 mwith integrated amplifi er; USB 1.1 ID 624 775-xx

USB hub If you need further USB ports or if the supply current is not suffi cient, a USB hub is required. The USB hub from HEIDENHAIN offers four free USB ports.

Power supply: DC 24 V/max. 300 mA ID 582 884-02

Cover 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. ID 508 921-01

55

Software for Data Transfer

TNCremo

(accessory)This PC software package helps the user to transfer data between the PC and the iTNC 530. The software is available free of charge on the HEIDENHAIN homepage in the Services/Downloads area.

Functions:Data transfer• File management• Data backup• Reading out the log• Reading out the screen content• Pallet management• 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 control’s screen to the PC. This makes it very simple to monitor the machine.

ID 340 447-xx

56

DNC Applications with iTNC

The development environments on Windows operating systems are particularly well suited as fl exible platforms for application development in order to come to terms with the increasingly complex requirements of the machine’s environment. The fl exibility of the PC software and the large selection of ready-to-use 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 processStandard or customer-specifi c PC software that decidedly • increases process security and equipment availabilitySoftware solutions controlling the processes of manufacturing • systemsInformation exchange with job management software•

HEIDENHAIN DNC

(option 18)The HEIDENHAIN DNC software interface (available as of NC software 340 49x-02) of the iTNC 530 is an attractive communication platform for this purpose. It provides all the data and confi guration capabilities needed for these processes so that an external PC application can evaluate data from the control and, if required, infl uence 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.

ID 340 442-xx

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 ID 584 421-01Network license for 14 workstations ID 643 492-01 for 20 workstations ID 643 494-01

For more information about HEIDENHAIN DNC, RemoTools SDK and virtualTNC, refer to the brochure HEIDENHAIN DNC.

57

Dual-processor

computer

With the MC 422 C dual-processor computer the user can enjoy the advantages of the standard Windows XP operating system as user interface. One processor attends to the real-time tasks and the HEIDENHAIN operating system, while the second processor is available exclusively for the standard Windows operating system, giving the user access to the world of information technology.

Here, too, ease of use is the highest priority:

The operating panel comprises a complete PC keyboard with • touchpad.The high-resolution 15-inch color fl at-panel display shows both • the iTNC user interface and the Windows applications.Standard PC devices, such as a mouse or drives, can easily be • connected to a control’s USB ports.Both processors operate independently, thereby ensuring the • maximum possible operational reliability.

Keep the following in mind when installing Windows applications:

HEIDENHAIN does not assist you in installing Windows • applications, and offers no guarantee for the correct function of the applications you installed.HEIDENHAIN is not liable for faulty hard disk contents caused • by installing Windows updates or additional application software.If HEIDENHAIN is required to render service after programs or • data have been changed, HEIDENHAIN will charge you for the service costs incurred.

iTNC 530 with Windows XP

58

Mounting Instructions

Mounting attitude When installing an MC 422 C/D, CC 42x, UV(R) 1xx, UM xxx or

UE 2xx D, take note of the minimum spacing, space needed for servicing and circulation, and the appropriate length and location of the connecting cables.

Air outlet

Air inlet

Leave space for air circulation!Temperatures of > 150 °C may occur with the UE 21x D with integrated braking resistor; do not attach any temperature-sensitive parts!

Leave space for servicing!

Leave space for air circulation and servicing!

Leave space for servicing and connecting cables!

*) Leave space for exchanging the HDR hard disk

UV(R), UE, UM MC 42x, CC 42x

59

Mounting and

electrical

installation

Keep the following in mind during mounting and electrical installation:

National regulations for power installations• Interference and noise immunity• Conditions of operation• Mounting attitude•

Degrees of

protection

The following components fulfi ll 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•

Electromagnetic compatibility

Intended place of operation

The unit fulfi lls the requirements for a Class A device in accordance with the specifi cations in EN 55 022, and is intended for use in industrially zoned areas.

Protect your equipment from interference by observing the rules and recommendations specifi ed in the Technical Manual.

Likely sources of interference

Noise is mainly produced by capacitive and inductive coupling from electrical conductors or from device inputs/outputs, such as:

Strong magnetic fi elds from transformers or electric motors• Relays, contactors and solenoid valves• High-frequency equipment, pulse equipment and stray magnetic • fi elds from switch-mode power suppliesPower 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 signalsKeep 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 potential compensating lines with a cross section of 6 mm• 2

Use only genuine HEIDENHAIN cables, connectors and • couplings

60

Overall Dimensions

MC 422 C; MC 422 DCC 42x

MC 422 C/D – 5 position encoder inputsCC 422 – 6 control loopsMC 422 C/D – Without position encoder inputsCC 424 B – 6 control loopsCC 422 – 6 control loops

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61

MC 422 C/DCC 42x

MC 422 C/D – 10 position encoder inputsCC 422 – 10 or 12 control loopsMC 422 C/D – Without position encoder inputsCC 424 B – 8 or 10 control loops

62

MC 422 C/DCC 424 B

MC 422 C/D – Without position encoder inputsCC 424 B – 12 or 14 control loops

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BF 150

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TE 520 B; TE 530 B

TE 520 B: Without touchpadTE 530 B: With touchpad

f = Cutout in machine panelm = Mounting surface


TE 535 Q

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PL 510; PL 511; PL 512PL 550

Dimensions in mm

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Adapter Cable for HR 410 and HR 520

Mounting opening for wall thickness S † 4 Mounting opening for wall thickness S > 4

HR 410

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HRA 551 FS

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Line Drop Compensator for Encoders with EnDat Interface

RS-422/RS-232-C Adapter

Connection to KTY

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USB Hub

n = 0 to 4L = Ordering length

USB Extension Cable with Hubs

75

Documentation

Items supplied with the control include:1 User’s Manual for HEIDENHAIN conversational programming• 1 User’s Manual for DIN/ISO programming• 1 User’s Manual for Cycle Programming• 1 smarT.NC Programming Pilot (brief user’s programming guide)•

This documentation must be ordered separately in the language required.Further documentation is available from HEIDENHAIN.

Technical

documentation

Technical Manual for • iTNC 530 In PDF format on HEIDENHAIN FileBaseTechnical Manual for • Inverters and Motors ID 208 962-xx

Mounting Instructions for • TS 220 ID 312 821-91Mounting Instructions for • TS 440 ID 632 756-9xMounting Instructions for • TS 444 ID 632 757-9xMounting Instructions for • TS 640 ID 632 760-9xMounting Instructions for • TS 740 ID 632 761-9xMounting Instructions for • TT 140 ID 297 510-xxMounting Instructions for • TT 449 ID 664 914-xx

User

documentation

iTNC 530 For NC software 340 49x-xx

Conversational• User’s Manual ID 670 387-xxCycle Programming• User’s Manual ID 670 388-xx

DIN/ISO• User’s Manual ID 670 391-xxsmarT.NC• Pilot ID 533 191-xx

Miscellaneous

User’s Manual for • TNCremo As integrated help and in PDF formatUser’s Manual for • TNCremoPlus As integrated help and in PDF formatUser’s Manual for • PLCdesign As integrated help and in PDF formatUser’s Manual for • CycleDesign As integrated help and in PDF formatUser’s Manual for • IOconfi g As integrated help and in PDF formatUser’s Manual for • KinematicsDesign As integrated help and in PDF format

Other

documentation

iTNC 530• brochure ID 363 807-xxTouch Probes• brochure ID 208 951-xxInverter Systems• brochure ID 622 420-xxMotors• brochure ID 208 893-xxIPC 6110/IPC 6120• Product Information ID 630 601-xxHR 550 FS• Product Information PDFHEIDENHAIN DNC• brochure ID 628 968-xxProduct Overview• Remote Diagnosis with TeleService ID 348 236-xxTouch Probes• CD-ROM ID 344 353-xxiTNC 530 Presentation• CD-ROM ID 373 080-xxiTNC Programming Station• CD-ROMdemo version ID 384 565-xx

76

HEIDENHAIN Service

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 { +49 8669 31-3101 E-mail: [email protected] programming { +49 8669 31-3102 E-Mail: [email protected] programming { +49 8669 31-3103 E-mail: [email protected] systems { +49 8669 31-3104 E-mail: [email protected] controls { +49 8669 31-3105 E-mail: [email protected]

Machine calibration On request, HEIDENHAIN engineers will calibrate your machine’s 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 specifi c customers•

For more information on dates, registration, etc. call in Germany:{ +49 8669 31-2293 or 31-1695| +49 8669 31-1999E-mail: [email protected]

77

Other HEIDENHAIN Controls

TNC 320

contouring control

Information:TNC 320 brochure

Compact contouring control for • milling, drilling and boring

machines

Three (optionally four) closed-loop • axes plus one closed-loop spindleAnalog speed command interface•

Integrated keyboard and fl at-panel color display (15-inch) • Program memory: 10 MB on Compact Flash memory card (CFR)• Program input in HEIDENHAIN conversational language, DIN/• ISO programs entered via USB keyboardFK free contour programming• Subprogramming and fi xed cycles• User aids:• Programming graphics, verifi cation graphics, program-run graphicsProgramming aids:• Milling, drilling and boring cycles, parametric programming, coordinate transformation, subprogrammingMachining with rotary or tilting tables (option)• Tool and reference-point tables• Connection for one HR electronic handwheel and one • TS workpiece touch probeData interfaces: Ethernet 100BaseT, RS-232-C/V.24, USB 1.1•

TNC 620

contouring control

Information:TNC 620 brochure

Compact contouring control for • milling, drilling and boring

machines

Up to fi ve closed-loop • axes plus one open-loop spindleDigital drive control• via HSCI interfaceIntegrated keyboard and fl at-panel color display (15-inch) • Program memory on integrated hard disk• Program input in HEIDENHAIN conversational language, • DIN/ISO programs entered via USB keyboardFK free contour programming• Subprogramming and fi xed cycles• User aids:• Programming graphics, verifi cation graphics, program-run graphicsProgramming aids:• Milling, drilling and boring cycles, parametric programming, coordinate transformation, subprogrammingMachining with rotary and tilting tables (option)• Tool and reference-point tables• Connection for one HR electronic handwheel and one • TS workpiece touch probeData interfaces: Ethernet 100BaseT, RS-232-C/V.24, USB 1.1•

Symbole

5-axis machining .......................................34

A

Absolute encoders ....................................40Accessories .................................................8Adaptive Feed Control (AFC) ....................39Axes ..........................................................33Axis feedback control ...............................36

B

Backlash ....................................................41BF 150 ................................................ 22, 63BTS 150 .............................................. 22, 66

C

Cable overview .........................................30Calibration sphere .....................................42CC 422 ......................................................20CC 424 B ...................................................21Commissioning and diagnostic aids .........47Context-sensitive help ..............................47Controller unit ...........................................20Control loop cycle times ...........................37Control systems ........................................14Cutting data calculation ............................53CycleDesign ..............................................53

D

Data interfaces ..........................................54DCM ..........................................................43Digital control ............................................36DNC applications ......................................56Documentation .........................................75DriveDiag...................................................47Dual-processor version .............................57

E

Electromagnetic compatibility ..................59Electronic handwheels .............................24Encoders ...................................................40Encryption of PLC data .............................49Ethernet ....................................................54Export version ...........................................16

F

Feedforward control .................................36Following error ..........................................36

H

HEIDENHAIN DNC ...................................56HR 130 ............................................... 26, 71HR 150 ............................................... 26, 71HR 410 ............................................... 24, 68HR 520 ............................................... 24, 69HR 550 FS .......................................... 25, 70HRA 110 ....................................................26HRA 551 FS ........................................ 25, 70Hysteresis .................................................41

Subject Index

78

I

Incremental encoders...............................40Industrial PC ..............................................28I/O modules ..............................................23IPC 6110 ....................................................28IPC 6120 ....................................................28iTNC 530 with Windows XP .....................57

J

Jerk ............................................................37Jerk limiting ...............................................37

K

KinematicsComp ......................................42KinematicsDesign .....................................44KinematicsOpt ..........................................42

L

Linear axes ................................................33Linear error ................................................41Log ............................................................48Logic diagram............................................48Look-ahead ................................................39

M

Main computer .........................................16Master keyword ........................................18MB 420 .............................................. 22, 67MB 520 .............................................. 22, 67MC 422 C ..................................................60Monitoring functions ................................43Mounting information ...............................58

N

NC software license .................................19Nonlinear errors ........................................41

O

OEM cycles...............................................53OEM options .............................................53Oscilloscope..............................................48Overall dimensions ...................................60

P

Pallet management ...................................53PLA 4-4......................................................23PLB 510 .....................................................23PLB 511 .....................................................23PLB 512 .....................................................23PLB 550 ....................................................23PLC ............................................................49PLC axes ............................................ 35, 50PLC basic program ...................................52PLC inputs/outputs ...................................23PLC positioning .........................................50PLC programming ....................................49PLC soft keys ............................................50PLC windows ............................................50PLD 16-8 ...................................................23PROFIBUS interface PCB .........................23Python OEM Process ...............................51

R

RemoTools SDK ........................................56Reversal peaks ..........................................41Rotary axes ...............................................33RS-232-C/V.24 ...........................................54RS-422/RS-232-C adapter .........................73RS-422/V.11 ...............................................54

S

Second spindle .........................................46SIK component .........................................18Sliding friction ...........................................41Snap-on keys .............................................27Software options ......................................17Spindle ......................................................45Spline interpolation ...................................39Stick-slip friction ........................................41Synchronized axes ....................................35

T

Table function ............................................48Tapping ......................................................46TE 520 B ....................................................64TE 530 B ............................................. 22, 64TE 535 Q ............................................. 22, 64Technical description .................................33TeleService ................................................48Thermal expansion ...................................41Tilting the working plane ..........................34TNCopt ......................................................47TNCremo...................................................55TNCremoPlus ...........................................55TNCscope .................................................48Tool management .....................................53Torque control ...........................................35Touch probes .............................................29Trace function............................................48

U

USB ...........................................................54USB cable .................................................54USB hub ..............................................54, 74

V

virtualTNC ..................................................56

NO HEIDENHAIN Scandinavia AB7300 Orkanger, Norwaywww.heidenhain.no

PH Machinebanks` CorporationQuezon City, Philippines 1113E-mail: [email protected]

PL APS02-489 Warszawa, Polandwww.apserwis.com.pl

PT FARRESA ELECTRÓNICA, LDA.4470 - 177 Maia, Portugalwww.farresa.pt

RO HEIDENHAIN Reprezentanta RomaniaBrasov, 500338, Romaniawww.heidenhain.ro

RS Serbia − BG

RU OOO HEIDENHAIN125315 Moscow, Russiawww.heidenhain.ru

SE HEIDENHAIN Scandinavia AB12739 Skärholmen, Swedenwww.heidenhain.se

SG HEIDENHAIN PACIFIC PTE LTD.Singapore 408593www.heidenhain.com.sg

SK KOPRETINA TN s.r.o.91101 Trencin, Slovakiawww.kopretina.sk

SL Posredništvo HEIDENHAINNAVO d.o.o.2000 Maribor, Sloveniawww.heidenhain-hubl.si

TH HEIDENHAIN (THAILAND) LTDBangkok 10250, Thailandwww.heidenhain.co.th

TR T&M Mühendislik San. ve Tic. LTD. STI·.

34728 Ümraniye-Istanbul, Turkeywww.heidenhain.com.tr

TW HEIDENHAIN Co., Ltd.Taichung 40768, Taiwan R.O.C.www.heidenhain.com.tw

UA Gertner Service GmbH Büro Kiev 01133 Kiev, Ukrainewww.gertnergroup.com

US HEIDENHAIN CORPORATIONSchaumburg, IL 60173-5337, USAwww.heidenhain.com

VE Maquinaria Diekmann S.A. Caracas, 1040-A, VenezuelaE-mail: [email protected]

VN AMS Co. LtdHCM City, VietnamE-mail: [email protected]

ZA MAFEMA SALES SERVICES C.C.Midrand 1685, South Africawww.heidenhain.co.za

DK TP TEKNIK A/S2670 Greve, Denmarkwww.tp-gruppen.dk

ES FARRESA ELECTRONICA S.A.08028 Barcelona, Spainwww.farresa.es

FI HEIDENHAIN Scandinavia AB02770 Espoo, Finlandwww.heidenhain.fi

FR HEIDENHAIN FRANCE sarl92310 Sèvres, Francewww.heidenhain.fr

GB HEIDENHAIN (G.B.) LimitedBurgess Hill RH15 9RD, United Kingdomwww.heidenhain.co.uk

GR MB Milionis Vassilis17341 Athens, Greecewww.heidenhain.gr

HK HEIDENHAIN LTDKowloon, Hong KongE-mail: [email protected]

HR Croatia − SL

HU HEIDENHAIN Kereskedelmi Képviselet1239 Budapest, Hungarywww.heidenhain.hu

ID PT Servitama Era ToolsindoJakarta 13930, IndonesiaE-mail: [email protected]

IL NEUMO VARGUS MARKETING LTD.Tel Aviv 61570, IsraelE-mail: [email protected]

IN HEIDENHAIN Optics & ElectronicsIndia Private LimitedChetpet, Chennai 600 031, Indiawww.heidenhain.in

IT HEIDENHAIN ITALIANA S.r.l.20128 Milano, Italywww.heidenhain.it

JP HEIDENHAIN K.K.Tokyo 102-0083, Japanwww.heidenhain.co.jp

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

ME Montenegro − SL

MK Macedonia − BG

MX HEIDENHAIN CORPORATION MEXICO20235 Aguascalientes, Ags., MexicoE-mail: [email protected]

MY ISOSERVE Sdn. Bhd56100 Kuala Lumpur, MalaysiaE-mail: [email protected]

NL HEIDENHAIN NEDERLAND B.V.6716 BM Ede, Netherlandswww.heidenhain.nl

AR NAKASE SRL.B1653AOX Villa Ballester, Argentinawww.heidenhain.com.ar

AT HEIDENHAIN Techn. Büro Österreich83301 Traunreut, Germanywww.heidenhain.de

AU FCR Motion Technology Pty. LtdLaverton North 3026, AustraliaE-mail: [email protected]

BA Bosnia and Herzegovina − SL

BE HEIDENHAIN NV/SA1760 Roosdaal, Belgiumwww.heidenhain.be

BG ESD Bulgaria Ltd.Sofi a 1172, Bulgariawww.esd.bg

BR DIADUR Indústria e Comércio Ltda.04763-070 – São Paulo – SP, Brazilwww.heidenhain.com.br

BY BelarusGERTNER Service GmbH50354 Huerth, Germanywww.gertnergroup.com

CA HEIDENHAIN CORPORATIONMississauga, OntarioL5T2N2, Canadawww.heidenhain.com

CH HEIDENHAIN (SCHWEIZ) AG8603 Schwerzenbach, Switzerlandwww.heidenhain.ch

CN DR. JOHANNES HEIDENHAIN (CHINA) Co., Ltd.Beijing 101312, Chinawww.heidenhain.com.cn

CZ HEIDENHAIN s.r.o.102 00 Praha 10, Czech Republicwww.heidenhain.cz

DE HEIDENHAIN Vertrieb Deutschland83301 Traunreut, Deutschland{ 08669 31-3132| 08669 32-3132E-Mail: [email protected]

HEIDENHAIN Technisches Büro Nord12681 Berlin, Deutschland{ 030 54705-240

HEIDENHAIN Technisches Büro Mitte08468 Heinsdorfergrund, Deutschland{ 03765 69544

HEIDENHAIN Technisches Büro West44379 Dortmund, Deutschland{ 0231 618083-0

HEIDENHAIN Technisches Büro Südwest70771 Leinfelden-Echterdingen, Deutschland{ 0711 993395-0

HEIDENHAIN Technisches Büro Südost83301 Traunreut, Deutschland{ 08669 31-1345

Vollständige und weitere Adressen siehe www.heidenhain.deFor complete and further addresses see www.heidenhain.de

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363 808-2C · 7.5 · 8/2011 · H · Printed in Germany

Documents

iTNC 530 Information for the Machine Tool · PDF fileInformation for the Machine Tool Builder August 2011. 2 ... † HEIDENHAIN inverter systems recommended ... TS 640 or TS 740 workpiece