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Technical Manual

iTNC 530

NC Software 340 490-02 340 491-02 340 492-02 340 493-02

September 2006

Contents

Volume I

Update Information Introduction Mounting and Electrical Installation Machine Parameters Modules, Markers and Words Conguring the Axes and Spindle

Volume II

CC 424 Controller Unit Machinen Integration PLC Programming Data Interface iTNC 530 with Windows 2000 Error Messages Subject Index

1 2 3 4 5 6 7 8 9 10 11 12 13

1 Update Information
1.1 General Information
Update Information for the iTNC 530 appears at irregular intervals, often as part of a new software version. This is preliminary information in PDF format, containing brief descriptions of new software functions as well as new hardware components. After the Update Information has been published, the new items are included in the iTNC 530 Technical Manual. Each Update Information is saved in the HEIDENHAIN FileBase on the Internet, where registered users can access it under http://filebase.heidenhain.de. The files are in the NC Milling iTNC530/Documentation folder in the FileBase. Registered users of the HEIDENHAIN FileBase receive an e-mail message when a new Update Information appears, as well as upon the publication of a new printed version of the Technical Manual for the iTNC 530.

September 2006

General Information

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HEIDENHAIN Technical Manual iTNC 530

1 Update Information No. 1


1.1 Releases
The following NC software was released: NC software 340 420-02 and 340 421-02 NC software 340 420-03 and 340 421-03 NC software 340 420-04 und 340 421-04 NC software 340 420-05 and 340 421-05 December 2001 January 2002 March 2002 May 2002

1.2 NC Software 340 420-xx


NC Software 340 420-02 Machine Parameters Export version 340 421-02 Release December 2001

MP1086.x is new: Maximum permissible jerk during single-axis movements at rapid traverse for the operating modes Program Run Full Sequence, Program Run Single Block und Positioning with Manual Data Input Input: 0: Function inactive 0.1 to 1000.0 [m/s3] MP7365.x has been expanded: Color settings of the oscilloscope MP7365.0 = $0FFFFFF Background MP7365.1 = $0808080 Grid MP7365.2 = $00000FF Cursor and text MP7365.3 = $0FF0000 Selected channel MP7365.4 = $0C08030 Channel 1 MP7365.5 = $000FF00 Channel 2 MP7365.6 = $0FF00FF Channel 3 MP7365.7 = $00000FF Channel 4 MP7365.8 = $0FFCF00 Channel 5 MP7365.9 = $000CFFF Channel 6 The path acceleration is calculated from the axis proportions. New signals in the integrated oscilloscope: I2-t monitoring of the motor I2-t monitoring of the power module Utilization of the motor Position difference in gantry axes The oscilloscope has six channels; of those, no more than four can display data from the current and speed controller. The signals of the oscilloscope can be referenced to the datum line and are therefore optimally adjusted in the display.

Configuring the Axes and Spindle

October 2003

Releases

11

Machine Integration

A starting and ending time can be entered for the log. An internal EMERGENCY STOP can be simulated with the code number FAILTEST in order to check the wiring of the machine. The control-is-ready output is reset. The NC and PLC are no longer operable. If the control is switched off by a POWERFAIL, Power Fail Interrupt is entered in the log. If no value is saved during the probing process, the error message No measured value saved <axis> appears. Extended ranges of the PLC operands: Markers M0 to M9999 (M4000 to M5999 are reserved for NC/PLC) Bytes B0 to B9999, words W0 to W9998, double words D0 to D9996 (B128 to B2047 reserved for NC/PLC) Timers T0 to T999 Counters C0 to C143 The functions FN15: PRINT and FN16: F-PRINT make it possible to write data from an OEM cycle to the PLC partition also.

PLC Programming

Miscellaneous

Enabled directories of a Windows computer can also be connected as a network drive: MOUNTDEVICE: //<computer name</<release name> MOUNTPOINT: <device name>: FILESYSTEMTYPE: smb OPTIONS: ip=<iii.iii.iii.iii>,username=<user name>, workgroup=<group>,password=<password> In the settings for network operation of the iTNC 530, the name and path to an ASCII file can be entered in the DOMAIN column. In this file, the IP addresses of network drives can be assigned to computer names. In the network settings, the computer name is then entered instead of the IP address. Example: PC1 160.1.180.20 PC2 160.1.180.21 In Cycles 202, 204 and 209 the spindle angle Q336 can be entered negative. New, expanded search function. If the control is not properly shut down, the file system is checked during the next startup and the result is entered in the log.

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HEIDENHAIN Technical Manual iTNC 530

NC Software 340 420-03 Machine Parameters

Export version 340 421-03

Release January 2002

MP4040 is new: Setting a PLC output after shutting down the control Input: 0 = do not set a PLC output 1 = only after shut down over Module 9279 2 = after shut down over Module 9279 or soft key MP4041 is new: Time after shut down of the control until setting the PLC output from MP4042 Input: 0 to 1000 [s] MP4042 is new: PLC output to be set after shutting down the control Input: 0 to 31 If more than four channels in the oscilloscope are to display data from the current and speed controller, the error message channel <number> cannot be displayed appears. During execution of field orientation there is a display of progress. A display of progress appears while the log file is created over the code number LOGBOOK. The results of evaluation of the soft-key resource file of the vertical soft keys is saved in an ASCII file along with the name <name of the soft-key resource file>.SYS.LOG. When the pocket table TOOL_P.TCH is reset, the data are taken over from the file PLC:\PROTO\PROTOTYP.TCH if it exists. Module 9279 expanded: Mode 2: Control shut down depending on MP4040, MP4041 and MP4042 The A, B and C axes can be used a helical axis.

Configuring the Axes and Spindle

Machine Integration

PLC modules

Miscellaneous

NC Software 340 420-04

Export version 340 421-04

Release March 2002

October 2003

NC Software 340 420-xx

13

NC Software 340 420-05 Machine Parameters

Export version 340 421-05

Release May 2002

MP1011 is new: Limit of rapid traverse on the path Input: 10 to 300 000 [mm/min] or [/min] MP1061 is new: Limitation of the path acceleration Input: 0.001 to 100.000 [m/s2] or [1000/s2] MP1146.x is new: When the control is switched off, the actual position of the axes is saved with an absolute encoder. During switch-on it is compared with the position values read by the encoder. If the positions differ by more than the difference defined in MP1146.x, a pop-up window appears with both positions. The new position must be confirmed with a soft key. If it is not confirmed, the error message Check the position encoder <axis> appears. Input: 0.0000 to 300.0000 [mm] MP1355 is new: With MP1355 you can set a double reference run. First, the absolute position of the speed encoder is read over the EnDat interface. If at a later time the reference mark of the position encoder is traversed, the control continues to work with this reference. For operation of the double reference run, the distance between the speed encoder and position encoder must be entered in MP1356.x. Format: %00000000000000 Input: 0: Reference run as defined in MP1350.x 1: Double reference run MP1356 is new: Distance between speed and position encoder for double reference run. After the double reference run has been activated in MP1355, when the reference mark is traversed for the first time the message Set MP1356.<axis number> to <value> appears. Enter this value in MP1356.x. Input: 99 999.9999 to +99 999.9999 [mm] or [] MP2202.x is new: MP2202.x overwrites the entry Line count of the rotary encoder (STR column) from the motor table for the selected motor (entry in MP2200.x). The new value is not saved with the motor table. Input: *: Input from the motor table active 0: No speed encoder (volts-per-hertz control mode) 1 to 999 999 MP2204.x is new: MP2204.x overwrites the entry Counting direction (DIRECT. column) from the motor table for the selected motor (entry in MP2200.x). The new value is not saved with the motor table. Input: *: Input from the motor table active +: Positive counting direction : Negative counting direction

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HEIDENHAIN Technical Manual iTNC 530

MP2206.x is new: MP2206.x overwrites the entry Type of encoder (SYS column) from the motor table for the selected motor (entry in MP2200.x). The new value is not saved with the motor table. Input: *: Input from the motor table active 0: No speed encoder (volts-per-hertz control mode) 1: Incremental rotary encoder with Z1 track 2: Aligned, absolute rotary encoder with EnDat interface 3: Absolute linear encoder with EnDat interface 4: reserved 5: Nonaligned absolute rotary encoder with EnDat interface 6: Incremental rotary encoder without Z1 track MP7370.x is new: Color settings of the small PLC window MP7370.0 = $0ECECEC Background MP7370.1 = $0FF0000 Color 1 MP7370.2 = $000FF00 Color 2 MP7370.3 = $00000FF Color 3 MP7370.4 = $0C0C0C0 Color 4 MP7370.5 = $0FFFFFF Color 5 MP7370.6 = $0000000 Color 6 MP7370.7 = $0000000 Color 7 MP7370.8 = $0000000 Color 8 MP7370.9 = $0000000 Color 9 MP7370.10 = $0000000 Color 10 MP7370.11 = $0000000 Color 11 MP7370.12 = $0000000 Color 12 MP7370.13 = $0000000 Color 13 MP7370.14 = $0000000 Color 14 MP7350 (frame of window) is used as color 15. MP7691 is new: With MP7691, the size of a log file can be given in which messages of the operating system are recorded. Only HEIDENHAIN can evaluate with log file. Set MP7691 = 0. Input: 0: Function inactive 1 to 10 [MB] Configuring the Axes and Spindle Previously, an incorrect setting of the axis configuration over the kinematic table could be corrected only by a change of the path in OEM.SYS and a restart of the control. To make this possible now also for the machine operator, the new column DOC was introduced in the assignment table. In this column, the machine tool builder can enter a comment on the kinematics. By entering the code number KINEMATIC, the machine tool builder calls a selection window with the entries of the column DOC. After a new kinematic configuration is selected, the control resets. After the code number FAILTEST is entered, before the simulation of an internal emergency stop, a message window is shown prompting execution of the test by soft key. In the integrated oscilloscope, the RESTORE SCREEN soft key can be used to reload the *.DTA signals saved in a file.

October 2003

NC Software 340 420-xx

15

PLC Programming

FN18: SYSREAD has been expanded: File information can be interrogated from selected files. ID56 NR1: Number of lines of the selected tool table NR2: Number of lines of the selected datum table NR3 IDX<Number of the first of 9 successive Q parameters for the axes X, Y, Z, A, B, C, U, V, W>: Quantity of the axes defined in the selected datum table (function identical with FN18: SYSREAD ID990 NR3) Module 9035 Reading status information

PLC modules

Transferred number 28 Machine mode in background

Return code 3: Tool table (in editing mode) 4: Pocket table (in editing mode)

Module 9163 Switching the modes of operation The module was expanded by an error code. Error detection: Marker M4203 W1022 Value 0 1 1 2 Meaning Operating mode switched Error code in W1022 Switching not possible for this control loop Incorrect operating mode or incorrect control-loop number

Miscellaneous

The help graphics of the probing and fixed cycles for the BF 150 were revised. The maximum input value for the LBREAK column of the tool table was increased from 0.9999 to 3.2767. When the MOD key is pressed, the Id. Nr. of the setup software is no longer displayed, since the NC software and the associated setup software are always released together. In Cycle 403 (ROT IN ROTARY AXIS) you can enter in Q337 whether the rotary axis is set after alignment to 0. Program section repeats and subprograms are displayed in a new status window. There is a zoom function in the 3-D display of the graphic in the Test Run. The status of the Machining time ON/OFF soft key in the Test Run is retained even after a power interruption. If another NC software is entered in the SIK as that installed, a message window appears after control startup that the control can be operated only as a programming station. NC error messages with more than 32 characters are displayed in two lines.

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HEIDENHAIN Technical Manual iTNC 530

1.3 Difference in the Tool-Change Macro between TNC 4xx and iTNC 530
In the TNC 426 / TNC 430, the tool number and the index are programmed as a number with one decimal place and read as such with FN18:SYSREAD ID60 NR1. In the iTNC 530 the tool number and index are treated as two separate parameters. The tool number is read with FN18: SYSREAD ID60 NR1 and the index with FN18: SYSREAD ID60 NR8. If a tool change macro of the TNC 426 / TNC 430 is used on the iTNC 530 in connection with indexed tools, the index is not transferred! Example TNC 426 / TNC 430 Indexed tool with number 4.1 FN18: SYSREAD Q1 = ID60 NR1 TOOL CALL Q1 Indexed tool with number 4.1 FN18: SYSREAD Q1 = ID60 NR1 FN18: SYSREAD Q2 = ID60 NR8 TOOL CALL Q1,Q2 Here 4.0 is read. Here 0.1 is read. T4 and index 1 are set here. 4.1 are read here. T4 and index 1 are read here.

Example iTNC 530

October 2003 Difference in the Tool-Change Macro between TNC 4xx and iTNC 530

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HEIDENHAIN Technical Manual iTNC 530

1 Update Information No. 2


1.1 Releases
The following versions of the NC software were released: NC software 340 420-06 and 340 421-06 NC software 340 420-07 and 340 421-07 NC software 340 422-01 and 340 423-01 July 2002 August 2002 August 2002

1.2 NC Software 340 420-xx


NC software 340 420-06 Machine parameters Export version 340 421-06 Release July 2002

MP110.x and MP111.x were expanded: An error message appears when values are entered for position encoder inputs that do not exist. The maximum input range of MP960.x was increased from +/ 99 999.9999 to +/ 1.79769313486E+308 (= 1.79769313486 10308). MP2160 has been expanded into MP2160.x: Input value 2 selects operation with HEIDENHAIN EcoDyn synchronous motors. For this to function, you must select from the motor table the motors with the designation QSY1xxx EcoDyn or QSY1xxx EcoDyn EnDat for MP2200.x. MP2195 is new: Suppress error messages from the HEIDENHAIN supply units Input: %xxxxxxxx 0: Error message is not suppressed 1: Error message is suppressed Bit 0: Reserved Bit 1: ERR.UZ.GR signal Bit 2: ERR.TMP signal Bit 3: Reserved Bit 4: ERR.IZ.GR signal Bit 5: RDY.PS signal Bit 6: ERR.ILEAK signal Bit 7: Reserved MP2220 has been expanded: Bit 1 Monitoring the rotational direction This monitoring function cannot be switched off for synchronous motors (entry SM in the column TYPE of the motor table). Bit 3 Activated motor brakes cause a change of the controlled system. This change can lead to vibrations when the controller is switched off while the brakes are on. Bit 3 = 0: Suppress vibrations Bit 3 = 1: Vibrations are allowed MP2304.x is new: Reference value for I2t monitoring of the power module Input: 0 to 1000.000 [ rated current of power module] 0: I2t monitoring of the power module switched off 1: Rated current of power module as reference value

October 2003

Releases

11

MP2308.x is new: Time between the output of the braking signal BRK (X51 to X62) and the switch-off of the controller (overlap time). Input: 0.001 to 0.500 [s] 0 = 0.200 s MP7263 has been expanded: With bit 1 you can configure the output of the column in the pocket table during backup and during conversion from binary format to ASCII. Bit 1 = 0: Output only the displayed columns Bit 1 = 1: Output all columns MP7357.x has been expanded: Color settings of the machine soft-key display MP7357.2 = $0000000 Inactive soft-key row MP7357.3 = $00000FF Active soft-key row MP7358.x has been expanded: Color settings of the programming soft-key display MP7357.2 = $0000000 Inactive soft-key row MP7357.3 = $00000FF Active soft-key row MP7370.x has been expanded: Color settings of the small PLC window MP7370.15 = $0FF2020 Color 15 MP7481.x is new: For each tool change operation between magazines you can specify the sequence with which the new tool and the tool be returned are to be output. M4540 remains in effect. Input: %xxxx 0: First, output the pocket of the tool to be returned 1: First, output the pocket of the new tool Bit 0: New tool from magazine 1 Bit 1: New tool from magazine 2 Bit 2: New tool from magazine 3 Bit 2: New tool from magazine 4 MP7481.0 Tool to be returned to magazine 1 MP7481.1 Tool to be returned to magazine 2 MP7481.2 Tool to be returned to magazine 3 MP7481.3 Tool to be returned to magazine 4 MP7482 is new: You can specify independently for each magazine whether it should operate with variable or fixed pocket coding. MP7480.x must be set to 3 or 4. Input: %xxxx 0: Magazine does not use fixed pocket coding 1: Magazine uses fixed pocket coding Bit 0: Magazine 1 Bit 1: Magazine 2 Bit 2: Magazine 3 Bit 3: Magazine 4 MP7684 has been expanded: Bit 7 Reserved Configuring the axes and spindle After switching on the controller (Module 9161) there is a delay of 50 ms in the switch-on of the current controller. This also delays the acknowledgment over Module 9162 by 50 ms. This may have to be taken into account in the PLC program.

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Machine integration

In the log, the end of an NC macro is indicated with the entry MACEND. If a *.PET table contains more than 999 PLC error messages, the excessive messages are ignored and the error message PET table: Too many lines appears. In the manual operating modes, the screen switchover key is active after the M or S function has been started. This makes it possible to display a PLC window when an M function starts. M4185 can determine whether an internal stop was performed. The marker must be reset by the PLC. New possible entries in the soft-key resource file *.SPJ: The entry VROOT in the header of the main menu defines a menu for the vertical soft-key row, while HROOT defines it for the horizontal row. The entry EMODE in the heading of the main menu defines a menu for the programming modes, and the entry MMODE defines a menu for the machining modes. The entry ENABLE: <marker> locks (marker = 1) or enables (marker = 0) a soft key. The entry STATUS: <marker or word> assigns an operand to a soft key (in addition to W302/W304). When the soft key is pressed, the marker is set or the soft-key number is entered in the word. The entry POPUPMENU: <menu name> displays a soft-key menu in the respective other soft-key row. The entry CLOSEPOPUPMENU closes this soft-key menu again. The entry LARGEWINDOW: <mask file for PLC window> or SMALLWINDOW: <mask file for PLC window> opens a large PLC window with the specified mask file. LARGEWINDOW opens a large PLC window over the entire screen, SMALLWINDOW opens a large PLC window instead of the graphic/status window. The entry CLOSEPLCWINDOW closes the PLC window again. The entry FirstInGroup indicates the first RADIO soft key in a group of RADIO soft keys, if more than one group with RADIO soft keys exists in a soft-key menu. If in addition to FirstInGroup, the entry STATUS: <word> also exists, the number of the pressed soft key is saved in the word (beginning with 0). The entries FirstInGroup and STATUS: <word> can also be used for groups of CHECK soft keys. The WATCH LIST soft key in the PLC main menu is for PLC diagnosis. With the WATCH LIST function you can create a table with dynamic display of the states of the selected operands FN18: SYSREAD ID52 NR2 IDX<tool number> finds the corresponding tool magazine.

PLC programming

October 2003

NC Software 340 420-xx

13

PLC modules

Module 9136 Switching the touch probe on/off Module 9136 switches a touch probe on X12 on or off once. If the touch probe does not supply a ready signal, and if M4056 is set (NC stop for deflected touch probe in all operating modes), the feed-rate enable is reset. Call: PS B/W/D/K <Touch probe state> 0: Switch off touch probe 1: Switch on touch probe 9136

CM

Error detection: Marker M4203 W1022 Value 0 1 1 Meaning Touch probe on or off Error code in W1022 Invalid touch probe state

Module 9157 Drive controller status The module was expanded by the status information 4 (spindle in operating mode 0 (bit 15 = 0) or operating mode 1 (bit 15 = 1)). Module 9148 Use nominal value as actual value With Module 9148 you can use the nominal value as actual value for selected axes when the position loop is open. This makes it possible to use the nominal value for certain internal functions such as the actual value display and calculations such as transformation chains of tilting axes. Call: PS PS CM B/W/D/K <Axis> Bits 0 to 13 represent axes 1 to 14 B/W/D/K <Mode> 0: Use nominal value as actual value 9148

Error detection: Marker M4203 W1022 Value 0 1 1 2 24 Meaning Nominal value used as actual value Error code in W1022 Invalid mode Invalid axes Module was called in a spawn job or submit job

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HEIDENHAIN Technical Manual iTNC 530

Module 9321 Find the current block number The current block number is ascertained with Module 9321. Call: PS CM PL B/W/D/K <String number (reserved for future applications)> 9321 B/W/D <Current block number>

Error detection: Marker M4203 W1022 Value 0 1 2 Meaning Block number has been found Error code in W1022 Invalid string number

Module 9305 Tool exchange in the pocket table The module was expanded by an error code. Error detection: Marker M4203 W1022 Value 0 1 2 6 20 21 30 Meaning Tools exchanged Error code in W1022 Invalid pocket number Magazine management using magazine rules is active Module was not called in a submit job or spawn job Module was called during NC program run No valid tool in the original pocket

Module 9306 Exchange tools between tool magazines The module was expanded by an error code. Error detection: Marker M4203 W1022 Value 0 1 1 2 6 20 21 30 36 Meaning Tools exchanged Error code in W1022 Invalid pocket number Invalid magazine number Magazine management using magazine rules is active Module was not called in a submit job or spawn job Module was called during NC program run No valid tool in the original pocket File error

October 2003

NC Software 340 420-xx

15

Module 9342 Find magazine and pocket number Module 9342 determines the magazine and pocket number from the tool number. The module takes the RSV column of the pocket table into account if magazine rules are in effect. If the module is used to find reserved pockets, it returns the first reserved pocket with ascending magazine number. However, further pockets can be reserved. In this case the search must be repeated with another start magazine for the search. Call: PS PS B/W/D/K <Tool number> B/W/D/K <Mode> 0: Look for occupied pocket 1: Look for reserved pocket B/W/D/K <Start magazine for the search> 9342 B/W/D/K <Magazine number> 1: Magazine could not be found B/W/D/K <Pocket number> 1: Pocket could not be found

PS CM PL PL

Error detection: Marker M4203 W1022 Value 0 1 1 2 20 30 36 Meaning Magazine and pocket number found Error code in W1022 Invalid mode Invalid start magazine for the search Module was not called in a submit job or spawn job Tool not found File error in pocket table

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HEIDENHAIN Technical Manual iTNC 530

Miscellaneous

If a tolerance for rotary axes is programmed with inactive HSC filter (MP1094 = 0), the error message rotary axis tolerance not allowed appears. In the Editing machine parameters operating mode, ASCII files with the extension .A (e.g. READ_MP.A) can be displayed. With M140 MB<retraction length> F<feed rate,> a feed rate can be optionally programmed in order to move away from the contour in the current tool axis direction. A network ping can be run in the network settings through the code number NET123. The software version of the control (standard or export version) is saved in the SIK. If the NC software is exchanged for another software version, after the control starts up a message appears that the control can be operated only as a programming station. This message must be acknowledged. If you exchange software from a standard version to the export version, the control asks whether the compressed files of the standard versions should be deleted from the hard disk. If you answer with YES, all compressed files with the names of the standard version are deleted from the hard disk. If the control hardware components have to be loaded with a new controller during control startup, a display of progress appears. With the NC block CYCLE CALL POS you can move to the specified position and call a cycle.

NC software 340 420-07

Export version 340 421-07

Release August 2002

October 2003

NC Software 340 420-xx

17

1.3 NC Software 340 422-xx


HEIDENHAIN released the new NC software 340 422-01 for the iTNC 530 in August 2002. This NC software will only be delivered if you specifically order it. There are new Users Manuals for this NC software: HEIDENHAIN conversational programming: Id. Nr. 375 738-xx Touch probe cycles: Id. Nr. 375 319-xx NC software 340 422-01 Export version 340 423-01 Release August 2002

Expansions since NC software 340 420-07: Machine parameters MP7294 is new: Disable axis-specific datum setting in the preset table Format: %xxxxxxxxxxxxxx Input: Bits 0 to 13 represent axes 1 to 14 0: Not disabled 1: Disabled After COPY SAMPLE FILE is executed, two new prototypes for pallet tables (PROTOPR.P and PROTO_TOPR.P), containing the column PRESET, are saved in the directory PLC:\PROTO. Multiple presets can be managed with the preset table TNC:\PRESET.PR. The presets are recalculated using the defined tilting-axis geometry. The cycle structure of the machining cycles was revised. If MP7475 = 1 (Use machine datum as datum for datum tables) and Cycle 7 (DATUM) is programmed, the error message Use preset table! appears. In Cycle 205 (UNIVERSAL PECKING) a lowered start point can be entered in Q379. In Cycle 220 (POLAR PATTERN) the type of traverse (straight line or circular arc) can be entered in Q365. Cycle 247 (SET DATUM) activates a preset from the preset table. In Cycles 400 (BASIC ROTATION), 401 (ROT OF 2 HOLES) and 402 (ROT OF 2 STUDS) you can enter in Q305 the line in the preset table in which the basic rotation is to be entered. In Cycles 410 to 418 you can decide in Q303 if the measured values are to be written in a datum table or preset table. In Cycles 414 (DATUM OUTSIDE CORNER) and 415 (DATUM INSIDE CORNER) the line in the preset table for the datum and basic rotation can be entered in Q305. Cycle 419 (DATUM IN ONE AXIS) can be used to set a datum in any axis. Cycles 420 to 430 take an active rotation into account.

Machine integration

Miscellaneous

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HEIDENHAIN Technical Manual iTNC 530

1 Update Information No. 3


1.1 Releases
The following versions of the NC software were released: NC software 340 420-08 and 340 421-08 NC software 340 422-02 and 340 423-02 NC software 340 480-02 and 340 481-02 October 2002 October 2002 October 2002

1.2 NC Software 340 420-xx


NC Software 340 420-08 Machine parameters Export version 340 421-08 Release October 2002

MP2230.x is new: By entering MP2230.x 0, the correct operation of the motor brake is tested each time the control is started. The test is carried out after the drive is switched on, but before the reference marks are traversed. A current with the strength <MP2230.x> <rated current of motor> is output. If the maximum permissible path from MP2232.x is exceeded, the error message 8130 Motor brake defective <axis> appears, and the axis remains controlled. In case of an error, the axis must be moved to a safe position, and physically supported, if necessary. Only then may the machine be switched off so that the defect can be corrected. If no current flows to the motor during the test, the error message DSP error 8140 <axis> appears. Input: 0 to 30.0 [ rated current of motor] 0: Do not test, or motor without brake 1.3: Recommended input value MP2232.x is new: Maximum permissible path for testing the motor brake. Input: 0 to 10 [mm] or [degrees] MP4000.x has been expanded: The number of indexes was increased from 16 to 32 (MP4000.0 to MP4000.31). MP4045 is new: If all PLC outputs are switched off (e.g., during PLC program compilation or due to a PLC run-time error), the outputs that can not be switched off by an emergency stop can be switched off delayed by 250 ms. Input: %xxxxxxx Bits 0 to 6 correspond to O24 to O30 0: Do not switch off output with delay 1: Switch off output with delay MP7310 has been expanded: Until further notice, bits 5 and 6 have no function. MP7246 has been expanded: Bit 1: Function of the DEL key 0: Deletion with the DEL key does not have to be confirmed. 1: Deletion with the DEL key must be confirmed via soft key.

October 2003

Releases

11

MP7680 has been expanded: Bit 14 is used to determine the behavior of an NC start after an NC stop and an internal stop. For example, if the spindle is stopped after an internal stop and is not automatically started again after an NC start, you can force a block scan before the NC start by setting bit 14 equal to 1. Bit 14 = 0: NC start permitted Bit 14 = 1: NC start only permitted after block scan MP7682 has been expanded: Bit 6 = 0: No precision stop with TOOL DEF. Bit 6 = 1: Precision stop with TOOL DEF (the NC program is stopped, and only continued after acknowledgment). Bit 7: The ISO editor of the iTNC 530 does not sort the block elements. Bit 7 = 0: Block elements are executed unsorted. Bit 7 = 1: Block elements are automatically executed sorted (but the NC block is not displayed sorted). Configuring the Axes and Spindle Machine Integration PLC modules The 5-V power supply is monitored. The limits are 4.75 V and 5.40 V. If the control is shut down or restarted by the PLC, the module and line number from which the command is called are entered in the log. PLC modules 9092, 9093 and 9094 have been expanded by the following element numbers: *.T file 30: Tool type for pocket table (PTYP) *.TCH file: 5: Tool type for pocket table (PTYP) 6: Reserve pocket (RSV) 7: Value 1 (P1) to 11: Value 5 (P5) In the Machine Parameter Programming mode of operation, you can enter the code number NET123 after pressing the MOD key in order to set the network configuration during commissioning. In the Machine Parameter Programming mode of operation, you can use the DELETE CHAR, DELETE WORD or DELETE LINE soft keys to delete the corresponding entries. A deleted word or line can be reinserted with the INSERT LINE / WORD soft key. The small character set for the BF 150 was revised. The maximum input value for the jog increment infeed was limited to 10 mm for the setup operation according to the EN 12417 (12/2001) specification. In Cycles 21 to 25, climb milling (with M3) is standard (Q15 = +1). Enter the code number VERSION to generate the file TNC:\version.a. System data is saved in this file for diagnostic purposes.

Miscellaneous

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HEIDENHAIN Technical Manual iTNC 530

1.3 NC Software 340 422-xx


NC Software 340 422-02 Machine parameters Export version 340 423-02 Release October 2002

MP2230.x is new: By entering MP2230.x 0, the correct operation of the motor brake is tested each time the control is started. The test is carried out after the drive is switched on, but before the reference marks are traversed. A current with the strength <MP2230.x> <rated current of motor> is output. If the maximum permissible path from MP2232.x is exceeded, the error message 8130 Motor brake defective <axis> appears, and the axis remains controlled. In case of an error, the axis must be moved to a safe position, and physically supported, if necessary. Only then may the machine be switched off so that the defect can be corrected. If no current flows to the motor during the test, the error message DSP error 8140 <axis> appears. Input: 0 to 30.0 [ rated current of motor] 0: Do not test, or motor without brake 1.3: Recommended input value MP2232.x is new: Maximum permissible path for testing the motor brake. Input: 0 to 10 [mm] or [degrees] MP4000.x has been expanded: The number of indexes was increased from 16 to 32 (MP4000.0 to MP4000.31). MP4045 is new: If all PLC outputs are switched off (e.g., during PLC program compilation or due to a PLC run-time error), the outputs that can not be switched off by an emergency stop can be switched off delayed by 250 ms. Input: %xxxxxxx Bits 0 to 6 correspond to O24 to O30 0: Do not switch off output with delay 1: Switch off output with delay MP7310 has been expanded: Until further notice, bits 5 and 6 have no function. MP7246 has been expanded: Bit 1: Function of the DEL key 0: Deletion with the DEL key does not have to be confirmed. 1: Deletion with the DEL key must be confirmed via soft key. MP7680 has been expanded: Bit 14 is used to determine the behavior of an NC start after an NC stop and an internal stop. For example, if the spindle is stopped after an internal stop and is not automatically started again after an NC start, you can force a block scan before the NC start by setting bit 14 equal to 1. Bit 14 = 0: NC start permitted Bit 14 = 1: NC start only permitted after block scan

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MP7682 has been expanded: Bit 6 = 0: No precision stop with TOOL DEF. Bit 6 = 1: Precision stop with TOOL DEF (the NC program is stopped, and only continued after acknowledgment). Bit 7: The ISO editor of the iTNC 530 does not sort the block elements. Bit 7 = 0: Block elements are executed unsorted. Bit 7 = 1: Block elements are automatically executed sorted (but the NC block is not displayed sorted). Configuring the Axes and Spindle Machine Integration PLC modules The 5-V power supply is monitored. The limits are 4.75 V and 5.40 V. If the control is shut down or restarted by the PLC, the module and line number from which the command is called are entered in the log. PLC modules 9092, 9093 and 9094 have been expanded by the following element numbers: *.T file 30: Tool type for pocket table (PTYP) *.TCH file: 5: Tool type for pocket table (PTYP) 6: Reserve pocket (RSV) 7: Value 1 (P1) to 11: Value 5 (P5) In the Machine Parameter Programming mode of operation, you can enter the code number NET123 after pressing the MOD key in order to set the network configuration during commissioning. In the Machine Parameter Programming mode of operation, you can use the DELETE CHAR, DELETE WORD or DELETE LINE soft keys to delete the corresponding entries. A deleted word or line can be reinserted with the INSERT LINE / WORD soft key. The small character set for the BF 150 was revised. The maximum input value for the jog increment infeed was limited to 10 mm for the setup operation according to the EN 12417 (12/2001) specification. In Cycles 21 to 25, climb milling (with M3) is standard (Q15 = +1). New: Cycles 251 (RECTANGULAR POCKET), 252 (CIRCULAR POCKET), 253 (SLOT MILLING) and 254 (CIRCULAR SLOT). Enter the code number VERSION to generate the file TNC:\version.a. System data is saved in this file for diagnostic purposes.

Miscellaneous

1.4 NC Software 340 480-xx


HEIDENHAIN released the new NC software 340 480-02 for the iTNC 530 with Windows 2000 in October 2002. The functionality of NC software 340 480-02 corresponds to 340 422-02. NC Software 340 480-02 Export version 340 481-02 Release October 2002

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1 Update Information No. 4


1.1 Releases
The following versions of the NC software were released: NC software 340 420-09 and 340 421-09 NC software 340 422-03 and 340 423-03 NC software 340 480-03 and 340 481-03 October 2002 January 2003 January 2003

1.2 NC Software 340 420-xx


NC software 340 420-09 Machine parameters Export version 340 421-09 Release December 2002

MP2220.x has been expanded: Bits 7 to 15: Reserved MP2254.x is new: The field angle can be determined in various manners. Input: 0: The field angle does not have to be determined via the FIELD ORIENT. soft key. It is determined when the drive is first switched on. 1: The field angle must be determined via the FIELD ORIENT. soft key. Only when using a CC 424: MP2560.x is new: MP2560.x defines the number of values used for building the mean value of the first order low-pass filter. Input: 0 to 20 Recommended input value: 0 For high-frequency interference oscillations on one spindle: 12

Miscellaneous

The combination of Cycle 12 (PGM CALL) with Cycle 220 (POLAR PATTERN) or Cycle 221 (CARTESIAN PATTERN) results in the No fixed cycle defined error message.

October 2003

Releases

11

1.3 NC Software 340 422-xx and 340 480-xx


NC software 340 422-03 340 480-03 Machine parameters Export version 340 423-03 340 481-03 Release January 2003 January 2003

Use the keyword PWMPARAMETER = in OEM.SYS to activate up to 30 y indexes of MP2xxx.y for the current and speed controller. The maximum input value of MP2620.x was increased from 30.000 [A] to 100.000 [A]. The maximum input value of MP6550 was increased from 20 000 [mm/min] to 300 000 [mm/min]. MP1120.x is new: The maximum motion of an axis when determining the field angle is monitored. Input: 0.0000 to 300.0000 [mm] or [] MP2220.x has been expanded: Bits 7 to 15: Reserved MP2254.x is new: The field angle can be determined in various manners. Input: 0: The field angle does not have to be determined via the FIELD ORIENT. soft key. It is determined when the drive is first switched on. 1: The field angle must be determined via the FIELD ORIENT. soft key. MP2256.x and MP2257.x are new: The determined field angle is entered in MP2256.x instead of in the NCDATA.SYS system file. For purposes of reliability and redundancy, either the serial number of the encoder (only for encoders with EnDat interface) or a unique control ID is entered as identification in MP2257.x. If the current identification does not match the entry in MP2257.x, an error message appears. When using an encoder with EnDat interface, the error message 8830 EnDat: no field angle <axis> appears. In any case the field angle must be determined anew, since the encoder does not match the field angle from MP2256.x When using an incremental encoder, the error message MP2257.<index> incorrect (ID=$<identification>) appears. The field angle from MP2256.x and the new identification (ID=$<identification>) for MP2257.x can only be assumed after determining that the same drive is meant (e.g. after changing controls). Danger In all other cases the field angle must be determined anew, since otherwise uncontrolled drive motions could occur!

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HEIDENHAIN Technical Manual iTNC 530

MP2607.x is new: Damping factor for the active damping of low-frequency interference oscillations (< approx. 20 Hz). Input: 0 to 30.000 0: No damping 1.5: Typical damping factor MP2608.x is new: Damping time constant for active damping of low-frequency interference oscillations. The time constant can be calculated according to the following formula: k MP2608.x = ---------------2f k: Factor from 0.8 to 1.0 f: Frequency to be damped (< approx. 20 Hz) Input: 0 to 0.9999 [s] 0: No damping 0.005 to 0.02: Typical damping time constant MP7160 has been expanded: Bit 4: During tapping, the tool axis can track the spindle, or it can be interpolated with the spindle. Interpolation can result in higher speed stability of the tool axis. The path jerk (spindle and tool axis) can be set via MP3415.3: a r = -------------------------MP3415.3 Whichever value is smaller from this formula and from MP1090.0 is valid. = 0: Tool axis tracked = 1: Tool axis and spindle interpolated MP7246 has been expanded: Bit 2: When testing an NC program in the Test Run operating mode (calculate machining time: active), a tool-usage file (*.T.DEP) can be created automatically. This contains all required tools (number, index, name, radius), the machining times (at 100% override) and program calls. = 0: Do not create tool-usage file = 1: Create tool-usage file MP7266.x has been expanded: MP7266.32Maximum shaft speed [rpm] (NMAX) MP7492.x is new: You can couple axes when setting a datum, meaning that the datum is set in more than one axis at once. Enter the number of the axis in which the same datum is to be set in MP7492.x The preset table function must be active. Input: 0 to 65535 1: Do not set a datum MP7492.0 Datum set in the first axis MP7492.1 Datum set in the second axis ... In order to see them more easily, comments and unused machine parameters are displayed with the color from MP7355.3 ($00000FF) in the machine parameter file.

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Only when using a CC 424: MP2250.x is new: The field angle can be determined in various manners. Input: 0: Same as input value 2 1: The field angle is determined when the motor brake is applied (MP2252.x is necessary). 2: The field angle is determined without moving the motor when the motor brake is applied (MP2254.x = 0 is used). 3: Same as input value 2, but the motor brake is released before the field angle is determined. Possibly more exact values can be determined than with MP2250.x = 2. MP2252.x is new: If you determine the field angle when the motor brake is applied, then you must define how far the motor can move against the brake for this movement to be recognized as a motion. Input: 0.0001 to 100 000 [mm] or [] MP2254.x is new: The field angle can be determined in various manners. Input: 0: The field angle does not have to be determined via the FIELD ORIENT. soft key. It is determined when the drive is first switched on. 2: The field angle must be determined via the FIELD ORIENT. soft key. During this determination, the relevant settings as well as the correct wiring are checked. MP2560.x is new: MP2560.x defines the number of values used for building the mean value of the first order low-pass filter. Input: 0 to 20 Recommended input value: 0 For high-frequency interference oscillations on one spindle: 12 Machine parameter MP7600.x has no function. The position controller cycle time results from the PWM frequency TPosition controller = 1:fPWM. MP7602 is new: MP7602 sets the PLC cycle time in steps of 3 ms. Invalid entries are rounded down. Input: 12 to 60 [ms] 0: 10.8 ms

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HEIDENHAIN Technical Manual iTNC 530

Configuring the axes and spindle

Up to 20 commands (positioning, override settings, etc.) for auxiliary axes can be executed per run-through of the PLC program. When commissioning with TNCopt, the machine axes must be moved. For safety purposes, a function of this type should be enabled on the control. The entry TNCOPT.LOCKSOFTKEYVISIBLE = YES in OEM.SYS makes the soft key TNCOPT OFF ON visible after pressing the MOD key. It is used to enable such functions. As a default, the soft key is always set to OFF when the control is started up. With the WRITE TO KINEMATIC AT COLUMN <column to be written to> CAPTURE <searched column> KEY <keyword> = <value> command you can overwrite individual cells in the active kinematics table in the Program Run operating modes. The line is selected by searching for the entry KEY in the column CAPTURE. The column COLUMN is overwritten with <value>. After entering the codenumber 555343 and pressing the SPECIAL TNC FUNCTIONS soft key, the ENTRY IN KINEMATIC TABLE soft key appears for this function. A circular interpolation test can be run in the oscilloscope. In the oscilloscope, you must select the CIRC operating mode, set Deviation in the channel settings, and then select the two axes with which the circular interpolation test is to be run. After starting the oscilloscope, start an NC program in which a circle is programmed. The circle center point must be at the origin of both axes. The oscilloscope records the deviations from the circle. An X/Y graph of two axes can be selected in the oscilloscope. The XY operating mode must be selected in the oscilloscope. Choose the YT operating mode for chronological representation. The machining plane position indication has been expanded by the following swivel-axis combination: Swivel head and rotary table: Axis sequence C fixed, A fixed, B fixed 90, A variable, B fixed +90, A fixed, C variable (tool axis Z) The entry PRESETTABLE = OFF in OEM.SYS deactivates the preset table after a control reset. The stored datums are no longer valid, and a new datum must be set in each axis (possible in all traverse ranges). The active status of preset tables is reported with M4589=1. When the control is started up, new cycle data is generated (with or without support from preset tables). In order to preserve the possibility of switching between active/inactive preset tables in OEM cycles, the following procedure could be followed: Create a separate directory on the PLC partition for each cycle project (PLC:\OEMCYC_ZIP\, PLC:\OEMCY2_ZIP\, PLC:\OEMCY3_ZIP\, etc.). For each cycle project, enter in OEM.SYS a keyword with the name of the .ZIP file to be unzipped, i.e. OEMCYC.ZIPNAME = ABC.ZIP, OEMCY2.ZIPNAME = DEF.ZIP, OEMCY3.ZIPNAME = GHI.ZIP. The ZIP files contain all information for the cycles, including the directory structure. When the control is started up, the appropriate ZIP files are unpacked in the folders. After the keyword KINEMATIC has been entered, more than 15 entries can be displayed in the selection window. When an NC program is stopped by an error message, the following additional information is entered in the log: NC program, line number, actual position, datum, datum shifts, tool number

Machine integration

October 2003

NC Software 340 422-xx and 340 480-xx

15

The PR.LINESLOCKED = entry in OEM.SYS is used to write-protect lines in the preset table, such as for the machine datum. Separate each line number with a comma, and connect line ranges with a dash: PR.LINESLOCKED = 1,48,22. Write-protection can only be assigned to the first 255 lines. Write-protected lines are shown in a different color. The active line is always writeprotected. Limit the maximum shaft speed of the tool in the NMAX column in the tool table. If a higher speed is programmed, the error message Calculated rpm too large appears. The maximum override value is limited to NMAX. The speed is not limited if - is entered under NMAX, or if NO ENT was pressed. Images in .BMP or .BMX format can be displayed in the PLC window. The following applies to the keyword in the mask file: GRAPHICS= <File name> [,<Layer>] [/c] <File name>: Name of the image file (*.BMP or *.BMX). If no path is entered, the path PLC:\LANGUAGE\<Language> is used. <Language> depends on MP7230.3. If %GraphicsResolution% is entered in the path, then this text is replaced by the current screen resolution (1024x768 or 640x480). The images must have a color depth of 16 or 24 bits, and a maximum size of 429 x 442 (BF 150) or 271 x 312 (BF 120) pixels. Images that are too large are truncated. <Layer> (optional): Layer of a BMX file to be displayed. If no entry is made, the basic image (layer 0) is displayed. /c (optional): If it is a BMX file, the layers are displayed cyclically, beginning with 0 or <Layer>. The cycle time is defined via the REFRESH = keyword. Example: GRAPHICS=PLC:\Images\%GraphicsResolution%\Test.BMX The file Test.BMX is searched for in the paths PLC:\Images\1024x768\ or PLC:\Images\640x480\. In the TCR file containing the magazine rules for a tool magazine the definition of the search sequence must be given for each magazine. It can no longer be given globally at the beginning of the file. If the search sequence is the same for each magazine, then it must be repeated after each magazine definition. Example: ... [magazine]4 [search]1 = 1 2 [search]2 = 2 ... Warning The definition(s) of the search sequence(s) must be adapted in all existing TCR files!

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HEIDENHAIN Technical Manual iTNC 530

PLC programming

FN17: SYSWRITE has been expanded: Use the keyword MPFRAGMENT<value> = in OEM.SYS to define up to 10 machine parameter subfiles (<value> from 0 to 9). They can also be activated with FN17: SYSWRITE. Changes to spindle machine parameters (MP3xxx or MP13xxx) are only active after an S output. All other machine parameters are active immediately. The changes also remain in effect if a new NC program is selected, but not if the control is restarted. ID1020 NR1 = <value> FN17: SYSWRITE and FN18: SYSWRITE have been expanded: Nine variables are available for storing and reading in machine statuses by using NC macros. MP7300 controls the clearing of the variables. As opposed to Q parameters, these variables can only be overwritten with FN17:SYSWRITE. ID590 NR1 IDX<1 to 9> FN18: SYSREAD has been expanded: It can find the current range of traverse. ID20 NR17 FN18: SYSREAD has been expanded: You can interrogate whether a line in the preset table is write-protected. A return code not equal to 0 means it is write-protected. ID530 NR2 IDX<line> FN18: SYSREAD has been expanded: The ASCII value of the axis designations defined in MP410.3 or MP410.4 can be read. ID1000 NR410 IDX<3 or 4> FN18: SYSREAD has been expanded: The system time of the control is read in seconds. ID320 NR1 IDX0 FN17: SYSWRITE and FN18: SYSREAD have been expanded: In order to write data to the new columns in the tool table (or to read it out), ID50 was expanded by the following NR: NR24: Probe center offset in reference axis (CAL-OF1) NR25: Probe center offset in minor axis (CAL-OF2) NR26: Spindle angle during calibration (CAL-ANG) NR27: Tool type for pocket table (PTYP) NR28: Maximum shaft speed [rpm] (NMAX) The entry NUMBERMP4230 = in OEM.SYS defines the number of indexes for MP4230.x. The maximum input value is 99; no entry or an invalid entry defines 32 indexes.

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If the NC macro defined under RESETINIT = in NCMACRO.SYS is not executed completely, you cannot switch to the Program Run operating modes. The error message Machine not initialized and the soft key INIT appear. The soft key can be used to restart the NC macro. The entry FNERROR = in OEM.SYS is used to indicate an ASCII file (*.A) that in lines 1 to 300 contains the error messages for FN14: ERROR = (0 to 299). The file must be located under PLC:\LANGUAGE\<language>, where <language> depends on MP7230.3. In order to receive additional information via the HELP key, ASCII files for the error cause and corrective action can be defined with the FNERRREASON = and FNERRFIX = entries. The setup of these files must correspond to that of the files for PLC error messages. PLC modules PLC modules 9092, 9093 and 9094 have been expanded by element number 31 (NMAX). In PLC module 9186, the soft-key function for feed-rate limiting can be carried out with transfer value 7. Module 9217 Display pop-up window for messages Module 9217 can be used in the Machine operating modes to display a popup window with the text of a file (max. 16 KB) and various soft-key rows. The pressed key or soft key is reported. Starting at a certain number of lines (up to 500 lines possible), a scroll bar is displayed automatically. Use the arrow keys or the PgUp and PgDn keys to scroll through the pop-up window. The keyboard is assigned to the pop-up window. The width of the window is determined by the longest line. The module should be called in a SPAWN job, since the module does not return until the window is closed, and therefore submit jobs would be blocked. Call: PS PS PS S <Window title> S <ASCII file with message text> B/W/D/K <Mode> 0: No soft-key row; clear window with CE 1: Soft-key row with OK soft key 2: Soft-key row with YES and NO soft keys 3: Soft-key row with YES, NO and END soft keys 9217 B/W/D <Pressed key or soft key> 1: Error 0: CE key 1: OK soft key 2: YES soft key 3: NO soft key 4: END soft key

CM PL

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HEIDENHAIN Technical Manual iTNC 530

Error detection: Marker M4203 W1022 Value 0 1 1 6 11 20 28 Miscellaneous Meaning Pop-up window displayed Error code in W1022 Invalid mode No connection to display server Invalid string for title Module was not called in a spawn job or submit job Pop-up window already active

If the 24-V voltage is missing at X44, the error message Supply voltage missing at X44 is displayed. A text file (jh_error.txt) including all NC error messages (with error numbers) is placed in the corresponding folder for each language under PLC:\LANGUAGE\. After pressing the MOD key and the DIAGNOSIS soft key, the two soft keys DSP DIAGNOSIS and HEROS DIAGNOSIS are displayed. DSP DIAGNOSIS: After pressing this soft key, various release, inverter, and PLC signals are displayed dynamically. After selecting the supply unit used and pressing the DSP STATUS soft key, the signals are displayed as in the PC software TNCopt and TNCdiag. HEROS DIAGNOSIS: After pressing this soft key, the file TNC:\herosdiagnose.txt is created. HEIDENHAIN uses this file for diagnosis of the operating system. The zoom function for the graphics was accelerated. When a touch probe cycle is called in the Manual Operation and Electronic Handwheel operating modes, and the current angles of the swivel axes do not coincide with those in the Tilt working plane function, the error message Axis angle not equal tilt angle appears. The PLANE function defines the position of the machining plane. The TILT MACHINING PLANE soft key appears after pressing the SPECIAL TNC FUNCTIONS soft key. The machining plane can be defined through space angles, Euler angles, projection angles, incremental angles, the entry of three points, or by two vectors. The programming of each function is aided by animated support graphics. This function is only available in conjunction with preset tables. The PLANE function can be programmed after M128. During remote control via the LSV2 protocol, keystrokes assigned to the PLC windows and PLC pop-up windows are evaluated. The file PLC:\PROTO\EXAMPLE.TAB is created after pressing the COPY SAMPLE FILE soft key. This template only contains the column Name, and is offered as a template when creating a new table. The Exchange touch probe battery error message no longer leads to the probing process being interrupted. Only the error message appears. If an appropriate tool-usage file exists when an NC program is started, then this data is compared with the tool table, and appropriate error messages are displayed if necessary. The value entered for TIME2 in the tool table must be at least 10% greater than the time required. A popup window appears when a datum from a touch-probe cycle is to be assumed into the active line of the preset table. When automatic programming graphics are active, a CYCLE CALL is carried out for SL cycles without an error message even if the contour was not described completely.

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NC Software 340 422-xx and 340 480-xx

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The screen mask for setting a datum in the touch probe cycles in the Manual Operation and Electronic Handwheel operating modes was changed. The combination of Cycle 12 (PGM CALL) with Cycle 220 (POLAR PATTERN) or Cycle 221 (CARTESIAN PATTERN) results in the No fixed cycle defined error message. After Cycle 2 (CALIBRATE TS), the determined probe radius is automatically assumed as the tool radius if MP7411 bit 1 = 1. The length of a touch probe can be calibrated with Cycle 9 (CALIBRATE TS LENGTH). In Cycles 210 (SLOT RECIP. PLNG) and 211 (CIRCULAR SLOT), the feed rate for the plunging depth can be defined with Q206. The approach behavior of Cycle 215 (C. STUD FINISHING) was optimized. In Cycle 403 (ROT IN ROTARY AXIS), the reference angle for the probing surface can be defined with Q380. Q305 and Q303 define whether and in which line of the preset or datum table the rotary axis angle is set to 0. In Cycle 431 (MEASURE PLANE), the tool axis coordinates of the three probing points are saved in Q parameters Q173 to Q175. This way the PLANE function can be used by entering three points.

1.4 Additional Enhancements to NC Software 340 480-xx


MP7235 was removed, meaning that on Windows PCs the time zone must be set correctly, since the time difference is calculated from this setting.

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HEIDENHAIN Technical Manual iTNC 530

1 Update Information No. 5


1.1 Releases
The following versions of the NC software were released: NC software 340 422-04 and 340 423-04 NC software 340 480-04 and 340 481-04 NC software 340 422-05 and 340 423-05 NC software 340 480-05 and 340 481-05 NC software 340 420-10 and 340 421-10 February 2003 February 2003 April 2003 April 2003 April 2003

1.2 NC Software 340 420-xx


NC Software 340 420-10 Miscellaneous Export version 340 421-10 Release April 2003

The approach behavior of Cycle 215 (C. STUD FINISHING) was optimized.

1.3 NC Software 340 422-xx and 340 480-xx


NC Software 340 422-04 340 480-04 Export version 340 423-04 340 481-04 Release February 2003 February 2003

NC Software 340 422-05 340 480-05 Machine parameters

Export version 340 423-05 340 481-05

Release April 2003 April 2003

MP1357.x is new: MP1357.x defines the behavior of W1032 (reference marks not yet traversed) during the double reference run. Input: 0: Reset W1032 if the current position was read via the EnDat interface of the speed encoder 1: Reset W1032 if the reference mark was traversed with the position encoder The meaning of the bits in MP 7500 depend on whether the function of the preset table is active or not (PRESETTABLE = entry in OEM.SYS).

October 2003

Releases

11

MP7500 Bit 0

Preset table active Tilted working plane 0: Off 1: On 0: Angles correspond to the position of the tilting axes of the head/table 1: Angles correspond to the spatial angle (the iTNC calculates the position of the tilted axes of the head/table) 0: The tilting axes are not positioned with Cycle 19 1: The tilting axes are positioned with Cycle 19 No function

Preset table not active Tilted working plane 0: Off 1: On 0: Angles correspond to the position of the tilting axes of the head/table 1: Angles correspond to the spatial angle (the iTNC calculates the position of the tilted axes of the head/table) 0: The tilting axes are not positioned with Cycle 19 1: The tilting axes are positioned with Cycle 19 0: The current tilting-axis position is taken into account with respect to the machine datum 1: The 0 position is assumed for the first rotary axis 0: Compensate mechanical offset during exchange of the spindle head when calling M128, M114 or tilted working plane 1: Compensate mechanical offset during PLC datum shift 0: The current tilting-axis position is taken into account with respect to the machine datum 1: The tilting-axis position that was entered with the 3-D ROT soft key applies. 0: Spatial angle C is realized through a rotation of the coordinate system. 1: Spatial angle C is realized through a rotation of the table. 0: The current tilting-axis position is taken into account with respect to the machine datum 1: The active tilting-axis position is a) derived from the tilting angles in the 3D ROT window if manual tilting is active b) derived from the reference coordinates of the rotary axes if tilting is inactive 0: The tilting axis positioning is considered depending on bit 3, bit 5 and bit 7 1: If manual tilting is active, the datum to be set for the principal axes X, Y and Z is recalculated back to the home position of the tilting element.

Bit 1

Bit 2

Bit 3

Bit 4

No function

Bit 5

Test of the tilting axis during datum setting in X, Y and Z 0: Current tilting-axis position must fit to the defined tilting angles 1: No test 0: Spatial angle C is realized through a rotation of the coordinate system. 1: Spatial angle C is realized through a rotation of the table. No function

Bit 6

Bit 7

Bit 8

No function

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HEIDENHAIN Technical Manual iTNC 530

1.4 Miscellaneous
In the iTNC 530, bits 9 to 15 are without function in NC software levels 340 420-x, 340 422-xx and 340 480-xx with module 9035 code 4 (displayed screen window).

October 2003

Miscellaneous

13

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1 Update Information No. 6


1.1 Releases
The following versions of the NC software were released: NC software 340 422-06 and 340 423-06 NC software 340 480-06 and 340 481-06 June 2003 June 2003

1.2 NC Software 340 422-xx and 340 480-xx


As of June 2003, after the release of the NC software 340 422-06, the iTNC 530 will be shipped with the NC software 340 422-xx as standard. NC Software 340 422-06 340 480-06 Machine parameters Export version 340 423-06 340 481-06 Release June 2003 June 2003

MP2220.x has been expanded: Bit 3CC 422 und CC 424: Switching off the controller when the motor brakes are activated 0: Suppress vibrations 1: Do not suppress vibrations Bit 5CC 422 and CC 424: Monitoring temperature too low 0: Active 1: Inactive Bit 7CC 424: Monitoring of encoder input frequency 0: Active 1: Inactive Bit 8CC 424: Compensate the mechanical offset during switch-on by gradually increasing the kV factor 0: Active 1: Inactive MP2234.x is new: With MP2234.x, you can suppress the output of the BRK signal over the PWM interfaces in order to control the motor brakes through HEIDENHAIN inverters. Bit 0 0. Signal is transmitted 1. Signal is not transmitted Bit 1reserved MP7266.x has been expanded: MP7266.33 Retract tool (LIFTOFF) MP7351 has been expanded: With MP7351.x, the colors of the error classes are defined for error messages from the PET table. MP7351.0: Error MP7351.1: Warning MP7351.2: Information The maximum input value of MP7492.x was reduced to 9.

October 2003

Releases

11

Standard color settings: MP7354.3 = $0A0A0A0 MP7355.3 = $0A0A0A0 MP7367.0 = $0ECECEC MP7494 has been added: M134 (exact stop at nontangential contour transitions when positioning with rotary axes) applies only for rotary axes. With MP7494 you can define a required exact stop for specific axes. Bits 0 to 13 represent axes 1 to 14 0: No exact stop 1: Exact stop MP7500 has been expanded: Bit 9: Reserved MP7620 has been expanded: Bit 7: Reserved MP7641 has been expanded: Bit 1: Reserved MP7672.x is new: Reserved, enter 0 MP7684 has been expanded: Bit 8: Reserved MP7690 has been expanded: Bit 0Evaluation of the electronic ID labels of HEIDENHAIN power modules 0: Active 1: Inactive Bit 0Evaluation of the electronic ID labels of HEIDENHAIN synchronous motors 0: Active 1: Inactive Configuring the Axes and Spindle The machining plane position indication has been expanded by the following swivel-axis combination: A+45, B variable, A45, C variable (tool axis Y) Traverse does not begin during tapping until after M4030 or M4031 has been set and after a cyclic PLC program scan. This makes it possible in the PLC program to recognize the start of a tapping cycle. With the CC 424 it is possible to change milling heads. Encoders with EnDat interface can be used. After the kinematics is switched over, the absolute value can be read out again by pressing the PASS OVER REFERENCE soft key. With MP2392.x you can set a power limit for the spindle when the ERR.IZ.GR signal is active.

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HEIDENHAIN Technical Manual iTNC 530

Machine Integration

With FN18: SYSREAD ID61 NR0 IDX<tool number> you can ascertain the tool change sequence. Return codes: 1: Sequence cannot be ascertained 0: Tool already in the spindle 1: Manual tool manual tool 2: Normal tool manual tool 3: Special tool manual tool 4: T0 manual tool 5: Manual tool normal tool 6: Normal tool normal tool 7: Special tool normal tool 8: T0 normal tool 9: Manual tool special tool 10: Normal tool special tool 11: Special tool special tool 12: T0 special tool 13: Manual tool T0 14: Normal tool T0 15: Special tool T0 This information is reported to the PLC at the same time with the pocket and magazine numbers. You can find this information with Module 9035. In the PET table the strings S4 to S15 can be used. In the MFUNCT.TAB table in the MANLOCK column can be used Y/N to define whether the M function is allowed in the manual modes, and in the NONESTED column with Y/N you can define whether the NC macro can be called from another NC macro. HEIDENHAIN power modules of the UM 1xxD or UM 1xxBD series and HEIDENHAIN synchronous motors with absolute encoders with EnDat interface are equipped with an electronic ID label. The product name, the ID number and the serial number are saved in this ID label. The units are automatically detected and, after confirmation by the user, are automatically transferred to MP2100.x or MP2200.x. During every further control restart, the control checks whether the connected units with electronic ID label match the entries in MP2100.x or MP2200.x. If not, an error message might appear. In exceptional cases, the evaluation of the electronic ID label can be deactivated with MP7690. Through the LIFTOFF column of the tool table, a function can be activated that retracts the tool from the workpiece by 0.1 mm in tool-axis direction after an NC stop. You must activate this function in M4620. This function must also be activated in the NC program with M148 (M149 deactivates it again). A tool change by M101 is transmitted delayed by at least one block and by no later than one minute. In the log, the source of the key inputs is registered under INFO: MAIN KEYSOURCE <source.> <Source> can accept the following entries: KEYBOARD PLC PLCNCSTART HANDWHEEL LSV2

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PLC Programming

The values of the machine parameters MP1054.x and MP7530.x can be read with FN18: SYSREAD ID1000 if they do not contain any formulas. The RESTART PLC soft key stops the PLC program and restarts it. Marker M4173 is supported. The column heading of the TRACE IN-CODE function have been revised. The compiled PLC program is saved in the control, i.e. after confirmation of power interruption, the PLC program need not be compiled. It is compiled only if one of the source files has changed. A binary PLC program can be created with PLCdesignNT for test purposes and transferred to the control. This does not change the entry in OEM.SYS. W1016 is new: The number of the most recently unsuccessfully executed PLC module is saved in W1016 for diagnostic purposes. Module 9035 expanded: The module was expanded by the following status information to find the information from FN18: SYSREAD ID61 NR0 IDX<tool number>: 50: Tool change sequence (see FN18: SYSREAD) 51: Read pocket number for reserve 52: Read magazine number for reserve 53: Read pocket number for inserting 54: Read magazine number for inserting Modules 9092, 9093 and 9094 have been expanded by element number 32 for tool retraction (LIFTOFF).

PLC modules

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HEIDENHAIN Technical Manual iTNC 530

Module 9072 Copying a byte block into a string Module 9072 copies a byte block into a string. The module does not check whether the byte block consists of valid ASCII characters. The content of the string may not be correctly displayed (e.g. due to special characters for stringend codes). A string end code is automatically set after the last copied byte. The module always copies the programmed byte block, regardless of any string-end code in the byte block. Call: PS PS PS CM B/W/D/K <start byte> B/W/D/K <length of the byte block> B/W/D/K <string number> 9072

Error detection: Marker M4203 W1022 Value 0 1 1 3 4 11 Meaning Byte block was copied into string Error code in W1022 Invalid length of the programmed byte block (max. 127 characters) Invalid address of the start byte Invalid sum of start byte and length of the byte block Invalid string

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Module 9140 Set axis-specific feed-rate limit With Module 9140 you can set axis-specific feed-rate limits. The limits are saved in sequential double words for each axis. Invalid feed-rate values are set to 0 and M4203, other axes retain their limits. Call: PS B/W/D/K <start double word> >= 0: Feed rate from corresponding double word 1: Maximum feed rate 2: Axis-specific rapid traverse from MP1010.x 3: Axis-specific manual feed rate from MP1020.x B/W/D/K <Number of axes or double words> 9140

PS CM

Error detection: Marker M4203 W1022 Value 0 1 1 2 3 5 24 Meaning Feed-rate limit is set. Error code in W1022 Invalid value of start address (< 3) Invalid number of axes or double words Invalid block length as of starting address No double word address Module was called in a spawn job or submit job

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HEIDENHAIN Technical Manual iTNC 530

Module 9141 Read the axis-specific feed-rate limit With Module 9141 you can read axis-specific feed-rate limits. The limits are saved in sequential double words for each axis. Call: PS B/W/D/K <start double word> >= 0: Feed rate from corresponding double word 1: Maximum feed rate 2: Axis-specific rapid traverse from MP1010.x 3: Axis-specific manual feed rate from MP1020.x B/W/D/K <Number of axes or double words> 9140

PS CM

Error detection: Marker M4203 W1022 Value 0 1 2 3 5 24 Miscellaneous Meaning Feed-rate limit is set. Error code in W1022 Invalid number of axes or double words Invalid block length as of starting address No double word address Module was called in a spawn job or submit job

If more than one error message occurs, you can display a list of them with the ERR key. The search function was expanded by the REPLACE ALL soft key. To be able to use the PLANE function with tilting axes and Hirth coupling, after the PLANE function the position of the angular axes can be transferred for the coordinate transformation with M114. The transferred coordinates must be in the Hirth grid. OEM.SYS is reevaluated during activation of the machine parameter programming operating mode and before downloading a machine parameter file. In connection with TNCremoNT 2.2, during the restoring of a backup, first OEM.SYS is transferred and also evaluated before transferring the machine parameter file. In the help window for error messages, further notes on the error message is shown under Additional information. Cycles 253 (SLOT MILLING) and 254 (CIRCULAR SLOT) were expanded by the parameters Q385 (FEED RATE FOR FINISHING) and Q366 (PLUNGING). Cycles 1 (PECKING) to 5 (CIRCULAR POCKET), 17 (RIGID TAPPING) and 18 (THREAD CUTTING) were moved in the cycle structure. They are programmable over the soft keys SPECIAL CYCLES and OLD CYCLS: Cycles 410 (DATUM INSIDE RECTAN.) to 416 (DATUM INSIDE CIRCLE) and 418 (DATUM FROM 4 HOLES) were expanded by the parameters Q381 (PROBING IN TS AXIS), Q382 (1ST CO. FOR TS AXIS), Q383 (2ND CO. FOR TS AXIS), Q384 (3RD CO. FOR TS AXIS) and Q333 (DATUM). Cycles 251 (RECTANGULAR POCKET) and 252 (CIRCULAR POCKET) were expanded by the parameters Q385 (FEED RATE FOR FINISHING). The pokket is cleared in a spiral path from the inside to the outside.

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Swivel-head axes are ignored when M116 is programmed. In Cycle 32 (TOLERANCE) the tolerance for rotary axes is also active with single and double filter (up to now it was active only with HSC filter). Cycle 3 (MEASURING) was expanded by the DATUM SYSTEM input box. With the UPPER/LOWERCASE ON OFF soft key, the search function in the ASCII editor can differentiate between upper and lower case letters. The manually set datum, which was set by the user with the axis keys, is automatically written into line 0 of the preset table. Pressing the Q key displays the newly arranged menu for FN functions. The submenus feature a Back soft key. With FN16: F-PRINT the output can be shown in a pop-up window. The protocol file screen: must be entered. After the MOD key and the UPDATE DATA soft key in the Machine parameter programming operating mode, the SP iTNC soft key appears. With this soft key you can install service packs that are released by HEIDENHAIN when required. An installed service pack is displayed after the MOD key through SP<x> after the ID number of the NC software. The tool insert file can be generated through an LSV2 command. If the program is aborted, the point of interruption is saved and is displayed after the RESTORE POS. AT soft key is pressed. It can be loaded with the SELECT LAST N soft key. If the program is aborted due to a power outage, or if the iTNC 530 with Windows 2000 was shut down in Windows, after the Power interrupted message is acknowledged, the NC program is aborted message appears (the power-fail monitoring must be active). TCPM FUNCTION can be programmed with the SPECIAL TNC FUNCT. And FUNCTION soft keys. FUNCTION TCPM is a further development of the M128 function with which you can define behavior during positioning of rotary axes. Unlike M128, with FUNCTION TCPM the user can himself define the behavior of various functions: F TCP/F CONT: Behavior of the programmed feed rate AXIS POS/AXIS SPAT: Interpretation of the NC coordinates programmed in the NC program PATHCTRL AXIS/PATHCTRL VECTOR: Type of interpolation between starting and target position With the CONVERT PROGRAM soft key: The FK programming can be resolved (FK -> H soft key). Two NC programs can be generated that only contain lines and circular arcs and can be run in the programmed sequence or the opposite sequence (CONVERT PGM .FWD/.REV) soft key.

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1.3 Additional Enhancements to NC Software 340 480-xx


Module 9133 was expanded by the code 2 (temperature of 2nd CPU). MP7225 is new: MP7225 defines the windows drives that are not supposed to appear in the TNC file management (PGM MGT). Input:A to Z If there are more than one drive, they are entered without spaces, e.g. MP7225 = CDE Hard disks that are shipped with 340 480-06, support the Windows 2000 MultiLanguage version. In the version you can select the language of the operating system. This new function cannot be retrofitted. The HeROS real-time operating system tests cyclically within 5 seconds whether a connection to the iTNC application exists under Windows, whether the file system can be accessed, and whether the X server for the display and keyboard is functioning. If one of these tests is impossible for more than 5 seconds, M4600 is set. M4600 is reset when all tests are possible again. If one test is impossible for more than 10 seconds, the control is shut down.

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1 10

HEIDENHAIN Technical Manual iTNC 530

1 Update Information No. 7


1.1 Releases
The following versions of the NC software were released: NC software 340 422-07 and 340 423-07 NC software 340 480-07 and 340 481-07 August 2003 August 2003

1.2 NC Software 340 422-xx and 340 480-xx


NC Software 340 422-07 340 480-07 Machine parameters Export version 340 423-07 340 481-07 Release August 2003 August 2003

The maximum input value for MP3142 and MP13142 (line count of the spindle position encoder) was increased from 9999 to 30000. MP4043 and MP4044 are new: If all PLC outputs are switched off (e.g., during PLC program compilation or due to a PLC run-time error), the outputs that can not be switched off by an emergency stop can be switched off delayed by 250 ms. MP4043 Outputs O0 to O15 Input: %xxxxxxxxxxxxxxxx Bits 0 to 15 correspond to O0 to O15 0: Do not switch off output with delay 1: Switch off output with delay MP4044 Outputs O16 to O23 Input: %xxxxxxxx Bits 0 to 7 correspond to O16 to O23 0: Do not switch off output with delay 1: Switch off output with delay MP7224.x has been expanded: MP7224.2 is used to disable the EDIT ON/OFF soft key for specified file types. If the soft key is disabled via MP7224.2 or the file is protected via MP7224.1, the error message Protected file! appears if you press this soft key. Changes to MP7235 (time difference to Universal Time) causes a reset. MP7237.x and MP7238.x have been expanded: The machine parameters support the PLC operating times 9 to 13 (MP7237.x bits 8 to 12, MP7238.8 to MP7238.12).

October 2003

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11

Configuring the axes and spindle

The integrated oscilloscope can be activated via the DIAGNOSIS, DRIVE DIAGNOSIS and OSCI soft keys without using code number 688379. Press the END key to switch from the oscilloscope display to the setup. Entering code number 807667 (PLC programming) followed by the DIAGNOSIS and DRIVE DIAGNOSIS soft keys or code number 688379 (oscilloscope) enables the I CONTROL soft key for adjusting the current controller. The input range for the number of pole pairs in the motor table was expanded from 99 to 999. In the Program Run, Single Block and Program Run, Full Sequence operating modes, press the TOOL USAGE TEST soft key to compare the data in the tool usage file with the data in the tool table. If the tool usage file is not current or does not exist, the error message Generate tool usage file! appears. Otherwise a popup window with the results of the comparison appears. For each soft key pressed, an entry is made in the log file, including the path to the appropriate image file. The DIAGNOSIS soft key is also available in the PLC Programming operating mode (code number 807667). The NC cyclically monitors the supply voltage and short circuits of the PLC outputs of a PL 510. The diagnosis functions are only available if at least one reference axis has a HEIDENHAIN synchronous motor with electronic ID label attached to it, or Option #14 (DSP Diagnostics) is enabled. Each traverse range uses its own preset table. The preset table of the current traverse range can be viewed in the Manual operating mode. FN17: SYSWRITE and FN18: SYSREAD refer to the active preset table. The maximum number of all dependencies for non-linear axis-error compensation is 15. Markers M4800 through M4999 are deleted before the first run of the PLC program (after compilation or restarting). The EDIT soft key is available on both rows of soft keys in the main menu of the PLC Programming operating mode. Within the WATCH LIST function, the BEGIN LINE and END LINE soft keys are available. The user interface of the TRACE function and the LOGIC DIAGRAM function were revised: Editor for selecting markers in the LOGIC DIAGRAM was revised Soft keys BEGIN , END , PAGE , PAGE in the TRACE function Soft keys START TRACE and FREEZE TRACE for starting and stopping the display Soft keys START LOGIC TRACE and STOP LOGIC TRACE for starting and stopping the TRACE function

Machine integration

PLC programming

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HEIDENHAIN Technical Manual iTNC 530

PLC modules

In Module 9133, the voltage in mV of the buffer battery can be determined with code 3. Calling Module 9203 with <number of soft key menu> < 0 supplies the current resource handle. If Modules 9246 or 9256 are used to write to a line that does not yet exist in a table, the file is filled with blank spaces up to the defined line. If 1 is given as the line number, the next empty line is used. Module 9073 Copying a string to a byte block Module 9073 copies a string into a byte block. The module does not check whether the string consists of valid ASCII characters. The module always copies over the entire programmed length of the byte block, regardless of any string-end code in the byte block. Call: PS PS PS CM B/W/D/K <target byte> B/W/D/K <length of the byte block> B/W/D/K <string number> 9073

Error detection: Marker M4203 W1022 Value 0 1 1 2 4 11 Meaning String was copied into byte block Error code in W1022 Invalid target byte Invalid length of the programmed byte block (max. 127 characters) Invalid sum of target byte and length of the byte block Invalid string

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Module 9350 Read data from the tool table Module 9350 reads the contents of a cell in the tool table with the status M. The value is read as an integer value. Call: PS PS PS B/W/D/K <Tool number> B/W/D/K <Tool index> 0: Main entry B/W/D/K <Element number> 0: Tool length L 1: Tool radius R 2: Not used 3: Replacement tool (1 if not defined) 4: Not used 5: Maximum tool age TIME1 6: Maximum tool age for TOOL CALL TIME2 7: Current tool age CUR.TIME 8: Tool radius 2 R2 9: Oversize for tool length DL 10: Oversize for tool radius DR 11: Oversize for tool radius 2 DR2 12: Tool locked TL (0=No, 1=Yes) 13: Number of tool teeth CUT. 14: Wear tolerance in length LTOL 15: Wear tolerance in radius RTOL 16: Cutting direction DIRECT. (0=+; 1=) 17: PLC status PLC 18: Tool offset for length TT: L-OFFS 19: Tool offset for radius TT: R-OFFS 20: Break tolerance for length LBREAK 21: Break tolerance for radius RBREAK 22: Tooth length LCUTS 23: Maximum plunge angle ANGLE 24: Tool number 25: Tool index 26: PLC value PLC-VAL 27: Probe center offset in reference axis CAL-OF1 28: Probe center offset in minor axis CAL-OF2 29: Spindle angle during calibration CAL-ANG 30: Tool type PTYP 31: Maximum speed NMAX 32: Retract tool LIFTOFF 9350 B/W/D <Element value> B/W/D <Error number> 0: No error, element value was read 1: Module was not called in a spawn job or submit job 2: File type does not exist 3: No tool table with status M 4: Line number does not exist 5: Incorrect element number

CM PL PL

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HEIDENHAIN Technical Manual iTNC 530

Error detection: Marker M4203 W1022 Value 0 1 2 7 20 36 Meaning Element value read Error code in W1022 Incorrect element number Line number does not exist Module was not called in a spawn job or submit job No tool table with status M

Module 9351 Write data to tool table Module 9351 writes the contents of a cell in the tool table with the status M. The value must be given as an integer value. Call: PS PS PS PS CM PL B/W/D/K <Tool number> B/W/D/K <Tool index> 1: Write all indexes of a tool B/W/D/K <Element number> See Module 9350 B/W/D/K <Element value> 9351 B/W/D <Error number> 0: No error, element value was written 1: Module was not called in a spawn job or submit job 2: File type does not exist 3: No tool table with status M 4: Line number does not exist 5: Incorrect element number 6: Element value is out of range 7: Error while writing to the file

Error detection: Marker M4203 W1022 Value 0 1 2 7 20 36 Meaning Element value written Error code in W1022 Incorrect element number Line number does not exist Module was not called in a spawn job or submit job No tool table with status M

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Miscellaneous

Cycle 232 (FACE MILLING) is used to face mill rectangular surfaces. Cycles 25x can be used with an inactive tool table. Q366 = 0 (PLUNGE) must be defined in the cycles. For Cycle 251 (RECTANGULAR POCKET), the error message Tool radius too large appears if the corner radius defined in Q220 is less than the tool radius. A new probe cycle in the Manual operating mode finds the distance between two points, as well as the mid-point. All touch probe functions in the Manual mode can also be used by manually touching the workpiece with the tool or other suitable devices. In place of the electronic trigger signal, the probing process can be initiated manually by pressing the actual-position-capture key. Rather than entering a feed rate in a traversing block, you can also enter a time in seconds over which the programmed block is to be traversed. The function is activated with the F T soft key, and is effective blockwise. For operating panels that also feature a rapid traverse potentiometer, the F MAXT soft key is also available. The PLANE function also features the TURN possibility for automatic positioning. As opposed to MOVE, there are no compensating movements of the linear axes when you tilt the rotary axes. Normal and tool directional vectors of LN blocks no longer need to be given standardized to the value 1. A progress indicator appears when sorting block numbers of an ISO machining program. The display of options upon entry of the SIK keyword was revised. An autorepeat function is in effect for the PG UP and PG DN keys, as well as for the PAGE and PAGE soft keys.

1.3 Hardware
There is a new, more powerful MC 422 B for the standard versions of the iTNC 530. With this hardware, the housing, hard disk, and SIK are all supplied separately. Properties of the MC 422 B: Pentium III with 800 MHz 128 MB RAM 133 MHz bus frequency HDR removable hard disk SIK with NC software license X133 omitted, X131 reserved The basic version of the iTNC 530 will still be supplied with the MC 422.

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HEIDENHAIN Technical Manual iTNC 530

Housing with main computer

Main computer (standard version) MC 422 B

Signal inputs

Id. Nr. of MC for BF 120 display unit 387 171-0x 387 172-0x

Id. Nr. of MC for BF 150 display unit 387 173-0x 387 181-0x 387 189-0x

Without position encoder inputs (for CC 424) 5 position encoder inputs Position: 1 VPP/EnDat 10 position encoder inputs MC 422 (basic version) 5 position encoder inputs Position: 1 VPP/EnDat MC 422 B (with Windows 2000) Without position encoder inputs (for CC 424) 5 position encoder inputs Position: 1 VPP/EnDat 10 position encoder inputs

367 224-0x

367 225-0x 387 175-0x 387 183-0x 387 191-0x

October 2003

Hardware

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HDR removable hard disk

HDR hard disk for iTNC 530 Export version Standard version Export version with Windows 2000 Standard version with Windows 2000 SIK with NC software license

Id. Nr. 387 546-51 387 546-01 387 545-51 387 545-01

SIK with NC software license Export version with 4 or 7 control loops Standard version with 4 or 7 control loops Export version with 5 or 8 control loops Standard version with 5 or 8 control loops Export version with 6 or 9 control loops Standard version with 6 or 9 control loops Export version with Windows 2000 with 4 or 7 control loops Standard version with Windows 2000 with 4 or 7 control loops Export version with Windows 2000 with 5 or 8 control loops Standard version with Windows 2000 with 5 or 8 control loops Export version with Windows 2000 with 6 or 9 control loops Standard version with Windows 2000 with 6 or 9 control loops 18

Id. Nr. 389 764-51 389 764-01 389 764-52 389 764-02 389 764-53 389 764-03 389 769-51 389 769-01 389 769-52 389 769-02 389 769-53 389 769-03

HEIDENHAIN Technical Manual iTNC 530

1 Update Information No. 8


1.1 NC Software 340 422-xx and 340 480-xx
Several descriptions from Updates 7 and 8 were revised. NC software 340 422-07 340 480-07 Export version 340 423-07 340 481-07 Release August 2003 August 2003

MP4043 and MP4044 are new: If all PLC outputs are switched off (e.g., during PLC program compilation or due to a PLC run-time error), the outputs that can be switched off by an emergency stop can be switched off delayed by 250 ms. The 24-V supply may not be shut off in an emergency stop. MP4043 Outputs O0 to O15 Input: %xxxxxxxxxxxxxxxx Bits 0 to 15 correspond to O0 to O15 0: Do not switch off output with delay 1: Switch off output with delay MP4044 Outputs O16 to O23 Input: %xxxxxxxx Bits 0 to 7 correspond to O16 to O23 0: Do not switch off output with delay 1: Switch off output with delay NC software 340 422-06 340 480-06 Export version 340 423-06 340 481-06 Release June 2003 June 2003

Module 9140 Set axis-specific feed-rate limit With Module 9140 you can set axis-specific feed-rate limits. The limits are saved in sequential double words for each axis. The address of the starting double word must be given. Along with a feed-rate value ( 0), the following limitations are possible in the double words: 1: Maximum feed rate 2: Axis-specific rapid traverse from MP1010.x 3: Axis-specific manual feed rate from MP1020.x Invalid feed-rate values are set to 0 and M4203, other axes retain their limits. Call: PS PS CM B/W/D/K <Start double word> B/W/D/K <Number of axes or double words> 9140

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Error detection: Marker M4203 W1022 Value 0 1 1 2 3 5 24 Meaning Feed-rate limit is set Error code in W1022 Invalid feed-rate value (< 3) Invalid number of axes or double words Invalid block length as of starting address No double word address Module was called in a spawn job or submit job

Module 9141 Read the axis-specific feed-rate limit With Module 9141 you can read axis-specific feed-rate limits. The limits are saved in sequential double words for each axis. Along with feed-rate values ( 0), the limitations 1, 2 or 3 (see Module 9140) are also transferred. Call: PS PS CM B/W/D/K <Start double word> B/W/D/K <Number of axes or double words> 9140

Error detection: Marker M4203 W1022 Value 0 1 2 3 5 24 Meaning Feed-rate limit is set Error code in W1022 Invalid number of axes or double words Invalid block length as of starting address No double word address Module was called in a spawn job or submit job

1.2 Hardware
A new variant of the MC 422 (standard and basic versions) was released: Variant xxx xxx-y2 Changes in MC 422 (standard and basic versions) Main computer revised

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1 Update Information No. 9


1.1 Releases
The following versions of the NC software were released: NC software 340 420-11 and 340 421-11 NC software 340 422-08 and 340 423-08 NC software 340 480-08 and 340 481-08 NC software 340 422-09 and 340 423-09 NC software 340 480-09 and 340 481-09 November 2003 October 2003 October 2003 November 2003 November 2003

1.2 NC Software 340 420-xx


NC software 340 420-11 Export version 340 421-11 Release November 2003

NC software 340 420-11 contains all of the functions of NC software 340 422-09. In the standard setting, datum management via preset tables is deactivated.

1.3 NC Software 340 422-xx and 340 480-xx


NC software 340 422-08 340 480-08 Configuring the axes and spindle Machine interfacing Export version 340 423-08 340 481-08 Release October 2003 October 2003

For the MC 422B, measurement of the CPU temperature via Module 9133 is not possible for the time being. If a service pack is installed, a corresponding information box appears during the Power interrupted message. In OEM.SYS you can use the keyword LOGOSP = to define the complete path of a specific logo that then appears instead of this information. The same conditions apply for the logo as for the standard logo.

NC software 340 422-09 340 480-09

Export version 340 423-09 340 481-09

Release November 2003 November 2003

December 2003

Releases

11

Machine parameters

MP4043, MP4044 and MP4045 have been removed. MP4060.x is new: If all PLC outputs are switched off (e.g., during PLC program compilation or due to a PLC run-time error), the outputs defined in MP4060.x are switched off delayed by the time defined in MP4061.x. The delay only affects outputs that cannot be switched off by emergency stop, since for the outputs that can be shut off by an emergency stop, the 24-V supply is shut off immediately. Input: 0 to 30 1: Do not switch off output with delay MP4061.x is new: Time period is defined by which the switch-off of the outputs defined in MP4060.x is to be delayed. Input: 0 to 5.000 [s] MP7230.x has been expanded: In MP7230.0 and MP7230.3, the conversational language of the MC 422B (with BF 150) can be set to Chinese by using input value 15. MP7621 is new: Reserved, enter 0. MP7640.x has been expanded: The HR 420 is activated with input value 11. MP7641 has been expanded: Bit 1 Stepped rotation of HR 420 0: Without detent positions 1: With detent positions Bit 2 Axis direction keys and rapid traverse on the HR 420 0: Controlled by the NC 1: Controlled by the PLC Bit 3 NC start / NC stop on the HR 420 0: Controlled by the NC 1: Controlled by the PLC During the automatic test of the motor brakes the sum of MP1110.x and MP2232.x applies to standstill monitoring. Non-linear axis-error compensation has been improved: Dependencies between the axes 1 to 14 can be defined. The maximum possible number of lines is 360. The spacing of the compensation points can be defined as desired (999.9999). If another *.COM file is to be used for the negative direction of traverse, the file name must end with the character "". Example: Entry in the *.CMA file: Axis_X. The compensation value table Axis_X.COM is used. If the compensation value table Axis_X.COM exists, it will be used for the negative traverse direction.

Configuring the axes and spindle

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Machine interfacing

The diagnostic functions are no longer optional and can thus be used at any time. The diagnostic functions have been expanded: After pressing the (Motor) I soft key, general information on control hardware and drive hardware appears. Use the and soft keys to select a control loop and to display detailed information. The EnDat SPEED soft key is used to display the information of absolute speed encoders with EnDat interface. The EnDat POSITION soft key is used to display the information of absolute position encoders with EnDat interface. The MOTOR DATA soft key is used to display the motor data from the motor table. The (Motor) ID LABEL soft key is used to display the electronic ID label of HEIDENHAIN QSY synchronous motors with absolute speed encoder. The (Power module) ID LABEL soft key is used to display the electronic ID label of HEIDENHAIN UM 1xxD power modules. The (Motor) TEST soft key is available after you have entered the code number 688379 and before you have acknowledged the Power interrupted message. After pressing the soft key, the Power interrupted message can be acknowledged and the drives can be switched on. The START TEST soft key is used to start an automatic test of the motor and inverter functions. The acknowledgment of an error message is recorded in the log with the entry INFO: MAIN ERRCLEARED <Date> <Time> as well as the error number and error message. The following markers were introduced for the HR 420: M4660: HR 420 assumes control M4661: NC start on HR 420 M4662: NC stop on HR 420 M4663: Rapid traverse key on HR 420 M4664: Spindle start on HR 420 M4665: Spindle stop on HR 420 M4666: + key on HR 420 M4667: key on HR 420 M4668: Ctrl key on HR 420 The marker M4057 is set during a touch probe cycle and reset when the touch probe cycle is canceled. To support the marker, FN17: SYSWRITE ID990 NR2 was expanded: 0.0: Touch probe monitoring off. M4057 is not used. 1.0: Touch probe monitoring on. M4057 is not used. 2.0: Touch probe monitoring off. M4057 is used. 3.0: Touch probe monitoring on. M4057 is used.

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PLC programming

The number of strings was increased from 16 to 100 (S0 to S99). FN17: SYSWRITE ID503 NR<line> IDX<column> is used to enter a value in the preset table. If M4753 is set, errors from PLC modules will be entered in the PLC log PLCDEBUG.LOG. There is a separate log for PLC events under PLC:\PLCDEBUG.LOG. The following events are entered: Start of the PLC after switch-on. Start and stop of the PLC. Errors from PLC modules (only if M4753 = 1). Run-time errors Symbolic operands can be used in the mask files for PLC windows. The Config. file for conditional compilation can be selected with the SELECT + COMPILE and SELECT COMPILER CONFIG. soft keys. PLCCOMPCFG = is automatically entered in OEM.SYS. For newly supplied MC 422B, new partition sizes of the hard disk are supported: Partition MC 422 B C: TNC: PLC: SYS: 25.87 GB 948.86 MB 956.70 MB MC 422 B (with Windows 2000) 12.97 GB 12.97 GB 957.00 MB 957.00 MB

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HEIDENHAIN Technical Manual iTNC 530

PLC modules

Module 9007 for determining the number of connected PLs (diagnostic information of PL 4xxB) now also supports the PL 510. Module 9137 (diagnostic information of the PL 510) was extended by information 12 (number of connected PL 510). Module 9221 (start PLC positioning) was extended by error code 6 (PLC positioning of axis already started). Module 9084 Display PLC error messages with additional data With Module 9084 you can display PLC error messages with additional data. You can insert place holders (%s, %d, %f) at any position of the error messages. The place holders are assigned the data from the module at run time. Only those place holders that are defined in the PLC error message will be replaced. %s is replaced by the string or the string content. The first occurrence of %d or %f in the PLC error message is replaced by the content of variable 1, and the second occurrence of %d or %f is replaced by the content of variable 2. %d is an integer, %f is a floating point number with three decimal places. Alternately, you can define the number of decimal places with %.1f to %.6f. If the module is called several times with the same line number of the *.PET table, the error message is entered only once in the queue. A maximum of 32 PLC error messages can be entered in the queue. If necessary, the error marker assigned is set. If the *.PET table or the line number is not found, the error message PLC ERROR <line number> appears. Call: PS PS PS PS CM B/W/D/K <Line number of the *.PET table> 0 to 999: Line number B/W/D/K/S<Data for %s> B/W/D/K <Data for %d or %f; variable 1> B/W/D/K <Data for %d or %f; variable 2> 9084

Error recognition: Marker M4203 W1022 Value 0 1 1 8 23 Meaning PLC error message with additional data displayed Error code in W1022 Line number not available Incorrect operating mode, compatibility error marker set Overflow of PLC error message queue

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Module 9277 Writing data into the OEM log With Module 9277 the PLC can write data into a specific OEM log. Up to eight OEM logs can be used at the same time. The module can be called from a cyclic PLC program or from a spawn job or submit job. The string for the log entry may contain two place holders (data1 and data2). Only specified place holders will be replaced. The output format is controlled through the entry %d for integers or the entry %f for floating point numbers with three decimal places. Alternately, you can define the number of decimal places with %.1f to %.6f. Example of a string for the log entry: Sdata1: %.2f data2: %d If the maximum log size of 1 MB is exceeded, the log is copied to <name>.LOG.OLD and a new log with the same name is created. Once the logs have been called, they remain open until the control is shut down. Call: PS PS PS PS PS B/W/D/K/S<Path with file name (without extension *.LOG)> B/W/D/K/S<String with place holder for log entry> B/W/D/K <Value for data1> B/W/D/K <Value for data2> B/W/D/K <Switch for additional entries> Bit 0 = 0/1: Entry without/with time stamp Bit 1 = 0/1: Entry without/with PLC cycle counter 9277

CM

Error recognition: Marker M4203 W1022 Value 0 1 2 22 Meaning Data written into OEM log Error code in W1022 Invalid string number or invalid string Message cannot be transmitted

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HEIDENHAIN Technical Manual iTNC 530

Module 9322 Information of the current NC program With Module 9322, you can determine the current block number of the active NC program. If the module is called from the cyclic PLC program, only the block number of the NC main program is determined. If the module is called from a spawn job or submit job, the path of the current NC program is determined in addition to the block number (from the block scan). Call: PS B/W/D/K <Mode> Call from a cyclic PLC program: Without effect. Call from a spawn job or submit job: 0: String and block number refer only to the active NC main program. Block number from block scan. 1: String and block number refer to the active NC program (also subprogram, cycle or macro). Block number from block scan. B/W/D/K <String number for path of the NC program or cycle> Call from a cyclic PLC program: Without effect. 9322 B/W/D <Block number of current NC program or cycle>

PS CM PL

Error recognition: Marker M4203 W1022 Value 0 1 1 2 Meaning Information of current NC program has been read Error code in W1022 Invalid mode Invalid string number

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Other functions

With the MC 422B, improved graphic display is available. Four soft keys are available for setting the speed for graphic simulation in the Test Run mode. With the projection in three planes in Test Run mode, the horizontal plane of a section starts at the top edge of the workpiece. After you have pressed the MOD key in the Programming and Editing mode of operation, the soft key for installing the service pack will be displayed. If more than one PLC error message occurs, you can display a list of them with the ERR key. With Cycle 8 (MIRROR IMAGE), you can now also program rotary axes as mirror axes. Old TNC 4xx programs were executed correctly before, but up to now it was not possible to program rotary axes as mirror axes. If you want to copy an externally prepared tool table, you now have the additional possibility of overwriting only those lines in TOOL.T that do not contain any data. For this purpose the REPLACE ONLY EMPTY LINES soft key has been introduced. Pressing the GOTO key in a DIN/ISO program no longer results in the control displaying the message GOTO line xxx jumped yyy.

1.4 Hardware
1.4.1 TS 640

TS 640 touch probe Touch-trigger probe with infrared transmission, for workpiece setup and measurement during machining. Id. Nr. 359 575-xx TS 640 Id. Nr. 377 686-xx SE 640 transmitterreceiver unit

TS 640

SE 640

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HEIDENHAIN Technical Manual iTNC 530

1.4.2 HR 410 There are new variants of the HR 410: HR 410 296 469-54 296 549-55 1.4.3 HR 420 Changes Revision Revision

HR 420 handwheel Portable handwheel with display and stepped rotation Id. Nr. 375 239-xx HR 420 handwheel

As of software version 340 422-09 or 340 480-09, the following functions are provided: Switching between the HR 420 and the control operating panel. Operation through the control operating panel is disabled. Spindle-speed and feed-rate override potentiometer on the HR 420. Status displays on the HR 420: Axis selection and display of the axis with position. Display of control-in-operation symbol, errors, symbol for tilted working plane. Display of spindle speed and feed rate. Display and change of infeed per rotation step. Setting of jog increment. NC start, NC stop, rapid traverse, axis movements in the positive and negative direction. Spindle start and spindle stop. Actual position capture in MDI mode. Entry and execution of M/S/F. Datum setting. Switching of operating modes. During an NC stop: Internal stop or manual traverse and return to positions. December 2003 Hardware 19

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HEIDENHAIN Technical Manual iTNC 530

1 Update Information No. 10


1.1 Releases
The following versions of the NC software were released: NC software 340 422-10 and 340 423-10 NC software 340 480-10 and 340 481-10 May 2004 May 2004

The following service packs for 340 422-09 and 340 423-09 were released: Service pack 1: 340 500-01 and 340 501-01 Service pack 2: 340 500-02 and 340 501-02 Service pack 1: 340 502-01 and 340 503-01 Service pack 2: 340 502-02 and 340 503-02 December 2003 March 2004

The following service packs for 340 480-09 and 340 481-09 were released: December 2003 March 2004

1.2 NC Software 340 422-xx and 340 480-xx


Service pack 340 500-01 340 502-01 NC software 340 422-09 340 480-09 Export version 340 423-09 340 481-09 Release December 2003 December 2003

Error messages entered more than once in the log are identified with Info: MAIN ERR_RECURRED. PLC error messages triggering an Emergency Stop are entered with the highest priority (independent of the priority from the *.PET table) in the error list. Therefore, these error messages always appear in the first position. The error message External EMERGENCY STOP has a lower priority, but still a higher priority than the top PLC priority. This means that PLC error messages triggering an Emergency Stop always appear in the first position in the error list. They are followed by External EMERGENY STOP and then by further PLC error messages. Cycle 32 (TOLERANCE) is reset depending on MP7300 (status display). Service pack 340 500-02 340 502-02 NC software 340 422-09 340 480-09 Export version 340 423-09 340 481-09 Release March 2004 March 2004

NC software 340 422-10 340 480-10

Export version 340 423-10 340 481-10

Release May 2004 May 2004

May 2004

Releases

11

Machine parameters

The PLC can change MP10 even while an NC program is running (PLC, RUN). The maximum input value for MP331.x and MP332.x has been increased to 1.797693135E+308. Large input values cannot be read by the PLC! MP1096 has been expanded: MP1096.0 specifies the tolerance at corners at machining feed rate. This value can be overwritten by the machine user with Cycle 32. MP1096.1 specifies the tolerance at corners at rapid traverse. This value cannot be influenced by the machine user. MP1522 is new: In addition to the nominal position value filters, MP1522 allows you to activate feed-rate smoothing. This smoothes jerks caused by a change in the feed rate. This reduces the machines tendency to vibrate, without significantly increasing the machining time. MP1522 should be approx. 0.5 ... 1 TMachine (TMachine = Period of resonant frequency of machine). Example: fMachine = 50 Hz; TMachine = (1 / 50 Hz) = 20 ms; MP1522 = 20. Since feed-rate smoothing results in an increase in speed at corners, the jerk must be adjusted (if necessary) to prevent damage to the contour. Input: 0 to 60 [ms] MP2195 has been expanded: Bit 0 Handling of status signals from HEIDENHAIN power supply units that are already inactive during control start-up. (Signals that change their status during operation are always identified as errors.) 0: Missing signals cannot be detected with Module 9066 and do not result in an error message when the drive is switched on. 1: After the PLC program has been compiled, missing signals can be detected with Module 9066 and trigger an error message when the drive is switched on. Signals that are not provided by the power supply unit must be suppressed with MP2195 (bit 1 to bit 6), because non-existent signals are always identified as errors. The input range for MP2542.x to MP2546.x was increased to 0 to 99.0 [dB]. The input range for MP2552.x to MP2556.x was increased to 0 to 30000.0 [Hz]. MP2562.x to MP2566.x were expanded: The filters can be used in the position or speed controller. The kV factor can be increased by using the filters in the position controller. After the kV factor has been increased up to the oscillation limit, a band-rejection filter can be defined for the oscillation frequency so that the kV factor can be further increased. Input: 1 = PT2 low-pass filter (speed controller) 2 = Band-rejection filter (speed controller) 11 = PT2 low-pass filter (position controller) 12 = Band-rejection filter (position controller) The input range for MP2572.x to MP2576.x was increased to 0 to 30000.0 [Hz]. MP5000 was expanded: Input value 3 allows you to disable the serial interfaces RS-232-C/V.24 and RS-422/V.11. MP5020.3 and MP5030.3 expanded for EXT4 (PLC) operating mode. MP5040 was expanded: MP5040.0 Data transfer rate in operating mode EXT3 MP5040.1 Data transfer rate for operating mode EXT4 MP7230.x was expanded: 14: Russian (with Cyrillic character set) 15: Chinese (simplified) 16: Chinese (traditional) These languages are available only with the MC 422B with BF 150. HEIDENHAIN Technical Manual iTNC 530

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MP7363.5 is new: Rapid traverse movements in the programming graphics are displayed with the color from MP7363.5. MP7460.x and MP7461.x are new: Reserved, input value: 0 MP7680 was expanded: Bit 15 - Suppress NC Start if the program is aborted A corresponding message window appears. NC Start is available after you have pressed the YES soft key, after program selection or after GOTO. 0: Function inactive 1: Function active Configuring the axes and spindle Axes for which master-slave torque control is active can be switched to single-axis operation during operation by overwriting MP850.x. Cycle 32 (TOLERANCE) is reset depending on MP7300 (status display). PLC positioning is done without nominal position value filter. The maximum braking power from MP2390.x may be greater than the power limit from MP2392.x. Up until now, the maximum braking power was limited to the value of the power limit. During a powerfail the braking time before switch-off of the drives has been extended to 10 s. The motor table has been expanded for a new 2nd order I2t monitoring. 2nd order I2t monitoring is not needed for most of the motors. For these motors, the entry from the T-AC column can be transferred to the Tth2 column. In this case, 1st order I2t monitoring is used. New columns in the motor table: Tth1: Thermal time constant for winding [s] Rth1: Thermal resistance between winding and lamination [K/W] Tth2: Thermal time constant for lamination [s] Rth2: Thermal resistance between lamination and cooling system [K/W] A step can be output in the integrated oscilloscope only after the code number 688379 or 807667 has been entered. The integrated oscilloscope has been expanded with the following signals: F TCPM: Feed rate for the tool point with M128 (feed rate without compensation motions) int. diagn.: Reserved for internal purposes In the integrated oscilloscope, the cursor is located on the trigger point only if it has not been moved after the measurement. If the cursor has been moved, it will remain at the point of the time axis to which it has been moved. The cursor does not return to the trigger point until a trigger parameter has been changed. The CC 424 supports backlash compensation via MP750.x and MP752.x. Machine interfacing A PLC soft key that is disabled in the soft-key project file with ENABLE:<Marker> appears dimmed (inactive). In the soft-key project file, conditional compilation with #if ... #endif and #ifdef ... #endif is possible. For test purposes, all LSV-2 telegrams can be entered in the log. After entering the code word LOGBOOK, this function must be enabled with the LSV-2 TELEGRAM OFF/ON soft key. Error messages entered more than once in the log are identified with Info: MAIN ERR_RECURRED.

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If M4754 is set, internal diagnostic information is entered in the log MYDEBUG.LOG. The marker should be set only for debugging purposes. Otherwise, unnecessary access to the hard disk will put a strain on the system. The speed-encoder test has been added to the diagnostic functions. This soft key is available after you have entered the code number 688379 and before you have acknowledged the Power interrupted message. After pressing the soft key, the Power interrupted message can be acknowledged and the drives can be switched on. The START TEST soft key is used to start an automatic test of the speed encoder. The display of analog signals contained in the diagnostic functions for the drive also shows the motor temperatures with the designation of the control loop. The following commands can be used in the print masks for the measurement log in the manual touch probe cycles: mm_display: The following values are displayed only if under MOD Change MM/INCH is set to MM. inch_display: The following values are displayed only if under MOD Change MM/INCH is set to INCH. all_display: The following values are displayed regardless of the setting in MM/INCH under MOD. If M4622 is set during the first run of the PLC program, the message window Waiting for M4622 appears after the reference marks have been traversed. The window does not disappear until you have reset M4622. In this way, you can delay the execution of the NC macro defined through RESETINIT = in the NCMACRO.SYS. The source of error is displayed in the new column Group of the error list (to be called with the ERR key). GENERAL OPERATING PROGRAMMING PLC PLC error messages triggering an Emergency Stop are entered with the highest priority (independent of the priority from the *.PET table) in the error list. Therefore, these error messages always appear in the first position. The error message External EMERGENCY STOP has a lower priority, but still a higher priority than the top PLC priority. This means that PLC error messages triggering an Emergency Stop always appear in the first position in the error list. They are followed by External EMERGENY STOP and then by further PLC error messages. New PLC operands: Set M4223 M4227 M4228 M4229 Error from PET table with NC Cancel active PLC error message with priority 0 (error) PLC error message with priority 1 (warning) PLC error message with priority 2 (info) NC NC NC NC Reset NC NC NC NC

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HEIDENHAIN Technical Manual iTNC 530

PLC programming

The function TRACE IN-CODE will also be available on an external PC with PLCdesignNT. The search function of the TRACE function has been improved. In the TRACE and TABLE functions, you can use the ADD TO WATCH LIST soft key to transfer the selected operand into the WATCH LIST. In the TABLE function the symbolic name of an operand can be entered with GOTO. The WATCH LIST function has been expanded: The ADD TO LOGIC DIAGRAM soft key allows you to transfer the selected operand into the logic diagram. A search function is available. First the SYMBOL column and then the ADDR column is searched for the search string. The HEX DECIMAL soft key allows you to change the number representation. The following information has been added to FN18: SYSREAD ID51: NR6: Type of tool (PTYP) NR7 to NR11: Value 1 (P1) to value 5 (P5) NR12: Pocket reserved (RSV) NR13: Pocket above locked (LOCKED_ABOVE) NR14: Pocket below locked (LOCKED_BELOW) NR15: Pocket at left locked (LOCKED_LEFT) NR16: Pocket at right locked (LOCKED_RIGHT)

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PLC modules

Module 9217 (pop-up window for messages) supplies error code 36 in W1022 if there is no ASCII file with the message text. A window shown with Module 9217 (pop-up window for messages) can be closed with Module 9261 (sending of events) through event $010000. Transfer parameter 2 (from MP50x0.3) has been added to Module 9100 (assign the data interface). Module 9179 Status information about spindle(s) Status information about the spindles can be ascertained with Module 9179. Call: PS PS CM PL B/W/D/K <Number of spindle> B/W/D/K <Code for status information> 0: Active spindle ("Number of spindle" is not evaluated) 9179 B/W/D <Status information>

Error recognition: Marker M4203 W1022 Value 0 1 1 2 Meaning Status information has been ascertained Error code in W1022 Invalid code for status information Invalid spindle number

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HEIDENHAIN Technical Manual iTNC 530

Module 9282 Tool usage test for pallet table Module 9282 allows you to check the tools used in a pallet table. The pallet file must be selected in the Program Run, Single Block or Program Run, Full Sequence operating mode. The tool usage file for the pallet table and the test result file in ASCII format are created. The test result file contains the results from the comparison of the tool usage file with the tool table. If a pallet call is given as the line number, all subordinate machining operations are checked. If a program call is given, only the tool usage file of the NC program is checked. Call: PS PS PS CM PL B/W/D/K <Line number of the pallet table> B/W/D/K/S<Name of the test result file (*.P.T.DEP)> B/W/D/K/S<Name of the tool usage file (*.T.DEP)> 9282 B/W/D <Result> 0: No error 1: Tool usage file of an NC program of the pallet table not available or no longer up-to-date 2: Tool life not sufficient 3: Required tool not available 4: Radius of required tool is incorrect 5: Tool is not in magazine 6: Tool usage file of an NC program of pallet table cannot be opened 7: Test result file could not be created 8: Test result file cannot be written to 9: Tool usage file of an NC program of pallet table cannot be read 10: No memory for creating the tool usage file

Error recognition: Marker M4203 W1022 Value 0 1 11 20 Meaning Tool usage test has been performed Error code in W1022 Invalid string programmed Module was not called in a spawn job or submit job

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Module 9343 Compilation and activation of magazine rules Module 9343 is used to compile and activate magazine rules (*.TCR), independent of the entry TCHRULES = in OEM.SYS. If the entry exists in OEM.SYS, the magazine rules are overwritten when Module 9343 is called. If an error occurs during compilation, the PLC program is stopped. The magazine rules must be activated during the first run of the PLC program or before the first call of Module 934x. Call: PS CM B/W/D/K/S<Path and file name of the magazine rules> 9343

Error recognition: Marker M4203 W1022 Value 0 1 11 20 38 Other functions Meaning Magazine rules have been compiled and activated Error code in W1022 Invalid string programmed Module was not called in a spawn job or submit job Error during compilation

The TOOL USAGE TEST soft key is also available for pallet tables. If a line with an NC program is active, the test is performed only for the NC program in question. If a line with a pallet entry is active, the test is performed for the complete pallet table. If the time programmed in AUTOSTART is in the past, the error message Starting time has passed appears. The Czech conversational language has been added to the measuring logs of the touch probe cycles. Several IP addresses for the control can be defined in a table. The active IP address is selected with the ACTIVATE LINE soft key. When you insert new lines in a table, a display of progress appears if required. In the programming graphics, the SHOW OMIT BLOCK NO. soft key allows you to show or hide the block numbers. The soft keys of the search function have been improved. The last defined speed for graphic simulation in the Test Run mode also remains in effect if the control is restarted. With some input functions (e.g. tool selection lists with Module 9216), the RETURN key can be used instead of the ENT key. A list of PLC operands with brief description in English and German (GLB_NC_de.DEF, GLB_NC_en.DEF) is contained in the control under PLC:\JH\. In the freely definable tables (e.g. *.P, *.CDT, *.TAB), English dialogs are shown instead of the Russian dialogs. M114 is effective locally in cycles, i.e. the function is canceled before the return to the main program. If you want M114 to also be effective in the main program, you must use FN17: SYSWRITE ID420 NR0 IDX0 = 0 (globally effective coordinate transformation). Rotary axes can be programmed within an M120 sequence. A maximum of eight datum shifts and six scaling factors can be shown in the status display. Mirrored axes are displayed in sequence one after another. This means that six axes can be displayed. HEIDENHAIN Technical Manual iTNC 530

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When entering data in screen forms (e.g. axis selection in the oscilloscope), you can use the ENT key to scroll forward and the NO ENT key to scroll backward. When a touch probe cycle is called in the Manual Operation and El. Handwheel operating modes, and the current angles of the swivel axes do not coincide with those in the Tilt working plane function, the error message Axis angle not equal tilt angle appears. With the PROBING ROT cycle, this warning can be acknowledged and the cycle can be executed. Enter information into the log with FN38: SEND. The function is available after you have entered the code number 555343. Example: NC program: FN38: SEND /Q parameter Q1: %f Q2: %f /+Q1 /+Q2 Entry in the log from the Program Run, Single Block or Program Run, Full Sequence operating mode: INFO: MAIN NCEVENT <Date and time> Q parameter Q1: <Value Q1> Q2: <Value Q2> Entry in the log from the Test Run operating mode: INFO: MAIN NCTEVENT <Date and time> Q parameter Q1: <Value Q1> Q2: <Value Q2> A maximum of three axes can be entered in Cycle 8 (MIRRORING). Parameter Q208 (FEED RATE FOR RETRACTION) has been added to Cycle 22 (ROUGH-OUT). Parameter Q21 (TOLERANCE) has been added to Cycle 28 (CYLINDER SURFACE) so that a slot with approximately parallel walls can be produced with a tool whose diameter must be smaller than the width of the slot. Traverse after machining depends on MP7420 bit 4. Cycle 29 (CYL. SURFACE RIDGE) allows you to machine a ridge on a cylinder surface. Cycle 39 (CYL. SURFACE CONTOUR) allows you to machine an open outside contour on a cylinder surface.

1.3 Additional Enhancements to NC Software 340 480-xx


Hard disks with NC software 340 480-10 supplied by HEIDENHAIN include Microsoft Service Pack 4 for Windows 2000 and Microsoft Patch KB835732. If you already have a hard disk, you can install these expansions at any time. Soft keys can be selected and soft-key rows can be switched by clicking the mouse. The Log Files button has been added to the iTNC Control Panel. This button is reserved for HEIDENHAIN diagnostic purposes. The start and shut-down of the control software is recorded in a log for internal diagnostic purposes.

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Additional Enhancements to NC Software 340 480-xx

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1.4 Hardware
There is the new, more powerful hardware MC 420 for the basic versions of the iTNC 530. With this hardware, the housing with the main computer, the hard disk and the SIK are all supplied separately. Properties of the MC 420: Celeron with 400 MHz 128 MB RAM 100 MHz bus frequency HDR removable hard disk SIK with NC software license One USB interface Only PL 510 connectable (and not PL 410B / PL 405B) Maximum of 6 control loops with the CC 422 Housing with main computer

Main computer (basic version) 5 position encoder inputs

Signal inputs

Id. Nr. of MC for BF 120 display unit

Id. Nr. of MC for BF 150 display unit 515 929-01

Position: 1 VPP/EnDat

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HEIDENHAIN Technical Manual iTNC 530

HDR hard disk HDR hard disk for iTNC 530 Export version Standard version SIK with NC software license SIK with NC software license Export version with 4 control loops without software options 1 + 2 Standard version with 4 control loops without software options 1 + 2 Export version with 5 control loops without software options 1 + 2 Standard version with 5 control loops without software options 1 + 2 Export version with 6 control loops without software options 1 + 2 Standard version with 6 control loops without software options 1 + 2 Options Option 1st additional control loop 2nd additional control loop Software option 1 Software option 2 Id. Nr. 354 540-01 353 904-01 367 591-01 367 590-01 Id. Nr. 510 085-51 510 085-01 510 085-52 510 085-02 510 085-53 510 085-03 Id. Nr. 387 546-51 387 546-01

May 2004

Hardware

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HEIDENHAIN Technical Manual iTNC 530

1 Update Information No. 11


1.1 Releases
The following service pack for 340 422-10 and 340 423-10 was released: Service pack 1: 531 482-01 and 531 483-01 Service pack 1: 531 484-01 and 531 485-01 NC software 340 422-11 and 340 423-11 NC software 340 480-11 and 340 481-11 Service pack 1: 340 422-11 and 340 423-11 Service pack 1: 340 480-11 and 340 481-11 Service pack 2: 340 422-11 and 340 423-11 Service pack 2: 340 480-11 and 340 481-11 September 2004

The following service pack for 340 480-10 and 340 481-10 was released: September 2004

The following versions of the NC software were released: August 2004 August 2004 September 2004 September 2004 September 2004 September 2004

1.2 NC Software 340 422-xx/340 423-xx and 340 480-xx/340 481-xx


Service pack 531 482-01 531 483-01 531 484-01 531 485-01 NC software 340 422-10 340 423-10 340 480-10 340 481-10 Release September 2004 September 2004 September 2004 September 2004

Under certain conditions, at the end of the cycle the machine moves to the center of the cylinder during execution of Cycle 28 (CYLINDER SURFACE). This applies to machines with rotary table and the entry PRESETTABLE = OFF in the OEM.SYS. NC software 340 422-11 340 480-11 Export version 340 423-11 340 481-11 Release August 2004 August 2004

This is the first NC software to support the MC 420.

October 2004

Releases

11

Machine parameters

MP2210.x is new (only CC 424): Some of the asynchronous spindle motors require a high magnetizing current at low speeds (n < nfield weakening). This magnetizing current can, however, lead to thermal motor problems at the rpm for field weakening. MP2210.x enables you to reduce the nominal voltage (and, as a result, the nominal magnetizing current) at the rpm for field weakening during idle running. The maximum nominal voltage is reached when n = 3 nfield weakening. The nominal voltage can be reduced by max. 60 % (MP2210.x = 60). Input: 0 to 99 [%] 0: Function inactive

Unominal

MP2210.x

nfield weakening

n 3 nfield weakening

MP2211.x is new (only CC 424): Reserved, enter 0 MP7310 was expanded: Bit 5The 3-D graphics (with representation of 5-axis machining) can also be deactivated with the MC 422B and MC 420. 0: Permit 2.5-D and 3-D graphics (also depends on hardware) 1: Permit only 2.5-D graphics (independent of hardware) MP7610.x is new (only CC 424): Reserved, enter 0 MP7691 was expanded: Diagnosis functions for the HeROS operating system. Can only be evaluated by HEIDENHAIN. Set MP7691.x = 0. PLC programming If the highlight is located in the WATCH LIST in the SYMBOL column or ADDR column, the ORDER soft key can be used to sort the WATCH LIST by the respective column.

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HEIDENHAIN Technical Manual iTNC 530

PLC modules

Module 9149 Set/Read commutation angle Module 9149 enables you to determine and set the commutation angle of a synchronous, torque or linear motor. For axes that cannot be moved when switched off (e.g. due to Hirth coupling), Module 9149 can be used to read out the commutation angle of the position at shutdown. The PLC can then store it in nonvolatile memory. After restarting the control, you can use the module to again set the commutation angle which is stored in nonvolatile memoryfor the axis concerned. This means that it is not necessary to determine the commutation angle again. Danger After the axis has moved away from the position at shutdown, the commutation angle is no longer valid and must no longer be used. When the control is shut down the next time, the commutation angle of the position at shutdown must be read out and stored again. Safety precautions: The commutation angle may be set only after you have ensured that the stored commutation angle corresponds to the current position (e.g. due to Hirth coupling). The module is suitable only for synchronous, torque, or linear motors in conjunction with nonaligned encoders without EnDat interface. The module responds with a value only if the reference mark has been traversed. The commutation angle for an axis can be set only once after the control is switched on and before the drives are first switched on. Call: PS PS PS B/W/D/K <Axis> B/W/D/K <Commutation angle in 0.001> 1 to 720000 B/W/D/K <Mode> 0: Read commutation angle 1: Set commutation angle 9149 B/W/D <Error code> 0: Commutation angle set/read 1: Module was not called in a spawn job or submit job 2: Invalid mode 3: Invalid axis number 4: Invalid commutation angle Error code from controller when mode 0 is active (read commutation angle): 100: Unknown reference position Error code from controller when mode 1 is active (set commutation angle): 200: Invalid motor type (no synchronous or linear motor) 201: Invalid encoder type (not non-aligned) 202: Invalid commutation angle 203: Commutation angle already set B/W/D <Commutation angle>

CM PL

PL

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13

Error recognition: Marker M4203 W1022 Value 0 1 1 2 20 45 Other functions Meaning Commutation angle set/read Error code in W1022 Invalid mode Invalid axis number Module was not called in a spawn job or submit job Error code from controller

Cycle 247 (SET DATUM), FN25: PRESET and FN17: SYSWRITE ID530 can also be used during a block scan. The conversational language Russian with Cyrillic characters can also be set when the BF 120 visual display unit and the MC 422 are used. Two text files are stored in the directories PLC:\LANGUAGE\GERMAN\ and PLC:\LANGUAGE\ENGLISH\. The file jh_error.txt contains all possible error messages and the file jh_error_help.txt contains the corresponding help texts. The speed for graphic simulation is displayed each time a simulation is started in the Test Run mode. When touch probe cycle 0 (REFERENCE PLANE) is used in conjunction with a rotary axis with modulo display, the maximum length of the probing path is limited to the modulo value from MP810.x and the measuring point is always approached in the probing direction (the probe retracts in the direction opposite to the probing direction). If the HR 420 is used, the smaller of the values set for the TE or HR 420 is used for the spindle or feed-rate override in all modes of operation, except the Manual mode. NC software Service pack 1 for 340 422-11and 340 423-11 Service pack 1 for 340 480-11and 340 481-11 Release September 2004 September 2004

An old value may be read when a customized FN function is used for reading data from the tool table. As a result, in customized measuring cycles, the measurement values determined were not taken into account in the geometry. NC software Service pack 2 for 340 422-11and 340 423-11 Service pack 2 for 340 480-11and 340 481-11 Release September 2004 September 2004

1.3 Additional Enhancements to NC Software 340 480-xx/340 481-xx


Hard disks with NC software 340 480-11 supplied by HEIDENHAIN include the following Microsoft Patches: KB823559, KB824105, KB823182, KB826232, KB828035, KB825119, KB828749, KB828741, KB837001, KB842526, KB841872, KB841873, KB840315, KB839645. If you already have a hard disk, you can install these expansions at any time.

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1 Update Information No. 12


1.1 Releases
The following service packs for 340 422-11 and 340 423-11 were released: Service pack 3: 340 422-11 SP3 and 340 423-11 SP3 October 2004 Service pack 5: 340 422-11 SP5 and 340 423-11 SP5 November 2004 The following service packs for 340 480-11 and 340 481-11 were released: Service pack 3: 340 480-11 SP3 and 340 481-11 SP3 October 2004 Service pack 5: 340 480-11 SP5 and 340 481-11 SP5 November 2004 The following versions of the NC software were released: NC software 340 490-01 and 340 491-01 NC software 340 492-01 and 340 493-01 November 2004 November 2004

1.2 NC Software 340 422-xx/340 423-xx and 340 480-xx/340 481-xx


Service pack 340 422-11 SP3 340 423-11 SP3 340 480-11 SP3 340 481-11 SP3 Service pack 340 422-11 SP5 340 423-11 SP5 340 480-11 SP5 340 481-11 SP5 NC software 340 422-11 340 423-11 340 480-11 340 481-11 NC software 340 422-11 340 423-11 340 480-11 340 481-11 Release October 2004 October 2004 October 2004 October 2004 Release November 2004 November 2004 November 2004 November 2004

November 2004

Releases

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1.3 NC Software 340 490-xx/340 491-xx and 340 492-xx/340 493-xx


Warning This NC software is executable only on the MC 422B and the MC 420, each with 128 MB of RAM. The BF 120 (resolution: 640 x 480 pixels) is no longer supported. New options The following options are enabled by entering a code number. HEIDENHAIN can give you the code number after having been informed of the SIK number. Option #18 #41 Description ID number

Access to control functions via the COM component 526 451-01 (HEIDENHAIN DNC) Enabling of additional dialog languages (please contact HEIDENHAIN if you require additional dialog languages) Feature Content Level, see page 20 530 184-01

#53

529 969-01

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HEIDENHAIN Technical Manual iTNC 530

Notes on the software exchange

When updating the NC software from 340 422-xx to 340 490-01, keep the following points in mind (the same applies to the dual-processor control and to export versions): The machine parameters of the nominal position value filters (MP1094 to MP1099.x) were restructured and shifted to MP12xx. See page 13. If you overwrite the PLC values of the nominal position value filters, the PLC program must be adapted to the new machine parameters. The old nominal position value filters (MP1094 to MP1099) can be reactivated by entering MPMODE = 340422 in the OEM.SYS file. MP12xx then have no effect. The kinematics can now be configured only via kinematics tables. Machine parameters MP7500, MP7510.x, MP7520.x, MP7530.x and MP7550.x were removed. No special adaptations to the PLC program are required for working with the new smarT.NC operating mode. If smarT.NC is active, marker M4163 (smarT.NC active) is set. For NC software versions up to 340 422-xx there is an internal connection between the feed-rate and rapid-traverse overrides. For example, if the value of the feed-rate override was manipulated via the PLC, this also had an effect on the rapid traverse. This connection was removed starting with NC software 340 490-01. In contrast to NC software 340 422-xx, a manipulation of W766 (% factor for feed-rate override) does not affect rapid traverse movements. Word W752 (rapid traverse potentiometer) is also effective if bit 5 is not set in MP7620. Note You might have to make changes to your PLC program. If you want to keep an existing OEM cycle project during software exchange, you must first adapt the project. The reason is that because it is now possible to freely assign file names of parameters, new file names were defined for some standard parameters. Proceed as follows: Download and install the current CycleDesign software version 4.0.260 from the HEIDENHAIN FileBase Open the existing CycleDesign project with the current CycleDesign version 4.0.260 Menu item File > Change variant... In the New variant pull-down menu, select the entry 34049001 and confirm with OK Confirm also the subsequent Update Information with OK Menu item File > Save Then transfer the file to the control or generate an installation and check its functions. Warning Without this procedure, after a software update to the version 340 49x the error message Key nonfunctional will appear when you press the CYCL DEF key

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Machine parameters

MP12 is new: NC axes can be switched axis-specifically into demo mode with MP12. The demo mode enables the simulation of axis motors that are not present on the machine. This permits you to put into operation and test axes that have not yet been mounted on the machine. The PLC program of the machine might need to be adapted. Input: Bits 0 to 13 represent axes 1 to 14 0: Demo mode not active 1: Demo mode active The control is not restarted if MP210 (direction of the encoder signals of the position encoder) is changed. The axis must be moved over the reference mark again after this change. MP709.x is new: MP709.x is used to influence the output of the backlash compensation (MP710.x). Input: 0: Previous behavior of MP710.x 1 to 1000: Time constant [ms]

MP710.x

Nominal value Reversal point MP709.x: Small input value MP709.x: Large input value MP709.x = 0

Nominal value

MP1094 to MP1099 were shifted: The machine parameters of the nominal position value filters were restructured, expanded and set to MP12xx. The filters are now selected with MP1200 / MP1201. The limit frequencies are set for each filter separately via MP1210 to MP1213. The previous nominal position value filters MP1094 to MP1099.xx can be reactivated with the MPMODE = 340422 entry in the OEM.SYS file. MP12xx then have no effect. Other improvements / changes: New advanced HSC filter introduced. An optimum limit frequency is automatically calculated for roughing (can be only programmed with Cycle 32) for both HSC filters. MP1212 functions as a maximum limit frequency. For single and double filters the minimum filter orders (previously MP1099.x) were replaced by maximum limit frequencies (now MP1210 and MP1211). 14 HEIDENHAIN Technical Manual iTNC 530

New MP 1200

Old MP

Function Selection of the filter type

Possible input value 0 = Single filter 1 = Double filter 2 = HSC filter 3 = Advanced HSC filter 0 = Single filter 1 = Double filter 0.0000 to 3.0000 [mm] 0.0000 to 3.0000 [mm] 0.0 to 166.0 [Hz] 0.0 to 166.0 [Hz] 0.0 to 166.0 [Hz] 0.0 to 166.0 [Hz] 0 = Do not include the tolerance 1 = Include the tolerance 0 = Do not include the tolerance 1 = Include the tolerance 0.1 to 1000.0 [m/s3] 0.1 to 1000.0 [m/s3] 0.1 to 1000.0 [m/s3] 0.1 to 1000.0 [m/s3]

1201

1095.1 Nominal position value filter in manual operation Tolerance for contour transitions at corners 1096.0 With machining feed rate 1096.1 With rapid traverse 1099.0 Limit frequency for single filter 1099.1 Limit frequency for double filter 1094 Limit frequency for HSC filter Limit frequency for advanced HSC filter HSC filter: Tolerance for curvature changes Advanced HSC filter: Tolerance for curvature changes 1097.x Max. permissible axis-specific jerk for single filter 1098.x Max. permissible axis-specific jerk for double filter 1098.x Max. permissible axis-specific jerk for HSC filter Max. permissible axis-specific jerk for advanced HSC filter

1202.0 1202.1 1210 1211 1212 1213 1222 1223 1230.x 1231.x 1232.x 1233.x 1240.x 1241.x 1242.x 1243.x

1097.x Max. permissible axis-specific jerk at curvature 0.1 to 1000.0 [m/s3] changes for single filter 1098.x Max. permissible axis-specific jerk at curvature 0.1 to 1000.0 [m/s3] changes for double filter 1097.x Max. permissible axis-specific jerk at curvature 0.1 to 1000.0 [m/s3] changes for HSC filter Max. permissible axis-specific jerk at curvature 0.1 to 1000.0 [m/s3] changes for advanced HSC filter MP1391 was changed: MP1391.0 Velocity feedforward control in the Manual and Handwheel modes of operation Input: Bits 0 to 13 represent axes 1 to 14 0: Operation with following error (lag) 1: Operation with velocity feedforward control MP1391.1 Acceleration feedforward control in the Manual and Handwheel modes of operation Input: Bits 0 to 13 represent axes 1 to 14 0: Acceleration feedforward control inactive 1: Acceleration feedforward control active

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MP2210.x is new (only CC 424): Some of the asynchronous spindle motors require a high magnetizing current at low speeds (n < nfield weakening). This magnetizing current can, however, lead to thermal motor problems at the rpm for field weakening. MP2210.x enables you to reduce the nominal voltage (and, as a result, the nominal magnetizing current) at the rpm for field weakening during idle running. The maximum nominal voltage is reached when n = 3 nfield weakening. The nominal voltage can be reduced by max. 60 % (MP2210.x = 60). Input: 0 to 99 [%] 0: Function inactive

Unominal

MP2210.x

nfield weakening

n 3 nfield weakening

MP2254.x was expanded (only CC 424): A new mode (MP2254.x = 3) for determining the field angle was introduced for the CC 424. The new mode behaves like MP2254.x = 2, but the drive must no longer be switched on by the PLC. The drive moves immediately after the FIELD ORIENT soft key is pressed. This mode can be used if: There are no brakes, or The brakes are always open in the Commissioning Current Controller mode of operation, or The user ensures that the brakes can be opened manually or with the PLC. Danger Hanging axes require a 100% compensation for weight. Please contact HEIDENHAIN if this is not the case. Warning The drive begins turning immediately after the FIELD ORIENT soft key is pressed. The traverse path of the drive is approximately two pole pairs. Limit switches are ignored! If axes move into an illegal area, press the emergency stop button!

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HEIDENHAIN Technical Manual iTNC 530

MP2260.x is new (only CC 424): Reserved, do not make any entries. MP7266.x was expanded: MP7266.34 to MP7266.36 Value for PLC (P1 to P3) MP7266.37 Reserved MP7266.38 Point angle (T-ANGLE) MP7266.39 Thread pitch (PITCH) MP7310 was expanded: Bit 5The 3-D graphics (with representation of 5-axis machining) can also be deactivated with the MC 422B and MC 420. 0: Permit 2.5-D and 3-D graphics (also depends on hardware) 1: Permit only 2.5-D graphics (independent of hardware) Bit 6: Reserved MP7312 is new: MP7312 is used to speed up the graphic simulation of the 3-D graphics (with display of 5-axis machining) in the Test Run mode. If no value is entered for the tool tooth length in the LCUTS column of the tool table, an infinitely long tooth length is assumed. MP7312 limits the tooth length if no value was given for the tooth length in the tool table, or if the tool was defined in the NC program. Input: = 0: No limitation, infinitely long tooth length > 0: Tooth length = 2 tool radius MP7312 The smaller the entered factor is, the faster the graphic simulation of the 3-D graphics runs. Useful values range from 10 to 20. MP7356.x was removed, MP7371.x is new: Color setting for status window and PLC window: MP7371.0: $0ECECEC Background MP7371.1: $0FFFFFFF Background elements MP7371.2: $00000FF Color elements MP7371.3: $00000FF Color positions MP7360.x was expanded: Color settings for 3-D graphics (with display of 5-axis machining) The first tool shown in the 3-D graphics is assigned the color defined in MP7360.8; the second tool receives the color defined in MP7360.9, etc. The ninth tool starts at MP7360.8 again MP7360.7 $0CC1919 Cutting plane MP7360.8: $06666CC Tool 1 MP7360.9: $066CC66 Tool 2 MP7360.10: $06666CC Tool 3 MP7360.11: $066CC66 Tool 4 MP7360.12: $0CC6666 Tool 5 MP7360.13: $0CC66CC Tool 6 MP7360.14: $066CCCC Tool 7 MP7360.15: $066CC19 Tool 8

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MP7375.x is new: Color settings for the new smarT.NC operating mode: MP7375.0: $0E8E8E8 Background: Forms MP7375.1: $0C0C0C0 Background: Unselected tabs MP7375.2: $0FFFFFF Background: Treeview and input fields MP7375.3: $0D0D0D0 Background: Inactive input field MP7375.4: $0D2D2D2 Background: Help graphics MP7375.5: $00022FF Cursor: Treeview and background of current field MP7375.6: $0A0E0FF Cursor: Treeview if the form is the focus MP7375.7: $0000000 Text color: Inactive input field MP7375.8: $0FFFFFF Text color: Active input field MP7375.9: $00000FF Text color: Radio buttons MP7375.10:$0A0A0A0 Text color: Inactive label MP7375.11:$0FF0000 Background: Radio and check buttons, mouseover MP7375.12:$000FF00 Global data PREDEF: Background MP7375.13:$0000000 Global data PREDEF: Text MP7375.14:$0FF0000 Global data changed: Background MP7375.15:$0000000 Global data changed: Text MP7375.16:$0FFFFC0 Tooltip: Background MP7365.17:$0000000 Tooltip: Text MP7375.18:$0FF0000 Dialog box title: Background MP7365.19:$0000000 Dialog box title: Text MP7375.20:$000FA00 Pattern generator: Points of the same height MP7375.21:$00000C8 Pattern generator: Currently active points MP7375.22:$0800000 Pattern generator: Deleted points MP7375.23:$0FF6432 Pattern generator: Hidden points MP7375.24:$07B342D Pattern generator: Rectangle for zoom MP7411 was changed: Only the values 0 and 1 can be entered in MP7411 (tool data in touch probe block). Bit 1 was removed. This simplifies the touch probe management for the machine user. 0: Use the calibrated data of the touch probe 1: Use the current tool data from the last TOOL CALL MP7500, MP7510.x, MP7520.x, MP7530.x and MP7550.x were removed. The kinematics can now only be configured with kinematics tables.

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HEIDENHAIN Technical Manual iTNC 530

MP7610.x is new (only CC 424): MP7610.x defines control loops as single-speed or double-speed with the bit codes: MP7610.0 first drive control board MP7610.1 second drive control board In order to remain compatible to older, permanently assigned settings, the two machine parameters have the following preassigned settings: MP7610.0: %1100 MP7610.1: %1111 This results in limitations for the usability of the PWM outputs. For the first controller PCB: MP7610.0 Bit 0 Bit 1 Bit 2 Bit 3 Control-loop speed: 0 = Single-speed 1 = Double-speed 0 = Single-speed 1 = Double-speed 0 = Single-speed 1 = Double-speed 0 = Single-speed 1 = Double-speed For the second controller PCB: MP7610.1 Bit 0 Bit 1 Bit 2 Bit 3 Control-loop speed: 0 = Single-speed 1 = Double-speed 0 = Single-speed 1 = Double-speed 0 = Single-speed 1 = Double-speed 0 = Single-speed 1 = Double-speed Active PWM outputs X57 X57 X58 X58 X59 X59 X60 X60 Active PWM outputs X51 / X53 X51 / X53 not active X52 / X54 X52 / X54 not active X55 X55 X56 X56

MP7684 was changed: Bit 4 Now only functions with M114. Bit 5, bit 6 No function: All compensating motions are taken into consideration for the advance speed reduction at corners with M128.

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Configuring the axes and spindle

A kinematics description can consist of up to 25 transformations (lines in the kinematics table). Using the TNCscopeNT computer software it is possible to capture online the oscilloscope data for up to 16 channels. New table of power stages introduced (INVERTER.INV): The column S (switch position of current sensor) does not yet have a function. The function of the Switch pos. of the current sensor column will be available starting with the release of NC software 340 490-02. Columns in the power stages table: NAME: Designation of the power stage PWM: PWM frequency [Hz] S: Switch position of the current sensor I-MAX: Peak current [A] I-N: Rated current [A] U-IMAX:Voltage of the current sensor [V] U-N-DC:Rated current for DC [A] T-DC: Thermal time constant DC [s] F-DC: Transition frequency to T-DC [Hz] T-AC: Thermal time constant AC [s] F-AC: Transition frequency to T-AC [Hz] T-IGBT:Protection time of the IGBTs [s] The ID number of the controller software is entered in the log. In the Editing machine parameters operating mode, system files (*.SYS) can be opened and changed. For example, in OEM.SYS the number of axes present (PWMPARAMETER = , AXISNUMBER = ) can be changed, and adapted to the existing machine parameter file. If the new smarT.NC operating mode is active, marker M4163 is set. In this case, the value 8 is in W272 (operating mode). For freely definable tables, the predefined column type Time / Date is possible. The column type is specified with X and the WIDTH field determines how many characters of the current time are automatically transferred into the file. The field is updated each time the table is write-accessed, and has the following format: hh:mm:ss dd.mm.yyyy At present, this feature for write access is realized from the PLC. Write access from NC programs (FN function) is available as of the NC software 340 490-02. If marker M4056 is set, the control tries to keep the TS 640 touch probe at ready notice. If this is not possible, positioning motions in the Manual and Handwheel modes of operation are interrupted with the Probe system not ready error message. After acknowledging the error message with CE, the touch probe can be freely traversed for 60 seconds in the Manual mode of operation. Then the error message is displayed again. Warning Touch-probe monitoring for the TS 640 is not active as long as the touch probe does not report that it is ready. Machine parameters MP2420.x and MP2430.x can be changed through the PLC.

Machine interfacing

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HEIDENHAIN Technical Manual iTNC 530

PLC programming

If the PLC Programming mode of operation is activated with write-protection with code number 807667 (and if a different code number was defined in OEM.SYS via PLCPASSWORD =), then the WATCH LIST soft key is available. If the highlight is located in the WATCH LIST in the SYMBOL or ADDR column, the ORDER soft key can be used to sort the WATCH LIST by the respective column. New function: I/O-FORCE LIST Independently of the currently running PLC program and the status of the hardware, the PLC inputs and outputs can be influenced via the I/O-FORCE LIST. The inputs and outputs can be selected in the TABLE and in the WATCH LIST with the ADD TO I/O-FORCE LIST soft key. A message confirms the addition to the I/O-FORCE LIST. Added inputs and outputs can no longer be changed in the TABLE with the SET and RESET soft keys. The green error message I/O-Force is active is output in the PLC Programming mode of operation if the FORCE LIST is active. Also, the affected inputs and outputs are color-coded in the TABLE. Danger The I/O-FORCE LIST can overrule safety-relevant monitoring operations in the PLC program! Make sure that hanging axes are supported! If the control is being operated as a programming station (MP7210 = 1 or 2), this status is displayed in the PLC Programming mode of operation. The available memory in the PLC partition (PLC:\) is shown in kilobytes in the PLC programming mode of operation. The PLC partition is also checked to see if there are at least 10 MB of memory available. If the available memory is less than 10 MB, the PLC partition: Not enough memory error message is output. In the cycles for tool measurement, the PLC program may command a gear shift during output of the spindle speed without interrupting the cycle. Marker M4186 is new: M4186 is set if an NC program is started in the Test Run operating mode. PLC modules 9158, 9164, 9165 and 9166 now support 14 axes. The number of axes had been limited to 12. Before the PLC program is converted, the symbols of the PLC soft-key project are converted automatically. No conflicts arise, because the PLC program and the soft-key project use the same symbol information.

PLC modules

Module 9035 (Reading the status information) expanded: If the code 100 is given in the call of Module 9035, the number of the tool axis can be determined. The tool axis can also be determined with markers M4526 to M4534, but only up to the 9th axis. Tool axes with greater numbers can be determined only via Module 9035. Module 9171(Oriented spindle stop) expanded: Incremental spindle positioning movements can be processed with Module 9171 (direction of rotation: 5). Module 9221 (Starting a PLC positioning movement) expanded: The PLC positioning of NC axes with Module 9221 is now also possible for the 10th to 14th axes. Active PLC positioning movements can be stopped with the new Module 9224, see page 16.

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Module 9045 Reading the 3-D ROT data Module 9045 reads the 3-D ROT data (swivel angle, axes, and operating mode) and saves them in words and double words. The swivel angles are saved in three successive double words beginning with the specified target address (format: 0.0001). The swivel axes are saved in bit-encoded format in the next word. The operating mode active for swiveling is saved in bit-encoded format in the word after that. The given target address must be a double-word address. You must be able to write to four sequential double words at the given target address. The following data are output as words and double words: D[n+0]: D[n+4]: D[n+8]: W[n+12]: W[n+14]: Swivel angle A Swivel angle B Swivel angle C Bit-encoded swiveled axes: Bits 0 to 2 correspond to axes A to C Bit-encoded: Bit 0 = Swiveling active in Program Run operating mode Bit 1 = Swiveling active in Manual operating mode

Call: PS CM

B/W/D/K <Target address double-word number [n]> 9045

Error recognition: Marker M4203 Value 0 1 Meaning 3-D ROT data read 3-D ROT data not read

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HEIDENHAIN Technical Manual iTNC 530

Module 9149 Set/Read commutation angle Module 9149 enables you to determine and set the commutation angle of a synchronous, torque or linear motor. For axes that cannot be moved when switched off (e.g. due to Hirth coupling), Module 9149 can be used to read out the commutation angle of the position at shutdown. The PLC can then store it in nonvolatile memory. After restarting the control, you can use the module to again set the commutation angle which is stored in nonvolatile memoryfor the axis concerned. This means that it is not necessary to determine the commutation angle again. Danger After the axis has moved away from the position at shutdown, the commutation angle is no longer valid and must no longer be used. When the control is shut down the next time, the commutation angle of the position at shutdown must be read out and stored again. Safety precautions: The commutation angle may be set only after you have ensured that the stored commutation angle corresponds to the current position (e.g. due to Hirth coupling). The module is suitable only for synchronous, torque, or linear motors in conjunction with nonaligned encoders without EnDat interface. The module responds with a value only if the reference mark has been traversed. The commutation angle for an axis can be set only once after the control is switched on and before the drives are first switched on. Call: PS PS PS B/W/D/K <Axis> B/W/D/K <Commutation angle in 0.001> 1 to 720000 B/W/D/K <Mode> 0: Read commutation angle 1: Set commutation angle 9149 B/W/D <Error code> 0: Commutation angle set/read 1: Module was not called in a spawn job or submit job 2: Invalid mode 3: Invalid axis number 4: Invalid commutation angle Error code from controller when mode 0 is active (read commutation angle): 100: Unknown reference position Error code from controller when mode 1 is active (set commutation angle): 200: Invalid motor type (no synchronous or linear motor) 201: Invalid encoder type (not non-aligned) 202: Invalid commutation angle 203: Commutation angle already set B/W/D <Commutation angle>

CM PL

PL

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Error recognition: Marker M4203 W1022 Value 0 1 1 2 20 45 Meaning Commutation angle set/read Error code in W1022 Invalid mode Invalid axis number Module was not called in a spawn job or submit job Error code from controller

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HEIDENHAIN Technical Manual iTNC 530

Module 9170 Finding the current torque With Module 9170 you can determine the averaged, maximum and minimum torque of a drive. The determined torque value depends on the PLC cycle time. Call: PS PS CM PL PL PL B/W/D/K <Axis> 0 to 13 and 15: Axes 1 to 14 and the spindle B/W/D/K <Mode> 0: Torque value in tenths of per cent of the nominal torque 9170 B/W/D <Determined torque value> B/W/D <Maximum torque value> B/W/D <Minimum torque value>

Error recognition: Marker M4230 W1022 Value 0 1 1 2 Meaning Torque value determined Error code in W1022 Invalid mode Invalid axis number

Module 9222 Status request of PLC positioning movement (module expanded) With Module 9222 you can interrogate the status of a PLC positioning movement. The status of an axis, or now also bit-encoded for all axes, can be interrogated. Call: PS B/W/D/K <Axis> Interrogation of an axis: 0 to 13 represent axes 1 to 14 Interrogation of all axes: 1: Target position reached 2: PLC positioning was started 3: Cancel PLC positioning 4: Limit switch 5: PLC positioning not possible 9222 B/W/D <Status> Interrogation of an axis: 1: Target position reached 2: PLC positioning was started 3: Cancel PLC positioning 4: Limit switch 5: PLC positioning not possible Interrogation of all axes: Status request of PLC positioning movement bit-encoded

CM PL

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Module 9224 Stop PLC positioning movements Individual PLC positioning movements can be stopped with Module 9224. If M4120 to M4128 are already set, they are reset. It is still possible to stop PLC positioning movements by resetting markers M4120 to M4128. Positioning movements of axes 10 to 14 can be stopped only with this module. Call: PS PS CM PL B/W/D/K <Axis> B/W/D/K <Mode> Reserved: 0 transferred 9224 B/W/D <Error> 0: Positioning is canceled 1: Invalid axis was programmed 2: This axis is not positioned by the PLC

Error recognition: Marker M4203 W1022 Value 0 1 2 9 Meaning PLC positioning was stopped Error code in W1022 Invalid axis (invalid axis number, auxiliary axis, or uncontrolled axis) Axis is not positioned by the PLC

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Other functions

New alternate mode of operation introduced: smarT.NC Cycle 240 (CENTERING) is used to create center bore holes. Number of Q parameters increased to 2000: Q200 to Q1399, reserved for HEIDENHAIN cycles Q1400 to Q1499, reserved for OEM cycles (CALL-active) Q1500 to Q1599, reserved for OEM cycles (DEF-active) Q1600 to Q1999 can be freely used by the machinist Mid-program startup of NC programs is possible with M128. The compensating motions of the axes are activated, if necessary, after the machine status has been restored, so that the compensating motions are superimposed over traverse motions of the axes. The SYS:\ partition of the iTNC 530 was increased from 1 GB to 2 GB. This makes it possible to store multiple NC software versions in compressed form on the control. This results in the following new partition sizes, available on newly delivered iTNC hard drives, see page 23: Partition iTNC 530 C: TNC: PLC: SYS: 25 GB 1 GB 2 GB iTNC 530 with Windows 2000 13 GB 13 GB 1 GB 1 GB

New dialog language: Slovenian The language can be activated with MP7230.x = 17, but must first be enabled via option #41. M150 is used to suppress the error message for the current positioning block. The maximum number of tool types in the magazine rules (tooltype) was increased from 9 to 20. The input range for the LBL, CALL LBL, FN9, FN10, FN11 and FN12 commands was expanded. The number of available label numbers was increased to 1000 (LBL 0 to LBL 999). In addition, you can now also assign names as labels (e.g. LBL Contour). The number of label names that can be used is unlimited. They are in addition to the 1000 available label numbers. New fields in the status display: The current time and the active spindle (S1 or S2) are displayed. The graphic simulation in the Test Run can be stopped with the STOP soft key even within a cycle or a contour pocket. If the current line in the program is not changed, press the START soft key to continue working from the point of interruption. The touchpad of the TE 530 / TE 530B can be connected to the USB port on the MC 42x(B). The touchpad can be used for soft keys and smarT.NC dialog fields. PLANE function expanded: PLANE EULER: Rot. angle of main coord. plane expanded from 0 to 180 to 180 to +180. The normal vector for PLANE VECTOR does not need to be entered in standardized form. The iTNC calculates the standardization itself. Input range: 99.9999999 to +99.9999999

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Enter points in the FADE column of the point tables (*.PNT) to hide them from machining (the hide block function in Program Run must be activated). The SPEC FCT key on the TE 530B is supported: The new SPEC FCT (special function) key makes it easier to access special functions (e.g. PLANE or FUNCTION TCPM). A progress bar is shown when searching through longer NC programs. In addition, the user is presented with a soft key for interrupting the search. In CYCL CALL PATTERN either the coordinate of the highest pattern point or the defined 2nd set-up clearance is traversed to (whichever of the two is higher). If the IP addresses for the network settings are entered in the ADDRESS column separated by commas, the commas are replaced by periods when the field is exited. If no tool table is selected, the file TNC:\TOOL.T is automatically loaded when starting a simulation in the Test Run operating mode. A tool table must be available during a test run with the new smarT.NC operating mode. If a soft key that is defined in a soft-key resource is pressed, the entry is made under the keyword SOFTKEY-IDENT: in the log. The following new columns were added to the tool table: P1, P2, P3: Freely definable Input: 99999.9999 to +99999.9999 T-ANGLE: Point angle for centering and drilling tools PITCH: Reserved KINEMATIK: Reserved The TYPE column of the tool table was increased to 10 input possibilities, and expanded by the following elements: BOR: Boring tool BCKBOR: Back-boring tool CENT: NC spot drill / center drill CSINK: Countersinking tool DRILL: Drilling tool MILL_R: Rough cutter MILL_F: Finishing cutter MILL_RF: Rough and finishing cutter MILL_FD: Floor finishing cutter MILL_FS: Side finishing cutter MILL_FACE: Face-milling cutter REAM: Reamer TAP: Tapping tool GF: Thread miller GSF: Thread miller with chamfer EP: Thread miller for single threads WSP: Thread miller with indexable insert BGF: Thriller ZBGF: Circular thread miller TSINK: Piloted counterbore

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HEIDENHAIN Technical Manual iTNC 530

The following possibilities exist for entering the feed rate: Milling tools: Feed rate per tooth (Fz) in millimeters or inches. The iTNC calculates the value for the feed rate F as follows: F = Fz number of teeth rpm Drilling tools: Feed rate per revolution (Fu) in millimeters per revolution or inches per revolution. The iTNC calculates the value for the feed rate F as follows: F = Fu rpm

November 2004 NC Software 340 490-xx/340 491-xx and 340 492-xx/340 493-xx

1 19

1.3.1 Feature Content Level Until now, each new NC software version contained error fixes as well as expanded functions. Users who wanted only the NC software update to eliminate the errors often felt bothered by the expanded functions. For this reason, error fixes and expanded functions will now be managed separately. If a new NC software is later loaded onto a machine with NC software 340 490-01, then as the default setting only the error fixes contained will be effective. The expanded functions will at first remain inactive. The expanded functions can then be enabled by entering a code number. HEIDENHAIN can give you the code number after having been informed of the SIK number and NC software version. The feature content level is defined in the SIK under option #53. The first time a control is switched on with the new NC software, if no feature content level is set in the SIK, a note appears asking to confirm the installed NC software as the initial version, or if another software version is to be installed. After pressing the MOD key, the feature content level is displayed in addition to the software versions. The feature content level is incremented with each new version of the NC software. The feature content level is set in the SIK: Automatically after 100 restarts By entering the code number 0 under option #53

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HEIDENHAIN Technical Manual iTNC 530

1.4 Additional Enhancements to NC Software 340 492-xx and 340 493-xx


PLC modules Module 9315 Bringing a Windows window to the front or minimizing it Module 9315 is used on the iTNC 530 with Windows 2000 and on the programming station to bring the window of a Windows application from the PLC to the foreground and make it active, or to minimize it. In the module call you enter the title of the window that is to be brought to the foreground. Uppercase and lowercase are ignored in the given window title, as well as any leading or trailing blank spaces. In order to bring a Windows application to the foreground, the user-specific Windows system parameter ForegroundLockTimeout must be set to 0 (default: 200000). Otherwise the activation of the window is signaled only by a blinking of its icon in the task bar. The system parameter is automatically set by a program in the Startup folder for the iTNC 530 with Windows 2000. The system parameter is not automatically changed on the programming station. Here there are two shortcuts in the Start menu, with which the parameter can be set to 0 (ON) or the default value 200000 (OFF). Call: PS B/W/D/K <Mode> 0: Bring window to the foreground 1: Minimize window B/W/D/K/S<Window title> 9315

PS CM

Error recognition: Marker M4203 W1022 Value 0 1 1 2 3 11 20 52 Meaning Windows window activated / minimized Error code in W1022 Invalid mode programmed Window with this title does not exist Invalid PLC string address was programmed Invalid string programmed for window title Call was not in a submit or spawn job Single-processor control, switch-over not possible

November 2004Additional Enhancements to NC Software 340 492-xx and 340 493-xx

1 21

Module 9316 Status interrogation of a Windows window The current status of a Windows window can be interrogated with Module 9316. Call: PS PS CM PL B/W/D/K <Mode> 0: Window status B/W/D/K/S<Window title> 9316 B/W/D <Window status> Bit 0: Window in foreground Bit 1: Window minimized

Error recognition: Marker M4203 W1022 Value 0 1 1 2 3 11 20 52 Meaning Windows window status determined Error code in W1022 Invalid mode programmed Window with this title does not exist Invalid PLC string address was programmed Invalid string programmed for window title Call was not in a submit or spawn job Single-processor control, status interrogation not possible

Module 9317 Determining a Windows window title Module 9317 is used to determine the title of the Windows window in the foreground at the time of the request. Call: PS PS CM B/W/D/K <Mode> 0: Title of the Windows window in the foreground B/W/D/K <PLC string address for window title> 9317

Error recognition: Marker M4203 W1022 Value 0 1 1 3 20 52 Meaning Windows window title determined Error code in W1022 Invalid mode programmed Invalid PLC string address was programmed Call was not in a submit or spawn job Single-processor control, title interrogation not possible

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1.5 Hardware
1.5.1 TE 530B

TE 530B TNC operating panel with touchpad With function keys for the new smarT.NC operating mode, as well as the new SPEC FCT key for calling special TNC functions. The IV and V keys are snap-ons, and can be switched. Id. Nr. 519 441-11 TE 530B

1.5.2 HDR Hard Disk

HDR hard disk for iTNC 530 340 490-xx: Standard version 340 491-xx: Export version 340 492-xx: Standard version with Windows 2000 340 493-xx: Export version with Windows 2000

Id. Nr. 524 571-01 524 571-51 524 572-01 524 572-51

November 2004

Hardware

1 23

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1 Update Information No. 13


1.1 Releases
The following versions of the NC software were released: NC software 340 422-12 and 340 423-12 NC software 340 480-12 and 340 481-12 December 2004 December 2004

1.2 NC Software 340 422-xx/340 423-xx and 340 480-xx/340 481-xx


Machine parameters MP709.x is new: MP709.x is used to influence the output of the backlash compensation (MP710.x). Input: 0: Previous behavior of MP710.x 1 to 1000: Time constant [ms]

MP710.x

Nominal value Reversal point MP709.x: Small input value MP709.x: Large input value MP709.x = 0

Nominal value

December 2004

Releases

11

MP2172 is new: If the control triggers an EMERGENCY STOP (i.e. via PLC or movement monitoring), the presently assigned delay time of 3 seconds for the SH1 signal (inverter enabling) may not be sufficient for decelerating the spindle. On controls with CC 42x, MP2172 now enables you to set any time between 1 second and 6 seconds as the delay time. Input: 0: Previous delay time of 3 seconds 1 to 6: Delay time in seconds (whole numbers) PLC modules The PLC modules 9158, 9164, 9165 and 9166 now support 14 axes. The number of axes had been limited to 12. PLANE functions expanded: PLANE EULER: Rot. angle of main coord. plane expanded from 0 to 180 to 180 to +180. This enables you to program all directions in space.

Other functions

1.3 Additional Enhancements to NC Software 340 480-xx/340 481-xx


Hard disks with Microsoft Windows 2000 and NC software 340 480-12 or 340 481-12 supplied by HEIDENHAIN include Microsoft Patches KB841533, KB840987, KB841356, KB834707, KB819696, KB839643, KB814078. The following changes were made to the Microsoft Windows 2000 installation: - Automatic Windows updates were deactivated. - The energy saver for the screen was deactivated. - The Microsoft Java Virtual Machine (MSJVM) was removed. If you already have a hard disk, you can install these expansions and settings at any time.

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1.4 New Hardware


1.4.1 New Versions of the CC 424 The configurable double-speed control loops of the CC 424 controller unit allow you to increase the controller performance. This enables you, for example, to achieve an excellent workpiece surface quality. Double-speed control loops are needed particularly for linear drives in order to achieve proper speed/position control factors required by high-efficiency mechanical systems. High-speed spindle motors requiring PWM frequencies greater than 5 kHz with short current controller cycle times can be operated only with doublespeed control loops. A maximum of 4 double-speed control loops can be configured on the CC 424 with 8 control loops, and a maximum of 8 double-speed control loops on the CC 424 with 12 control loops. Please note that the maximum number of available control loops may be reduced through the configuration of double-speed control loops. See Setting the Controller Performance in MP 7610.x on page 10.

1.4.2 CC 424 with 8 Control Loops

CC 424 controller unit with 8 control loops The product program now also includes a CC 424 controller unit for up to 8 control loops. It is equipped with: - 8 PWM outputs - 8 speed encoder inputs - 8 position encoder inputs This CC can be used as of NC software: - 340 490-01 - 340 491-01 - 340 492-01 - 340 493-01 Id. Nr. 521 755-01 CC 424 8 control loops

December 2004

New Hardware

13

1.4.3 CC 424 with 12 Control Loops

CC 424 controller unit with 12 control loops The product program now also includes a CC 424 controller unit for up to 12 control loops. It is equipped with: - 12 PWM outputs - 12 speed encoder inputs - 12 position encoder inputs This CC can be used as of NC software: - 340 490-01 - 340 491-01 - 340 492-01 - 340 493-01 Id. Nr. 533 569-01 CC 424 12 control loops

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1.4.4 Connection Overview MC 422B and CC 424 with max. 8 control loops X201 to X208
X15 X17X19 X80

Position encoders Speed encoders Speed encoders PWM output Nominal value output, analog TS touch trigger probe TT 130 touch trigger probe Handwheel Ethernet data interface RS-232-C/V.24 data interface RS-422/V.11 data interface RS-232-C/V.24 (only for Windows 2000) RS-422/V.11 (only for Windows 2000) USB interface 24 V reference signal for spindle 24 V for "control-is-ready" output PLC output PLC input 24 V PLC supply voltage Keyboard unit Machine operating panel PLC expansion PLC analog input BF 150 monitor Reserved Power supply Reserved

X15 to X20 X80, X81 X51 to X58 X8, X9 X12 X13 X23 X26 X27 X28 X127 X128 X141, X142 X30 X34 X41 X42 X44 X45 X46 X47 X48 X149 X131 X69

X16 X18X20 X81

X51 X53 X55 X57

X52 X54 X56

X58

X74 X69 X201X203 X205 X202X204 X208 X207

X206

X150 at bottom of housing

X121, X125, X165 X74 X150 B

5-V power supply Axis-specific drive release Signal ground Equipment ground (YL/GN)

Warning Do not engage or disengage any connecting elements while the unit is under power!

December 2004

New Hardware

15

MC 422B and CC 424 with max. 12 control loops X201 to X206 X209 to X214
X15 X17X19 X82 X84 X86

Position encoders Position encoders Speed encoders Speed encoders PWM output PWM output Nominal value output, analog TS touch trigger probe TT 130 touch trigger probe Handwheel Ethernet data interface RS-232-C/V.24 data interface RS-422/V.11 data interface RS-232-C/V.24 (only for Windows 2000) RS-422/V.11 (only for Windows 2000) USB interface 24 V reference signal for spindle 24 V for "control-is-ready" output PLC output PLC input 24 V PLC supply voltage Keyboard unit Machine operating panel PLC expansion PLC analog input BF 150 monitor Reserved Power supply Reserved

X15 to X20 X82 to X87


X16 X18X20 X83 X85 X87

X51 X53 X55

X51 to X56 X59 to X64


X59 X61 X63

X8, X9 X12 X13


X52 X54 X56 X60 X62 X64

X74 X69 X201X203 X205 X169 X209 X213

X211 X202X204 X206 X210 X214

X23 X26 X27 X28 X127 X128 X141, X142 X30 X34 X41 X42 X44 X45 X46 X47 X48 X149 X131 X69, X169

X212

X150, X151 at bottom of housing

X121, X125, X165 X74 X150, X151 B

5-V power supply Axis-specific drive release Signal ground Equipment ground (YL/GN)

Warning Do not engage or disengage any connecting elements while the unit is under power!

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1.4.5 Dimensions CC 424 for max. 8 control loops

December 2004

New Hardware

17

CC 424 for max. 12 control loops

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HEIDENHAIN Technical Manual iTNC 530

1.4.6 Prerequisites for Operation The CC 424 with 8 or 12 control loops is only supported as of software versions 340 490-xx 340 491-xx 340 492-xx 340 493-xx This NC software is, however, only executable on the MC 422B and the MC 420, each with at least 128 MB of RAM. 1.4.7 Machine Parameters Since the hardware program has been expanded from 6 or 10 control loops to 8 or 12 control loops for the CC 424, please keep the following settings of MP7610.x in mind: MP7610.x was expanded (only CC 424): MP7610.x defines control loops as single-speed or double-speed with the bit codes: MP7610.0 first drive control board MP7610.1 second drive control board In order to remain compatible to older, permanently assigned settings, the two machine parameters have the following preassigned settings: MP7610.0: %1100 MP7610.1: %1111

December 2004

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19

1.4.8 Setting the Controller Performance in MP 7610.x

Configuration of MP 7610.x for the CC 424 versions Bit Value No. 6 ctrl. loops 0 (SS) 1 (DS) 8 ctrl. loops 0 (SS) 1 (DS) 10 ctrl. loops 0 (SS) 1 (DS) 12 ctrl. loops 0 (SS) 1 (DS)

Bits of MP 7610.0 for 1st drive control board (= number of DSP) 0 1 2 3 X51 X53 X52 X54 X55 X56 X51 X52 X55 X56 X51 X53 X52 X54 X55 X57 X56 X58 X51 X52 X55 X56 X51 X53 X52 X54 X55 X56 X51 X52 X55 X56 X51 X53 X52 X54 X55 X56 X51 X52 X55 X56

Bits of MP 7610.1 for 2nd drive control board (= number of DSP) 0 1 2 3 No. of axes (standard) No. of axes (maximum) 6 6 X57 X58 X59 X60 10 X57 X58 X59 X60 X59 X61 X60 X62 X63 X64 10 X59 X60 X63 X64

10

12

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HEIDENHAIN Technical Manual iTNC 530

1 Update Information No. 14


1.1 Overview
1.1.1 Released Service Packs The following service packs were released for 340 422-12 and 340 423-12: Service pack 1: 340 422-12 SP1 and 340 423-12 SP1 Service pack 2: 340 422-12 SP2 and 340 423-12 SP2 Service pack 3: 340 422-12 SP3 and 340 423-12 SP3 Service pack 1: 340 480-12 SP1 and 340 481-12 SP1 Service pack 2: 340 480-12 SP2 and 340 481-12 SP2 Service pack 3: 340 480-12 SP3 and 340 481-12 SP3 Service pack 1: 340 490-01 SP1 and 340 491-01 SP1 Service pack 2: 340 490-01 SP2 and 340 491-01 SP2 Service pack 1: 340 492-01 SP1 and 340 493-01 SP1 Service pack 2: 340 490-01 SP2 and 340 491-01 SP2 1.1.2 Released NC Software The following versions of the NC software were released: NC software 340 490-02 and 340 491-02 NC software 340 492-02 and 340 493-02 July 2005 July 2005 January 2005 March 2005 April 2005

The following service packs were released for 340 480-12 and 340 481-12: January 2005 March 2005 April 2005

The following service packs were released for 340 490-01 and 340 491-01: March 2005 June 2005

The following service packs were released for 340 492-01 and 340 493-01: March 2005 June 2005

September 2005

Overview

11

1.2 NC Software 340 422-xx/340 423-xx and 340 480-xx/340 481-xx


Important notes With the introduction of the diagnosable UM 1xxD power modules, the rated current and maximum current of some power modules were increased. The MOTOR.AMP table for power modules was therefore expanded by the new types of power modules. The increased currents were unfortunately not considered. This means that the current NC software versions contain a MOTOR.AMP to which the new types, but not the correct currents, were added. This applies to the power modules listed below: UM 112D (Id. Nr. 519 971-xx) UM 122D (Id. Nr. 519 972-xx) UM 113D (Id. Nr. 518 703-xx) UM 114D (Id. Nr. 510 509-xx) If such a power module is operated with the old MOTOR.AMP, this may result in reduced surface quality of the workpiece. Starting with service pack 3, the NC software already includes the updated MOTOR.AMP. This software, as well as the updated MOTOR.AMP, can be downloaded from the HEIDENHAIN Filebase (NC-INFO). After updating, check the settings of the affected control loops. Please also check any user-defined MOTOR.AMP on the PLC partition, which is preferably used by the control, but cannot be updated during installation of a service pack. Service packs The following service packs have been released: Service pack 1 340 422-12 SP1 340 423-12 SP1 340 480-12 SP1 340 481-12 SP1 Service pack 2 340 422-12 SP2 340 423-12 SP2 340 480-12 SP2 340 481-12 SP2 Service pack 3 340 422-12 SP3 340 423-12 SP3 340 480-12 SP3 340 481-12 SP3 NC software 340 422-12 340 423-12 340 480-12 340 481-12 NC software 340 422-12 340 423-12 340 480-12 340 481-12 NC software 340 422-12 340 423-12 340 480-12 340 481-12 Release January 2005 January 2005 January 2005 January 2005 Release March 2005 March 2005 March 2005 March 2005 Release April 2005 April 2005 April 2005 April 2005

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1.3 NC Software 340 490-01/340 491-01 and 340 492-01/340 493-01


1.3.1 Important Notes With the introduction of the diagnosable UM 1xxD power modules, the rated current and maximum current of some power modules were increased. The MOTOR.AMP table for power modules was therefore expanded by the new types of power modules. The increased currents were unfortunately not considered. This means that the current NC software versions contain a MOTOR.AMP to which the new types, but not the correct currents, were added. This applies to the power modules listed below: UM 112D (Id. Nr. 519 971-xx) UM 122D (Id. Nr. 519 972-xx) UM 113D (Id. Nr. 518 703-xx) UM 114D (Id. Nr. 510 509-xx) If such a power module is operated with the old MOTOR.AMP, this may result in reduced surface quality of the workpiece. Starting with service pack 1, the NC software already includes the updated MOTOR.AMP. This software, as well as the updated MOTOR.AMP, can be downloaded from the HEIDENHAIN Filebase (NC-INFO). After updating, check the settings of the affected control loops. Please also check any user-defined MOTOR.AMP on the PLC partition, which is preferably used by the control, but cannot be updated during installation of a service pack. Warning This NC software is executable only on the MC 422B and the MC 420, each with 128 MB of RAM. The BF 120 (resolution: 640 x 480 pixels) is no longer supported. 1.3.2 Service Packs The following service packs have been released: Service pack 340 490-01 SP1 340 491-01 SP1 340 492-01 SP1 340 493-01 SP1 Service pack 340 490-01 SP2 340 491-01 SP2 340 492-01 SP2 340 493-01 SP2 NC software 340 490-01 340 491-01 340 492-01 340 493-01 NC software 340 490-01 340 491-01 340 492-01 340 493-01 Release March 2005 March 2005 March 2005 March 2005 Release June 2005 June 2005 June 2005 June 2005

September 2005 NC Software 340 490-01/340 491-01 and 340 492-01/340 493-01

13

1.4 NC Software 340 490-02/340 491-02 and 340 492-02/340 493-02


1.4.1 Important Notes Upgrade functions (Feature Content Level) Until now, each new NC software version contained error fixes as well as expanded functions. Users who wanted only the NC software update to eliminate the errors often felt bothered by the expanded functions. For this reason, error fixes and expanded functions will now be handled separately within the software. If a new NC software is later loaded as an update onto a machine with NC software 340 490-01, then as the default setting only the error fixes contained will be effective. The upgrade functions will at first remain inactive (see New options and upgrade functions on page 1 6). The upgrade functions can then be enabled by entering a code number. HEIDENHAIN can give you the code number after having been informed of the SIK number and NC software version. The upgrade functions are defined as feature content level (FCL) in the SIK under option #53. The first time an NC software with upgrade functionality is installed on a control (i.e. no FCL has been set in the SIK), then the entire scope of functions can be used (including the upgrade functions.). The FCL is then automatically set after 100 restarts, or by entry of the code number 0 under option #53, and all upgrade functions belonging to this software version are enabled as well. A note appears asking to confirm the installed NC software as the initial version, or if another initial software version is to be installed. If the FCL has already been set in the SIK of a control, then after an update (e.g. from software 340 490-02 to -03), the new upgrade functions of the newer software version can only be used after entry of a code number from HEIDENHAIN. After pressing the MOD key, the current status of the FCL is displayed in addition to the software versions. The FCL is incremented with each new version of the NC software. If the upgrade functions are enabled via the FCL for a software version, then all upgrade functions of this software version and all its predecessors are available. For example, if the FCL for version 340 490-03 is set, then all upgrade functions from version 340 490-02 are also available immediately.

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HEIDENHAIN Technical Manual iTNC 530

If a newer software version, e.g. 340 490-06, is simply loaded onto a control, then the already existing upgrade functions remain available, but the upgrade functions of the newer version cannot be used. They must be enabled by entering a new code number.

Executability of SW 340 49x-02 Warning This NC software is executable only on the MC 422B and the MC 420, each with 128 MB of RAM. The BF 120 (resolution: 640 x 480 pixels) is no longer supported.

September 2005 NC Software 340 490-02/340 491-02 and 340 492-02/340 493-02

15

1.4.2 Description of the New Functions New options and upgrade functions The following options are enabled by entering a code number. HEIDENHAIN can give you the code number after having been informed of the SIK number. Option #40 Description DCM Dynamic Collision Monitoring: Collision monitoring via definitions of collision bodies within the kinematics description. Additional Languages Slovenian is now available as an additional dialog language. DXF Converter: Conversion of DXF files generated using CAD software for inclusion in plain-language NC programs. ID number 526 452-01

#41

530 184-01

#42

526 450-01

#53

Upgrade functions as Feature Content Level (FCL), 529 969-01 see page 4 Plain-language programming functions: Cycle 441: Global touch-probe parameters: Cycle for global setting of touch-probe parameters CAD point filter (offline): Point filter for smoothing NC programs externally created from CAD data 3-D line graphics: Display of the traverse motions as three-dimensional line graphics Virtual tool axis: Manual traverse in the active tool axis system (at program interruption) smarT.NC functions: Coordinate transformation: Units 7, 8, 10 and 11 for coordinate transformation PLANE function: Unit 140, Tilting the Working Plane Contour-pocket depth: A separate depth can be assigned to each subcontour Graphic block scan: Block-scan with graphic support and re-entry at any location within a hole pattern Miscellaneous: Expanded USB functionality (USB 1.1): USB devices which use the VFAT or ISO 9660 file system are detected and connected automatically DHCP and DNS: Network connection of the iTNC via DHCP and DNS

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HEIDENHAIN Technical Manual iTNC 530

Update to SW 340 490-02

Update of 340 422-xx and 340 480-xx Please note that there were already significant changes in the update from the software versions named above to version 340 490-01 (e.g., machine parameters, kinematics, etc.) This is also of importance for a successful update to version 340 490-02. Therefore, before updating to version 340 490-02, please also read Update Information No. 12. Note Please note that when using the TNCremoNT computer software from HEIDENHAIN to transfer the software to the iTNC, the files with the extensions *.zip and *.omf are transmitted in binary format. Updating from 340 422-12 and 340 490-01 (iTNC 530 without Windows) The set-up files for the software update to 340 490-02 are no longer available in the previous format. Rather, the update is performed with the setup.omf and setup.zip files mentioned above. Therefore, please pay attention to the new procedure for updates. The NC software versions 340 422-12 and 340 490-01 already support updating with the new file format and the new dialog-guided process. To install version 340 490-02, proceed as follows:
8

Either on a network drive connected to the control, or on the TNC partition, create a directory with the name 340490_002 (e.g. TNC:\340490_002\...). Please pay attention to the naming convention of <Id.Nr.>_<Ver> with a 6-digit ID number and a 3-digit version number. Copy the update files (setup.omf and setup.zip) into this directory. Open the dialog box for file selection with Programming and Editing > MOD > Code Number 95148 > MOD > UPDATE DATA > iTNC <- NCV (new: LOAD ZIP) Select the directory or drive in which the created update directory is located (in the example above your must select TNC:\) The iTNC recognizes directories containing setup files, and offers them in the Files window. For example, 340490.002 (DIR). Select the software version and follow the instructions on the screen. Note If you want to update to version 340 490-02 from a version earlier than 340 422-12, you must first update the control to at least version 340 422-12 and then follow the procedure described above.

8 8 8 8 8

Updating from 340 480-xx and 340 492-01 (iTNC 530 with Windows) Follow the normal procedure for installation on the iTNC 530 with Windows. Machine parameters Form entry of MPs expanded The following functions are possible for entry in forms (e.g., for MP1054): Exponential calculation with the ^ character Example: MP1054.1:REF*0.1e^6+15 (REF in 0.0001 [mm]) Entry of x instead of REF (shorter)

September 2005 NC Software 340 490-02/340 491-02 and 340 492-02/340 493-02

17

New CC424: MP1160 LIFTOFF during power failure With MP1160 you can specify how far the tool is to retract from the contour using the LIFTOFF function in case of a power failure (DSP error). (MP1160 also exists on the CC422, but has no function) Input: 0.0000 to 1.0000 [mm] Default: 0.0000 [mm] New: MP1250.x Axis-specific jerk at corners during rapid traverse In the Machine Parameters 1250.x you can axis-specifically enter a factor for the jerk at corners (MP 123x.x) for rapid traverse. At transitions between rapid traverse motions, the jerk set in MP123x.x multiplied by this factor is active. Useful settings for this factor can be determined as follows. MP1250.x = MP1202.1 / MP1202.0 Input: 0.0000 to +30.0000 1: Previous behavior New: MP1262 and MP1263 Minimum filter order In order to optimize the LIFTOFF function when the machine is operating with the HSC filter, it has been made possible to shorten the reaction time for this. A high filter order has the advantage of good filtering. The disadvantage is a longer reaction time. This is very important for the LIFTOFF function, since if the power fails, for example, then the milling procedure must be concluded as quickly as possible by retracting the tool. If the time required for this is too long, the filter order can be reduced. As a rule, the default setting of 31 in Machine Parameters 1262 and 1263 is sufficient, and the previous behavior is maintained. In addition, values less than 15 are automatically considered to be 15. If the filter order is changed, the filter characteristics change, meaning that this reduction of the filter order makes it necessary to check the settings for the filter limit frequency (MP 121x): - MP1262 (filter order for HSC filter) >= 1.1 / (MP1212 * interpolator cycle time) - MP1263 (filter order for advanced HSC filter ) >= 0.67 / (MP1213 * interpolator cycle time) Input: 0 to 31 [filter order] 31: Previous behavior New: MP1290 Maximum angle tolerance for DCM (in combination with option #40) In connection with DCM (Dynamic Collision Monitoring), the machine manufacturer must enter a default maximum permissible angle tolerance via MP1290 (usually 0.1). This MP is considered with active collision monitoring in combination with active M128 and rotary axis filter (Cycle 32 with Angle Tolerance). An angle tolerance programmed with Cycle 32 is then limited to this value, i.e. the maximum effective angle tolerance is the value from MP1290. If DCM is switched off (via soft key or by switching to kinematics without collision-object definitions), the value programmed in Cycle 32 is in effect again. This is necessary, since DCM cannot yet take into account active angle tolerances when the machine is in motion. The angle entered in MP1290, in combination with the machine kinematics, is the basis for the allowance defined in MP1292 for collision-object calculations by the control. Input: 0.0000 to 3.0000 [] Default: 3 []

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New: MP1292 Manual allowance for DCM (in combination with option #40) For the DCM collision monitoring you enter here the necessary oversizes for the collision bodies with active DCM and active separate rotary axis filter (M128 or TCPM function and Cycle 32 with angle tolerance). Input: 0 to 1000 [mm] Default: 0 [mm] The following should be considered for the oversizes: For the rotary axes, such as a rotary table, assume the largest possible radius during rotation (usually the table radius), or for a swivel head the distance from the tool tip (longest tool) to the most distant point of the swivel head. Use this information to calculate the non-considered offset of the rotary axis. Do so by using the maximum angle tolerance entered in MP1290 to calculate the offset in the following manner: Example: Swivel head With maximum tool length: 200 mm, head length: 480 mm, angle tolerance: MP1290: 0.1 [] soffset = r sin (MP1290) soffset = 680 mm sin (0.1) soffset = 1.19 mm Since the oversize entered in MP1292 is added to each length of the bodies in the calculation, the oversize to be entered in MP1292 must be halved: MP1292 = soffset / 2 MP1292 = 1.19 / 2 MP1292 = 1 mm (rounded up from 0.595 mm) Since the resolution in MP1292 must be entered as an integer value in millimeters, the values input must be rounded up. Note Please note that when operating with multiple rotary axes, the offsets can summate, and so you must add the oversizes together. Example: OversizeTilting table = 0.595 [mm] OversizeRotary table = 0.396 [mm] MP1292 = 1 mm (rounded up from 0.991 mm) New: MP2172 MP2712 can be used to delay the switch-off of the SH1 signal (inverter release) by one to six seconds after an internal emergency stop has been triggered (DSP error). It makes additional braking time available in exceptional cases. Input: 0 to 6 [s] as an integer 0: Previous default of 3 s

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New CC 424: MP2260.x TRC (Torque Ripple Compensation) Certain motors with permanent magnets (linear, torque and some synchronous motors) have an increased, position-dependent variation of the motor torque (not QSY motors from HEIDENHAIN). This can be the result of two things: - During idle running, the cogging due to attractive forces of the permanent magnets - When under load, the torque ripple from higher harmonics, resulting from the opposing electromotive forces (generator effect) In practice, both causes always occur together, i.e. the torque of the motor is subject to periodic oscillations. This can have a negative effect on the controllability of the motor, which can result in a greater following error, and under circumstances, lower surface quality of the workpiece. To compensate for the cogging, a compensation current ascertained specifically for each motor can now be added.

The parameters for calculating this compensation are stored in a special TRC file on the iTNC (PLC:\MP\TRC xx_<motor name>.trc; xx = index of the motor axis; motor name = Name of the motor from the motor table (up to 29 characters). The iTNC is informed of the file name via MP2260.x. If MP2260.x is followed by a blank line, no compensation is ascertained for this axis. Example: MP2260.0: 00_MotNameFromMotTab ;Motor of 1st axis MP2260.1: ;Motor of 2nd axis, no compensation Due to the complexity of the parameters required, they can only be determined by the TNCopt commissioning software tool from HEIDENHAIN. Please refer to the TNCopt documentation. Note The TRC function can only be used with PWM frequencies up to 5 kHz. A TRC file can only be used on the control on which the adjustment has been made. A TRC file must be re-created if the motor or even the encoder is exchanged. A TRC file can only be generated for synchronous motors or for linear or torque motors.

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New: MP4020 bit 13 Monitoring of housing fan The correct operation of the MCs or CCs housing fan is now monitored (speed > 1500 rpm). This monitoring can be switched off with MP4020 bit 13. Input: 0: Monitoring not active 1: Inactive New: MP6151 With MP6151 you can perform the pre-positioning of the probe cycle at the machines rapid traverse speed. Input: 0: Pre-position with speed from MP6150 1: Pre-position at rapid traverse New: MP6166 If MP6166 Probing direction of the touch probe in consideration of an active basic rotation is activated, the probing directions in the manual measuring cycles and with an active basic rotation are transformed in the rotated plane. Input: 0: Inactive 1: Active Note This behavior is not in effect for the calibration cycles and the cycles for determining the basic rotation. New: MP7400 Look-ahead ((with software option 2) Number of NC blocks that the interpolator uses to calculate the path in advance. The greater the number of blocks for advance calculation, the higher the possible feed rate. However, this improved effect is only noticeable with many short traverse blocks in the micron range. The default setting is almost always sufficient, and requires less computing time. Input: 0: 256 blocks (previous configuration and default setting) 1: 512 blocks 2: 1024 blocks New: MP7493 Tolerance when setting a reference point with M114 (automatic compensation of machine geometry when working with tilted axes). The maximum deviation of the current tool orientation relative to the tool axis (of the tilted coordinate system) during reference-point setting is entered here. For example, this machine parameter is needed for setting a reference point when the PLANE function is active with Hirth-coupled PLC axes (, see page 28). Input: 0 to 30.0000 [degrees] Default: 0.005

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New: MP7503 Virtual tool axis ((upgrade function) When moving the axes in the manual operating modes, and when reapproaching the contour after a program interruption, you can now select via soft key the coordinate system of the tool. The axes can be moved in the current tool axis direction even before traversing the reference marks. To accomplish this, the last position of the rotary axes before power-off is stored remanently for incremental encoders. These remanently stored axis values are shown in an info window, and must be acknowledged by the machine operator. Input: 0: Inactive 1: Active

New: MP7683 bit 8 In MP7683 bit 8 you specify whether during tool-oriented machining in the Program Run, Full Sequence operating mode the workpieces should be machined until a tool change, or whether the program is only interrupted after the entire pallet has been machined (behavior previously depended on bit 1). Input: 0: Program interruption at tool change 1: Machine pallet completely New: MP7684 bit 9 Rapid five-axis machining with many rotary-axis motions During five-axis NC machining with many rotary axis motions and in combination with M128, a new method for calculation is used if bit 9 is set. This permits a significantly greater amount of motion by rotary axes (up to factor 4). However, if per positioning block this value is greater than 2 degrees, or handwheel superpositioning is active (M118), the previous procedure is used. Input: 0: Inactive 1: Rapid rotary milling active

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HEIDENHAIN Technical Manual iTNC 530

New: MP7691.3 MP7691.3 is used to record all messages from the NC kernel. They are saved in the following directory: TNC:\klog\0.log - 9.log These diagnostics are only possible together with a technician from HEIDENHAIN. Input: 1 to 10 (= 10 files of 10*[MP7691.3] kB each) 0: inactive (default - recommended) Changed: MP2302.x MP2302 can now also be changed by the PLC and via LSV. Changed: MP2304.x MP2304 can now also be changed by the PLC and via LSV. Changed: MP4310.x You can now also enter the general parameters for the PLC in binary format. Input: $0000 [hexadecimal] %0000 0000 0000 0000 [binary] Configuring the axes and spindle Maximum currents with UM/UR xxx D It is now possible to take advantage of the higher maximum currents listed for the PWM frequencies 3.333 kHz and 4 kHz in the Inverter Systems and Motors Technical Manual. The iTNC takes all necessary data and settings from the new power module table called inverter.inv, which replaces the old power module table motor.amp. If the higher currents are not needed, you can continue to use the motor.amp table. The iTNC follows a specific sequence when looking for the power module table: 1. PLC:\mp\inverter.inv 2. PLC:\mp\motor.amp 3. SYS:\mp\inverter.inv 4. SYS:\mp\motor.amp The new inverter.inv power module table is structured as follows: NAME: Designation of the power module PWM: PWM frequency in [Hz] at which the power module is driven S: Switch position of the current sensor. Is required for HEIDENHAIN inverters whose name ends in D in order to use the higher currents named above. Input 0 or 1 I-MAX: Maximum current of the inverter output in [A] I-Nom: Rated current of the inverter output in [A] U-Imax: Current sensor voltage in [V] at I-MAX I-N-DC: Permissible continuous current in stationary rotating field or until F-DC is reached in [A] T-DC: Time constant, how long maximum current can be applied to a stationary synchronous motor in [s] F-DC: Lower motor base frequency down to which the motor can be loaded with I-N-DC in [Hz] T-AC: Cycle duration for the duty cycle S6-40% in [s] F-AC: Motor frequency from which I-MAX is permissible in [s] T-IGBT: Protection time of the IGBTs in [s]

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Inclined milling with counting axes In order to make inclined milling possible on machines whose rotary axes are only counting axes (non-controlled axes), the following technique has been introduced: With M128 inactive (TCPM: the position of the tool tip remains constant when positioning tilting axes), the machine operator sets the rotary axes to the required nominal values. When M128 is activated, the control assumes the actual values of the non-controlled rotary axes, and uses them to calculate the changed position of the tool center point. The display of axes X/Y/Z is updated with the newly calculated values, and the compensating movement is performed with the next positioning. As long as M128 is active, the positions of the non-controlled rotary axes are monitored. If the positions of these axes deviate by more than the values defined in MP1110.x (standstill monitoring), then an error message is displayed and the momentary machining is interrupted. This function is even permitted after a program interruption with the MANUAL TRAVERSE soft key. In this case the new compensating movement is determined after switching with the APPROACH POSITION soft key. Machine interfacing Autorepeat function for PLC soft keys An autorepeat function can be activated for certain soft keys (ACTION and PULSE) by entering the following keywords: Example: ACTION Act_Softkey STATUS:M1100 REPEATINTERVAL:100 REPEATDELAY:200 REPEATDELAY: <delay time in ms>. Defines the length of time the soft key must be pressed for the autorepeat function to activate. REPEATINTERVAL: <interval in ms>. Defines the interval at which the function assigned to the soft key is triggered (e.g. for setting a marker). New STATE soft key Using the keyword STATES: <number of states>, you can manage multiple states for a soft key (STATE). In order to display these states, the BMX file of the soft key must include the corresponding number of possible states, and a PLC word memory must be assigned. If a PLC bit memory is assigned, only two states can be managed. In the following example, a value is assigned to the PLC word W1000 via a BMX soft key with five possible states. Values from 0 to 4 are assigned here: SOFTKEY spindle_attr.bmx State_Softkey STATE State_Softkey STATUS:W1000 STATES:5 New HIDE soft key keyword The keyword HIDE assigns a marker to a soft key (all types). If this marker receives the value 1, then that soft key is hidden, or exchanged for an empty soft key. PLC programming New functions for PLC in the LOGIC DIAGRAM The recording time for the LOGIC DIAGRAM function was doubled, in order to make recording times of at least 20 seconds possible. The duration of the recording after a trigger event can be set in the window for operand selection in 4 steps [2.7 s, 5.4 s, 10.8 s, 21.5 s]. In addition, the gating logic of the operands [AND, OR] must be set. If present, the symbolic names of the selected operands are displayed.

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HEIDENHAIN Technical Manual iTNC 530

Freely-definable soft-key menu for HR 420 Via the PLC, the iTNC can now also manage freely-definable soft keys on the HR 420. The corresponding entries are made in the soft-key resource file (*.spj). The soft keys for the vertical and horizontal soft-key rows of the iTNC can also be defined here. It is now possible to switch from the basic menu of the HR 420, via the FCT (Function) soft key, to a freely-definable submenu structure, whose description and functions are specified in the soft-key resource file. This menu is displayed in the fourth row of the HR 420. Four ASCII characters are available for each soft key. However, if each soft key uses all four characters, then there is no empty space between the soft-key designations. In addition, you can optionally have a menu title with 20 characters displayed in the third row of the HR 420 display for each menu. The scope of function of the soft keys on the handwheel is restricted somewhat compared to the vertical and horizontal soft keys of the iTNC screen. The following definitions are possible: Entries for the menu definition and type of soft key in the HR 420 menu: Entry ; SKMENU ENDSKMENU Parameters Description Comment Beginning or end of the definition of a soft-key menu. The name of the menu must be specified. The soft keys are automatically assigned to the correct menu rows. Also note the additional parameters for this keyword. HRROOT Freely-definable root menu when called from the basic handwheel menu via the FCT (Function) soft key Freely-definable submenu, called via the keyword NODE ...

HRMENU

TITLE:<name> Menu title: Freely definable text in the third line of the HR 420 The parameter TITLE: can also be surrounded by quotation marks. This permits blank spaces in the menu title. NODE Soft key jumps to a submenu. Is confirmed via W306 to the PLC. The soft-key name and the name of the submenu must be indicated. Soft key jumps to a submenu. Is confirmed via W306 to the PLC. The soft-key name and the name of the submenu must be indicated. Vacant soft key, is shown as ... You can also specify a softkey name. Function soft key. Is confirmed via W306 to the PLC. The soft-key name must be indicated. STATUS:<marker An operand is assigned to the soft key (in or word> addition to W306). If a marker is indicated and the soft key is pressed, the marker is set. If a word is indicated, the soft key number is entered (index number in the *.sys file, e.g. Softkey.sys).

BACK

BLANK ACTION

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Entry PULSE

Parameters

Description

The soft key is reported to the PLC via W306 for the duration of the PLC cycle. A soft-key name must be indicated.

The soft-key types RADIO, CHECK and STATE may not be used. Other parameters, such as ENABLE, HIDE, REPEAT, etc. are not yet available. Additional keywords and parameters for the description of soft keys in the HR 420 menu: Keyword TX Parameters #I<text> #A<ASCII value> Description Language-neutral text for the description of a soft key (up to 4 ASCII characters) Input of an ASCII value as a possibility for displaying special characters. This value must be entered in decimal notation as three digits. Special characters include - 128 = Arrow up - 129 = Arrow down - 133 = Return symbol in the menu

A combination of the parameters named above is possible, e.g. #IUp#128 to display Up The following example shows the configuration of a soft-key menu on an HR 420. PLC SOFT-KEY Project File - Version 1.0 SKPATH PLC:\SK\1024x768\ ... TX #IUp#A128 HR_SK1 TX #IDn#A129 HR_SK2 TX #ISta HR_SK3 TX #IPul HR_SK4 TX #IEND HR_SK5 ... SKMENU HRRootMenu HRROOT TITLE:Menu: Laser Head ACTION HR_SK1 STATUS: MG_LASER_HEAD_UP ACTION HR_SK2 STATUS: MG_LASER_HEAD_DOWN NODE HR_SK3 HRSubMenu ACTION HR_SK4 STATUS: M1122 BACK HR_SK5 ENDSKMENU

Definition of the soft keys with their description

Root menu of the handwheel menu

SKMENU HRSubMenu ACTION HR_SK6 ... BLANK ENDSKMENU

HRMENU Submenu of the handwheel menu

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Rapid navigation in the PLC status tables In the (MIOCTBWDS) table view of markers, words, etc., you can quickly switch the view to the corresponding operand table with the m, i, o, c, t, b, w, d and s shortcut keys. The b, c, and d keys are an exception in the B, W, D and HEX views, since they are needed for the entry of hexadecimal values. Terminating an NC strobe PLC messages that would terminate an NC strobe are only released once all functions that are only permitted during the strobe have been completed. PLC texts in UNICODE PLC texts in the operating mode and dialog windows from error fixes and the ERROR.A and DIALOG.A files can now be displayed in UNICODE. Starting with version 3.1 of PLCtext, it is possible to generate the files in the corresponding format. Note If texts from these files are also used in the PLC window, then they cannot be in UNICODE, but must rather use UTF8-coding. D372 Maximum spindle speed with potentiometer setting The PLC double word D372 makes the maximum spindle speed including the spindle potentiometer available to the PLC program. This makes it possible to already acknowledge within the ramp the M functions for switching on the spindle by comparing the actual and maximum speeds. MPFRAGMENTFILE By entering MPFRAGMENTFILE = <path\file name> in the OEM.SYS file, you specify a file containing the paths to machine-parameter subfiles, which can be activated via FN17. The value entered in the FN17 SYSWRITE ID 1020 NR1 = <line number> function then corresponds to the MP subfile reference in this file. This makes it possible to enter any number of MP subfiles (until now only 10 files MPFRAGMENT0-9 = <path> in OEM.SYS). Changes to spindle machine parameters (MP3xxx or MP13xxx) are only active after an S output. All other machine parameters are active immediately. The changes also remain in effect if a new NC program is selected, but not if the control is restarted. FN18 ID310 for M116 You can use the FN 18: SYSREAD Q<no.> = ID310 NR116 function to determine whether M116 is active. If the value ascertained does not equal 0, M116 is active. FN16 F-PRINT 31 variables can now be output per line with the FN16: F-PRINT function. FN18 ID630 NR0 You can use the FN18: SYSREAD Q<no.> = ID630 NR0 IDX <no.> function to ascertain whether the SIK option <no.> is set. If the SIK option is set, the function returns the value1.0. Otherwise it returns 0.0. FN18 ID630 NR1 You can use the FN18: SYSREAD Q<no.> = ID630 NR1 function to display the Feature Content Level (FCL) in order to ascertain the possible upgrade functions. If no Feature Content Level is set, the function supplies the value 1.0. Otherwise, for example, it supplies 2.0 for Feature Content Level 2.

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FN17/FN18 ID2000 Block function With the FN17/FN18 ID2000 NR functions you can transfer up to eight variables in a call between an NC program and the PLC. In addition, using FN17 you can now also transfer PLC bytes, words, and double words, not just markers. Example: FN 17: SYSWRITE ID 2000 NR10 IDX1000 = BLOCK Q1620 - Q1627 Here the contents of parameters Q1620 to Q1627 are written to PLC markers M1000 to M1007. No. 10 20 30 40 50 60 70 80 Description PLC markers PLC inputs PLC outputs PLC counters PLC timers PLC byte PLC word PLC double word IDX No. of marker No. of input No. of output No. of counter No. of timers No. of byte No. of word No. of double word X X X FN17 FN18 X X X X X X X X X

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PLC modules

Changed: Module 9223 (Free Rotation) Module 9223 can now also be used for PLC axes. Changed: Module 9038 (Read Axis Information) Status information number 9 is used to ascertain whether the axis being interrogated is a slave axis. Number 9: 0 = No slave axis 1 = Slave axis Module 9133 Output of Hardware Information (changed) PLC Module 9133 is used to ascertain the supply voltages (numbers 4 and 5) as well as the shaft speed of the housing fan (number 6). Call: PS B/W/D/K <Mode> 0: Internal temperature sensor in [C] 1: Temperature CPU1 (basic PCB) in [C] 2: Temperature CPU2 (additional PCB) in [C] 3: Voltage of buffer battery in [mV] 4: 5-V supply voltage of main board 5: 3.3-V supply voltage 6: Shaft speed of the housing fan 9133 B/W/D <Value>

CM PL

Error recognition: Marker M4203 W1022 Value 0 1 2 8 Meaning Value was determined Error code in W1022 Invalid number given No second CPU present (for number 2)

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Module 9143 Activating the brake test The brake test can be activated with PLC Module 9143. It is performed axisspecifically with the settings from MP2230.x and MP2232.x, or with special given values. Call: PS PS PS CM B/W/D/K <Axis> 0 to 13 and 15: Axes 1 to 14 and the spindle B/W/D/K <Factor for rated current> Value in 1/1000, 0: Value from MP2230.x B/W/D/K <Max. permissible path> Path in 0.1 m, 0: Value from MP2232.x 9143

Error recognition: Marker M4203 W1022 Value 0 1 2 Meaning Brake test started Error code in W1022 Invalid axis number

Module 9185 Touchpad status PLC Module 9185 is used to lock or enable the touchpad (X142) on the keyboard connected via USB. It is also possible to interrogate the status. Call: PS B/W/D/K <Mode> 0: Enable touchpad (UNLOCK) 1: Lock touchpad (LOCK) 2: Status request 9185 B/W/D <Status> -1: Status not defined 0: Touchpad is enabled 1: Touchpad is locked

CM PL

Error recognition: Marker M4203 W1022 Value 0 1 2 Meaning Function was performed Error code in W1022 Invalid mode

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New smarT.NC functions

DXF converter (Option #42) Contour programs (*.HC files) can be generated directly by the DXF converter. Note In order to take full advantage of the DXF converters function, you need a screen pointing device (such as a UCB mouse or touchpad), in order to select the contour elements, for example. Coordinate transformation (upgrade function) The datum shift, rotation, mirroring, and scaling factor coordinate transformations are now available in form view. PLANE Function (upgrade function) The PLANE function is now also available in form view. Graphic block scan (upgrade function) Block scan with graphically-supported possibility for selecting the entry point if it is within a point file. Contour-pocket depth (upgrade function) Within the contour pocket you can now assign a separate depth to each subcontour (or height for island contours). Copy/Paste/Cut Copying/Pasting/Cutting of units is now possible via soft keys or the keyboard commands CTRL+C/CTRL+V/CTRL+X. Switch between alternatives for feed rates Switch via soft key between the possible feed rates: F (feed rate in mm/min), Fz (feed rate per tooth in mm/tooth) and Fu (feed rate in mm/rev). Entry of the cutting velocity VC When entering the spindle shaft speed, it is now possible to enter it as a prescribed cutting velocity (at the cutting edge). The iTNC then calculates the spindle speed necessary. The VC soft key was introduced for this purpose. Tool selection window Tool data can now be edited in the tool selection window. Incremental entry of machining positions Machining positions can now be entered incrementally directly in a machining units form. This is possible as an option starting from the second position in the form. You can switch to incremental entry either via soft key or the I key. Assumption of workpiece blank The workpiece blank is automatically assumed from the unit program into a new contour description program.

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Plain-text dialog keys in forms The orange keys (X, Y, Z, P, I) of the standard keyboard now also function within contour programming in smarT.NC. QuickInfos in forms QuickInfo texts are now available for most input fields and option boxes in the forms. QuickInfo texts contain information about the respective functions, and appear on the screen when the mouse remains on the element for more than one second.

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New plainlanguage programming functions

DXF converter Contour programs (*.H files) can be generated directly by the DXF converter (software option).

Note In order to take full advantage of the DXF converters function, you need a screen pointing device (such as a UCB mouse or touchpad), in order to select the contour elements, for example. Entry of the cutting velocity VC When entering the spindle shaft speed, it is now possible to enter it as a prescribed cutting velocity (at the cutting edge). The iTNC then calculates the spindle speed necessary. The VC soft key was introduced for this purpose. FK-H conversion The functionality of this conversion no longer depends on the setting of the Automatic Drawing On/Off soft key. That means that this function is no longer restricted to the PROGRAM+GRAPHICS screen layout. The soft-key row for converting from NC programs is now available in all screen layouts in the Programming and Editing operating mode via the CONVERT PROGRAM soft key. Two soft keys are now offered for the conversion of NC programs with free contour programs into simple plain-language programs. The Convert FK->H Structure soft key maintains the program structure, and the NC blocks with free contour programming are replaced by plainlanguage blocks. Programs with Q parameters cannot be converted with this soft key. The Convert FK->H Linear soft key outputs a linearized program. This program follows the actual machining sequence. All programs can be converted with this soft key. CAD point filter (offline) (upgrade function) With this new function, externally created NC programs can be filtered. The NC programs are read out, and the traverse paths are recalculated and smoothed. The result is a new NC program with smoothed contours. It is saved with the file name amendment _FLT (e.g. contour_FLT.h). The filter function also generates useful additional path points when the gaps between individual contour segments are too large. This can also increase the size of the NC program. This function is called in the Programming and Editing operating mode, via the CONVERT PROGRAM soft key and then the new soft key for the point filter. Machining depth of subcontours For contours which you connect via the contour formula, you can now assign separate machining depths for each subcontour. New ISO functions PLANE Function The PLANE function is now available in ISO programming for tilting the machining plane. The syntax is identical with the plain-language syntax.

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New touch probe functions

Cycle 441 Rapid Probing (upgrade function) The new touch probe Cycle 441 is available, with which you can globally set different touch probe parameters (e.g. positioning feed rate) for all subsequently used touch probe cycles. This makes it easy to optimize the programs so that reductions in total machining time are achieved. Probing with active basic rotation in manual operating modes The TNC now also takes into consideration an active basic rotation (if activated via MP6166) for the probing functions in the Manual (El. Handwheel) operating modes. Under consideration of the active angle of rotation, the touch probe moves at an angle in the direction you programmed. Measuring log on the TNC screen Cycles 420 to 431 for automatic tool measurement can now also display the measuring log in a pop-up window on the screen. If you set parameter Q281 = 2, then the control interrupts program run and displays the measurement result. Press the NC Start button to close the pop-up window and continue program run.

New handwheel functions

Freely-definable soft-key menu for HR 420 Via the PLC, the iTNC can now also manage freely-definable soft keys on the HR 420. See PLC programming on page 14. New behavior with the HR 420 The feed-rate potentiometers of the HR 420 and the keyboard unit are no longer switched over automatically when the handwheel is selected or deselected. In order to switch the potentiometers, you must press the <CTRL> + <Handwheel> keys on the handwheel. A selection menu appears on the handwheel display, asking whether the potentiometers on the operating panel or the handwheel are to be active. F1 = HW: Handwheel F2 = KBD: Keyboard If the handwheel potentiometers are active, but the handwheel itself is not, a message appears on the control screen. Small pop-up window for HR 420 The pop-up window for the active HR 420 was made smaller, in order to improve the view of the display beneath it.

Programming station (Id. Nr. 340 494-02 and new: Id. Nr. 386 753-02)

Scope of function of the programming station All software options (SIK) are now enabled for the programming station software. Virtual keyboard (programming station with USB dongle) A new programming station (Id. Nr. 386 753-02) is being presented with the release of NC software 340 49x-02. It is operated via soft keys and a virtual keyboard, which is controlled via the mouse. It is enabled with the USB dongle included in delivery. This means that no keyboard unit is required. A screen resolution of at least 1280 x 1024 pixels is necessary for this.

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PLC basic program for programming station When installing the programming station, the PLC basic program can now also be installed, ready-to-run, from the setup menu. You must select Userdefined installation during the setup, and then select the installation of the PLC basic program. This permits you to simulate functions in the machine operating modes In addition to the horizontal and vertical soft keys, which you click with the mouse, various functions (such as the simulation of axis and spindle motions) can be performed with key combinations from the keyboard unit. When you start the programming station, the error message 98 TNC programming station active appears. This is an opportunity to read a brief description of how to perform these functions. Press the Help key to call this brief description. You can simulate the following machine functions with both the keyboard unit and the mouse. Function NC start NC stop Axis plus Axis minus Emergency stop Vertical soft key 1 (top) : Vertical soft key 6 (bottom) Key combination [CTRL] + S [CTRL] + X [CTRL] + Arrow Up [CTRL] + Arrow Down [ALT] + X [SHIFT] + [CTRL] + [ALT] + 1 : [SHIFT] + [CTRL] + [ALT] + 6

Public key PLC The new, additional public key PLC was introduced for the PLC programming interface (code number 807667). It only functions with the programming station software. Indication of digital outputs in MP120.x In MP120.x, digital outputs can now be entered in the software for the programming station (e.g. X51 to X64).

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iTNC Operation and technique

3-D line graphics (upgrade function) The powerful 3-D LINES viewing option has been added to the Programming and Editing operating mode. It is activated via the soft key of the same name, which is available using the key for the screen layout. The following functions are now available in this viewing option: Display of the currently selected traverse path in the NC program with its own color within the 3-D graphics (see figure) 3-D rotation with the mouse, including display of the active coordinate system Standard zoom functions with very high resolution Standard motion and rotation functions via soft keys

Table editor in form view Tables (with the extension *.TAB) can now be edited in a form view. You can switch to it with the LIST FORM soft key after having selected the table.

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HEIDENHAIN Technical Manual iTNC 530

Automatic determination of the dynamic load (only CC 424) The dynamic load (inertia) of axes can automatically be detected with a measuring cycle created by the OEM. The result measured is the maximum torque which occurred, in % of the rated torque. It is determined between the beginning and end of a measurement, and can be stored in a buffered variable. The values can be output at any time. This makes it possible, using the measured value and an NC macro, to automatically adapt the machine parameters by selecting an appropriate MP subfile. FN 17 SYSWRITE ID621 NR 0 IDX <axis> = 0 to start the measurement. FN 18 SYSREAD Q<n> = ID621 NR 0 IDX <axis> to read the result and stop the measurement. FN 17 SYSWRITE ID 590 NR 2 IDX <axis> (is not cleared when a program is selected) and FN 17 SYSWRITE ID 590 NR 3 IDX <axis> (secure from power failure) for storing the result (IDX = 1..30). FN 18 SYSREAD ID 590 NR <2 or 3> IDX <axis> for reading the stored value (IDX = 1..10). Creation of an NC macro, which is run when a program is concluded with M02, M30 or END PGM (keyword RUNENDPGM in NCMACRO.SYS). In the Manual operating mode, this macro must also be saved in the M-function table under M02 and M30. FN 17 SYSWRITE ID 120 IDX 2 to deactivate a machine parameter subfile. LIFTOFF at powerfail (only CC 424) If the power fails and LIFTOFF is enabled (M148 must be active, column LIFTOFF in the tool table = Y, PLC: M4620=1), an attempt is made to lift the tool from the contour by the distance given in MP1160 with the help of the remaining energy of the dc-link. Certain conditions must be maintained before and during LIFTOFF. The 24-V power supply must be maintained for at least 1 second (USB for 24 V, or buffer capacity or capacitor) The PLC may not switch off the controller via Module 9161 AC-Fail may not be evaluated (MP2150 = 3) The wye-delta contactor combination may not fail, otherwise the spindle could not be controllable during liftoff Note LIFTOFF only functions with HEIDENHAIN inverters.

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Reference-point setting with the PLANE function, Hirth-coupled axes and active M114 If rotary axes with Hirth coupling are positioned via PLC or NC, angles can only be entered according to a certain grid. Machining can be performed in any plane by tilting the plane with the PLANE function and programming the rotary axis grid coordinates with M114 (automatic compensation of the machine geometry when working with tilting axes). Starting with software 340-49x-02, it is possible to save and set reference points in this state. The iTNC uses the nominal positions of the rotary axes programmed in M114 to calculate the reference point. With MP7493 the machine manufacturer can enter a maximum deviation of the rotary axes based on the nominal position resulting from the orientation of the working plane. The control accepts this deviation when setting reference points and when measuring with M114. The default value for this machine parameter is 0.005. The iTNC then uses the current ACTUAL/NOMINAL positions (MP7682, bit 1) of the rotary axes to calculate the reference point. Note Please note that in this procedure the tool might not be perpendicular to the tilted working plane.

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HEIDENHAIN Technical Manual iTNC 530

Network: IP address via DHCP (upgrade function) Using the code number NET123 and the DEFINE NET soft key, DHCP can now be entered as the network address in the ADRESS column. In this case the control automatically retrieves the network address (IP address), the subnet mask (MASK column) and any necessary broadcast address (BROADCAST column) from a DHCP server on the network (Dynamic Host Configuration Protocol). If necessary, DHCP can also be entered in the ROUTER column, so that the IP address of a default router can automatically be retrieved by the DHCP server. If necessary, the IP address of the control can be determined by the network from the network name. This name can be found on the control under DEFINE NET in the HOST column. On the network the IP address can be ascertained via command line (DOS window) with the ping <HOSTNAME> command (e.g. ping TNC_123). Below is the example for the configuration of a table which is accessed via Programming and Editing, MOD, code number NET123 and the DEFINE NET soft key: ADRESS DHCP Note In order to maintain the simple procedure for establishing a network connection between the control and the computer software from HEIDENHAIN, such as TNCremoNT, TNCopt or PLCdesignNT, the newest versions of the software also support the entry of host names or network names instead of the IP address. For example, if the name TNC_123 is entered via code number NET123 and the DEFINE NET soft key in the HOST column, it can be entered in TNCremoNT in the IP address field for configuring the connection. MASK BROADCAST ROUTER HOST TNC_123 DOMAIN NAMESERVER DHCP

Network: Name resolution via DNS (upgrade function) Via code number NET123 and the DEFINE NET soft key, the name of a domain can be entered in the DOMAIN column, and the IP address of a Domain Name Server (DNS) in the NAMESERVER column. This resolves the symbolic computer names in this domain, and the entry of IP addresses in the mount table (via the DEFINE MOUNT soft key) is no longer needed. If DHCP is entered in the DOMAIN column, entering a domain name and an IP address of the name server is not necessary. These are then automatically assigned by the network.

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Expanded USB functionality (USB 1.1) (upgrade function) When attached, USB devices that use the VFAT or ISO 9660 file systems (not NTFS or other systems) are detected and connected automatically. The file manager features soft keys for removing and reconnecting these devices to the directory tree. These appear when the More Functions soft key is pressed, if the USB memory device was selected in the file manager. If this is not the case, only the soft key for reconnection is shown.

Note In order to remove a USB memory device, you must always press the More Functions and

soft keys. Otherwise data on the data carrier could be lost. HEIDENHAIN has successfully tested the following USB memory devices: Type Floppy Floppy Manufactu Device rer TEAC TEAC VendorID ProductID Revision 0000 0000 1000 fc02 0702 0007 0005 9380 2168 9384 0.00 0.00 1.33 11.10 0.02 1.00 1.00 1.00 2.00 1.05

TEAC FD-05PUW 0644 TEAC FD-05PUB 0644 USB CD-ROM 210PU USB2-IDE Controller UNKNOWN USB MiniStick TS512MJFLASH Flash Disk Mass Storage 0644 07ab 05e3 0c76 0c76 058f 0ea0 058f

CDROM TEAC CDROM FREECOM HD Stick Stick Stick Stick Stick

UNKNOWN USB TO IDE QDI TrekStor Transcend Transcend Generic

Other devices are also supported, but the customer must test them on a caseby-case basis. New software update guidance, starting with NC software 340 490-02 The update functionality of the iTNC was revised. See New Update Procedures Once Software 340 49x-02 Has Been Installed on page 32. Access to PRESET table The preset table can now be accessed from the first soft-key row. The SET DATUM and INCREMENT soft keys were moved to the second soft-key row. Now the line of the currently active preset is also the active line when the preset table is accessed.

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HEIDENHAIN Technical Manual iTNC 530

New functions in the PRESET table Two new functions are available in the preset table. You can now incrementally correct a preset already saved for an axis set a preset in an axis set a preset in an axis to 0 directly enter a value in the PRESET table

Cycle dialogs in UTF8 The dialogs of parameters for OEM cycles can now be displayed as UTF8encoded texts (e.g. for Asian languages). In order to create these OEM cycle projects, you need at least version 4.2 of CycleDesign and version 3.1 of PLCtext. Axis traverse limits for PLC auxiliary axes For rotary and PLC auxiliary axes for which axis traverse limits were entered in MP810, you can now enter axis traverse limits in the Manual and Program Run operating modes via the MOD key. The limit-switch monitoring for these axes must have been activated in MP812. New design for soft keys All soft keys were redesigned. Switch-off during power interruption The control can now already be switched off in the power interrupt state with the Shutdown soft key. Editing system files The function introduced in software 340 49x-01 for editing system files (*.SYS) in the editor for machine parameters was disabled. Czech texts with special characters The texts in Czech (e.g. dialogs, DSP error messages and their help texts) are now displayed with the appropriate special characters.

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1.4.3 New Update Procedures Once Software 340 49x-02 Has Been Installed Previous The previous procedure for software updates can continue to be used. In addition, service packs can be selected and deleted in the selection dialog box. The following files are now necessary for an update, and must be located in the same directory: - setup.zip - setup.omf (setup.exe in Windows) - setup.ini (this is to be created by the OEM, and is only necessary if the update is to occur according to a specific sequence) Please note that this currently means that the version of the software to be installed is not displayed in advance. Note You can download the two files necessary for the update (setup.zip and setup.omf) from the HEIDENHAIN FileBase under NC Milling iTNC530 > Software as a single ZIP file, e.g. 340490_002.zip, and unzip them in your Update directory. Software updates and service packs are loaded in the same manner. Automatic update possible. If your directories are structured appropriately, this method makes it possible to update the control automatically when it is booted. If there is an install directory on your iTNC containing a setup.ini control file, an update is performed automatically according to the instructions in this control file (see Control file for automatic update (setup.ini) on page 1 34). The following directories are checked during booting for the presence of a control file: iTNC without Windows - TNC:\install\ or, if a USB memory device is connected - USB0:\install\ (USB0: first partition of the first USB memory device) iTNC with Windows - D:\install\ or, if a USB memory device is connected - G:\install\ (G: corresponds to the drive letter of the USB memory device network drives are not permitted!) Start the update via the keyword SETUP No naming convention according to the usual format is necessary Copying of the update files (setup.omf/exe and setup.zip) to the system partition occurs automatically as part of the update program in directories with the following naming convention: iTNC without Windows - Software update: SYS:\zip\<Id.Nr.>_<ver> - Service pack: SYS:\zip\<Id.Nr.>_<ver>_SP<n> iTNC with Windows - Software update: C:\Program Files\install\<Id.Nr.>_<ver> - Service pack: C:\Program Files\install\<Id.Nr.>_<ver>_SP<n>

Whats new?

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HEIDENHAIN Technical Manual iTNC 530

Warning No manual changes may be made to these directories, since they might be required for restoring earlier software versions. A query appears, asking whether the necessary binary to ASCII conversions should be performed. If yes, then a procedure in case there is not enough memory is requested: - Cancel if not enough memory - Delete largest or oldest files first This can be automated in the control file mentioned above. Only files whose binary version has changed are converted. The NC software has been prepared in such a manner that when an update is performed or a service pack loaded, the PLC program and PLC partition can be updated as well, according to the requirements of the OEM. When the NC software is updated, the OEM uses the HEIDENHAIN PC software PLCdesignNT to add all necessary files to the setup.zip archive. These files are copied to the appropriate locations during an update. Note The support necessary for this from PLCdesignNT will be available starting in the next release (version 2.3). It is not possible to update only the PLC data but not the NC software. If the PLC:\_mpupdate directory is created during the automatic update by the OEM, then files that automatically update or expand the active and selected MP or OEM.SYS files when the control is started can be saved here. Files containing the name merge.* (merge.mp and merge.oem.sys) expand the MP and OEM.SYS files by the entries contained in them. Files containing the name overwrite.* (overwrite.mp and overwrite.oem.sys) contain updated entries for the corresponding files, and overwrite entries with the same names in the MP and OEM.SYS files. MP subfiles are ignored here. After successful installation, these ASCII files are automatically reconverted to binary format.

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Control file for automatic update (setup.ini)

In order to automate an update as much as possible, a control file with the name setup.ini is necessary. This file can be created with a simple text editor. An example of a setup.ini file: Interactive=1 Confirm=1 Language=GERMAN SavePlc=TNC:\backup\340422_012.zip The following settings are selectable: Parameters Interactive=[0,1] Description Deletion of the NC software archive (old software versions) and binary to ASCII conversion must be confirmed by the user. 0: No 1: Yes [default] Start of update and reboot process must be confirmed by the user 0: No 1: Yes [default] A service request is triggered after an update (only if remote diagnosis is active) 0: No [default] 1: Yes Binary to ASCII conversion with automated update process (not with service pack) 0: No 1: Yes [default] The setup archive to be installed is copied to the directory SYS:\zip (iTNC with Windows: C:\Program Files\install). This makes it possible to return to this software version later. 0: No 1: Yes [default] Procedure during binary to ASCII conversion during automated update if there is not enough memory available on the TNC or PLC partition DATE: Delete oldest files first SIZE: Delete largest files first CANCEL: Cancel the update [default] Procedure is there is not enough room on the SYS partition for the update DATE: Delete oldest archive first SIZE: Delete largest archive first CANCEL: Cancel the update [default]

Confirm=[0,1]

ServiceRequest=[0,1]

ConvertToAscii=[0,1] (only if Interactive=0)

CopyToSys=[0,1]

DeleteFiles= [DATE,SIZE,CANCEL] (only if Interactive=0)

DeleteArchives= [DATE,SIZE,CANCEL] (only if Interactive=0)

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Parameters Language=[ENGLISH, GERMAN] (only if Confirm=0)

Description Language for the dialog guidance during the update if no user activities are required for starting the update and rebooting (Confirm=0) GERMAN: German dialog text ENGLISH: English dialog text [default] Delete the source files (setup.zip, setup.ini, setup.omf/exe) once the update has completed successfully 0: No [default] 1: Yes Delete the setup.ini file after a successful update. 0: No [default] 1: Yes If the software is updated from 340 49x-02 or higher to a newer version, then the entire PLC partition can be stored as a ZIP file in binary format. This makes it possible to restore this software state including the PLC files. Here you enter the path and file name for the ZIP file in which the entire PLC partition is saved in binary format. Please consider the software version when assigning the file name. The Restore function is used to restore the PLC data to a certain software state. Here you enter the path and file name for the ZIP file containing the PLC data state (in binary format) appropriate to the NC software version to be installed. This should be the ZIP file which was saved with the SavePlc function, containing the corresponding PLC state and saved on the PLC partition.

DelSource=[0,1]

DeleteIni=[0,1]

SavePlc=<name>

RestorePlc=<name>

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New update for iTNC without Windows

Manual update The following procedure is used to perform a manual update (without a setup.ini file in the setup directory) or an installation of a service pack:
8 8 8 8 8 8 8

HEIDENHAIN recommends making a backup for the control Connect the drive or USB device containing the files necessary for the update (setup.zip, setup.omf) In the Programming and Editing mode, press the MOD key Enter the keyword Setup In the browser, select the directory and the corresponding Setup.omf file Select the desired language for the update guidance Choose the desired action for the event that there is not enough memory available on the TNC or PLC partition for the binary to ASCII conversion: - Cancel if not enough space: The update procedure is cancelled if there is not enough space available, and a message to this effect appears. In this case you must save the files (*.h, *.i, and tables) externally, if they are needed, and then remove them manually in order to make space for the conversion. - Delete largest files first: The largest files (*.h, *.i, and tables) are deleted until there is enough space for the conversion. - Delete oldest files first: The oldest files (*.h, *.i, and tables on the PLC and TNC partitions) are deleted until there is enough space for the conversion. If there is not enough space on the SYS partition, select deletion of the oldest setup files. This procedure is repeated until there is enough memory space available. Confirm the update actions listed and that are to be performed. After the update has finished successfully, confirm the restart of the control. Note If a setup.ini file exists in the setup directory when you update manually, then the update is performed according to the instructions in this file. See Control file for automatic update (setup.ini) on page 34.

8 8

Automated update If one of the following directories exists when an iTNC without Windows is booted, - TNC:\install\ or, if a USB memory device is connected - USB0:\install\ (USB0: first partition of the first USB memory device) and if a setup.ini control file is saved in this directory, then an automated update is performed according to the instructions in this control file (see Control file for automatic update (setup.ini) on page 1 34). An automated update is usually a part of a manual update. This means that you can use the control file to reduce the number of user actions necessary for the update to a minimum, and at the same time make a backup of the PLC partition.

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HEIDENHAIN Technical Manual iTNC 530

Update via remote operation How to perform an update via remote operation:
8 8

In the Programming and Editing mode of the iTNC, press the MOD key On the iTNC, activate remote maintenance by pressing the Service ON soft key. A service request is triggered and a connection is established. Transmit the setup.omf and setup.zip files to a suitable directory on the control (e.g. TNC:\update) Continue the update via remote operation as described under Manual update

8 8

Notes on updating via remote operation If remote maintenance is active when the update is started, the remote maintenance is deactivated (this does not affect the current remote operation). After the reboot or after the update was cancelled due to an error, a service request is triggered. The service request information indicates whether the update was successful. If the control does not boot due to missing or incorrect machine parameters, a service request is triggered until the power interrupt stage of the boot process is reached. New update for iTNC with Windows Manual update The following notes apply to software updates and installations of service packs for the iTNC with Windows: The actual update process is started as previously in Windows. Service packs are now installed according to this method. The soft keys on the control for installing service packs have been omitted. Since the update procedure itself is now capable of stopping the NC software in order to perform an update, the procedure for stopping the NC software via the Control Panel has been omitted. In addition, analogous to the iTNC without Windows, manual binary to ASCII conversion is no longer necessary. This can now also be performed during the update procedure. A warning appears if no automatic conversion is possible. Automated update If one of the following directories exists when an iTNC with Windows is booted, - D:\install\ (D: corresponds to the TNC partition) or, if a USB memory device is connected - G:\install\ (G: corresponds to the drive letter of the USB memory device network drives are not permitted!) and if a setup.ini control file is saved in this directory, then an automated update is performed according to the instructions in this control file (see Control file for automatic update (setup.ini) on page 1 34). If this file does not exist, the update must be started manually via the SETUP keyword. An automated update is usually a part of a manual update.

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1.5 Additional Enhancements to NC Software 340 492-xx and 340 493-xx


Installation The following changes were made to the Windows 2000 installation for newly delivered removable hard drives (HDR): Automatic Windows updates were deactivated The energy saver for the screen was deactivated Microsoft Hotfix KB814078 was loaded The Microsoft Java Virtual Machine (MSJVM) was removed

Note HEIDENHAIN recommends deactivating the screens energy saver for existing installations.

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1.6 Hardware
1.6.1 TE 520 B General information The TE 520 B is the same as the TE 530B, with a SPEC FCT key and keys for smarT.NC, but without a touchpad. In some cases the TE 530 B cannot be used because of its touchpad. The USB cable is longer than 36 m When using two operating panels, which are switched with the BTS 1xx, only one touchpad can be active (touchpad at X142). The new TE 520 B keyboard unit should be used in these cases. TE 520 B TNC operating panel without touchpad With function keys for the new smarT.NC operating mode, as well as the new SPEC FCT key for calling special TNC functions. The IV and V keys are snap-ons, and can be switched.

Id. Nr. 535 835-01 TE 520 B

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Dimensions
400 3760.2 8 12 30 +1 0 25 +1 0

2580.2

274

M5 8 +1 0

5.5 M5

1 4

11x45 2580.2 251 +1 0

(7)

3760.2
+1 f 384 0

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HEIDENHAIN Technical Manual iTNC 530

10

1.6.2 iTNC 530 Programming Station iTNC 530 programming station The iTNC 530 programming station was revised: Keyboard adapted to the TE 520 B: with SPEC FCT key and keys for smarT.NC, without touchpad No potentiometers New housing design iTNC 530 programming station TE 520 B TNC operating panel without touchpad With function keys for the new smarT.NC operating mode, as well as the new SPEC FCT key for calling special TNC functions. The IV and V keys are snap-ons, and can be switched.

Id. Nr. 532 524-01 Programming station Included in delivery: Programming station software on CD TE 520B keyboard in new housing design with additional keys for smarT.NC and the soft keys

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Programming station with virtual keyboard

The programming station is now available just as software with an integral keyboard. The TNC-specific functions are called via a virtual keyboard using the mouse. All necessary keys are included, and so even without the separate TE 520B keyboard unit, you have a fully-functional programming station. It is enabled with the USB dongle included in delivery.

Id. Nr.:

386 753-02

Included in delivery:CD-ROM, USB dongle Availability: Note Your screen resolution must be at least 1280x 1024 pixels in order to use the virtual keyboard of the programming station. Series (with release of NC software 340 49x-02)

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HEIDENHAIN Technical Manual iTNC 530

1.6.3 UV 106B General information UV 106 B power supply unit for analog HEIDENHAIN contouring controls The UV 106 B power supply unit was designed so that the iTNC 530 could be used with a compact, coordinated system for analog nominal shaft-speed interfaces (+/ 10 V). It supplies the iTNC 530 with the supply voltages necessary for operation. The UV 106 B (Id. Nr. 546 581-01) is being introduced as a replacement for the UV 106 (Id. Nr. 366 572-11).

Id. Nr. 546 581-01 UV 106 B UV 106 B Specifications Specifications Power supply (at X31) Protection Load capacity (5 V) Power consumption Degree of protection Module width Weight ID number UV 106 B 400 Vac 10 % 50 Hz 6.3 A / gRL 20 A Max. 400 W IP 20 159 mm 4 kg 546 581-xx

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Dimensions of UV 106B

M5

24.5+0.2 158.25+0.75

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HEIDENHAIN Technical Manual iTNC 530

1.6.4 UV 105 B (Non-HEIDENHAIN Inverter Systems) General information The UV 105 B (Id. Nr. 532 556-01) was designed solely for the use of HEIDENHAIN controls in connection with non-HEIDENHAIN inverter systems. It is essential for the supply voltages of the HEIDENHAIN control units. UV 105 B power supply unit for the operation of HEIDENHAIN controls with non-HEIDENHAIN inverter systems

Id. Nr. 532 556-01 UV 105B

UV 105 B

Specifications Specifications Power supply (at X31) Protection Load capacity (5 V) Power consumption Degree of protection Module width Weight ID number Warning The UV 105 B is not compatible with the UV 105 (Id. Nr. 344 980-xx), and no HEIDENHAIN inverter components can be operated with this supply voltage. UV 105B 400 Vac 10 % 50 Hz 6.3 A / gRL 20 A Max. 400 W IP 20 159 mm 3 kg 532 556-01

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Status signals via ribbon cable Note For the control to be able to evaluate the status signals of the power supply unit, the ribbon cable of the UV 105 must be connected with X69 of the control. Connection: 50-pin ribbon connector 1a to 5b 6a to 7b 8a 8b 9a 9b 50-pin ribbon connector +5 V 16b +12 V 17a +5 V (low-voltage 17b separation) 0 V (low-voltage 18a separation) +15 V 18b 15 V 19a Assignment Assignment GND RDY.PS GND ERR.ILEAK GND PF.PS.AC (only UV 120, UV 140, UV 150, UR 2xx) GND Do not assign GND Do not assign GND Do not assign GND Reserved (SDA) GND Reserved (SLC) GND RES.LE GND

10a 10b 11a 11b 12a 12b 13a 13b 14a 14b 15a 15b 16a X74: 5-V connection of the UV 105 B Connection:

UZAN 0V IZAN 0V RES.PS 0V PF.PS.ZK GND ERR.UZ.GR GND ERR.IZ.GR GND ERR.TMP

19b 20a 20b 21a 21b 22a 22b 23a 23b 24a 24b 25a 25b

Wire color of 5-V connection BK RD

5-V terminal on CC 42x 0V +5 V

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HEIDENHAIN Technical Manual iTNC 530

X31: Supply voltage for UV 105 B

Supply voltage: 400 V 10 % Connection: Connecting terminal U V Assignment Phase 1 / 400 Vac 10 % / 50 Hz to 60 Hz Phase 2 / 400 Vac 10 % / 50 Hz to 60 Hz Equipment ground (YL/GY), 10 mm2 Cable: Wire cross section: 1.5 mm2 (AWG 16) Line fuse: 6.3 A (gRL) Siemens Sitor type Positive dc-link voltage of the nonHEIDENHAIN inverter system Negative or reference potential of the dc-link voltage of the non-HEIDENHAIN inverter system Cable: Wire cross section: 1.5 mm2 (AWG 16) The dc-link connection of the UV 105B is protected by the additional PCB on the non-HEIDENHAIN inverter system (4 A)

+Uz Uz

Tightening torque: for the connecting terminals 0.7 Nm (6.5 - 7 lbs/in) Grounding terminal: 10 mm2 (AWG 6) Strain relief: Ensure that the connecting cables are not subject to excessive strain Note If you are using non-HEIDENHAIN inverter systems, you must connect the supply voltage to the terminals U and V via an isolating transformer (300 VA, basic insulation as per EN 50 178 and VDE 0550). Warning When using an isolating transformer, do not ground this isolating transformer on the secondary side! The isolating transformer decouples the line voltage from ground. Grounding the isolating transformer on the secondary side leads to an addition of the dc-link voltage and the supply voltage. This could destroy the UV 105B! Please keep this in mind in your circuit diagrams.

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UZ: Supply of the UV 105 B with UZ

Since the power to the UV 105B is supplied through the dc-link, the voltage fed into the dc-link by the motors that are still running can be used during line voltage failures. The UV 105B uses this voltage to maintain the power supply to the control until the non-HEIDENHAIN inverter system has been shut down properly by the control. Connecting terminals UZ (UDC) +UZ (+UDC) Assignment DC-link voltage DC-link voltage +

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HEIDENHAIN Technical Manual iTNC 530

Dimensions for UV 105 B

M5 M4 5.5 50

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HEIDENHAIN Technical Manual iTNC 530

1 Update Information No. 15


1.1 Service Packs
The following service packs have been released: Service pack 340 490-02 SP1 340 491-02 SP1 340 492-02 SP1 340 493-02 SP1 Service pack 340 490-02 SP2 340 491-02 SP2 340 492-02 SP2 340 493-02 SP2 Service pack 340 490-02 SP3 340 491-02 SP3 340 492-02 SP3 340 493-02 SP3 Service pack 340 490-02 SP4 340 491-02 SP4 340 492-02 SP4 340 493-02 SP4 NC software 340 490-02 340 491-02 340 492-02 340 493-02 NC software 340 490-02 340 491-02 340 492-02 340 493-02 NC software 340 490-02 340 491-02 340 492-02 340 493-02 NC software 340 490-02 340 491-02 340 492-02 340 493-02 Release October 2005 October 2005 October 2005 October 2005 Release November 2005 November 2005 November 2005 November 2005 Release December 2005 December 2005 December 2005 December 2005 Release February 2006 February 2006 February 2006 February 2006

April 2006

Service Packs

11

1.2 Hardware
There is a new, more powerful MC 422C for the standard versions of the iTNC 530. As of May 2006, this hardware replaces the single-processor version of the MC 422B. The MC 422C will at first only be available in a single-processor version. Dualprocessor versions will continue to be delivered as MC 422B for the time being. Properties of the MC 422C: Pentium III with 800 MHz 256 MB RAM

Main computer (standard version) MC 422C

Signal inputs

Id. Nr. of MC for BF 150 display unit 587 929-01 587 932-01 587 934-01

Replaces Id. Nr.

Without position encoder inputs (for CC 424) 5 position encoder inputs Position: 1 VPP/EnDat 10 position encoder inputs

387 173-01 387 181-01 387 189-01

All accessories (e.g. SIK, HDR, etc.) for the new MC 422C hardware are identical to the hardware for the MC 422B. Please note that the iTNC 530 software can only run on the MC 422C if the following software versions are installed: Id. Nr. 340 490/491-02: Service pack 05 available starting the middle of April 2006 Id. Nr. 340 422/423-13: New software version 340 42x-14 is planned The main differences between the MC 422C and the MC 422B are: Instead of a two-row connector (X47), the connection of the PL 51x features a three-row connector (X147). HEIDENHAIN supplies an adapter cable for X147 (Id. Nr. 587 789-A5) with every MC 422C. This makes it possible to connect the PL 51x with the previous connection cable (371 045-xx). However, HEIDENHAIN does not recommend connecting the PL 51x with the 371 045-xx connection cable for a longer period of time. Instead you should use the 371 046-xx connection cable for the connection to X147. Connector X9 for additional analog outputs is missing. Only connector X8 with six analog outputs is present. If this presents you with difficulties, please contact HEIDENHAIN. A second USB connection (X142) is located on the bottom of the housing of the MC 422C.

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HEIDENHAIN Technical Manual iTNC 530

1.2.1 Important Notes about the MC 422C Warning Regarding the MC 422C hardware, please note: The new MC 422C hardware only runs as of software 340 490/491-02 service pack 5 or software 340 422/423-14 or higher. If you accidentally install a lower software version in connection with the MC 422C, then a corresponding error message appears when the control is booted. The boot procedure is aborted. If you have difficulties with this remodeling, your control doesnt boot, or you want to exchange a defective MC 422B for an MC 422C, please contact the HEIDENHAIN service department. Proceed as follows when replacing an MC 422B with an MC 422C:
8 8

Use the MC 422B to install the 340 490/491-02 SP5 or 340 422/423-14 software on the hard disk. Completely switch off your machine after you have finished the installation. Warning Do not engage or disengage any connecting elements while the unit is under power!

Remove the MC 422B hardware. Remove the HDR on which the new software was installed. Please refer to the notes in the Technical Manual. Install the HDR in the new MC 422C hardware. Install the MC 422C and reconnect all connecting elements. Please refer to the connection overview of the MC 422C.

8 8

April 2006

Hardware

13

1.2.2 Comparison of the Connections: MC422C and MC422B

MC 422C

MC 422 B

Connector X1-X5 X6, X35-X38 X8 X9

Function Actual position value Nominal value output 1 Nominal value output 2 (only MC 422B) Touch trigger probe 1 Touch trigger probe 2 Measuring touch probe Handwheel Ethernet COM 1 COM 2 Spindle ref. 24 V (UE) PLC output PLC input CRT display unit VGA/XGA 24 V (PLC) Keyboard unit Machine operating panel PL 51x Analog input TFT display unit VGA (640x480) Profibus Reserved Reserved USB USB TFT display unit XGA (1024x768) Reserved

X149

X127

X12 X13 X14 X23 X26 X27 X28 X30 X34 X41

X128

X14

X42 X43 X44 X45 X46 X47, X147 X48


X147

X49 X121 X125 X131 X141 X142 X149 X165

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HEIDENHAIN Technical Manual iTNC 530

1.2.3 Connection Overview of MC 422C / 5 Position Encoder Inputs and CC 422 with 6 Control Loops

X1 to X5 X35 to X38 X15 to X20


X149

Encoder for position Vacant Encoder for speed PWM output Nominal value output, analog TS touch trigger probe TT 130 touch trigger probe Handwheel Ethernet data interface RS-232-C/V.24 data interface RS-422/V.11 data interface

X51 to X60 X8 X12 X13 X23 X26 X27 X28

X14

X141, X142 X30 X34 X41 X42 X44 X45 X46 X147 X48 X149 X131 X69 X121 X165, X166

USB interface 24 V reference signal for spindle 24 V for control-is-ready output PLC output PLC input 24 V PLC supply voltage Keyboard unit Machine operating panel PLC expansion PLC analog input BF 150 monitor Reserved Power supply Reserved Reserved

X147

X150, X142 at bottom of housing

X74 X150 B

5-V power supply Axis-specific drive release Signal ground Equipment ground (YL/GN)

Warning Do not engage or disengage any connecting elements while the unit is under power!

April 2006

Hardware

15

1.2.4 Dimensions of MC 422C / 5 Position Encoder Inputs and CC 422 with 6 Control Loops Note All dimensions are in millimeters [mm].

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HEIDENHAIN Technical Manual iTNC 530

1 Update Information No. 16


1.1 Overview
1.1.1 Released Service Packs The following service packs were released for 340 422-12 and 340 423-12: Service pack 4: Service pack 4: Service pack 1: Service pack 2: Service pack 3: Service pack 4: Service pack 5: Service pack 6: Service pack 7: Service pack 1: Service pack 2: Service pack 3: Service pack 4: Service pack 5: Service pack 6: Service pack 7: 1.1.2 Released NC Software The following versions of the NC software were released: NC software 340 490-03 and 340 491-03 NC software 340 492-03 and 340 493-03 NC software 340 422-13 and 340 423-13 NC software 340 480-13 and 340 481-13 NC software 340 422-14 and 340 423-14 NC software 340 480-14 and 340 481-14 June 2006 June 2006 March 2006 March 2006 May 2006 May 2006 December 2005

The following service packs were released for 340 480-12 and 340 481-12: December 2005

The following service packs were released for 340 490-02 and 340 491-02: October 2005 November 2005 December 2005 February 2006 April 2006 May 2006 July 2006 (SP 7 available as full version)

The following service packs were released for 340 492-02 and 340 493-02: October 2005 November 2005 December 2005 February 2006 April 2006 May 2006 July 2006 (SP 7 available as full version)

September 2006

Overview

11

1.2 NC Software 340 422-13/340 423-13 and 340 480-13/340 481-13


1.2.1 Description of the New Functions Machine parameters Formula input for MPs expanded The following functions are possible for entering formulas (e.g., for Machine Parameter 1054): Exponential calculation with the ^ character Example: MP1054.1:REF*0.1e^6+15 (REF in 0.0001 [mm]) Entry of x instead of REF (shorter) New: MP7691.3 Kernel-Trace Size of the log file with messages from the NC kernel. 10 files are created that are 10[MP7691.3] kilobytes large. TNC:\KLOG\ 0.log 9.log Input: Each file with 1 to 10 [KB] 0: Inactive (default) Changed: MP7420 bit 4 Cycles for milling pockets with combined contours Position after completion of the cycle. Input: 0: Tool moves to the same position as before the cycle was called 1: iTNC moves in the tool axis to the clearance height Changed: MP2630.x The input range was extended. Input: 100.000 to +100.000 [A] PLC programming New: Marker 4186 The PLC marker 4186 is set at the start of an NC program in the Test Run mode of operation. New: Marker 4187 The PLC marker 4187 is set when the Power interrupted message is displayed. It is deleted after the compilation of the PLC program. iTNC Operation and technique SHUTDOWN soft key During control start-up, the SHUTDOWN soft key is now already available in the Power interrupted state. Test current for switch-off test Before the switch-off test, the current is measured in order to determine the test current. This function can be deactivated with MP560 bit 5 = 1. Profibus diagnosis The current Profibus cycle time is displayed on the basic screen in PLC mode, provided that a Profibus is connected. HR 420 pop-up window The size of the pop-up window that appears when the HR 420 handwheel is activated was reduced so that it takes up only a small portion of the control screen.

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HEIDENHAIN Technisches Handbuch iTNC 530

Other functions

Executing cycles with two spindles Up to now, it was not possible to program certain cycles with an open-loop first spindle and a closed-looped second spindle (Cycles 13, 17, 18, 202, 204, 207, 209). These cycles can now be programmed if one of the two spindles is a closed-loop spindle. Languages The Czech texts are now displayed with language-specific special characters. Character set for Unicode The character set for Unicode was expanded. The help texts were expanded and improved. Entries into the log were expanded and improved.

September 2006 NC Software 340 422-13/340 423-13 and 340 480-13/340 481-13

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1.3 NC Software 340 422-14/340 423-14 and 340 480-14/340 481-14


1.3.1 Description of the New Functions Machine parameters New: MP7392 Time after which the screen saver becomes active Input: 1 to 99 [min] 0: No screen saver Support of the new MC 422 C hardware

iTNC Operation and technique

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HEIDENHAIN Technisches Handbuch iTNC 530

1.4 NC Software 340 490-01/340 491-01 and 340 492-01/340 493-01


1.4.1 Important Notes With the introduction of the diagnosable UM 1xxD power modules, the rated current and maximum current of some power modules were increased. The MOTOR.AMP table for power modules was therefore expanded by the new types of power modules. The increased currents were unfortunately not considered. This means that the current NC software versions contain a MOTOR.AMP to which the new types, but not the correct currents, were added. This applies to the power modules listed below: UM 112D (ID 519 971-xx) UM 122D (ID 519 972-xx) UM 113D (ID 518 703-xx) UM 114D (ID 510 509-xx) If such a power module is operated with the old MOTOR.AMP, this may result in reduced surface quality of the workpiece. Starting with service pack 1, the NC software already includes the updated MOTOR.AMP. This software, as well as the updated MOTOR.AMP, can be downloaded from the HEIDENHAIN Filebase (NC-INFO). After updating, check the settings of the affected control loops. Please also check any user-defined MOTOR.AMP on the PLC partition, which is preferably used by the control, but cannot be updated during installation of a service pack. Warning This NC software is executable only on the MC 422B and the MC 420, each with 128 MB of RAM. The BF 120 (resolution: 640 x 480 pixels) is no longer supported. 1.4.2 Service Packs The following service packs have been released: Service pack 340 490-01 SP1 340 491-01 SP1 340 492-01 SP1 340 493-01 SP1 Service pack 340 490-01 SP2 340 491-01 SP2 340 492-01 SP2 340 493-01 SP2 NC software 340 490-01 340 491-01 340 492-01 340 493-01 NC software 340 490-01 340 491-01 340 492-01 340 493-01 Release March 2005 March 2005 March 2005 March 2005 Release June 2005 June 2005 June 2005 June 2005

September 2006 NC Software 340 490-01/340 491-01 and 340 492-01/340 493-01

15

1.5 NC Software 340 490-02/340 491-02 and 340 492-02/340 493-02


1.5.1 Important Notes Upgrade functions (Feature Content Level) Until now, each new NC software version contained error fixes as well as expanded functions. Users who wanted only the NC software update to eliminate the errors often felt bothered by the expanded functions. For this reason, error fixes and expanded functions will now be handled separately within the software. If a new NC software is later loaded as an update onto a machine with NC software 340 490-01, then as the default setting only the error fixes contained will be effective. The upgrade functions will at first remain inactive. The upgrade functions can then be enabled by entering a code number. HEIDENHAIN can give you the code number after having been informed of the SIK number and NC software version. The upgrade functions are defined as feature content level (FCL) in the SIK under option #53. The first time an NC software with upgrade functionality is installed on a control (i.e. no FCL has been set in the SIK), then the entire scope of functions can be used (including the upgrade functions.). The FCL is then automatically set after 100 restarts, or by entry of the code number 0 under option #53, and all upgrade functions belonging to this software version are enabled as well. A note appears asking to confirm the installed NC software as the initial version, or if another initial software version is to be installed. If the FCL has already been set in the SIK of a control, then after an update (e.g. from software 340 490-02 to -03), the new upgrade functions of the newer software version can only be used after entry of a code number from HEIDENHAIN. After pressing the MOD key, the current status of the FCL is displayed in addition to the software versions. The FCL is incremented with each new version of the NC software. If the upgrade functions are enabled via the FCL for a software version, then all upgrade functions of this software version and all its predecessors are available. For example, if the FCL for version 340 490-03 is set, then all upgrade functions from version 340 490-02 are also available immediately.

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HEIDENHAIN Technisches Handbuch iTNC 530

If a newer software version, e.g. 340 490-06, is simply loaded onto a control, then the already existing upgrade functions remain available, but the upgrade functions of the newer version cannot be used. They must be enabled by entering a new code number.

Executability of SW 340 49x-02 Warning This NC software is executable only on the MC 422 B and the MC 420, each with 128 MB of RAM. The BF 120 (resolution: 640 x 480 pixels) is no longer supported.

September 2006 NC Software 340 490-02/340 491-02 and 340 492-02/340 493-02

17

1.6 NC Software 340 490-03/340 491-03 and 340 492-03/340 493-03


1.6.1 Important Notes Memory expansion for Feature Content Level 03 The increase of the Feature Content Level to 03 leads to problems with some of the new features if the MC does not have enough main memory. If the MC being used has no more than 128 MB of main memory, then it is not possible to activate the context-sensitive help system or the Asian languages. The first time that you activate Feature Content Level 03, a dialog window appears after the control has been booted stating that the main memory of the MC does not suffice for the context-sensitive help or the Asian languages. You can acknowledge this message with the OK soft key. If you try to call these functions in the future, the Not enough main memory error message appears. Acknowledge this error message by pressing the CE key. In order to use all features without any limitations, you must increase the main memory of your control to at least 256 MB. Please contact the HEIDENHAIN service department for this. You do not need to increase the main memory if you do not want to use the help system or the Asian languages. This does not impair any of the other features. Since February 2006, all MC 420 (index A), MC 422B (index A) and MC 422C main computers are shipped with a main memory of 256 MB. The RAM of the MC can be checked in the herosdiagnose.txt file. The RAM of the MC is listed in [kB] under the Total Memory heading. Proceed as follows to create the herosdiagnose.txt file:

While in the Programming and Editing operating mode, press the MOD key. Press the DIAGNOSIS soft key, and then the HEROS DIAGNOSIS soft key.

Going back to 340 49x-02 Software 340 49x-02 service pack 07 is available as a full version in order to go back to software 340 49x-02 from software 340 49x-03 on an MC 422C. This way you do not have to first install the 340 49x-02 basic version and then install the appropriate service pack. This would lead to a control using an MC 422C no longer being operable, since the basic version of software 340 49x-02 does not support the MC 422C. Note When going back to 340 49x-02 from 340 49x-03, install the 340 49x-02 SP7 software immediately in order to avoid problems!

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HEIDENHAIN Technisches Handbuch iTNC 530

1.6.2 Service Packs The following service packs have been released: Service pack 340 490-02 SP1 340 491-02 SP1 340 492-02 SP1 340 493-02 SP1 Service pack 340 490-02 SP2 340 491-02 SP2 340 492-02 SP2 340 493-02 SP2 Service pack 340 490-02 SP3 340 491-02 SP3 340 492-02 SP3 340 493-02 SP3 Service pack 340 490-02 SP4 340 491-02 SP4 340 492-02 SP4 340 493-02 SP4 Service pack 340 490-02 SP5 340 491-02 SP5 340 492-02 SP5 340 493-02 SP5 Service pack 340 490-02 SP6 340 491-02 SP6 340 492-02 SP6 340 493-02 SP6 Service pack 340 490-02 SP7 340 491-02 SP7 340 492-02 SP7 340 493-02 SP7 NC software 340 490-02 340 491-02 340 492-02 340 493-02 NC software 340 490-02 340 491-02 340 492-02 340 493-02 NC software 340 490-02 340 491-02 340 492-02 340 493-02 NC software 340 490-02 340 491-02 340 492-02 340 493-02 NC software 340 490-02 340 491-02 340 492-02 340 493-02 NC software 340 490-02 340 491-02 340 492-02 340 493-02 NC software 340 490-02 340 491-02 340 492-02 340 493-02 Release October 2005 October 2005 October 2005 October 2005 Release November 2005 November 2005 November 2005 November 2005 Release December 2005 December 2005 December 2005 December 2005 Release February 2006 February 2006 February 2006 February 2006 Release April 2006 April 2006 April 2006 April 2006 Release May 2006 May 2006 May 2006 May 2006 Release July 2006 July 2006 July 2006 July 2006 19

September 2006 NC Software 340 490-03/340 491-03 and 340 492-03/340 493-03

1.6.3 Description of the New Functions New options and upgrade functions The following options are enabled by entering a code number. HEIDENHAIN can give you the code number after having been informed of the SIK number. Option #41 Description Additional Languages The following languages are now available as additional dialog languages: Slovak Latvian Norwegian Korean Estonian #44 Global PGM Settings: Possibility of superimposing various coordinate transformations and settings in the program-run modes of operation. AFC Adaptive Feed Control: With adaptive feed control the TNC automatically regulates the contouring feed rate after a teach-in cut depending on the respective spindle power in percent. 530 184-02 530 184-03 530 184-04 530 184-06 530 184-07 576 057-01 ID

#45

579 648-01

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HEIDENHAIN Technisches Handbuch iTNC 530

Option #53

Description Upgrade functions as Feature Content Level 03 (FCL), see page 1 6 TNCguide, context-sensitive help system (user documentation) smarT.NC functions: Feed-rate reduction during machining of contour pockets When clearing out a contour pocket, traverse paths where the tool is in full engagement result, such as in narrow channels or when shifting to the next clearance path. Now you can define a percent value by which the TNC reduces the feed rate in such situations. New UNITs for presetting The new UNITs 408 and 409 are available for presetting in the center of a slot or a ridge. Contour pocket on point pattern The new UNIT 130 was introduced with which any contour pocket can be machined on any point pattern. Parallel programming In the Programming and Editing mode of operation you can now also use the smarT.NC user interface. If an .HU program is selected, the TNC automatically starts smarT.NC. If you want to open an .HU program with the plain language dialog editor, use the OPEN WITH function in order to select which editor the TNC should start. Behavior between two machining points An approach height can now be defined for each machining point in a point pattern. The TNC then approaches this position at the height you defined. Use: Moving over chips or other hindrances Plain-language programming functions: Feed-rate reduction during machining of contour pockets When clearing out a contour pocket, traverse paths where the tool is in full engagement result, such as in narrow channels or when shifting to the next clearance path. Now you can use parameter Q401 to define a percent value by which the TNC reduces the feed rate in such situations.

ID 529 969-01

September 2006 NC Software 340 490-03/340 491-03 and 340 492-03/340 493-03

1 11

Option #53

Description Upgrade functions as Feature Content Level 03 (FCL), see page 1 6 Touch probe functions: New probe cycles for presetting The new touch-probe cycles 408 and 409 are available for presetting in the center of a slot or a ridge. New 3-D probing cycle The new touch-probe Cycle 4 is available, with which you can perform a measurement in three dimensions. You define the direction of traverse via three incremental traverse paths in X, Y and Z. You can receive the results of the measurement in either the workpiece or the machine coordinate system.

ID 529 969-01

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HEIDENHAIN Technisches Handbuch iTNC 530

Machine parameters

New: MP732 Axis-error compensation for rotary axes With MP732, the non-linear axis-error compensation (activated via MP730) can be projected onto the traverse range for a specific axis. This is especially useful when using rotary axes with a limited traverse range. Instead of the previous range of 0 to 360, you can now make entries of 90 to +90, for example. Input: %987654321 bit-encoded 0: Previous behavior 1: Active New: MP1012.x Second axis-specific rapid traverse With MP1012.x you can enter a second axis-specific rapid traverse as an alternative to MP1010.x. Use the FN17: SYSWRITE ID 20 NR 18 = <value> function to switch between the two machine parameters. MP1012 can only be used in the Program Run, Single Block, Program Run, Full Sequence and MDI operating modes. <value> = 0: MP1010 and MP1011 active <value> = 1: MP1012 active, MP1011 not active, meaning that the possible increase in the contouring feed rate is not limited. The rapid traverse from MP1010 in connection with MP1011 is always active at program end and when a program is first selected. Input: 10 to 300 000 [mm/min or /min] New: MP1085.x Axis-specific jerk for contouring movements With MP1085.x you set an axis-specific maximum permissible jerk for motions in the Program Run, Single Block, Program Run, Full Sequence and MDI operating modes, as long as the feed rate is not equal to FMAX or is less than the value in MP1092. Until now, this value was set for all axes in MP1090.0. The value in MP1090.0 will continue to be used as the maximum permissible jerk for motions in all axes. Even with interpolating axes this value is the maximum jerk for the entire machine. The formula shown can be used to calculate a guide value for MP1085. The formula is conceived for the calculated jerk to be large enough that the acceleration of the axis is not impaired. Input:0.1 to 1000 [m/s3]
2

MP1060 60000 MP1085 -----------------------------------------------MP1010

September 2006 NC Software 340 490-03/340 491-03 and 340 492-03/340 493-03

1 13

New: MP1086.x Axis-specific jerk for rapid-traverse movements With MP1086.x you set an axis-specific maximum permissible jerk for motions in the Program Run, Single Block, Program Run, Full Sequence and MDI operating modes, if the feed rate is equal to FMAX or is greater than the value in MP1092. Until now, this value was set for all axes in MP1090.1. The value in MP1090.1 will continue to be used as the maximum permissible jerk for rapid-traverse movements in all axes. Even with interpolating axes this value is the maximum jerk for the entire machine. The formula shown can be used to calculate a guide value for MP1086. The formula is conceived for the calculated jerk to be large enough that the acceleration of the axis is not impaired. Input: 0.1 to 1000 [m/s3] 0: Not active (then also for FMAX value in MP1085.x)
2

MP1060 60000 MP1086 -----------------------------------------------MP1010 Note HEIDENHAIN recommends entering the permissible jerk for each axis in MP1085.x and MP 1086.x. This way the jerk is based on the weakest axis participating in a motion. The value in MP1090.x should be chosen correspondingly greater than until now (340 49x-02) or greater than the largest axis-specific jerk (or the value 0 should be entered to omit limiting by MP1090.x) so that the control has the possibility of using the optimum jerk and therefore the optimum acceleration for interpolating axes. If you enter a jerk for one or more axes (e.g. rotary axes) that is lower than the value previously (before 340 49x-03) entered in MP1090.x, reduced speeds can occur during contouring movements. However, this behavior only occurs if you used MP1090.x to subject axes to a greater than ideal load for the axes. If you want to avoid this behavior, then you must enter the same values in MP1085.x or MP1086.x and MP1090.x, which results in the same behavior as previously (340 490-02). However, this leads to a loss of the speed advantage gained with the interpolation of axes with NC software 340 49x-03. The calculated path jerk is always to the smallest axis-specific jerk of the participating axes. New: MP1205 Reduction of the starting feed rate MP1205 was introduced in order to lower the contouring feed rate at the beginning of a contour element. This slower contouring feed rate can be used to improve the accuracy when machining corners at contour transitions. MP1205 is only in effect if MP7684 bit 10 = 0, which activates the changed calculation of the feed rate for the beginning of a contour element. Input: 0: Not active (fast but somewhat less precise) 1: Active (slow but likely more precise) New CC 424: MP2184.x Reserved Input: 0 New CC 424: MP2186.x Speed-dependent switching of the PWM frequency MP2186.x specifies the shaft speed at which the PWM frequency 5 kHz is switched to twice the PWM frequency (see page 1 64). Input: 0 to 100 000 [rpm]

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HEIDENHAIN Technisches Handbuch iTNC 530

New CC 424: MP2188.x Speed-dependent switching of the PWM frequency MP2188.x specifies the shaft speed at which the original PWM frequency ( 5 kHz) is returned to (from twice the PWM frequency > 5 kHz as the result of MP2186.x). MP2188.x must be < MP2186.x (see page 1 64). Input: 0 to 100 000 [rpm] New CC 424: MP2192 Trigger threshold for LIFTOFF With MP2192 you enter a percent value of the dc-link voltage Uz as trigger threshold for the detection of a powerfail. If the dc-link voltage Uz drops below the value resulting from MP2192, an NC stop and LIFTOFF are performed. If you enter the value 0 for MP2192, only the UV ready signal is monitored. If you enter a value in MP2192 greater than the typical value of 400 V for a powerfail, LIFTOFF is performed correspondingly earlier and with more energy in the dc-link. MP2192 must be > MP2194. The entered value must be > 400 V for this function to be useful. HEIDENHAIN recommends a value of 80%. Input: 0 to 100 [%] Warning This function can only be used in combination with regenerative HEIDENHAIN inverters. Refer to the notes about the LIFTOFF function in the Technical Manual. New CC 424: MP2194 DC-link voltage as of which the spindle is braked in a powerfail With MP2194 you enter a voltage value in [V] of the dc-link voltage. If the dclink voltage Uz drops below the value in MP2194, the spindle is actively braked. Normally energy is recovered during braking of the axes with LIFTOFF. This does not apply to linear motors with poor efficiency. Here energy is needed in order to brake an axis. This means that a load is placed on the dc-link during the braking procedure. In certain circumstances this can mean that there is no longer enough energy to perform LIFTOFF. The only energy source in the system may be a rotating spindle. If the dc-link voltage drops below the value in MP2194, the spindle is braked and energy is recovered. This should make enough energy available in order to perform LIFTOFF completely. The entered value must be > 400 V for this function to be useful. HEIDENHAIN recommends a value of 450 V. Input: 0 to 3000 [V] Warning This function can only be used in combination with regenerative HEIDENHAIN inverters. New: MP2208.x Inductivity of the series reactor With MP2208.x you can overwrite the value for Inductivity of the series reactor L in the motor table. Input: * = Entry from the motor table active Value of the series reactor in [H]

September 2006 NC Software 340 490-03/340 491-03 and 340 492-03/340 493-03

1 15

New: MP2209.x Mass moment of inertia of a drive motor With MP2209.x you can overwrite the value for Mass moment of inertia J in the motor table. This makes it possible to react to additional, rigidly coupled inertias. Input: * = Entry from the motor table active Value of the mass moment of inertia in [kgm2] New CC 424: MP2640.x Torsion compensation With MP2640.x you can perform a torsion compensation between the position and speed measuring systems. The torsion compensation regulates the difference in position that results from the elasticities between the motor (rotary encoder) and the position measuring system. An additional torsion motion is added to the speed controller. In MP2640.x you enter a factor for each drive for the elasticity. HEIDENHAIN recommends using MP2640 as a replacement for MP2606, since MP2640 can be used to take additional effects into account. Input: 0.001 to 30.000 [m/A] 0: Not active The block diagram shows how the torsion compensation works:

1: Torsion compensation 2: Position controller 3: Speed controller 4: Current controller power module 5: Motor 6: Elastic coupling 7: Machine 8: Linear encoder

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HEIDENHAIN Technisches Handbuch iTNC 530

New: MP3350 and MP3351 Monitoring of the spindle speed With MP3350 and MP3351 you set the maximum permitted excess spindle speed. An NC stop with a subsequent emergency stop is trigged if the actual spindle speed is greater than the nominal spindle speed + the permitted excess speed. With this function you can also have the spindle be monitored for unexpected start-up. In MP3350 you enter a relative value in percent, and in MP3351 as absolute value, for the permissible excess speed. The absolute value in MP3351 is only used if the absolute value that results from MP3350 is less than the value in MP3351. If you want to use monitoring of the spindle speed for spindles with gear stages, then you should be more generous with the tolerance that results from MP3350 and MP3351, since the spindle speed can vary significantly when switching between the gear stages. Input MP3350: 0 to 100 [%] Input MP3351: 0.001 to 100 000.000 [rpm] 0: Monitoring off

New: MP3530 and MP13530 Increased spindle power for roughing With MP3530 and MP13530 you can avoid a reduction in the maximum spindle power during roughing due to changes in load when the tools teeth are engaged in the material. Here the spindle speed is increased higher than previously when there is no load. It is now increased above the nominal speed, which was not the case previously. Energy is stored in the inertia of the spindle, and is then available when the teeth engage the material. This increases the mean power, and the mean speed corresponds to the nominal speed. If MP3530 or MP13530 are set, an overshoot can occur when the nominal speed is reached. If this overshoot impairs the performance, then you may have to deactivate the increase of the spindle power. Input: 0: Not active 1: Increased spindle power for roughing

September 2006 NC Software 340 490-03/340 491-03 and 340 492-03/340 493-03

1 17

Expanded: MP4310.x Miscellaneous PLC parameters The input range was expanded with the MP4310.7, MP4310.8 and MP4310.9 indexes. These are saved to the corresponding PLC memories. MP4310.7 to M4412-M4427 or W990 MP4310.8 to M4428-M4443 or W992 MP4310.9 to M4444-M4459 or W994 Expanded: MP7230.x Conversational language MP7230.18 = Norwegian (Option #41) MP7230.19 = Slovak (Option #41) MP7230.20 = Latvian (Option #41) MP7230.21 = Korean (Option #41) MP7230.22 = Estonian (Option #41) New: MP7246 bit 3 Settings file for AFC (Adaptive Feed Control) By setting MP7246 bit 3, the *.H.AFC.DEP table for control settings is generated for the adaptive feed control in a teach-in cut. Input: 0: Do not generate settings file for AFC 1: Generate settings file for AFC New: MP7263 bit 2 Display the Edit ON/OFF soft key in the pocket table MP7263 bit 2 can be used to hide the Edit ON/OFF soft key when displaying the pocket table. This makes it possible to prevent manual editing of the pocket table. Input: 0: Display soft key 1: Do not display soft key New: MP7362.4 Background: Unselected tab You can use MP7362.4 to select the color of the unselected tabs in the graphics window. Default setting: $0C0C0C0 New: MP7392.1 Type of screen saver With MP7392.1 you select the type of screen saver that starts after the time in MP7392.0 expires. Input: 0: No screen saver 1: Default screen saver of the X server 2: 3-D line graphics New: MP7432 Limit-switch tolerance for M140/M150 With MP7432 you can enter a tolerance for the limit switches. The limit switches can then be traversed with M140/M150 by this tolerance without an error message. Retraction with M140/M150 can still be performed if a limit value has been entered and the axes are still within the tolerance. If the axes are still within the tolerance, they can even be moved outside of the traverse range, but only to another limit switch. If one or more axes that are already slightly outside the limit-switch range are to be moved to the same limit switch, the axes are not moved. No limitswitch error message appears if the axes are still within the tolerance of the limit switch. Input: 0.0001 to 1.0000 [mm] 0: Limit-switch tolerance off New: MP7483 Tool name/number for TOOL CALL With MP7483 you specify if the tool name or number or both can be used for TOOL CALL/TOOL DEF. For example, if a tool number is used even though only tool names are allowed (MP7483 = 1), an NC error message is output. Input: 0: Names and numbers are permitted (as before) 1: Only names are permitted 2: Only numbers are permitted 1 18 HEIDENHAIN Technisches Handbuch iTNC 530

New: MP7506 Selection of kinematics at booting With MP7506 you can make an advance selection of which entry in the kinematics table is to become active when the control is booted. Selection is made by entering the line number of the desired kinematics in KINELIST.TAB. Input: 0 to 999 1: Function not active Note Please note that with this feature, the same kinematics are always active whenever the control is booted. If you change the actual kinematics of the machine before booting, this is not taken into account. The kinematics set via MP7506 are still active after booting even after such a change. New: MP7630 Recovery time after EMERGENCY STOP test is configurable If you use protective contactor combinations, this may lead to problems if the EMERGENCY STOP test is also performed with these combinations. The reason for this is the recovery time of such assemblies after an emergency stop. In some cases it is greater than 200 ms. In order to maintain these specifications, the Control is ready output (X41/34) remains off for the time in MP7630 after detecting the 0 level at the control-is-ready signal acknowledgment input (X42/4). This time for step 4 (see flowchart) can now be configured in MP7630. This time is to be set so that the protective contactor combinations can become ready again. Input: 0: Previous behavior 1 to 999 [ms]

X41/34

X42/4 1 2 3 4 5 6 7 8 9

New: MP7672.x HR 410, distance per handwheel step If MP7641 bit 1 is set, then with MP7672.x you can set the distance per handwheel step for the HR 410. Different distances per step can be set for three speed stages. Input: 0.0000 to 1.0000 [mm] New: MP7674.x Handwheel subdivision factor MP7674.x can always be used to set a minimum axis-specific subdivision factor for the HR 130, HR 330, and HR 332. It can be used for the HR 410 if MP7641 bit 1 is not set (without detent encoder). Input: 0: No limitation 1 to 10

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New: MP7675.x Handwheel maximum distance MP7675.x has no meaning for the HR 130, HR 330, or HR 332. If MP7641 bit 1 is set (with detent encoder) for the HR 410 or HR 420 , then a maximum distance in [mm] per detent can be entered for each axis. If MP7641 bit 1 is not set (without detent encoder) for the HR 420 , then a maximum distance in [mm] per handwheel revolution can be entered for each axis. These limitations serve to prevent the movement monitoring from becoming active because of abrupt motions resulting from handwheels with large gear ratios on axes with poor dynamics. Input: 0: No limitation 0.0001 to 10.0000 [mm] New: MP7682 bit 8 Behavior of M8 You can control the behavior of M8 at the end of cycles 202 and 204 with MP7682 bit 8. Input: 0: At the end of cycles 202 and 204, the status of M8 is restored to that before the cycle call (behavior unit now). 1: At the end of cycles 202 and 204, the status of M8 is not restored automatically. New: MP7682 bit 9 Load tilted working plane With MP7682 bit 9 you control whether the status of the Tilt working plane function in an NC program is loaded into the Manual operating mode during a program interruption. Input: 0: The status of the Tilt working plane function is not loaded into the Manual operating mode during a program interruption (behavior until now). 1: The status of the Tilt working plane function is loaded into the Manual operating mode during a program interruption. New: MP7684 bit 10 Modification of the calculation of the contouring feed rate MP7684 bit 10 introduced a modified calculation of the contouring feed rate at the beginning of a contour element. The modified calculation improves the surface quality at contour transitions, which can lessen the accuracy at corners. This can be deactivated by setting MP7684 bit 10. Input: 0: Active 1: Previous behavior New: MP13350 and MP13351 Monitoring of the spindle speed With MP13350 and MP13351 you set the maximum permitted excessive spindle speed. (see MP3350 and MP3351) Input MP13350: 0 to 100 [%] Input MP13351: 0.001 to 100 000.000 [rpm] 0: Monitoring off Changed: MP1090.x Limiting the path jerk Limits the path jerk that results from MP1085.x or MP1086.x. MP1090.0 takes effect for movements not at FMAX or when the feed rate is less than the value in MP1092. MP1090.1 takes effect for movements at FMAX or when the feed rate is greater than the value in MP1092. This limitation can be switched off by entering the value 0 in MP1090.x. Input: 0.1 to 1000 [m/s3] 0: Not active Changed: MP1820 and MP1830 Multiplication factor and characteristic curve kink point The characteristic curve kink point for operation with servo lag, defined via MP1820 and MP1830, can now also be used with the CC 424.

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Changed: MP1092 Feed-rate threshold for MP1085.x and MP1086.x With MP1092 you specify a feed-rate threshold for the various jerk parameters in MP1085.x and MP1086.x. If the programmed feed rate is less than the value in MP1092, the parameters in MP1085.x apply. If the programmed feed rate is greater than the value in MP1092, the parameters in MP1086.x apply. This way you have the same behavior as previously for all axes via MP1090.0 and MP1090.1. Enter the value 0 in MP1092 to deactivate this feed-rate limit. Then the jerk parameters from MP1085.x apply to movements not at rapid traverse. The values in MP1086.x become active for movements at FMAX. Input: 1 to 300 000 [mm/min] (behavior until now) 0: Not active Changed: MP2050 Functionality of drive enabling MP2050 can now also be overwritten by the PLC or the LSV2 protocol. Changed: MP2100 Type of axis power modules A change to MP2100 no longer leads to an automatic restart. Changed: MP2150 Powerfail MP2150 can now also be overwritten by the PLC or the LSV2 protocol. Changed: MP2182.x Current controller cycle time Set MP2182.x = 2 if you want to use automatic PWM frequency switching. The PWM frequency of a power stage is then doubled at a certain speed, based on a PWM frequency 5 kHz. In MP2186.x and MP2188.x you define the speeds at which switching occurs. The current controller cycle time is always (if MP2182.x = 2) based on the high PWM frequency. Changed: MP2195 Suppress error message of the HEIDENHAIN supply units MP2155 can now also be overwritten by the PLC or the LSV2 protocol. Changed: MP2420.x Proportional factor for the current controller Automatic calculation of the P factor for synchronous and asynchronous motors is now possible. Automatic calculation is not to be used for linear synchronous and torque motors. The calculated value is entered in the MP file. An * is appended to the calculated value to show that the parameter was determined automatically. Input: 0 to 9999.99 [V/A] * = automatic calculation of the P factor Changed: MP2430.x Integral factor for the current controller Automatic calculation of the I factor for synchronous and asynchronous motors is now possible. Automatic calculation is not to be used for linear synchronous and torque motors. The calculated value is entered in the MP file. An * is appended to the calculated value to show that the parameter was determined automatically. Input: 0 to 9999.99 [V/A] * = automatic calculation of the I factor Changed: MP2630.x Holding current for vertical axes The input range was extended. Input: 100.000 to +100.000 [A] Changed: MP3142 and MP13142 Line count of the rotary encoder on the spindle The input range was extended. Input: 100 to 100 000 [lines] Changed: MP7260 to MP7267 MP7260 to MP7267 can now also be overwritten by the PLC or the LSV2 protocol.

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Changed: MP7261.x Size of the pocket tables The input range was extended. Input: 0 to 9999 Changed: MP7246 bit 0 MP with multiple function Disabling of the generation of paraxial positioning blocks via MP7246 bit 0 is available again. Input: 0: Generation permitted 1: Generation not permitted Changed: MP7266.x Tool table: Tool data The input range was extended by the index MP7266.40. MP7266.40 for AFC: Control strategy name for Adaptive Feed Control Removed: MP7235 Time difference to the Universal Time set in the BIOS This is now realized with the Set System Time dialog box. Open this dialog box by pressing the MOD key in the Programming and Editing operating mode, and then the SET DATE/TIME soft key.

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PLC programming Warning HEIDENHAIN would like to point out the following information for the processing of signals in the PLC: For all PLC markers, the status 0 (not set) must be used as the safe status. Only this way can the safety of a machine be ensured if the power fails. The following must be kept in mind for remanent markers: Remanent markers, bytes, words and double words can also be deleted (e.g. if the buffer battery is empty). In order to detect this state, we recommend setting a flag marker in the remanent memory. Set this marker once, at a time when it is ensured that all signals in the PLC are valid. This marker should be used as a reference in the PLC program. As long as this marker is set, the remanent markers have not been deleted (e.g. by an empty buffer battery or an error in the PLC). If this flag marker is deleted, all remanent markers are invalid. An appropriate safety reaction with an error message must occur if this happens. In order to attain an optimum level of safety for your machine and the operator, HEIDENHAIN recommends the combined use of these safety measures. In connection with this, a possibility for outputting the cause of the last PLC run-time error was introduced. PLC word W1002 can be used to determine the last PLC run-time error that led to the stop of PLC program execution. If a PLC run-time error occurs, the generated error code is saved in W1002 and simultaneously in the remanent memory of the control. When a new PLC runtime error occurs, W1002 and the value in the remanent memory are overwritten. If the control is restarted or a PLC program start is triggered in some other manner (by Compile, Restart PLC or acknowledgment of PLC run-time errors), the value in W1002 regenerates itself via the information in the remanent memory. Once the value has been entered in W1002 again, this information is deleted from the remanent memory. This way the last PLC run-time error is always available in W1002, even after the PLC is restarted. In addition, the error code can already be seen in the PLC table as early as in the Power interrupted status after the control has been restarted. The error code in W1022 can be output and evaluated in the PLC program. The following applies to the evaluation of the error code, which should be performed during the first PLC run-through: W1002 = 0: No PLC run-time error occurred before the last PLC program start W1002 = 1: Error information in W1002 is invalid (e.g. because of an error in the hardware). If necessary: Implement safety reaction. W1002 50: PLC run-time error with number code (see the PLCdesignNT help for the error name). If necessary: Implement safety reaction.

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Configuration data of the PLC You use the PLC configuration file to influence the memory allocation of the control and change the configuration data of the PLC. Enter certain keywords to perform changes. After compilation by the PLC, the NC detects the changed settings, and the control must be restarted. The values you enter may only be greater than the default values. Available keywords: Keyword DEFINE Description Configuration definitions for controlling the conditional compilation, soft-key menu generation and cycle-project configuration. System parameters that may not be changed are identified by a preceding and following $ character. Depending on which options have been set, they are defined via the compiler and can be used for conditional compilation. For more information about this, please refer to the PLCdesignNT help. Start address of the bytes, words or double words whose data remains stored after a power interruption (remanence). Default value: 0 End address of the bytes, words or double words whose data remains stored after a power interruption (remanence). The range defined by REMBYTEMIN and REMBYTEMAX may not be larger than 1024 bytes. Default value: 1 = Deactivated REMBYTEMIN = 0 Example

REMBYTEMIN

REMBYTEMAX

REMBYTEMAX = 200

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Keyword REMMARKERMIN

Description Start address of the markers whose data remains stored after a power interruption (remanence). Default value: 0 End address of the bytes, words or double words whose data remains stored after a power interruption (remanence). The range defined by REMMARKERMIN and REMMARKERMAX may not consist of more than 2048 markers. Default value: 1 = Deactivated A total of 100 000 bytes is available for all keywords, timers, counters and strings combined Number of markers available. Default value: 10000 Size in bytes for the byte/word/double word memory. Default value: 10000 Number of input markers available. Default value: 384 Number of output markers available. Default value: 192 Size in bytes for the byte/word/double word memory range used by the Profibus inputs. Default value: 1000 Size in bytes for the byte/word/double word memory range used by the Profibus outputs. Default value: 1000

Example REMMARKERMIN = 0

REMMARKERMAX

REMMARKERMAX = 150

MARKERS

MARKERS = 15000

BYTES

BYTES = 20000

INPUTS

INPUTS = 450

OUTPUTS

OUTPUTS = 250

INPUTBYTES

OUTPUTBYTES

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Multiple I/O-Force Lists possible It is now possible to make multiple lists available for the I/O Force function in the PLC operating mode. If an I/O Force List is open, press the PGM MGT key to switch to an existing list or create a new list. Create a new I/O Force List by entering a new file name with the extension .FLT. The selected list is identified by the automatically generated FORCELISTPATH = PLC:\*.FLT entry in OEM.SYS. M4623 Disable DNC operation The start of DNC operation can be disabled with the PLC. Set the marker M4623 in order to disable the start of DNC operation via an LSV2 connection. This setting can be interrogated via an LSV2 telegram. W274 Keys for spindle speed override If +/ and 100% keys are used for the spindle-speed override, then it can be seen in W274 if these keys are pressed. Value 256 for the 100% key, value 257 for the + key and value 258 for the key. FN18 ID20 NR13 You can use the FN 18: SYSREAD Q<no.> = ID20 NR13 function to interrogate the number of the active spindle (0 or 1). FN18 ID30 NR52 You can use the FN 18: SYSREAD Q<no.> = ID30 NR52 IDX <NR> function to ascertain whether a string or a numeric value was transferred in the <NR> Q-parameter number. If <NR> was used to transfer a tool number, the function returns 0, and if a tool name was transferred the function returns 1. FN18 function ID990 NR10 must be used to convert a tool name to the corresponding tool number for further processing. FN18 ID990 NR10 You can use the FN 18: SYSREAD Q<no.> = ID990 NR10 IDX <NR> function to ascertain the tool number that belongs to the tool name contained in <NR.>

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Example of how the FN18 functions for tool name and number can be used. In this example the Q-parameter number Q330 could have been transferred as a string or a number from a cycle. The following example can be used for further processing: ... FN 9: FN 18: IF +Q330 EQU +0 GOTO LBL 131 SYSREAD Q35 = ID1000 NR7483 Interrogate MP7483 whether tool name and number are permitted Interrogate if the tool name is programmed No tool name programmed Tool name programmed Tool name is not permitted

FN 18: FN 9: FN 10: FN 14: LBL 46 FN 18:

SYSREAD Q30 = ID30 NR52 IDX330 IF +Q30 EQU +0 GOTO LBL 45 IF +Q35 NE +2 GOTO LBL 46 ERROR = 1094

SYSREAD Q330 = ID990 NR10 IDX330

Determine the tool number for the tool name

FN 10: FN 14: LBL 45 FN 10: FN 9: FN 14: LBL 34 FN 18: ...

IF +Q330 NE -1 GOTO LBL 34 ERROR = 1092 No tool number could be found

IF +Q35 NE +1 GOTO LBL 34 IF +Q330 EQU +0 GOTO LBL 34 ERROR = 1093 Tool number = 0 always permitted Tool number not permitted

SYSREAD Q0 = ID50 NR22 IDX330

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FN18 ID56 NR4 You can use the FN 18: SYSREAD Q<no.> = ID56 NR4 function to ascertain the number of lines of a freely definable table opened with FN26: TABOPEN. The function returns the value 1.0 if no table is open at the time of reading. FN18 ID240 NR8 You can use the FN 18: SYSREAD Q<no.> = ID240 NR8 IDX <NR> function to ascertain the current ACTUAL positions of the axes in the REF system. With IDX <NR> from 1..9 the coordinates of the axes X, Y, Z, A, B, C, U, V and W are read. FN18 ID990 NR4 You can use the FN 18: SYSREAD Q<no.> = ID990 NR4 function to interrogate whether the touch probe is deflected. If it is deflected, the value 1.0 is returned. If not, the value 0.0 is returned. FN17 ID53 NRxxx With FN 17: SYSWRITE ID 53 NRxxxx IDXxxxx = <value> you can edit all the data of all indexes of an indexed tool. The function behaves like FN 17 ID50, only that here the same value is written to all indexes. With NRxxxx you indicate a column of the active tool table and with IDXxxxx a tool number of the indexed tool for which <value> is written to all indexes. The following NC block is used to completely disable all indexes of the current indexed tool: FN 17: SYSWRITE ID 53 NR7 = 1.0. FN17 ID290 NR5 With FN 17: SYSWRITE ID 290 NR5 = <value> you can transfer <value> = 0 to deactivate the temperature compensation in the kinematics table. It can be activated again with <value> = 1. Temperature compensation is always active if the program is interrupted. FN17 ID622 NR0 With FN 17: SYSWRITE ID 622 NR0 IDX1.0 = <value> you can transfer a <value> for the time in seconds after which the teach-in cuts for AFC are ended automatically. The function behaves like the pressing of the EXIT LEARNING soft key after the appropriate time. This function is deactivated again by programming <value> = 0. FN17 ID2020 NR1 FN 17: SYSWRITE ID 2020 NR1 makes it possible for you to set PLC markers M4030 and M4031 for tapping. This way a brief resetting of marker M4031 in Cycle 209 can be prevented. FN17 ID1000 FN 17: SYSWRITE ID 1000 NR<MP number> IDX<MP index> = <value> makes it possible to change machine parameters in the process memory. The change remains in effect until a reboot is performed or an MP file or MP subfile is selected, writing a new value to the MP. The unit of the <value> must be the same as the unit of the MP in the MP file. Note When reading or writing machine parameters with the FN17/FN18 function ID1000, the value of corresponding MPs are always read and written in millimeters, even if inches are used in the NC program instead of millimeters.

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New soft key within the WATCH LIST function: The new TABLE soft key is available in the third soft-key row. Select any operand in the WATCH LIST. Press the TABLE soft key to get directly to the selected operand in the table of the PLC memories. Symbolic names with more than 24 characters in the WATCH LIST Names for operands with more than 24 characters can now by entered in the SYMBOL column of the WATCH LIST without getting an error message. Characters after the 24th position (number of significant characters) are truncated.

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PLC modules

Changed: Module 9035 (Reading the status information) Module 9035 with index 4 (displayed screen window) now supplies in bits 4 and 12 the information of whether the PLC status window is being displayed. Bit 4 always = 0, since the window can never be displayed Bit 12 = 1: PLC status window present in the machine screen Changed: Module 9158 (Torque limiting by the PLC) Error code 2 is now also returned in W1022 for Module 9158 if the axis number of an axis is invalid, if it is an open-loop axis, or if it is temporarily not a closed-loop axis. Changed: Modules 9180 to 9184 (Simulation and disabling of keys and key groups) The modules 9180, 9181, 9182, 9183 and 9184 now also support vertical soft keys. This is achieved in Modules 9183 and 9184 with the new keygroup code 7 (vertical soft keys, switchover key for vertical soft keys). Changed: Module 9222 (Status request of PLC positioning movement) In the Program Run modes, Module 9222 reports with value 6 the status PLC positioning temporarily halted (stop in the Automatic operating modes). Changed: Module 9245 (Read a field from a table) Module 9245 and the tableread function (PLC screen masks) can now be used to read data, including strings, from system tables like the tool table and pocket table (*.T and *.TCH). Data can be read from all freely definable tables. The error codes have changed accordingly: Marker M4203 W1022 Value 0 1 1 2 3 7 20 29 30 Meaning Field was read Error code in W1022 Line does not exist in table Incorrect file handle or table was opened in buffered mode Impermissible string numbers Module could not read from the table Module was not called in a spawn or submit job The opened file is not a valid table Field name does not exist in table

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Module 9048 Interrogating the operating states of axes Module 9048 is used to interrogate the operating state of a certain axis or for all axes together. Call: PS B/W/D/K <Axis number> Axis number: Individual information for a programmed axis 1: Information for all axes, bit-coded as axis mask B/W/D/K <Status information> 0: Brake test active/inactive 1: Free rotation active/inactive 9048 B/W/D <Status> Interrogation of an individual axis: 1/0 = active/inactive Interrogation of all axes: Bit-coded axis mask

PS

CM PL

Error recognition: Marker M4203 W1022 Value 0 1 1 2 Meaning Status has been read Error code in W1022 Invalid value for status information Invalid axis programmed: If status information 0 was transferred, then this error occurs if an invalid axis number, an open-loop axis or an axis that is temporarily not a closed-loop axis was selected. If status information 1 was transferred, then this error occurs if an invalid axis number, an open-loop axis or an axis that is temporarily not a closed-loop axis was selected, or if a slave axis or the NC axis is not a rotary axis.

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Module 9064 Status information about collision monitoring With Module 9064 you interrogate whether collision monitoring is active in the currently selected operating mode. Call: PS B/W/D/K <Mode> 0: Interrogation of DCM status in the current operating mode 9064 B/W/D <Status information> With Mode 0 0: Monitoring not active 1: Monitoring active

CM PL

Error recognition: Marker M4203 W1022 Value 0 1 1 Meaning Status has been read Error code in W1022 Invalid value for mode

Module 9065 Status of the commissioning function (expanded) Module 9065 is used to activate commissioning functions and ascertain status information dealing with the determination of the field angle of an axis. Conditions: Synchronous, linear and torque motors determine the field angle each time the control is started if no EnDat or Z1-track encoders are used. For the duration of determining the field-angle (about 5 to 7 seconds), <Mode> 1 returns bit-coded the axes for which field-angle determination is active. Module 9162 reports that the rotary encoder is not ready while the field angle is being determined. A PLC error message can be suppressed if determining is active. Call: PS B/W/D/K <Mode> 0: Axes for which the field angle is being determined with a commissioning aid and an internal oscilloscope 1: Axes for which automatic determination of the field angle is active 9065 B/W/D <Axes bit-coded>

CM PL

Error recognition: Marker M4203 W1022 Value 0 1 1 Meaning Axes have been determined Error code in W1022 Invalid value for mode

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Module 9066 Status of HEIDENHAIN hardware (changed) Module 9066 interrogates the status information of HEIDENHAIN hardware components, including the SIK component. The module can only be called in cyclic PLC programs. Call: PS B/W/D/K <Code for hardware components> 0: HEIDENHAIN inverter 1: SIK ID 9066 B/W/D <Status information> Code 0: HEIDENHAIN inverter Bit 0: Not used Bit 1: dc-link voltage too high Bit 2: Heat sink temperature too high Bit 3: Short-circuit of a motor phase with Uz Bit 4: dc-link current too high Bit 5: Power supply unit not ready Bit 6: Leakage current too high Code 1: SIK ID

CM PL

Error recognition: Marker M4203 W1022 Value 0 1 2 24 Meaning Status has been read Error code in W1022 Invalid value for code Module was called in a spawn or submit job

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Module 9128 Torque limiting by the PLC Module 9128 can be used to program a maximum torque for the programmed axis. The torque of the drive is limited to the programmed value. The value 1 cancels the torque limitation and the value from the motor data becomes effective again. The torque can be limited in [mA] or in [0.1%] of the rated current. Condition: The module is only executable in the cyclic PLC program. The programmed value for the maximum torque may not be higher than the value in the motor data. If the programmed value is higher than the value in the motor data, the value in the motor data is used as the limit. A torque value of 0 cannot be programmed. Programming a torque value of 1 cancels limitation. The original value from the motor data becomes effective again. The unit of the resulting torque is [mA]. If a drive is switched off, the torque from the motor data becomes effective when it is switched on again. Call: PS B/W/D/K <Mode> 0: Current in [0.1%] of the rated current 1: Current in [mA] (like Module 9158) B/W/D/K <Axis number> 15: Spindle B/W/D/K <Torque> 1: Cancel the torque limiting 9128

PS PS CM

Error recognition: Marker M4203 W1022 Value 0 1 1 2 24 Meaning Torque limiting programmed Error code in W1022 Invalid value for torque Invalid value for axis number or mode, axis is an openloop axis or is temporarily not a closed-loop axis Module was called in a spawn or submit job

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Module 9129 Status of torque limiting by the PLC Module 9129 is used to determine the current status of torque limiting for the programmed axis. The momentary maximum torque can be determined in [mA] or in [0.1%] of the rated current. Condition: The module is only executable in the cyclic PLC program. The greatest possible return value is the value resulting from the motor data. If torque limiting is not active, the maximum current can be determined from the motor data. Call: PS B/W/D/K <Mode> 0: Limiting active/inactive 1: Current in [mA] 2: Current in [0.1%] of the rated current B/W/D/K <Axis number> 15: Spindle 9129 B/W/D <Status> Mode 0: 0 = Limiting active / 1 = Limiting inactive Mode 1: Current in [mA] Mode 2: Current in [0.1%] of the rated current

PS CM PL

Error recognition: Marker M4203 W1022 Value 0 1 2 24 Meaning Status has been read Error code in W1022 Invalid value for axis number or mode, axis is an openloop axis or is temporarily not a closed-loop axis Module was called in a spawn or submit job

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Module 9173 Speed-dependent wye/delta switchover With Module 9173, a monitoring function dependent on the speed can be realized for the wye/delta switchover of the spindle. A switchover request is detected by Module 9174, which supplies the current status of the wye/delta operation. If a switchover is necessary, this is still done by Module 9163. The actual speed is assumed during the switchover. The readiness of the current controller is automatically rescinded when Module 9163 is called. Condition: The module should not be called cyclically. A single call is enough for activation, deactivation or changing. Additional information: Useful combinations for <Mode> parameter: xx0 Deactivate monitoring 001 Monitoring on, Switchover compatible 011 Monitoring on, Accelerated but safe switchover, Wait for readiness of current controller 111 Monitoring on, Fastest switchover possible Call: PS B/W/D/K <Mode> Bit 0: 0 = Monitoring off (function deactivated) 1 = Monitoring on (automatic assumption of the actual speed during switchover) Bit 1: 0 = Switchover compatible to previous switchover; switchover same as first switch-on of spindle 1 = Switchover accelerated Bit 2: 0 = Wait for readiness of current controller 1 = Do not wait for readiness of current controller B/W/D/K <Switchover speed from wye to delta operation> B/W/D/K <Switchover speed from delta to wye operation> 9173

PS PS CM

Error recognition: Marker M4203 W1022 Value 0 1 1 Meaning Speed-dependent monitoring active Error code in W1022 Invalid speeds (switchover speed of wye operation switchover speed of delta operation), or negative speed

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Module 9174 Spindle status regarding wye/delta switchover Module 9174 supplies the current spindle status for wye/delta operation. In order to receive one of the two Request switchover x -> x status values, the speed-dependent wye/delta switchover monitoring in Module 9173 must be active. Call: CM PL 9174 B/W/D/K <Status> 0: Spindle in wye operation 1: Request for wye -> delta switchover 2: Spindle in delta operation 3: Request for delta -> wye switchover

Module 9216 Pop-up window with tool selection lists (expanded) Module 9216 was expanded by Mode 3. With it, the selection list also displays tools for which a pocket is reserved in the magazine. Call: PS B/W/D/K <Mode> 0: Tools in tool table not in the magazine 1: Tools in tool table in the magazine 2: Empty pockets in the magazine 3: Tools with reserved pockets in the magazine

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Module 9248 Copying, renaming and deleting files Module 9248 is used to copy, rename and delete files. This module can be used to access all mounted drives. Any necessary file conversions (ASCII --> binary, binary --> ASCII) are performed automatically during the copy process. Conditions: The file names must contain drive information (e.g. PLC:) and file types. The file types are used to determine whether a conversion is necessary. If a conversion must be performed, then the file types must be identical. The file types are used to determine whether renaming is permissible. If the file type remains the same during renaming, then there are no limitations. If the file type is changed, then renaming is only permitted between certain file types. Dependencies with other files are not considered when deleting files. Call: PS PS PS B/WD/K/S <Name of the source file> B/W/D/K/S<Name of the target file> Only with mode 0 or 1 B/W/D/K <Mode> 0: Copy 1: Rename 2: Delete 9248

CM

Error recognition: Marker M4203 W1022 Value 0 1 2 7 Meaning Successful execution of module Error code in W1022 Module was called in an invalid mode setting Error during file conversion, invalid source or target string, error during copying without file conversion, or source file does not exist Module was not called in a submit job or spawn job Not identical file types, conversion not possible

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Module 9300 Locking/releasing the pocket table (expanded) Module 9300 locks the pocket table for pocket switching with Modules 9305, 9306 and now also 9301, 9302 or 934x, and then releases it again. The module can now also be called while an NC program is running. This means that error code 5 has been removed. The module had returned it when the module was called during a running NC program. Error code 6 was introduced in its place. This results in the following behavior: Call: PS B/W/D/K <Lock/release pocket table> 0: Release the pocket table 1: Lock the pocket table 9300 B/W/D <Error> 0: Pocket table locked/released 1: Pocket table could not be locked 2: Pocket table could not be released 3: Transfer parameter invalid 4: Module was not called in a spawn job or submit job 5: Not used 6: Code 0: Pocket table already released Code 1: Pocket table already locked

CM PL

Module 9304 Copy pocket-table entry to PLC memory Module 9304 copies the contents of the freely definable columns p1 to p5 of a pocket-table entry into the word memory of the PLC. Call: PS B/W/D/K <Magazine number> PS B/W/D/K <Pocket number> PS B/W/D/K <Double-word address> CM 9304 Error recognition: Marker M4203 W1022 Value 0 1 1 2 4 20 36 Meaning Successful execution of module Error code in W1022 Invalid pocket number programmed Invalid magazine number programmed Invalid double-word address programmed Module was not called in a spawn job or submit job Error in file handling

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Module 9305 Tool exchange in the pocket table (expanded) Until now the module could only be called at standstill or during a strobe output. Now the module can also be called during a running NC program if the pocket table has been locked by the PLC with Module 9300 against other accesses. The meaning of error number 21 in W1022 changes correspondingly. Error recognition: Marker W1022 Value 21 Meaning Module was called during an NC program run without any locking in place

Module 9306 Exchange tools between tool magazines (expanded) Until now the module could only be called at standstill or during a strobe output. Now the module can also be called during a running NC program if the pocket table has been locked by the PLC with Module 9300 against other accesses. The meaning of error number 21 in W1022 changes correspondingly. Error recognition: Marker W1022 Value 21 Meaning Module was called during an NC program run without any locking in place

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Module 9311 Dynamically change values for friction compensation Module 9311 is used at run-time to prescribe other values for the friction compensation. The original values from MP2610.x, MP2612.x and MP2614.x are temporarily overwritten in the DSP. The MP file remains unchanged. Conditions: This function is supported as of the DSP hardware CC 424. Call: PS PS PS PS CM B/W/D/K <Axis number> B/W/D/K <Current in [mA]> 0..30000 replaces the value in MP2610.x B/W/D/K <Path in [0.1 m]> 0..10000 replaces the value in MP2612.x B/W/D/K <Path in [0.1 m]> 0..10000 replaces the value in MP2614.x 9311

Error recognition: Marker M4203 W1022 Value 0 1 1 2 19 24 Meaning New values assumed for axis number Error code in W1022 Invalid value as replacement for machine parameter Invalid axis number programmed Function is not supported by the DSP board (CC 422) Call was not from a cyclic program

Module 9312 Change machine parameters in the current machineparameter file Module 9312 is used to dynamically overwrite the values of the machine parameters of the active machine-parameter file or the process memory of the DSP. Conditions: For numbers the values must be returned as an integer. The decimal point is shifted by the number of possible decimal places. For example, if MP910.0 is to be set to 100.12 mm, then the <MP value> transferred must be 1001200. (4 possible decimal places lead to a multiplication by 10 000). For non-indexed machine parameters, zero must be programmed as the index. Once the NC program has started, the module operates only during the output of M/G/S/T/T2/Q change signals. Depending on the changed machine parameters type, the geometry is reinitialized. Not every MP can be changed by the PLC.

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Call: PS

PS

PS PS PS

CM PL

B/W/D/K <Mode> Bit 0: 0 =Modify MP numerical value (MP is a number) 1 =Modify MP string (MP is a string) Bit 1: 0 =Modify parameter in file (bit 2 is then relevant) 1 =Modify parameter in process memory (behavior like Module 9031) Bit 2: 0 = Change file and immediately assume new value(s) in NC 1 = Change file and do not immediately assume new value(s) in NC Will be assumed at next call with bit 2 = 0 B/W/D/K/S<File name> not supported at present (a value must be transferred, but the value entered is not evaluated yet) B/W/D/K <MP number> B/W/D/K <MP index> B/W/D/K/S<MP value> Depending on the mode, the MP value is interpreted as a PLC string number, PLC constant string or number 9312 B/W/D <Error code> 0: No error 1: Parameter does not exist or cannot be changed 2: New value for parameter is invalid 3: Error while saving 4: Call was not in a submit or spawn job 5: Call during running NC program without change signal 6: Invalid PLC string for file name or MP value 7: Parameter file does not exist

Error recognition: Marker M4203 Value 0 1 Meaning No error See error code

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Module 9313 Read machine parameters Module 9313 reads the contents of machine parameters from the process memory or from the current machine-parameter file. For machine parameters defined as numerical values, the content can also be read as a string. Machine parameters defined as strings cannot be read as numbers. Call: PS B/W/D/K <Mode> Bit 0: 0 = Read MP as numerical value (MP must be a number) 1 = Read MP as string (MP can be a number or text) Bit 1: 0 = Read MP from file 1 = Read MP from memory B/W/D/K/S<File name> not supported at present (a value must be transferred, but the value entered is not evaluated yet) (only the active MP file can be read from) B/W/D/K <MP number> B/W/D/K <MP index> B/W/D/K/S<Target word or target string> Mode bit 0 = 0: Interpretation as a double-word address Mode bit 0 = 1: Interpretation as a PLC string number 9313 B/W/D <Error> 0: No error 1: MP number, PLC string or PLC double-word address invalid 2: No : separator in MP file, e.g. (MP 10: %0111) 3: MP value outside permissible value range 4: MP not found in file 5: No MP file found 6: Call was not in a submit or spawn job 7: MP (defined as string) cannot be read as a number 8: No system memory

PS

PS PS PS

CM PL

Error recognition: Marker M4203 Value 0 1 Meaning No error See error code

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Module 9322 Information of the current NC program (changed) With Module 9322, you can determine the current block number of the active NC program. If the module is called from the cyclic PLC program, only the block number of the current NC main program is read in real time. If the module is called from a spawn job or submit job, the path of the current NC program is determined in addition to the block number (from the block scan). Constraints: Because of the geometry look-ahead, the call from the cyclic PLC program only supplies the block number in real time, but no information about the NC program. Call from the cyclic PLC program: For all traverse blocks that are not generated from an NC program, a cycle or an NC macro, block number 1 is read. Call from the cyclic PLC program: After the NC program is cancelled or after the end of the NC program, the last block number executed is returned. Call: PS B/W/D/K <Mode> When called from a cyclic PLC program, the setting of <Mode> is without effect. The block number of the active NC program is always returned. When called from a spawn job or submit job: 0: String / block number and path refer only to the active NC (sub)program. Block number from block scan. 1: String / block number and path refer to the active NC (sub)program or cycle. Block number from block scan. 2: Only the name of the NC main program without information about the block number (block number is set to 0 when executed correctly). B/W/D/K <String number for path of the NC program or cycle> Call from a cyclic PLC program: Without effect. 9322 B/W/D <Block number of current NC program or cycle> 1: Error if error marker is set 1: Block number in certain cases, if call was from a cyclic PLC program

PS CM PL

Error recognition: Marker M4203 W1022 Value 0 1 1 2 Meaning Information of current NC program has been read Error code in W1022 Invalid mode Invalid string number

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Module 9390 Open the online help window with the controls browser With Module 9390 you open an online help window with the controls browser. The module can be called from a cyclic PLC program or from a spawn job or submit job. The extension .CHM can be given in the call, but is not necessary. Constraints: The .CHM help file must be stored language-sensitive in the TNC:\tncguide\de directory, or in TNC:\tncguide\en etc. If an empty string is given as file name, the main.chm file is used. Depending on the link in main.chm the context number then branches to the OEMx.CHM specified there. If 0 was given as the help number, or if the given number could not be found in the help system, the start page of the given help file is opened. If the help system could not be started (e.g. the *.CHM file is missing), an NC error message with a reference to this PLC module is generated. Call: PS PS CM <File name> from string number S0/S1/... or S file or S K/B/W/D <Help number of the HTML page to be opened from the respectively valid help-number range> 9390 SXX

Error recognition: Marker M4203 W1022 Value 0 1 2 22 Meaning No error Error code in W1022 Invalid parameter or parameter does not exist Help system could not be started

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Module 9391 Display an error number with additional offset With Module 9391 you can display with an additional offset a PLC error message from the .PET table. Module 9391 behaves like Module 9085. The module can be called from a cyclic PLC program or from a spawn job or submit job. An offset is added to the value for the help number in the .PET file in order to generate the actual help number. This way a group error number can be defined for an (OEM) device in the .PET table. The error number (used as an offset) supplied by the device in case of error then leads to the appropriate help text. Two new columns were added to the .PET table for this. In the column ONLName you enter the file name of the help file that is to be called additionally in connection with an offset. In the ONL-Number column you enter the ID (=help number) of the HTML page in the help file to be opened. The offset is added to this ID (=help number) during the module call, and is given by the module. This makes it possible to refer to specific HTML pages in addition to the more general PLC error message. Constraints: The .CHM help file must be stored language-sensitive in the TNC:\tncguide\de directory, or in TNC:\tncguide\en etc. An OEM-specific OEMx.CHM file is necessary. If no OEMx.CHM file is indicated, the online help is not called. All other reactions saved for this error in the .PET table are performed. Call: PS PS CM K/B/W/D <Line number in the .PET error table> K/B/W/D <Offset for the help number in .PET> 9391

Error recognition: Marker M4203 W1022 Value 0 1 2 Meaning No error Error code in W1022 Invalid parameter or parameter does not exist

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New smarT.NC functions

DXF: Divide contour elements (software option) In the DXF converter you can now also divide poorly connecting contour elements so that they are selectable as individual contours. DXF: Extract machining positions (software option) Along with contour programs (*.HC files), point files (*.HP files) can also now be generated directly by the DXF converter. Behavior between two machining points (upgrade function) An approach height can now be defined for each machining point in a point pattern. The TNC then approaches this position at the height you defined. Useful for: Moving over chips or other hindrances. Contour pocket on point pattern (upgrade function) A contour pocket can be machined on a point pattern using Unit 130. Rapid probing (upgrade function) Various touch-probe parameters can be set globally using Unit 441. Touch probe Cycles 408 and 409 (upgrade function) It is now possible to set presets in the center axis of a slot or ridge using Units 408 and 409. Editor in the Programming and Editing operating mode (upgrade function) Creation and editing of *.HU and *.HC programs on the simulation side of the control in smarT.NC mode. Feed-rate reduction during machining of contour pockets (upgrade function) When clearing out a contour pocket, traverse paths where the tool is in full engagement result, such as in narrow channels or when shifting to the next clearance path. Now you can define a percent value by which the TNC reduces the feed rate in such situations. Tool table in the smarT.NC look and feel The tool table TOOL.T can now also be edited in the smarT.NC operating mode. The depiction was adapted to smarT.NC. Expanded file management The file management in smarT.NC was revised completely. End angle can be defined for a pitch circle instead of an angle increment As part of the pitch-circle definition, an end angle can now be defined instead of an angle increment in a point pattern. Climb milling/up-cut milling for helical finish milling In Unit 208 it is possible to define the milling direction (climb milling/up-cut milling).

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Scale in the pattern generator A scale can now be shown in the pattern generator, so that the dimensions of the defined machining pattern can be determined. Zoom function in the pattern generator A zoom function is now available in the pattern generator, with which the view of the defined machining pattern can be magnified. Align workpiece with Units 401 and 402 Units 401 (basic rotation over 2 holes) and 402 (basic rotation over 2 studs) were expanded for the purpose of compensating via rotation in the C axis a misalignment determined with the cycles. Rapid traverse with the PLANE function FMAX can now be programmed with the PLANE function. The rapidtraverse override potentiometer functions accordingly when this function is executed. Selection of datum number With the datum shift (Unit 7) you can now select a datum number from a datum table via soft key. Tool names with measuring cycles for workpiece measurement For cycles for workpiece measurement, a tool name can now be defined for the tool to be corrected instead of the tool number. Remanently store control settings Settings for the control in the smarT.NC operating mode are saved beyond the run-time of a process or a reset of the control.

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New plainlanguage programming functions

DXF: Divide contour elements In the DXF converter you can now also divide poorly connecting contour elements so that they are selectable as individual contours. DXF: Extract machining positions Along with contour programs (*.HC files), point files (*.HP files) can also now be generated directly by the DXF converter. Feed-rate reduction during machining of contour pockets (upgrade function) When clearing out a contour pocket, traverse paths where the tool is in full engagement result, such as in narrow channels or when shifting to the next clearance path. Now you can define a percent value by which the TNC reduces the feed rate in such situations. Climb milling/up-cut milling for helical finish milling In Cycle 208 it is possible to define the milling direction (climb milling/up-cut milling) via parameter Q351. Text strings in Q-parameter programming Strings can now also be used and processed when programming Q parameters. Text strings possible in CYCLE DEF In CYCLE DEF, individual cycle parameters can now be entered as text strings instead of as numerical values or constants. Tool names with measuring cycles for tool measurement For cycles for workpiece measurement, a tool name can now be defined for the tool to be corrected instead of the tool number. Tilted status during program interruption If bit 9 is set in MP7682, then if the MANUAL OPERATION soft key is pressed during a program interruption, the Tilting ON/OFF status from program run is assumed in the Manual operating mode. That way the tilted status is exactly as it was defined in the program. Safety clearance at the end of Cycle 27 For Cycle 27, a retraction in the direction of the tool axis to the safety clearance is now only done after machining a contour pocket if MP7420 bit 4 is set.

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New touch probe functions

New probe cycles for presetting (FCL 3 function) The new touch-probe cycles 408 and 409 are available for presetting at the center of a slot or a ridge. New 3-D probing cycle (FCL 3 function) The new touch-probe Cycle 4 is available, with which you can perform a measurement in three dimensions. You define the direction of traverse via three incremental traverse paths in X, Y and Z. You can receive the results of the measurement in either the workpiece or the machine coordinate system. Align workpiece with Cycles 401 and 402 Cycles 401 (basic rotation over 2 holes) and 402 (basic rotation over 2 studs) were expanded for the purpose of compensating via rotation in the C axis a misalignment determined with the cycles. Measuring results available globally Measuring results of the cycles for datum setting (408 to 419) are now available for further use in Q parameters.

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New NC functions

Global PGM Settings (software option #44) Possibility of superimposing various coordinate transformations and settings in the program-run modes of operation.

Warning The following must be observed when using the Global PGM Settings: Basically, all settings in the Global PGM Settings remain active when executing cycles and NC programs. However, when executing macros or PLC positionings, all Global PGM Settings are automatically deactivated. If you disable one or more axes via Global PGM Settings, then this disabling is only cancelled within a macro or during the PLC positioning. However, if you transfer axis position values to the PLC (e.g. with FN19) within a cycle or NC program and then perform a positioning with the PLC, then this positioning really is performed with all axes. However, if the axis position values transferred from a cycle or an NC program are not approached, due to the Global PGM Settings, then this can lead to a crash during the subsequent PLC positioning. M118 cannot be deselected in cycles if handwheel superimpositioning has been activated in the Global PGM Settings. However, handwheel superimpositioning is automatically deactivated in the Global PGM Settings when executing a macro. If you read the position values of an axis via the PLC, then when you interrogate the nominal values, the nominal value programmed in an NC program is returned, not the actual value of the axis. If further actions derive from the nominal value, then this can lead to problems, since these value do not necessarily reflect the actual position values of the axes. If you interrogate the actual value of an axis, then the actual position is returned.

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Changed NC functions

Additional status display The additional status display was improved. The following changes and improvements were made: The additional status display is now shown in forms, structured with tabs. You switch between the tabs via soft keys. The STATUS PGM, STATUS POSITIONS, STATUS TOOL and STATUS COORDINATE TRANSFORMATIONS tabs can be selected directly, and the other status displays are selected with soft keys. The most important status information is now collected on an overview page. A progress bar with the current program run time in % is now shown in the PGM status. In addition, the actual and programmed feed rate are shown as numerical values. The active machining cycle and the active parameters programmed in Cycle 32 Tolerance are shown in the CYC status. The active basic rotation is now also shown in the TRANS status. Only the status information important for test run is shown in the Test Run operating mode. If the Global Program Settings software option is available, two additional tabs containing information about the activated functions are shown. If the Adaptive Feed Rate Control software option is available, the additional AFC tab containing information about the feed-rate control is shown. PLANE function FMAX can now be programmed for the positioning speed of the PLANE function. Tool-usage file The total machining time of the program is now also available in the toolusage file. This time serves as the basis for the progress display in the additional status display when the program is being executed. Tool-pocket table Up to 9999 magazine pockets can now be managed in the tool-pocket table. Network protocol The TNC can now also be connected via NFS version 3. A higher datatransfer speed is available in this mode. Circular motions with active rotation Circles that were not traversed in the active main plane can now also be machined in combination with Cycle 10 Rotation. Until now an undefined motion occurred, and an error message was output if the rotation was increased. Collision with M140/M150 If M140 or M150 is active, then no more error message is shown if there would be a collision. Similar to the limit switches, positioning is ended if the programmed motion results in a collision.

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iTNC Operation and technique

New multiturn encoders are supported If a software version less than 340 49x-02 SP7 is being used, then the error code 0x7F in the EnDat defective <error code> <axis> error message has another meaning in addition to the error codes in the Technical Manual. If a motor with a newer generation multiturn encoder is attached to a CC 424 with a software less than 340 49x-02 SP7, the EnDat error 0x7F is reported. In this case the NC software must be updated to 340 49x-SP7 or 340 49x-03. The motors will be equipped with these rotary encoders no earlier than 2007. Reversing a software update If a target file for the SavePlc parameter is given in the setup.ini file, then a software update can be reversed. The iTNC then automatically saves a link to the file that is necessary in order to reverse the update. After an update, the -SETUP code number is entered on a single-processor control, and the Setup Back button is pressed in the iTNC Control Panel on a dual-processor control in order to reverse an update. The previous software version is then reinstalled. The PLC partition is restored from the *.zip file that was entered under SavePlc= in the setup.ini file. Please note that a subdirectory in which you want to save the *.zip file must be created on the TNC partition before the update, otherwise the update is cancelled when backing up the old PLC partition. Only updates from one full software version to another can be reversed. You cannot reverse the installation of service packs. Note A software update can only be reversed if the new software was updated onto a software as of version 340 49x-03. If you install version 340 49x-03 onto version 340 49x-02, then this update cannot be reversed with SETUP. New ending for setup files Until now, setup files ended with .omf. The ending .elf is also possible with NC software 340 49x-03. Function of the LOAD SP soft key changed The LOAD SP soft key, which is available in the Programming and Editing operating mode after pressing the MOD key, now functions identically to the SETUP code number. This means that now instead of selecting a directory, a setup.elf or setup.omf file in the appropriate directory must be selected in order to install a new software version. This soft key can be used for installing service packs and full versions.

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Common USB stick for single- and dual-processor versions You can now save two different update procedures for automatic software updating on one USB stick. This makes it possible to use just one USB stick for updating iTNCs with and without Windows 2000. In addition to the install directory, the following directories are also checked for the presence of the setup files when the control is booted: iTNC without Windows - USB0:\installsingle\ (USB0: first partition of the first USB memory device) iTNC with Windows - G:\installdual\ (G: corresponds to the drive letter of the USB memory device) Automatic setting of the FCL with a new SIK On a control in which no FCL was set in the SIK (after installation of such a software), the FCL was automatically set to the highest value supported by the software after the control had been restarted 100 times. As of 340 49x-03, this automatic setting of the FCL does not take place until the control has been restarted 255 times. Positioning of open-loop counter axes A new mechanism ensures that open-loop counter axes (MP120.x = 0) are traversed to the position required by the NC program. The execution of the NC program is interrupted at the point where the counter axes are programmed. An appropriate display points out a difference between the nominal and actual value. Only once this difference has been fixed can the program be continued. Tool-usage file expanded The new WTIME column has been added to the tool-usage file. It indicates how long a tool was selected during the program. It also includes the times where the tool was moved without M3/M4, as well as times where it was moved at FMAX. In contrast to this, the TIME column only indicates the time that the tool was used to machine a workpiece (spindle on and not at rapid traverse!). If the tool-usage file is created in the Test Run operating mode, the entered times may deviate minimally from the actual machining times. In the Test Run operating mode an override of 100% is used for calculation. In addition, two new lines were integrated in the tool-usage file: The line TIMETOTAL contains the sum of all entries in the TIME and WTIME columns. In the other columns this line contains the value 0. The PATH column in the TOOLFILE line contains the tool table that was active when the tool-usage file was created. This makes it possible to output an error message when checking the tool usage in the Program Run modes if the active tool table does not match the TOOL.T file. Feed-rate limiting for M128 The speed for compensating movements with M128 is now also limited via the PLC and the FMAX soft key, in addition to MP7471.

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Oscilloscope starting from the message for power interruption It is now possible to operate the oscilloscope with reduced functions starting from the Power interrupted message. If you enter the code number DSP123 before calling the oscilloscope, then starting from the Power interrupted message the data are recorded and can be displayed via the oscilloscope. Note Please note that the control has not finished booting at this time, and that the displayed values can therefore deviate from the correct or expected values. Log entries The log entries for the arrow keys and the TAB key were changed as follows: Cursor Left, Cursor Right, Cursor Up, Cursor Down, Tab. Differences between positions at switch-on and switch-off for axes with EnDat encoders are now entered in the log. Data from a PLC positioning is now entered in the log. If errors occur in the kinematics description when using the old format, they are entered under KINEMATIC in the log. If a file or table column is not found, the file or column name is entered in the log. If a soft key defined by a resource file and having an overlay value is pressed, the overlay value is entered in the log. Additional log A second log parallel to the existing log was introduced. It is in the batterybuffered RAM, and so enables access to the log data on the control even without a hard disk. Enter the code number LOGBOOK1 to output it and save it as an ASCII file. This log is not available for the programming station. Limit external access to the control External access to the control via LSV2 can be limited to specified computers. If the entry REMOTE.PERMISSION = <computer>;<computer> exists in the TNC:\TNC.SYS file, then only the computers listed will be granted access to the control. The <computer> entry can be either the names or IP addresses of computers, and must be separated by semicolons. Access to the control is refused if the REMOTE.PERMISSION entry exists in the TNC:\TNC.SYS file but the computer is not listed. If the REMOTE.PERMISSION entry does not exist, then every computer can access the control. Disable software options for General Key Use the keyword LOCKEDOPTIONS = <option>[,<option>[,...]] in OEM.SYS to select software options that can then not be enabled by the General Key. <option> is the number of the software option to be disabled. This way you can disable those software options for which your machine is not prepared. Example: LOCKEDOPTIONS = 44,45

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Recognition of rotary axes improved The fact that an axis is a rotary axis could until now only be defined for NC axes (A, B, C) via MP100.x. If an angle encoder with distance-coded reference marks was used on a PLC axis, the error message Encoder defective was generated during a zero crossover. Now this information is detected for a rotary axis either in the axis designation (MP100.x) in the momentary traverse range or by the entry in MP810. PLC texts in UTF8 The PLC texts for PLC soft keys, FN14 error messages (UTF8 code in ERROR.A or FN14 file) and PLC mask files (UTF8 code in ERROR.A or DIALOG.A) can now be displayed as UTF8-encoded texts (e.g. for Asian languages). For the FN14 error messages and the PLC mask files, the UTF8 code must then exist in the files used. PLC texts that are to be displayed in the PLC status window may not be UTF8 encoded. As an alternative, the English character set may be used. Dialogs for user parameters and soft-key descriptions for the HR 420 cannot be displayed in Asian languages. If such dialogs are used, the English language is displayed instead. The ASCII characters of the values 0xEF, 0xBB and 0xBF serve to indicate the UTF8 code. These three characters must be in the correct sequence as the first three characters in the appropriate file, and only serve to indicate the UTF8 code. Read MP file without activation In the PLC Programming operating mode, files with the extension .MP or an unknown extension can be opened with the ASCII editor. You can use the PGM MGT key in the PLC Programming operating mode to open files, but the values of the machine parameters cannot be changed (write protection). This way you can open *.MP files for reading them without activating them.

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Edit NC programs on the PCL partition It is now possible to open NC programs with the NC editor in the PLC Programming operating mode. If in the PLC Programming operating mode you select via the PGM MGT key a *.H file on the PLC partition for editing, the control automatically switches to the Programming and Editing operating mode. Restore machine status In the PLC:\MGROUPS.SYS file you can now enter an M function in up to four groups. During block scan, the M function is collected for all groups in which it occurs, and is then considered during restoration. However, this could lead to such M functions being executed more than once when restoring the machine status. This function only makes sense if the ORDER = PRIO option has not been entered. Setting the system time via soft key (Only on single-processor controls) After pressing the MOD key in the Programming and Editing mode of operation, the SET DATE/TIME soft key is available. After pressing this soft key, the following window in which you can enter the system time appears. If you make any changes to these settings, the control must be restarted. Set the time zone for the control to automatically switch between standard and daylight savings time.

Adaptation of the motor tables for EcoDyn motors The two entries N-XH (Upper speed) and N-FS (Rotational speed for weakened-field operation) were added to the motor tables for EcoDyn motors. Until now the value for both these entries was 0, and they were not active. The adaptation of these two entries generally improves the behavior of the motors in weakened-field operation. Accelerate 3-D graphics during program test The function of MP7312 or the LCUTS column, as described in Update Info 12, is now supported. By entering in MP7312 as small a value as possible between 1 and 8, you should be able to detect an acceleration of the graphic simulation (the 3-D graphics) in the Test Run operating mode. However, HEIDENHAIN instead recommends entering the real values of the corresponding tooth lengths of the tools in the LCUTS column of the tool table.

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Wye/delta switchover of the spindle without spindle stop With the 340 49x-03 software it is possible to switch between wye and delta operation of the spindle without having to stop the spindle. However, only one gear stage can be used in order to use this direct switchover. This must be configured correspondingly via MP3010, MP3210 and MP351x. The flowchart shows the principle procedure for direct switchover of the modes via the PLC:

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The diagram shows in principle how you can determine the switchover speeds for the wye/delta switchover:

1: Lower switching speed = n(intersection) 2% to 4% of nmax 2: Speed at which the two characteristic curves intersect: n(intersection) at n(S1_wye) = n(S1_delta) 3: Upper switching speed = n(intersection) + 2% to 4% of nmax Danger The contactor for the wye/delta switchover may not be switched under load!

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Expanded SIK functions The display and management of the SIK options, Feature Content Level and General Key was revised. Press the MOD key and enter the code number SIK to display the input mask for SIK functions:

The display gives you the following information and possibilities for settings: NC Information: Display ID number Rev. Control Type Performance Class Features Meaning Software Software version Type of control Type of main computer Characteristics of the control

SIK Information: Display Identifier (SIK ID) Control Type Performance Class Features Meaning SIK number Type of control Type of main computer Characteristics of the SIK

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Display SIK ok, wrong SIK (Control Type mismatch), wrong SIK (Features mismatch), wrong SIK (Performance Class mismatch), no SIK (Programming Station) or no SIK

Meaning Status of the SIK

General Key: The General Key permits you to enable and test all new Feature Content Level functions and software options. The General Key is valid for 90 days after the first enabling. After these 90 days have expired, the General Key can only be used again after the software version on your control has been updated. Display Status Meaning NONE dd.mm.yyyy General Key was not used yet for this software version. Date up to which all options will be available. It is not possible to enable them again after this date. General Key has expired for this software version. Enabling is not possible.

EXPIRED

Set

Pressing the Set button or the SET GENERAL KEY soft key opens a window in which you press the Apply button or the SET GENERAL KEY button again to enable all options for 90 days. If this is done successfully, the General Key has been set message appears and the expiration data of the General Key is shown in the Status field. Pressing the Expire button or the EXPIRE GENERAL KEY soft key opens a window in which you press the Apply button or the EXPIRE GENERAL KEY button again to expire the General Key immediately. Be aware that it is then no longer possible to enable the General Key for this software version!

Expire

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Feature Content Level (FCL): Danger If you reduce the Feature Content Level, then all new FCL functions and expanded features will be set to the desired lower version. Only error fixes remain active. This action can only be reversed by entering a valid code number again.

Display Actual Value Installed Software Supports Set

Meaning Current version of the Feature Content Level Highest possible FCL with the current software Pressing the Set button or the SET FCL soft key opens a window in which you can enter the code number for the desired Feature Content Level under Enter Key Code. HEIDENHAIN can give you the code number after having been informed of the SIK number. Then press the Set FCL button or the SET FCL soft key to confirm the entry. If this is done successfully, the message Feature Content Level has been set appears. Pressing the Reduce button or the REDUCE FCL soft key opens a window in which you can enter the desired lower Feature Content Level under New (lower) FCL. Please note that this action can only be reversed by entering a valid code number again. If you really want to reduce the Feature Content Level, then press the Apply button or the REDUCE FCL soft key to confirm the entry. If this is done successfully, the message Feature Content Level has been reduced appears.

Reduce

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SIK Options: All available software options and their corresponding numbers are listed in a table. The check marks in the first column indicate which software options have been enabled on your control. To enable additional software options, proceed as follows:

Press the MOD key and enter the code number SIK to display the input mask for SIK functions. In the table on the right side of the screen, use the arrow keys or the mouse to select the software option you want to enable. Pressing the Set Option button or the SET OPTION soft key opens a window in which you can enter the code number for the desired software option under Enter Key Code. HEIDENHAIN can give you the code number after having been informed of the SIK number. Enter the code number and confirm the entry by pressing the Apply button or the SET OPTION soft key. If this is done successfully, the message Option <number> has been set appears, and the option is checked in the table.

When you leave this table of SIK functions by pressing the END soft key or the END key, you are requested to reboot the control if you have made any changes. Press the emergency stop button and press the Reboot Now! button or the REBOOT NOW soft key to reboot the control and activate the changes.

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New functions of the CC 424

Characteristic curve kink point for control with servo lag The characteristic curve kink point for operation with servo lag, defined via MP1820 and MP1830, can now also be used with the CC 424. Maximum braking time of 5 seconds rescinded Until now the switch-off procedure was allowed to take a maximum of 5 seconds until standstill. After 5 seconds at most the drive controllers (current and speed controllers) were switched off and SH2 was set. However, under certain circumstances high-speed spindles and torque motors with much inertia require more time to brake to a standstill from the maximum speed. For this reason the maximum braking time of 5 seconds was rescinded. Now the drives are braked until standstill, and only then is SH2 set. Speed-dependent switching of the PWM frequency This function is used with high-speed spindle drives. This switchover is only possible for double-speed control loops. In MP2186.x and MP2188.x, a speed-dependent hysteresis for switching the PWM frequency is specified. It only takes effect if the value in MP2188 is less than the value in MP2186. This function is associated with MP2182.x and MP2180.x Only if MP2182.x = 2, and MP2180.x 5 kHz, does the switching of the PWM frequency take effect. Please note that the adjustment of the current controller (MP2420, MP2430) is based on the lower PWM frequency 5 kHz. Adaptation of the current-controller parameters and consideration of the power-module derating are performed automatically. Using this function provides several benefits: At lower speeds and therefore a lower PWM frequency, the power module provides a comparatively high current. This results in a relatively high maximum motor torque. On the one hand, losses due to harmonics in the motor become more important as the speed increases, and on the other hand, the relationship between the electrical frequency and the PWM frequency worsens. These two disadvantages can be counteracted by increasing the PWM frequency. The resulting reduction of the current normally is insignificant, since in part due to motor characteristics, very high motor currents are mostly no longer possible or needed at higher speeds. Note The speed-dependent switching of the PWM frequency is only permitted with power modules from HEIDENHAIN. Danger Speed-dependent switching of the PWM frequency with non-HEIDENHAIN power modules can lead to malfunctions, and possibly to damage of the power modules. Therefore, only use this function with power modules from HEIDENHAIN.

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When determining the optimum switching speed for the PWM frequency, you should consider that the maximum motor current decreases as the speed rises, due to the finite dc-link voltage. The current for the drive depends on the maximum permissible motor current and power-module current. The smaller of the two values limits the current for the drive. The value of the maximum power-module current is reduced by approx. 30% because of the derating when doubling the PWM frequency. The optimum switching speed results from the intersection of the maximum current curve of the motor with the maximum current curve of the power module for the high PWM frequency. You can determine the maximum current curve of the motor spindle by using the TNCscopeNT software. Record the current Inoml/S in dependency of the speed. The spindle must be accelerated to the maximum speed so that the derating behavior can be seen in the curve. The figure shows the behavior when the values entered for the switching speed (MP2186.x, MP2188.x) are too low. This then results in a speed range where the current for the motor is less than the permitted and maximum current, resulting in inconsistencies in the motors torque behavior.

1: Red line: Maximum current for the drive, resulting from the entries in MP2186.x and MP2188.x 1: Dashed line: Maximum possible current for the drive (Imax motor) 2: Switching point for the PWM frequency set too low 3: Optimum switching point for the PWM frequency 4: Maximum power-module current at low PWM frequency 5: Maximum power-module current at high PWM frequency (Imax power module) Summary The speed is switched at the intersection of the two current curves (Imax motor, Imax power module) so that no inconsistencies in the torque behavior of the motor occur. For better controllability (no harmonics at higher PWM frequencies), it might already make sense to switch at lower speeds. The best speed to switch at must be determined by experimenting. The value above should serve as an initial value.

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More master-slave torque axes possible PWM outputs X55/X57 and X56/X58 can now be used on a CC 424 with 8 and 14 control loops to operate master-slave torque axes. Until now no more than two master-slave torque axes were possible on X51/X53 and X52/X54. C-axis operation possible C-axis operation is now possible with the CC 424 in the same manner as with the CC 422. The position encoder inputs of the CC 424 are used for Caxis operation. Counter axes and analog controlled axes are possible It is now possible with the CC 424 to operate uncontrolled axes (counter axes) or analog controlled axes (MP120 input value < 51) via the position encoder inputs. Monitoring the nominal speed If the nominal speed exceeds the maximum motor speed (N-MAX from the motor table) by more than 15%, an error message is output and an emergency-stop reaction is triggered. When using an EcoDyn motor, the error is triggered when the maximum permissible voltage is exceeded. Determining the field angle Drive remains controlled After the commutation angle has been determined successfully, the 8150 Field angle ascertainment successful error message is now output. The drive now remains controlled. Switch-on time via Module 9161 reduced The delay when switching on the axes via Module 9161 was reduced. Errors of a supply module lead to an NC stop and an emergency stop Errors of the supply module (e.g. excessive Uz or Uv temp.) now lead to an NC stop (if M148 then LIFTOFF) with a subsequent emergency stop. In earlier versions there was no NC stop. Overcurrent cutoff The momentary current is monitored by the CC 424, and the following errors now lead to an immediate cutoff: Excessive actual current: If the actual current exceeds the maximum permissible current (depending on the power module and motor), the error 0xC3C0 (Motor current too high) is triggered. Excessive current offset: If the offset current exceeds the permissible threshold (50% of the maximum current), the error 0xC600 (Current offset too high) is triggered. One possible reason could be a phase to earth fault.

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1.6.4 DCM Dynamic Collision Monitoring Warning The following must be noted as of version 340 49x-03 when editing kinematics or associated tables. Only if this is followed are changes to the kinematics detected by the collision monitoring: If kinematics or an associated table (e.g. CMO descriptions) are edited in an NC program or NC macro with FN26:TABOPEN and FN27:TABWRITE, then they must be closed after the changes are made. This occurs automatically at the end of a program or if FN26:TABOPEN is called again. Activation of the kinematics is permitted with FN17:SYSWRITE ID290 NR1 here, since this FN17 function automatically closes all tables before activation. If a changed table is activated by the PLC via Module 9097 before it has been closed, the changes are not detected. If kinematics or an associated table are opened and edited by the PLC via Modules 9240 through 9246, they must be closed by the PLC after the changes have been made. This must be done before activation of the kinematics (e.g. via Module 9097), a tool call or a change of the tool data with M4538. If kinematics or an associated table are edited with the table editor, the editor must be exited with the END or PGM MGT keys. If the changed kinematics are activated (e.g. with PLC Module 9097 or FN17:SYSWRITE ID290 NR1) before the editor has been exited, the changes will not take effect.

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Transformations in CMOs

Software version 340 490-03 makes it easier to describe collision monitored objects (CMO) for the collision monitoring. It is now possible to insert the coordinate transformations directly into the object-description file of a CMO. Shifts and rotations can be entered in a CMO definition table via the keyword TRANS, an axis (X, Y, Z, A, B or C) in the AXIS column and a value in the new COORD column. This functions like entering the description of a kinematics configuration. The coordinate transformations in a CMO definition file are only effective within the respective object-description file, but there it affects all subsequent objects. This makes it possible in just one object-description file to describe rotated and unrotated objects, to describe multiple objects after a rotation that then all have the same position, and to shift the datum and then perform a rotation. The following kinematics section will be used as an example to show the changes in the description of the CMOs.

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The description of the kinematics with CMOs previously looked like this: NR 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 .. KEY TOOLFILE CMO Trans Trans Trans CMO Trans Trans Trans Trans Trans Trans CMO Trans Trans Trans Trans Trans MachAxis CMO MachAxis MachAxis ... Z X B Z Y X Z B Z-Portal -135 -70 140 0.025 145 A Y Z Y Z B -15 105 -67 -140 70 135 HEAD_Addition Z Y A 67 -105 15 IR_Receiver HEAD AXIS COORD ON/OFF FILE DONTTEST

[END] The definition table for IR_Receiver: NR 0 1 KEY Cylinder Cylinder X 0 0 Y 0 0 Z -35 -57 AXIS Z Z RADIUS 35 30 HEIGHT DOC 35 22 Connector IR_Receiver IR_Receiver

[END]

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The definition table for HEAD_Addition: NR 0 1 [END] The possibility of including the transformation of a CMO into the CMOs own definition table improves the clarity of the kinematics table. This also makes it easier to integrate CMOs, since there are no changes to the actual kinematics of a machine. The description of the kinematics with CMOs can look like this as of 340 49003: NR KEY 0 TOOLFILE 1 CMO 2 CMO 3 CMO 4 Trans 5 Trans 6 MachAxis 7 CMO 8 MachAxis 9 MachAxis .. ... [END] AXIS COORD ON/OFF FILE HEAD IR_Receiver HEAD_Addition X Z B Z X 0.025 145 Z-Portal DONTTEST KEY Cuboid X -40 40 Y -20 00 Z -40 40 AXIS RADIUS HEIGHT DOC HEAD Addition

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Transformations that were only contained in the kinematics tables for the description of CMOs are omitted completely and instead integrated in the CMO definition table. The new definition table for IR_Receiver: NR 0 1 2 3 KEY Trans Trans Trans Cylinder X Y Z AXIS Z Y A Z Z COORD RADIUS HEIGHT DOC 67 -105 15 Position1 35 35 Connector IR_Receiver 30 22 IR_Receiver

0 0

0 0

-35 -57

4 Cylinder [END]

As an alternative, the X, Y and Z columns can be used for the description of transformations, but then no entry is permitted in the AXIS column. If there is an entry in the AXIS column, the X, Y and Z columns are ignored. The new definition table for HEAD_Addition: NR 1 2 3 KEY Trans Trans Cuboid X Y -140 -20 00 Z 70 -40 40 AXIS COORD RADIUS HEIGHT DOC B -40 40 135 HEAD Addition

4 [END]

Transformations in the CMO definition table must always occur before the definition of objects. These transformations only serve to describe the position and orientation of the CMOs, and do not need to be cancelled in order to describe the further kinematics of the machine. If there is a transformation at the end of a definition table, the error message Kinematic table defective is output.

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Changing CMOs in NC programs

The NC function WRITE TO KINEMATIC was expanded in order to adapt the position, orientation and size of CMOs to new situations even during execution of an NC program. It is now possible to search active CMO definition tables for keywords (KEY) and to overwrite individual cells in the table. When entering keywords in the DOC column, make sure that each keyword is only entered once. Note If you change the kinematics tables or CMO definition tables with WRITE TO KINEMATIC, then the values in the tables are overwritten. If you do not rescind the changes you made with WRITE TO KINEMATIC in the NC program, the new values remain in the table. The changes to the machine kinematics are then not just temporary. Example for a change to a CMO definition table in an NC program: Comment: 0 : 5 6 : 4 3 4 4 : WRITE TO KINEMATIC AT COLUMN COORD CAPTURE DOC KEY Position1 = 15 WRITE TO KINEMATIC AT COLUMN HEIGHT CAPTURE DOC KEY IR_Receiver = 22 Write original value to cell in table again Write original value to cell in table again WRITE TO KINEMATIC AT COLUMN COORD CAPTURE DOC KEY Position1 = 25 WRITE TO KINEMATIC AT COLUMN HEIGHT CAPTURE DOC KEY IR_Receiver = 45 Overwrite cell in the kinematics table Overwrite cell in the kinematics table BEGIN PGM N545TCM MM

Specifying the tool axis in the kinematics

It is now possible to specify a permitted tool axis in the kinematics table. This way you can permit only a certain tool axis to be selected with a TOOL CALL. A tool axis is defined in the kinematics table with the ToolAxis keyword in the KEY column and by indicating an axis (X, Y, Z, U, V, W). As an alternative, the tool axis can also be defined in a SUBFILE or TOOLFILE. If a different tool axis is selected with a TOOL CALL, the Tool axis not allowed error message is output and an NC stop is triggered. The error message is generated as well if no tool axis is programmed in the TOOL CALL and no tool axis has been defined modally.

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So that the kinematics can be switched, the tool axis is not checked during the switch. This makes it possible to change the tool axis by switching the kinematics. The axes can be traversed without a subsequent TOOL CALL to activate the new, permitted tool axis, but the entry under ToolAxis and the active tool axis are not checked. Warning The following must be kept in mind when specifying a tool axis: After the kinematics have been switched, checking of the tool axis must be activated with a TOOL CALL. A tool axis may only be defined once via ToolAxis in the machine kinematics. If ToolAxis is defined more than once, then only the first instance is used. If the ToolAxis is to be switched via the kinematics tables, then the definition of the tool axis should be performed in the various SUBFILEs. This way you avoid multiple definitions in one kinematics description. Uniform kinematics It is now possible to use uniform kinematics on machines with and without software option #40. An error message is no longer generated when a kinematics description with CMOs is used on a control without the DCM software option. Danger This means that an error message no longer appears if DCM is not available. Even if there are CMOs in the kinematics tables, there is no protection against collisions without software option #40 (DCM). DCM with counter axes The changes in position of manually-operated counter axes in the Manual Operation and El. Handwheel operating modes are now detected by the collision monitoring. However, counter axes and controlled axes may not be moved simultaneously if collision monitoring is to be effective. In the Positioning with MDI, Program Run Single Block, Program Run Full Sequence and smarT.NC machining modes, the counter axes may only be moved at standstill, M strobe, etc., in order to ensure protection by DCM against collisions. The NC axes can then also be moved in the machining modes while being protected against collision. Danger If you position manually-operated counter axes during execution of an NC program or during an individual NC block (during calculation of path interpolations), the new positions of the counter axes cannot be detected or considered by DCM. There is no protection against collisions.

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1.6.5 AFC Adaptive Feed Control (Software Option #45) With adaptive feed control (AFC), the contouring feed rate is regulated depending on the respective spindle power in percent. This is done with the help of the feed-rate override factor, which is normally determined in the PLC by the setting of the override potentiometer. If AFC is active, then this factor is no longer formed from the potentiometer, but rather from the spindle power and other process data, and the contouring feed rate is calculated. The iTNC then automatically changes the value of the feed-rate override factor, with the goal of maintaining the spindle power at a constant reference value. The main benefit of this process control, along with ensuring the quality of the machining procedure (e.g. detection of cutter breakage or wear), is the optimization of the machining time, which is intended to ensure or improve productivity and efficiency. Changes in the material (harder sections), deviations in oversizes and tool wear lead to the danger of overloading the spindle. AFC can be effective in counteracting this. Benefits of adaptive feed control: Optimizing the machining time: By regulating the feed rate, the attempt is made to maintain the maximum spindle power learned over the entire machining time. The total machining time is reduced by increasing the feed rate in machining zones where less material is being removed. Tool monitoring: The tool life of a tool is increased by reducing the feed rate when the maximum spindle power learned is exceeded, until the time when this reference spindle power is reached again. If it is detected that the maximum spindle power was exceeded and at the same time the minimum feed rate could not be maintained, a programmed switch-off reaction is performed. This avoids subsequent damages due to cutter breakage or wear. Protecting the machine mechanics Damages to the machine due to overload can be avoided by reducing the feed rate ahead of time and with appropriate switch-off reactions. Documentation by capturing and saving the learning and process data. Limitations regarding the use of AFC: AFC cannot be used with analog spindles. AFC cannot be used in volts-per-hertz control mode.

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The following graphic schematically shows the principle of adaptive feed control:

1: Feed rate 2: Air cut 3: Beginning of machining 4: Feed-rate calculation during machining 5: Feed rate calculated by AFC 6: Feed rate programmed in the NC program 7: Cutting depth 8: Workpiece

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Operating states of AFC General information about Learning

The two main operating states of adaptive feed control are Learning and Controlling and Monitoring. A learning phase must be completed before AFC can be activated. This learning phase serves to ascertain the corresponding reference power of the spindle PREF for each individual machining step. The learning phase is divided into one or more learning sections. The beginning of a learning section or machining section is defined by the output of M function M03 or M04 (Spindle on right/left) in an NC program after a TOOL CALL has been processed. The end of the cut is defined by the spindle stop (M function M05). The NC macros M3.H, M4.H and M5.H must be assigned to these spindle M functions in the MFUNCT.TAB table. At the beginning of cutting with M3 or M4, the FN17 block FN 17:SYSWRITE ID 622 NR0 IDX 0.0 =+1 must be programmed in the M-function macro for starting a cut after the M function. At the end of cutting with M5, the FN17 block FN 17:SYSWRITE ID 622 NR0 IDX 0.0 =+0 for ending a cut must be programmed before M5. This way AFC can be used without having to change the existing NC program. The only restriction is that no M-function macros can be executed with active radius compensation. Before calling the macros, the radius compensation must be deactivated, and reactivated after the macro if necessary. The beginning of another section can be defined for the same tool with another call of M03 or M04. In order to exclude a tool from AFC (e.g. touch probe, tap, ), the AFC column must be undefined (empty) in the TOOL.T tool table. Otherwise in this column you must enter the identifier from the global control parameter table AFC.TAB. This identifier selects the control parameter block from the table AFC.TAB. If a cutting data table .CDT exists and is used, the basic control setting in the AFC column of this table is read. This means that the entry in the cutting data table has precedence over the entry in the tool table. The data ascertained during each learning section of the reference machining, especially the maximum spindle power, are saved with a generated cutting number in a table. They form the foundation for the subsequent controlled machining with active AFC. As an alternative to the generated cutting number, the value in NR can be used as the cutting number by programming discrete FN17 cutting blocks. However, the programmer must then ensure that the numbers are entered correctly and sequentially. The learning phase can consist of an entire machining process with multiple tools, but it also can also be stopped after a certain time in which the important parameters for the respective tools have been determined. The learning phase can be ended either manually via a soft key or automatically after a programmed time for the machining step has expired.

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With FN 17: SYSWRITE ID 622 NR0 IDX1.0 = <value> you can transfer a <value> for the time in seconds after which the teach-in cuts are ended automatically. The function behaves like the pressing of the EXIT LEARNING soft key after the appropriate time. This function is deactivated again by programming <value> = 0. At any time during the teach-in cut, you can change the machining feed rate with the feed-rate override potentiometer any way you want, and so influence the ascertained reference load. The file generated in this step is given the name of the selected NC program and receives .AFC.DEP as the file extension. .DEP is appended because this file depends on an existing .H file. E.g. an NC program with the name MACHINING.H results in a file with the name MACHINING.H.AFC.DEP. This file, and the global parameter table AFC.TAB as well, are set up as freely definable tables, and form view is also possible (switch via soft key). However, the format is prescribed and cannot be changed.

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Details of the learning phase: The spindle power is only recorded once the nominal speed has been reached, since the spindle is operated at a constant speed, and acceleration and braking phases are not included in the machining. Saving of the spindle power in air (idle power) in order to later evaluate only the power used during the actual machining process. Detection of entry into the material by the cutter when the idle load is exceeded by 2%. Saving of the maximum value of the spindle power of a learning section as reference for the control. Saving of the machining time of each learning section. Monitoring for stationary spindle or deviation from the nominal speed during active feed not at FMAX. Note Below a certain minimum tool diameter (e.g. 5 mm), in some circumstances it may not make sense to use AFC, since the actual data may become too small for safe control. This can be specified in the tool or cutting data table by leaving the AFC column empty. The entry in the cutting data table makes it possible for the basic setting to depend on the pairing of the tool and workpiece materials. If it becomes necessary in other cases for AFC to abort a machining step, there are two possibilities: By leaving the AFC column empty in the tool or cutting-data table. By deactivating AFC via targeted switch-off with FN 17:SYSWRITE ID 622 NR0 IDX 0.0 =+0 in the NC program or a corresponding M-function macro. If you use the M-function macros for M3 and M4, then the FN 17 block must follow the call of the M-function macro. This way you end the cut for AFC before machining actually takes place. If the learning process is ended during a learning step, either via the EXIT LEARNING soft key or because the programmed time (FN17 - ID622) has expired, the control immediately begins regulating the feed rate adaptively. The value determined up to that point is used as the spindle reference value, and is entered in <NAME>.H.AFC.DEP. This is useful if it can be seen that the spindle power will not increase significantly any further in this step.

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General information about Controlling

The maximum spindle power was determined for each learning and machining step. By changing the feed-rate factor within programmable limits (e.g. 70% to 130%), the software continuously attempts to match the momentary spindle power to the reference value during machining. This way the feed rate can be increased for areas where only a small amount of material is being cleared, and a slower feed rate can be used when there is more material than usual or the cutter is becoming dull. This protects the spindle drive and the tool from overload. If a disturbance in the process occurs during machining, a programmable switch-off reaction is performed. This occurs if the feed rate falls below the minimum feed-rate factor (e.g. 70%) at the reference spindle load. You can then assume that the cutter has become dull or has broken. If the feed rate falls below the defined value of 30% of the programmed feed rate, an NC stop is performed. This defined error reaction cannot be influenced, and occurs independently of the programmed overload reaction. Controlling can be switched off and on again via soft key at any point during machining. Controlling is also always switched off if the value set for the override potentiometer is manually reduced by more than 10%. The potentiometer is then effective again instead of AFC. Adaptive feed control must then be switched on again via soft key. A potentiometer value less than or equal to 50% is also always effective, i.e. AFC is inactive then. If the potentiometer value exceeds these 50% while AFC is on, then AFC becomes active again. The maximum spindle power that occurs while under control is ascertained and saved for evaluation later. The machining time of each machining section is also saved. The events AFC ON, AFC OFF, potentiometer manually changed -> AFC OFF are entered in the log of the iTNC. Tasks of AFC in each machining section: Detection of entry into the material by the cutter when the idle load is exceeded by 2%. Regulate to entry speed until a path corresponding to the cutter radius has been cleared, but at most 600 ms. Calculation of the optimum feed-rate factor. Monitoring for overload and switch-off reaction. Saving the maximum value of the spindle power for the evaluation. Detection of exit from the material by the cutter when the power is below the programmed exit load, and regulation to the exit speed until a path corresponding to the cutter radius has been traversed. After detection of traverse in air, regulate to the programmed idle feed rate. AFC is not in effect when machining at rapid traverse, since FMAX is used in the IPO, and at times override for FMAX.

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Automatic selection of the Learning / Controlling status

If an NC program is selected for machining and started, and if AFC is active, then it is first checked whether an associated <name>.AFC.DEP file exists in the same directory as the NC file. If this is the case, then the data in this file are immediately used as control parameters, and machining is performed with adaptive feed control. If this file does not exist, the first machining run is used as the learning phase and the file is created. If the AFC file is determined to be incomplete during machining, the missing steps are automatically performed in the Learning mode, thereby generating the missing data. When Learning is deactivated (M05, manually via soft key, or with FN 17), the learned data are saved and the status of this data block is set to Controlling. During Controlling, the data blocks are read in the same sequence they were learned, the step numbers are evaluated and other parameters (tool number, index) are checked to see if they match. Files for machining The following requirements are mandatory for controlling to be activated: An NC program must have been selected (<name>.H). The column AFC must be enabled in the tool table via MP7266.40. If you are working with a <name>.CDT cutting table, then you must create an AFC column and enter any desired control strategy there. If an entry in the cutting data table intersects with an entry in the tool table, the entry in the cutting data table has priority. M-function macro files M3.H, M4.H, M5.H (and possibly more). MFUNCT.TAB macro definition.

Associated files

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The three files of adaptive feed control: File of the global control parameters: AFC.TAB In the AFC.TAB table, which must be saved in the TNC:\ root directory, you enter the basic control settings with which the TNC is to perform the feed-rate control. The data in this table are default values that are copied during the teach-in cut to the file associated with the respective machining program, where they serve as the basis for controlling. Control parameters for the subsequent standard control strategy are already saved there. Other settings can be programmed as desired. The static control parameters that must be programmed in AFC.TAB for each cutting-data set are: Column NR AFC Function Current line number in the table (has no other function) Name of the control strategy. You must enter this name in the AFC column of the tool table. It specifies the association of the control parameters to the tool. Minimum feed rate at which the TNC is to perform an overload reaction if the feed rate falls below this value for one second. Enter the value in percent of the programmed feed rate. Maximum feed rate in the material, to which the TNC may increase automatically. Enter the value in percent of the programmed feed rate. Feed rate at which the TNC should traverse when the tool is not cutting (feed rate in air). Enter the value in percent of the programmed feed rate. Feed rate at which the TNC should traverse when the tool enters or exits the material. Enter the value in percent of the programmed feed rate.

FMIN

FMAX

FIDL

FENT

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Column OVLD

Function Reaction that the iTNC is to perform if an overload occurs: M: Perform an NC-function macro defined by the OEM S: Immediately perform an NC stop F: Perform an NC stop once the tool has retracted E: Only display an error message on the screen : Do not perform an overload reaction The iTNC performs the overload reaction if during active controlling the maximum spindle power is exceeded for more than one second and at the same time the feed rate is below the minimum you defined.

POUT

Spindle power at which the TNC is to detect an exit from the workpiece. Enter the value in percent of the learned reference load. Recommended value: 8% Sensitivity (aggressiveness) of the regulation. A value between 50 and 200 can be entered. 50 is controlling with a slow response, whereas 200 is very aggressive controlling. Aggressive controlling reacts quickly and with large changes in value, but tends to create overshoots. Recommended input value: 100 The value entered here is written to word W342 at the beginning of a cut. The module cannot be called in the cyclic PLC program. Depending on this, any necessary fine adjustments to the adaptive feed control can be performed from the PLC program.

SENS

PLC

Example of an AFC.TAB:: NR 0 AFC Standard FMIN 60 FMAX 140 FIDL 150 FENT 70 OVLD POUT 5 SENS 100 PLC 0

Proceed as follows to create an AFC.TAB file (only necessary if the file does not already exist):

Select the Programming and Editing operating mode. Select the file manager: Press the PGM MGT key Select the TNC:\ directory Create the new AFC.TAB file and confirm with the ENT key. The TNC displays a list with table formats. Select the AFC.TAB table format and confirm with the ENT key. The TNC creates the table with the Standard control strategy.

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Settings file with the control parameters: <name>.H.AFC.DEP This file is automatically created during the learning phase, and filled with values. It contains all control information for the cuts that occur in the NC program. You can manually change all entries, except TNR and IDX, at any time in order to adapt the control parameters specifically to the NC program. Call the <name>.H.AFC.DEP via the SETTINGS TABLE soft key. It contains the following additional information: Column NR TOOL IDX PREF N POUT ST Function Number of the machining section Number or name of the tool with which the machining section was performed (cannot be edited) Index of the tool with which the machining section was performed (cannot be edited) Reference load of the spindle. The TNC determines the value as a percent of the spindles rated power. Code whether a tool number (0) or tool name (1) was programmed in the NC program. Exit load of the spindle. The TNC uses the value as a percent of the reference load PREF of the spindle. Status of the machining step L: (= Learning) A teach-in cut will be performed for this machining cut next time, and the iTNC will overwrite the values already entered in this line. C: (= Controlling) The teach-in cut was performed successfully. The next time it is machined, AFC will control the feed rate. AFC Name of the control strategy used. If the control strategy given in the tool table is not in AFC.TAB, then the entry default is in this column. Default settings are then used for adaptive feed control.

Example of a <name>.H.AFC.DEP file after a successful teach-in cut: NR 0 TOOL 2 IDX 0 FMIN 60 FMAX 140 FIDL 150 FENT 70 OVLD POUT 5 PREF 64 SENS 100 ST C PLC 0 AFC Standard

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Proceed as follows to select (and edit) the <name>.H.AFC.DEP file.


Select the Program Run, Full Sequence operating mode Switch the soft-key row Select the table of AFC settings with the TABLE SETTINGS soft key If necessary, enter any improvements. Edited entries are identified by an * before the name of the control strategy.

Protocol file with the actual data of the control: <name>.H.AFC2.DEP The iTNC stores various pieces of information for each machining step of a teach-in cut in this file. During adaptive control the iTNC updates the data and performs various evaluations. Call the <name>.H.AFC2.DEP file via the EVALUATE TABLE soft key. Column NR TOOL IDX SNOM SDIF LTIME CTIME TDIFF PMAX Function Number of the machining section Number of the tool with which the machining section was performed (cannot be edited) Index of the tool with which the machining section was performed (cannot be edited) Nominal speed of the spindle [rpm] Maximum difference of the spindle speed in % of the nominal speed Machining time for the teach-in cut Machining time for the control cut Machining time difference between learning and controlling in % Maximum spindle power that occurred during machining. The TNC shows the value as a percent of the spindles rated power. Reference load of the spindle. The TNC shows the value as a percent of the spindles rated power. Reaction that the iTNC performed because of an overload: M: Perform an NC-function macro defined by the OEM S: Immediately perform an NC stop F: Perform an NC stop once the tool has retracted E: Only display an error message on the screen : Do not perform an overload reaction The iTNC performs the overload reaction if during active controlling the maximum spindle power is exceeded for more than one second and at the same time the feed rate is below the minimum you defined. BLOCK 1 84 Block number at which the machining cut begins. HEIDENHAIN Technisches Handbuch iTNC 530

PREF OVLD

Example of a <name>.H.AFC2.DEP file after a cut with active AFC: NR TOOL 0 2 IDX SNOM SDIFF LTIME 0 100 0 3.5 00:00:4 0 CTIME 00:00:3 2 TDIFF PMAX PREF OVLD 20.0 70. 2 64 -

Proceed as follows to select the <name>.H.AFC2.DEP file.


Select the Program Run, Full Sequence operating mode Switch the soft-key row Select the table of AFC settings with the SETTINGS TABLE soft key Select the protocol file with the EVALUATE TABLE soft key

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NC-function macro at overload

The entry M in the OVLD column of AFC.TAB can be used to call an NC-function macro for each control strategy as a reaction to an overload. The AFC detects that the spindle load has been exceeded if the actual feed rate is below the value in FMIN for more than one second. No more than one minute after the overload has been detected is the NC macro performed. The path for the NC macro must be entered in the PLC:\ncmacro.sys file via the keyword AFC as follows: AFC = <path><ncmacro>.H e.g.: AFC = PLC:\NC_MACRO\AFC_STOP.H If this entry is not in the ncmacro.sys file or the NC macro does not exist, then the NC program is stopped with the corresponding error message. The FN17 function SYSWRITE ID990 NR11can also be used for the AFC NC macro. It makes it possible to perform a tool change with subsequent positioning. This way replacement tool can be inserted in a tool-change procedure as part of an AFC NC macro. Use the following NC macro for this: 1 2 3 4 5 6 7 8 ;Read current tool number: Q1 FN 18: SYSREAD Q1 = ID20 NR1 ;Read maximum tool life of the tool (at TOOL CALL): Q2 FN 18: SYSREAD Q2 = ID50 NR10 IDXQ1 ;Set current tool life of the tool to maximum tool life FN 17: SYSWRITE ID50 NR11 IDXQ1 = Q2 ;Insert the replacement tool using repositioning logic FN 17: SYSWRITE ID990 NR11 = 0

The new FN function FN 17: SYSWRITE ID990 NR11 cannot be used with active radius compensation if the tool change is performed in a change macro. This new FN function works with a tool change only with PLC positioning.

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Default settings for using AFC

Adaptive feed control is a software option (option #45), and must therefore be enabled separately for each machine. The following settings must then be made on the control: Create the TNC:\AFC.TAB file, and define one or more control strategies. Set MP7246 bit 3 so that the <NC name>.H.AFC.DEP table for control settings can be generated for adaptive feed control. A separate file is created for each NC program in the learning phase. Use MP7266.40 to enable the AFC column in the tool table, or to create the AFC column in a *.CDT cutting data table. Enter the name of the control strategy appropriate for each tool in the AFC column of the tool table or cutting data table. If you do not enter a control strategy for the tool used in the NC program, AFC will not be in effect for this tool. If you are in the AFC column in the tool table, you can use the SELECT AFC CONTROL SETTING soft key to select a control strategy from AFC.TAB. Set the macro execution for the M functions M3, M4, M5 and any other M functions in the PLC:\MFUNCT\MFUNCT.TAB table. Create the M-function macros M3.H, M4.H, M5.H and any others in the PLC:\MFUNCT\ directory. In order to edit FN17, the appropriate code number (555 343) must first be entered. Note The M-function macros cannot be called if radius compensation is active in the NC program. Before calling the macros, radius compensation must be deactivated, and reactivated after the macro if necessary. M-function macros with which M3 or M4 automatically define the beginning of a cut for AFC, and M5 defines the end of a cut: 0 BEGIN PGM M3 MM 1 M3 2 FN 17:SYSWRITE ID 622 NR0 IDX 0.0 =+1;after M3 3 END PGM M3 MM 0 BEGIN PGM M4 MM 1 M4 2 FN 17:SYSWRITE ID 622 NR0 IDX 0.0 =+1;after M4 3 END PGM M4 MM 0 BEGIN PGM M5 MM 1 FN 17:SYSWRITE ID 622 NR0 IDX 0.0 =+0;before M5 2 M5 3 END PGM M5 MM

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Note The M-function macros for M3, M4 and M5 (as listed above) are used to write the control settings for the various cuts sequentially, in the same order as the cuts in the NC program, into the <NC name>.H.AFC.DEP file. You cannot use these M-function macros to assign a permanent number to the individual cutting data blocks. This means that you cannot use the Program Run, Single Block operating mode to perform a teach-in cut for just a single cut. You must always run the entire NC program so that AFC can update the correct lines in <NC name>.H.AFC.DEP. However, the FN 17:SYSWRITE ID 622 function offers you the possibility of numbering all the cuts of an NC program, making a permanent assignment possible. This is considered in the Program Run, Single Block operating mode, and you can retroactively carry out the learning process for individual cuts. You must deactivate the execution of the given M-function macros for this. The definition of the beginning and end of a cut via the FN 17:SYSWRITE ID 622 function must then occur separately for each cut in the NC program. Note You cannot use just any numbers when numbering the cuts in the NC program. The beginning of the first cut must be started after M3 or M4 with FN 17:SYSWRITE ID 622 NR0 IDX 0.0 =+1 and be ended before M5 with FN 17:SYSWRITE ID 622 NR0 IDX 0.0 =+0. NR must be incremented for each further cut. Targeted access to individual cutting data blocks is only possible with sequential numbering.

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Initial learning and controlling with AFC

After you have entered the settings described above, proceed as follows to carry out a learning phase for an NC program:

In the Program Run, Full Sequence operating mode, load the NC program for which the learning procedure is to be carried out, e.g. <NC name.H.> Activate AFC with the ADAPTIVE FEED CONTROL and FEED CONTROL ON soft keys. This creates and displays the <NC name.H.AFC.DEP> table of control settings. Start the NC program. The learning procedure is performed automatically for each individual machining cut. Note You do not have to run the entire machining step in the learning mode. If the cutting conditions do not change significantly, you can switch to the control mode immediately. Press the EXIT LEARNING soft key, and the status changes from L to C. At any time during the teach-in cut, you can change the machining feed rate with the feed-rate override potentiometer any way you want, and so influence the ascertained reference load. You can repeat a teach-in cut as often as you want to. Manually change the status from ST back to L. It can be necessary to repeat a teach-in cut if the programmed feed rate was much too high, and you had to turn the feedrate override way back during the machining step. You can teach any number of machining steps for a tool. A machining step always starts with M3 or M4, and ends with M5. For machining steps in which the tool remains the same, but it appears useful to define multiple steps for AFC, you can program another M3 or M4. Each M3 or M4 defines the beginning of a new cut.

All control settings for the individual cuts of an NC program are saved as a table in the <NC name>.H.AFC.DEP file (SETTINGS TABLE soft key), where they are used for future machining. The status of each cutting data block changes from L (learning) to C (controlling) after a successful teach-in cut. The data determined in the learning phase is saved in the <NC name>.H.AFC2.DEP file (EVALUATION TABLE soft key).

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Once the NC program has been run, the learning procedure is finished for adaptive feed control. The status in the <NC name>.H.AFC.DEP file (SETTINGS TABLE soft key) must have switched from L (learning) to C (controlling) for each cut. This way a valid settings file exists for adaptive feed control. As long as the status is not set to L (learning) and adaptive feed control has been activated with the AFC ON soft key, the NC program is run with AFC.

If you start the NC program again, the feed-rate override is changed by the adaptive feed control. The control tries to maintain the spindle power as constantly as possible at the reference value PREF of the spindle power. The data in the <NC name>.H.AFC2.DEP file (EVALUATION TABLE soft key) determined in the learning phase is compared with the values from machining with AFC.

Activating/ deactivating AFC

Proceed as follows to activate or deactivate adaptive feed control:


Select the Program Run, Full Sequence operating mode Switch the soft-key row Activate adaptive feed control: Set the AFC soft key to ON Deactivate adaptive feed control: Set the AFC soft key to OFF Note If adaptive feed control is active, the TNC assumes the functions of the feed-rate override. If you reduce the feed-rate override by more than 10% of the current setting, then the TNC switches AFC off. In this case the TNC displays a window, which you can acknowledge with the CE key. If you set the feed-rate override to less than 50%, the value of the override potentiometer takes effect. However, AFC is not automatically switched off here. If the value of the override potentiometer later exceeds the 50% again, AFC assumes control again. The TNC shows various pieces of information in the additional status display when adaptive feed control is active.

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1.6.6 TNCguide Context-Sensitive Help System for the iTNC 530 (User Documentation) (FCL 3 function) The help system was integrated on the basis of the CHM help format known from Windows. The CHM format was introduced by Microsoft in 1997 with the HTML help system, and is now used by many Windows programs. It is a collection of individual HTML files that are collected in a single compressed file. Mozilla Firefox is used as the browser on the single-processor version of the iTNC 530. The dual-processor version of the iTNC 530 and the iTNC 530 programming station use Internet Explorer or the standard browser configured for your PC. In principle, the iTNC 530 will be able to open and display any CHM files, including those prepared by the OEM. HEIDENHAIN will generally supply the following documentation in the form of CHM files together with the iTNC software: Users Manual for Conversational Programming Users Manual for Touch Probe Cycles smarT.NC Pilot Collection of all NC error messages The Users Manual for the programming station is also supplied with the iTNC 530 programming station. Context-sensitive entry points are defined for these files, meaning that pressing the HELP key brings the user directly to the appropriate location in the documentation. If no context-sensitive entry point is available, the TNC opens the parent main.chm book file, in which all CHM files in the respective (language-sensitive) help directory are shown. The user navigates to the desired entry with the mouse or the arrow keys. TNCguide can also be opened with the mouse: after clicking the help symbol, shown to the right directly above the soft-key row, the mouse pointer changes to a question mark. If the user then clicks a soft key, the TNC starts the help system and displays the description of this soft key, if a context-sensitive entry point exists. If no context-sensitive entry point is available, the control opens the parent main.chm book file, as described above.

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Basic conditions for the OEM

So that CHM files created by OEMs can be shown in the main.chm book file, the conditions listed below must be followed: The OEMx.CHM files must be stored in the TNC:\tncguide\de directory, or in TNC:\tncguide\en, etc. When the dialog language is switched (with MP7230), the iTNC searches the corresponding language subdirectory when the help system is called. HEIDENHAIN recommends placing an OEMx.CHM file in English in each language subdirectory if you dont translate your documentation into every language. This ensures that online help is available for all topics, regardless of the language settings on the control (MP7230). If no OEMx.CHM file exists in the language subdirectory, no OEM-specific help is shown when the online help is called. HEIDENHAIN has already defined the names for the CHM files created by the OEM, so that these files can be displayed as books (if they exist) within the parent main.chm book file: Name of the CHM file OEM1.chm OEM2.chm OEM3.chm OEM4.chm OEM5.chm OEM6.chm OEM7.chm OEM8.chm OEM9.chm OEM10.chm Help-number range from 10 000 000 11 000 000 12 000 000 13 000 000 14 000 000 15 000 000 16 000 000 17 000 000 18 000 000 19 000 000 to 10 999 999 11 999 999 12 999 999 13 999 999 14 999 999 15 999 999 16 999 999 17 999 999 18 999 999 19 999 999

The help-number range shows the context-sensitive entry points that are permanently defined for each file in order to simplify entry via the parent main.chm book file. The following links contain useful information about HTML help as well as software for downloading: http://msdn.microsoft.com/library/en-us/htmlhelp/html/vsconHH1Start.asp http://www.helpware.net/ HEIDENHAIN recommends using Mozilla Firefox 1.0.x to check how the HTML pages are displayed, since it is used on the control. The view differs somewhat from the view in Internet Explorer, especially regarding the page layout. However, this does not replace a thorough test of the CHM file on the control.

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Using PLC modules to call CHM files created by the OEM: PLC Module 9391 is introduced, with which a PLC error message is displayed, and in addition an offset is added to the value of the error number (= ONL Number) in the .PET table in order to generate the actual help number. This way a group error number can be defined for an (OEM) device in the .PET table, and the error number (used as an offset) supplied by the device in case of error then leads to the appropriate help text. This requires an OEM-specific *.CHM file, which must be indicated in the .PET table (= ONL Name). Additionally, PLC Module 9390 is also introduced, with which a help window can be opened directly by the PLC. Every possible way of calling your OEM help file offers you the possibility of showing the entire directory (including HEIDENHAIN help files) in the directory tree, or just the directory of your OEM help file. This selection is made when calling the help file. If you enter main.chm as the help file in the call (via PLC module, *.PET file, soft key or NC error), then the entire directory is shown. If you enter your OEM help file OEMx.CHM as help file in the call, then only the directory of your help file is shown. Files and structure of the help system All online help available on a control can be called separately as well as within the online help system. In order for the call within the entire system to function, the conditions described below must be followed: The help system is structured as follows: main.chm Welcome page of the help system jh1.chm jh2.chm ... oem1.chm oem2.chm oem3.chm ...

The HTML pages of the individual online help topics exist completely independently of each other. Special entries combine the tables of contents and collate the index entries (see below). Contents The table of contents of main.chm contains merge objects: <OBJECT type=text/sitemap> <param name=Merge value=oem1.chm::/merged.hhc> </OBJECT>

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HEIDENHAIN has specified here the name of the CHM file and the file name merged.hhc of the table of contents contained therein. When the welcome page of the help system (main.chm) is called, all existing help files linked with merge commands are included. Each table of contents is only displayed if it exists in a file named merged.hhc. This is why it is essential that you include the directory structure of your help as merged.hhc when your generate your OEMx.CHM files. The first level of this table of contents should have exactly one entry: the title of the help file. This title than appears as a book in the entire table of contents, and can be opened by the user in order to show the subordinate headings. Along with the actual HTML pages, the following files must be included when generating the OEMx.CHM files: *.hhc file In this file you describe the structure and format of your help system. If you call your help file via main.chm, then this file must be named merged.hhc. If your help file is to be called directly, without main.chm, then the directory tree in the *.hhc file that you indicated as content file when you created the CHM file is used. *.hhk file In this file you list all entries that are to be shown in the index later, and create the links to the corresponding HTML pages. At least one entry is necessary here in order for your help file to be displayed. *.hhp file This file is the project file that is necessary for generating an OEMx.CHM file. *.h file (only necessary for context-sensitive help) In this file you use the #define command to establish connections between error numbers, from the respectively valid ranges of error numbers, and any variables. Example: #define IDH_OEM1_CHAP1 10000000 #define IDH_OEM1_Page1_1 10000100 *.txt file (only necessary for context-sensitive help) In this file you establish the connection between the variables and the corresponding HTML pages, which are then called. Example: IDH_OEM1_CHAP1=chapter1.html IDH_OEM1_Page1_1=page11.html

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INDEX Note: Merging of the indexes only functions if each file involved contains at least one index entry, meaning at least one index entry is also necessary for the OEM help file. In addition, the entry Binary Index=Yes must be set in the project file (*.hhp). The project file of main.chm contains the following entries: [MERGE FILES] jh1.chm jh2.chm ... oem1.chm oem2.chm oem3.chm ...

This collates and displays the index entries of all present and named help files when the index of main.chm is called. Context-sensitive call In a context-sensitive call of the OEM help, the index display starts from the OEM help, and here the index entries can only be collated if all other help files *except* the current OEM file itself are entered in the project file of the OEM help. HEIDENHAIN makes a complete list of the file names available. Summary for OEM help Project file: Binary Index=Yes Project file: [MERGE FILES] with current list *except* its own file name! Table of contents: merged.hhc Title of the help, can be opened as a book. Index: At least one index entry.

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Designing soft keys for contextsensitive help

In order to establish context sensitivity in combination with soft keys, the additional HELPID and HELPFILE soft keys must be entered in the descriptions of the soft keys. Use HELPID to assign to a soft key an ID (= error number) from the respectively valid range of error numbers. With the HELPFILE attribute you indicate in which *.chm file the error number can be found (e.g. OEM1.chm) or via which file the error number is to be searched for (e.g. main.chm). The assigned error number, in combination with the *.txt and *.h files, is used to call the appropriate HTML page when the help is called. If you enter main.chm as the HELPFILE, the entire directory structure with the HEIDENHAIN help files is shown. If you enter only one file (e.g. OEM1.CHM), then only the directory of this file is shown. The OEMx.CHM files must be stored in the TNC:\tncguide\de or TNC:\tncguide\en, etc, directories. When the dialog language is switched (with MP7230), the iTNC searches the corresponding language subdirectory when the help system is called. You can enter HELPFILE for each soft key, or once for all soft keys. Example: PLC SOFTKEY Project File - Version 1.0 ; Path for the soft-key help file HELPFILE 'TNC:\tncguide\de\oem1.chm' ... ; here the assignment of a HELPID to the soft keys without ; indication of a *.chm file. This automatically links to the ; help file named above. ACTION Action2_Softkey HELPID:10000000 PULSE Pulse1_Softkey HELPID:10000100

BLANK ENDSKMENU or: PLC SOFTKEY Project File - Version 1.0 ... ; here the assignment of a HELPID and a HELPFILE to ; the soft keys. This automatically links to the ; help file entered. ACTION Action2_Softkey HELPID:10000000 HELPFILE:TNC:\tncguide\de\oem1.chm PULSE Pulse1_Softkey HELPID:10000100 HELPFILE:TNC:\tncguide\de\eoem1.chm BLANK ENDSKMENU

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Enhanced error notification

PLC error messages For each entry (i.e. error message) in the PET file, the machine manufacturer can enter the name of a help file (*.CHM) and a help number within this *.CHM file. This is done with the two new columns in the PET table, ONL Name and ONL Number. The called help files mustas mentioned earlier be present and language-sensitive in the TNC:\tncguide\de, TNC:\tncguide\en, etc. directories. When a PLC error message is current and the user then presses the ERR key and the HEIDENHAIN TNCguide soft key, the appropriate chapter from this file is shown (context-sensitive call). If a help number but no *.CHM file is indicated, the main.chm file is automatically shown. If the OEM has adhered to the permanently defined help-number ranges for the respective files (see above for the help-number ranges), then the correct, context-sensitive help page is shown in this case as well. NC error messages The machine manufacturer has the possibility of calling his own additional error descriptions for NC errors. This is also done with a separate CHM file. With the OEMERRORCHM.FILE and OEMERRORCHM.OFFSET entries in OEM.SYS, context-sensitive links to any page in the OEM file can be created. Under OEMERRORCHM.FILE you must enter the *.CHM file in which the error number is to be searched. If main.chm is entered under OEMERRORCHM.FILE, the error number is searched for from there and the entire directory tree of main.chm is displayed. If the error number is not found, the start page of main.chm is shown. Under OEMERRORCHM.OFFSET you must enter an error number that is used as an offset. The number of the NC error is added to the number entered here. The resulting error number is then searched for. Example: OEMERRORCHM.FILE = main.chm OEMERRORCHM.OFFSET = 10000000 If, for example, the NC error message Key nonfunctional is shown (NC error number 938), the resulting error number = 10000938. If you press the ERR key now, two soft keys are offered. If you press the HEIDENHAIN TNCguide soft key, the HEIDENHAIN error description appears. If you press the MACHINE MANUFACTURER soft key, the resulting error number (e.g. 10000938) is searched for in the given CHM file. The appropriate page is opened if the error number exists, otherwise the start page of the given file opens. The help files to be called mustas mentioned earlier be present and language-sensitive in the TNC:\tncguide\de, TNC:\tncguide\en, etc. directories. The MACHINE MANUFACTURER soft key is only displayed if one of the two entries named exists in OEM.SYS.

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Including an OEM-specific online help file

Once you have created a valid *.chm file, proceed as follows in order to display your own OEM-specific help file in the HEIDENHAIN TNCguide:

You may need to rename your *.chm file. You must use one of the names reserved by HEIDENHAIN for OEM help files. e.g. OEM1.CHM Use TNCremo to transfer the help file to the control. Store your help file in the appropriate language directory: TNC:\tncguide\de, TNC:\tncguide\en, etc. If you have created only an English help file, HEIDENHAIN recommends placing it in the other language directories as well. Press the HELP key to call the TNCguide. Your help file should now automatically be included in the TNCguide directory tree.

National languages

CHM files will not be available for all possible TNC dialog languages at the time the NC software is released. We are planning on delivering the German and English languages with the software, and the CHM files in other languages will be made available for free downloading (for unregistered users as well, of course) from our FileBase. The user then simply downloads the appropriate file(s) for the respective language(s), and stores them in the directory defined by us on the TNC hard disk: TNC:\tncguide\de or the appropriate language subdirectory. A readme.a file is located in the respective language directories on the TNC hard disk under TNC:\tncguide\. This file describes the procedure for loading the CHM files from our FileBase. The following link leads directly to the CHM files on the FileBase: http://filebase.heidenhain.de/public/?open[]=179&open[]=92&open[]=177&o pen[]=178#GROUP179

Online help files and TNCremoNT

Starting in November, a new version of TNCremoNT will be available from HEIDENHAIN. It has been optimized for handling the online help files (file extension .chm) of NC software version 340 49x 03. Transfer of *.chm files: Online help files are binary files. If TNCremoNT is updated to version 2.5, the file extension .chm is automatically added to the list of binary file types. Otherwise the list of binary file types must be amended manually under Extras > Configuration on the Mode tab in order to transfer them correctly. Performing a backup of the TNC via TNCremoNT: Online help files are automatically untagged during creation of the scan list used for the backup. This also applies to CHM files desposited on the control be the OEM. Reason: The *.chm files saved on the control require a large amount of memory, and do not need to be backed up, since they are freely available from the HEIDENHAIN homepage. By the way: This setting can be applied to other file types as well in TNCbackup under Edit > Settings.

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1.7 Hardware
1.7.1 TE 535P General information The new operating panel corresponds to the TE 530B with machine operating keys.

Technical characteristics: NC operating panel: Same as TE 530B Machine operating panel: 6 axis-direction keys 12 function keys Keys for spindle start and spindle stop All keys in the machine operating panel are snap-on keys. EMERGENCY STOP button Key for control voltage ON (RAFI key) Two bore holes for additional RAFI buttons (shipped blocked with a cover) or key switches. Optional: Three-stage key switch for selecting the operating mode (ID 238 495-02)

ID 547 577-xx

TE 535P

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Connection overview X3 D-sub, 37-pin male Pin no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 PLC input

X3 / X10:

Key symbol

X10 D-sub, 37-pin male Pin no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

PLC input

Key symbol

I128 I129 I130 I131 I132 I133 I134 I135 I136 I137 I138 I139 I140 I141 I142 I143 I144 I145 I146 I147 I148 I149 I150 I151 I152

X Y Z IV Page through form X+ Y+ Z+ IV + VI VI+ Spindle right Tool change Flush water on Retract axis Spindle start Chip conveyor direction Chip conveyor on NC start NC stop Rapid traverse V Spindle stop V+ Retract tool

Free Free Free Free Free Free Free Free Free Free Free

VI+ Chip conveyor on Spindle on Coolant on Internal cooling on FN1 FN2 FN3 Release No function Not assigned Not assigned VI Not assigned Not assigned

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HEIDENHAIN Technisches Handbuch iTNC 530

Some machine keys are transmitted via connector X10 of the machine operating panel. These signals must be processed by the PLC via PLC inputs on connector X42 of the MC 4xx. Key assignment for machine operating panel
S 1 S 2 S 3 S 4 S 5 S 7 S 8 S 9 S 10 S 11 S 12

S 14

S 15

S 16

S 17

S 18

S 20

S 21

S 22

S 23

S 27

S 28

S 29

S 30

S 31

S 33

S 34

S 35

S 36

S 38

S 39

Dimensions
400 3760.2 8 12 0 59 +1 0 45 +1 0

3540.2

370

M5

1.7
17.9
16 . 2

302
2

330.5

8 +1 0

366.25

5.5

1 4

M5

3540.2

354 +1 0

11x45

3760.2
+1 f 384 0

September 2006

Hardware

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10

10.4

1.7.2 PLB 511/PLB 512 PLC basic modules The PLB 511 and PLB 512 PLC basic modules have been available since March 2006. The PLD 16-8 and PLA 4-4 PLC modules can be used as input and output modules.

PLB 511 with 6 slots

ID 556 941-01 PLB 512 with 8 slots

PLB 511

ID 557 125-01

PL 512

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Commissioning and configuration

The new PLB 511 and PLB 512 basic modules can be used immediately, without updating the control software, and also in combination with the PLB 510. A mixed configuration of the basic modules is possible. The same cable is used for the connection as for the PLB 510. The configuration and interrogation within the PLC is performed as with the PLB 510. The following basic conditions must be taken into consideration: The control always and only detects PLB basic modules with 4 slots. A PLB 511 and a PLB 512 are each always interpreted as two PLBs with 4 slots each. As before, a maximum of 16 PLC I/O modules (slots), distributed over all PLBs used, can be addressed. Due to the fixed addressing in blocks of 4 slots, the non-existent slots 7 and 8 on a PLB 511 with 6 slots are wasted (see the example for two PLBs with 6 slots). In compatible mode, only the digital inputs/outputs of slots 1 to 4 function on a PLB 512. The digital inputs/outputs of slots 5 to 8, analog inputs and status information cannot be used. The sum of all logically existing PLs must be less than or equal to four PLs. In addition, the following must be considered for controlling from a PLC program: In order to use PLB 511 or PLB 512 completely, the corresponding PLC modules must be called for two PLs in each case. Slots 5 to 8 cannot be addressed. Here a recalculation to another basic module and slots 1 to 4 must occur. A PLB 511 presents the non-existing slots 7 and 8 as empty.

Using PLC Modules

Module 9007 Diagnostic information Diagnostic information 3 (number of connected PLs) supplies two modules per PLB 511 or PLB 512. Module 9002, 9005, 9008, 9009 Read PL inputs/Set PL outputs These modules must each be called twice for each PLB 511 or PLB 512. Module 9137, 9138 Read diagnosis/Read analog inputs These modules address the required information in the following format: Basic-module number/slot/number of the information. Here the slots 5 to 6 (PLB 511) or slots 5 to 8 (PLB 512) must be recalculated to another basic module and to slots 1 to 2 or 1 to 4 respectively.

September 2006

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1 103

Using address ranges

Address ranges when using four PLB 510 modules with 4 slots each:

Address ranges when using two PLB 511 or PLB 512 modules:

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HEIDENHAIN Technisches Handbuch iTNC 530

Examples of possible combinations:

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1 105

Examples of combinations that are not possible:

A combination of PL 410 and PLB 511 or PLB 512 is not possible:

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HEIDENHAIN Technisches Handbuch iTNC 530

Example

This example uses the following system. It is assumed that the number of the logical PL corresponds to its physical position.

The following picture shows what the control sees:

PLC Module 9007 supplies the value 4 for the Number of connected PLs.

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1 107

The digital inputs are read as follows from the PLC program: PS CM PS CM PS CM PS CM K+0 9002 K+1 9002 K+2 9002 K+3 9002 * Second PLB510, I320..I383 * PLB512 (5th to 8th slot), I256..I319 * PLB512 (1st to 4th slot), I192..I255 * First PLB510, I64..I127

Or realization via loop programming (principle depiction): PS PS CM PL WHILET PS block CM 9002 INC block ENDW K+0 K+3 9007 DG_blockNumber * Number of connected PLs

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The analog inputs can be read out from the PLC program as follows (assuming that both PLB 510s have analog modules in their first slots, and the PLB 512 has them in the 4th and 8th slots) The third analog input is read in each case. PS PS PS CM PL PS PS PS CM PL * * * * * * * * * * K+0 K+3 K+2 9138 DG_Analog_PL510_1_Slot4_AE3 K+1 K+3 K+2 9138 DG_Analog_PL512_Slot4_AE3 * Analog value * Analog value * Number of the central module * Number of slots 0..3 * Analog inputs from 0 to 7 * Number of the central module * Number of slots 0..3 * Analog inputs from 0 to 7

The following program section would be incorrect since slot 7 doesnt exist for the control. Slots 4 to 8 are seen as a separate PL. The addressing must be adapted to the PLB 510. PS PS PS CM PL K+1 K+7 K+2 9138 DG_Analog_PL512_Slot4_AE3 * Analog value * Number of the central module * Number of slots 0..3 * Analog inputs from 0 to 7

Slots 4 to 8 of the PLB 512 can be accessed with this program section. PS PS PS CM PL PS PS PS CM PL K+2 K+3 K+2 9138 DG_Analog_PL512_Slot4_AE3 K+3 K+3 K+2 9138 DG_Analog_PL510_4_Slot4_AE3 * Analog value * Analog value * Number of the central module * Number of slots 0..3 * Analog inputs from 0 to 7 * Number of the central module * Number of slots 0..3 * Analog inputs from 0 to 7

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Dimensions
148 PL 510/550: 139, PL 511: 183, PL 512: 227 3.25 51 95 132

X2

X3

135

X1

78

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HEIDENHAIN Technisches Handbuch iTNC 530

1.7.3 CML 110 Capacitor Module General information The CML 110 (Capacitor Module Low Voltage) for realizing the LIFTOFF function in case of a powerfail has been available for the iTNC 530 with CC 424 since April 2006. The LIFTOFF function can protect workpieces and tools from damage. If the LIFTOFF function is activated (please see the iTNC 530 Technical Manual), the iTNC 530 attempts to use the energy remaining in the dc-link to lift the tool off of the workpiece in the case of a powerfail. In this case, the various enablings for operating the control system must be maintained during the LIFTOFF. The CML 110 ensures the 24-V supply for this. CML 110 capacitor module for 24-V power supply Specifications Power supply: Capacity: Max. charging current: Inner resistor (discharge) maximum: typical: Discharge current is not limited. ID 574 087-01 CML 110 Danger Before service or maintenance work, you must ensure that the CML 110 has been completely discharged. Connection The CML 110 capacitor module is connected via X1 parallel to the 24-V power supply (++/- -). 156 mOhm 65 mOhm 24 V 5.0 F 2.4 A

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Utilizability

Calculating the utilizability of the CML 110: A successful LIFTOFF mainly depends on sufficient energy being available in the dc-link of the inverter system. Generally it suffices if the energy in the dclink is available for the duration of one second. The 24 V supply must also be ensured for precisely this time. The following formula can be used to check this: t = RL x C x In (UO/UC) where: t = time until UC is reached RL = ohmic load of the consumers C = capacity of the CML (for CML 110 = 5.0 F) ln = natural logarithm UO = output load of the power supply unit with which the CML is operated UC = lowest voltage at which the consumers still fulfill their function Example: During operation, the triggering of the control components requires a total current of 10 A at 24 V. This is equivalent to an ohmic load of 2.4 Ohm. In addition, the voltage for the 24-V components may not sink below 18 V (e.g. switching voltage of the contactors), for example. This means: t = 2.4 Ohm x 5.0 F x ln(24 V/18 V) t = 3.45 s If the line voltage fails, then in the best case the voltage will not fall below 18 V until 3.45 seconds have passed. This is significantly longer than 1 second, and so the CML 110 is suitable for LIFTOFF here. If the capacity of the CML 110 should not suffice, then you can also switch more than one CML 110 in parallel. However, here you must note that a maximum charging current of 2.4 A per CML 110 is to be expected at switchon. The full power of the 24-V power supply unit can only be used once all CMLs have finished charging.

Dimensions
125 135 +2 0

102.5

Hutschiene 35 mm EN 50 022 Mounting rail 35 mm EN 50 022

55

14.9

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HEIDENHAIN Technisches Handbuch iTNC 530

106.5

1.7.4 USB Hub General information A USB hub for integration in the control operating panel will be available as of October 2006. The touch pads of TE 530B and TE 535 P and other USB units can be connected to this hub. A 24-V power supply is needed for the USB hub. The hub can be installed in the operating panel in such a way that the USB sockets X141 and X142 can be accessed from outside the operating panel. You can protect these sockets against splash water with the optional cover cap (Id. Nr. 508 921-01). The cover is secured with a double-sided adhesive tape (shaped part that is included) and adjusted using adjustment pins. The positions of the holes necessary for the adjustment pins and the cutout for X141/X142 in the operating panel can be seen in the dimension drawing. USB hub for integration in the operating panel Specifications Supply voltage: 24 V Inputs: X1 Power supply 24 V / max. 300 mA (as per IEC 742/VDE0551) X140 USB-B input USB-A output on rear: X141, X142 USB-A output on front: X143, X144 Maximum load capacity of the outputs: 2 x 100 mA, 2 x 500 mA, any distribution ID 582 884-01 USB hub Cover cap (IP 52)

ID 508 921-01 Cover cap

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Connection overview

1: USB connecting cable 354 770-xx. For lengths starting from 12 m, a USB connecting cable with amplifiers (365 499-xx) must be used. 2: USB connecting cable 354 770-xx. Connection to X143 or X144. The other connection remains vacant. 3: Optional cover cap as protection against splash water 508 921-01 4: USB memory stick, USB cable, etc. to external devices (for any uses) 5: Operating panel

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HEIDENHAIN Technisches Handbuch iTNC 530

Dimensions
Zubehr Abdeckung Accessory cover

M3

50

17.5

109 1000.2 A

28

80

700.2

3.4 68

500.2 2.5

300.2

37

17.5

3.5 19 42 600.2

93.2 A 180

m = Montageauschnitt
Mounting hole

September 2006

Hardware

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40

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1 Update Information No. 17


1.1 Overview
1.1.1 Released Service Packs The following service packs were released for 340 422-14 and 340 423-14: Service pack 1: Service pack 2: Service pack 1: Service pack 2: Service pack 1: Service pack 1: 1.1.2 Released NC Software The following versions of the NC software were released: NC software 340 490-03 and 340 491-03 NC software 340 492-03 and 340 493-03 September 2006 September 2006 June 2006 October 2006

The following service packs were released for 340 480-14 and 340 481-14: June 2006 October 2006

The following service packs were released for 340 490-03 and 340 491-03: November 2006

The following service packs were released for 340 492-03 and 340 493-03: November 2006

November 2006

Overview

11

1.2 NC Software 340 49x-03 Service Pack 1


1.2.1 Important Notes PLC positioning with active collision monitoring (DCM) As of software version 340 49x-03, when DCM is active PLC positioning commands will not be executed until all axes have traversed the reference points. The NC will issue the error message "DCM: Traverse reference points." Since a considerable time, it has been possible to define the PLC basic program (by using configuration parameters) so that, subsequent to the reference run, an axis is automatically moved to a defined position by means of a PLC positioning command (e.g. rotary axis to 0, Z axis to clearance height). Also, you can configure all axes to traverse the reference points in the defined sequence (standard setting) upon NC start. The PLC automatically generates an NC start for this purpose. The context described above has the following consequences: PLC positioning movements are no longer possible in the reference run mode when DCM is active. There is a danger of collision because on the one hand the PLC does not check the PLC positioning movements for correct execution, and on the other the automatic NC start prevents the machine operator from seeing the NC error message. But in spite of this, the reference run for the next axis starts automatically. Solution: HEIDENHAIN has released the Service Pack 01, which allows you to define the PLC module 9221 so that collision monitoring is set inactive for a PLC positioning movement in a specific axis. HEIDENHAIN provides a new PLC program ("Basis_53") on the filebase, which monitors the PLC positioning movement for complete execution and informs the machine operator about a possible collision at the respective position. The error message "Warning! DCM not yet active, permit positioning of axis <axis> ? must be acknowledged by the machine operator by pressing NC start in order to start the PLC positioning movement (e. g. rotary axis to 0, Z axis to clearance height). To prevent the danger of a collision, the machine operator must check the current axis positions. The process can be interrupted at the respective position by pressing the NC stop key or an axis-direction key. The reference run can then only be continued manually by pressing the axis-direction keys.

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HEIDENHAIN Technical Manual iTNC 530

If you are using software version 340 49x-03, the following problem can occur with a PGM call: With long programs that contain a PGM CALL after block 65 535, it can occasionally happen that the called program is not executed completely. Please supply machines with iTNC 530 and software version 03 only with Service Pack 1 and take care that machines in the field with software version 03 are updated with Service Pack 1. If you need assistance, please contact the HEIDENHAIN service department. Unjustified error messages with EnDat encoders Until December 2005, a protocol was used in the EQN 1325 and ECN 1313 EnDat encoders that caused the unjustified "EnDat defective ..." error message if the encoder was connected to a CC 422 with a certain version of the control software. This error message always occurs when the control is booted. This can lead to problems with the software versions currently in use if an exchange motor featuring such an EnDat rotary encoder is installed. If the "EnDat defective ... " error message appears when exchanging a motor with an EnDat encoder on a CC 422, HEIDENHAIN recommends updating the control software to one of the versions listed below. You can determine in advance if a motor with EnDat encoder can be used by checking if the serial number of the encoder (not the motor) has the index "A." You must remove the motors encoder cover in order to read it. If an unusable encoder is mounted in the motor, it must be exchanged; or the corresponding, operational software version listed below must be installed when mounting the motor on the control. Affected software 340 49x-01 (all SPs) Up to and including 340 49x-02 SP 2 Up to 340 422/23-12 including SP 3 Up to 340 480/81-12 including SP 3 340 420/21-xx Corrected as of software 340 49x-02 SP 3 340 422/23-12 SP 4 340 480/81-12 SP 4 No error correction planned, update to version 340 422/23 necessary

November 2006

NC Software 340 49x-03 Service Pack 1

13

1.2.2 Description of the New Functions Machine parameters MP 2206.x Overwrite Type of encoder from the motor table On a CC 424 the input value 4 can now be entered in MP 2206.x (linear motor with one reference mark). The commutation angle must not be determined by using the current controller window. It is determined automatically when the drive is switched on (MP2254.x = 0). When the reference mark is traversed for the first time, it is saved in MP 2256.x. Module 9170 Finding the current torque (expanded) Unlike the description in the Technical Manual, the PLC module 9170 up until now gave the current nominal torque value in percent instead of tenth of percent when Mode 0 was active. Module 9170 now allows you to read the current torque value in percent (Mode 0) or tenth of percent (Mode 1). <Mode> = 0: Torque value in percent of the nominal torque <Mode> = 1: Torque value in tenth of percent of the nominal torque Module 9221 PLC positioning (expanded) With module 9221, you can now deactivate collision monitoring for a specific PLC positioning movement. This means that it is also possible to position an axis when DCM is active and the reference marks have not yet been traversed in all axes. In Module 9221, bit 3 is now available for <Mode>: Bit 3 = 0: Behavior as before (collision monitoring is active) Bit 3 = 1: Collision monitoring is deactivated A PLC positioning command can only be executed if collision monitoring is deactivated for all axes involved in the positioning movement. The deactivation of collision monitoring for the PLC positioning movement does not affect the status information provided by Module 9064. Module 9312 Change machine parameters in the current machine-parameter file (modified) Module 9312 is used to dynamically overwrite the values of the machine parameters in the active machine-parameter file and the DSP process memory, or only in the DSP process memory. For machine parameters defined as numerical values, the new value can also be programmed as a string. Conditions: For numbers the values must be returned as an integer. The decimal point is shifted by the number of possible decimal places. For example, if MP910.0 is to be set to 100.12 mm, then the <MP value> transferred must be = 1001200. (4 possible decimal places lead to a multiplication by 10 000). For non-indexed machine parameters, zero must be programmed as the index. Once the NC program has started, the module operates only during the output of M/G/S/T/T2/Q change signals. Depending on the changed machine parameters type, the geometry is reinitialized. Not every MP can be changed by the PLC.

PLC modules

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HEIDENHAIN Technical Manual iTNC 530

If a new value for a machine parameter defined as a numerical value is programmed as a string, the value is converted to the decimal system (even if the new value is programmed in the "$0004" or "%0000011111" format, for example). If the new values are immediately transferred after the modification of the active machine-parameter file and the process memory (bits 1 and 2 not set in the parameter "Mode"), the marker 4174 (first run after MP was changed) is set. If the new machine parameters are not transferred immediately, the new values will become effective when the module is called again without bit 2 being set. Call: PS B/W/D/K <>Mode> Bit 0: 0 =Modify MP numerical value (MP is a number) 1 =Modify MP string (MP is a string) Bit 1: 0 = Modify parameter in file and memory (bit 2 is then also relevant) 1 = Modify parameter in process memory (behavior like Module 9031) Bit 2: 0 =Modify file and memory and immediately assume value(s) in NC 1 =Modify file and memory, do not immediately assume new value(s) in NC Will be assumed at next call with bit 2 = 0 B/W/D/K/S<>File name> not supported at present (a value must be transferred (e.g. S""), but the value is not evaluated yet) B/W/D/K <>MP number> B/W/D/K <>MP index> B/W/D/K/S<>MP value> Depending on the mode, the MP value is interpreted as a PLC string number, PLC constant string or number 9312 B/W/D <>Error code> 0: No error 1: Parameter does not exist or cannot be changed 2: New value for parameter is invalid 3: Error while saving 4: Call was not in a submit or spawn job 5: Call during running NC program without change signal 6: Invalid PLC string for file name or MP value 7: Parameter file does not exist

PS

PS PS PS

CM PL

Error recognition: Marker M4203 Value 0 1 Meaning No error See error code

November 2006

NC Software 340 49x-03 Service Pack 1

15

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HEIDENHAIN Technical Manual iTNC 530

1 Update Information No. 18


1.1 Overview
1.1.1 Released Service Packs The following service packs were released for 340 490-02 and 340 491-02: Service pack 09: Service pack 09: 1.1.2 Released NC Software The following versions of the NC software were released: NC software 340 490-03 and 340 491-03 NC software 340 492-03 and 340 493-03 September 2006 September 2006 December 2006

The following service packs were released for 340 492-02 and 340 493-02: December 2006

December 2006

Overview

11

1.2 NC Software 340 49x-02 Service Pack 09


1.2.1 Important Note Warning Starting immediately, please only ship all machines with iTNC 530 and software version 340 49x-02 with service pack 09! Error description: When approaching the reference marks, an incorrect point can be determind in rare instances. This affects machines equipped as follows: iTNC 530 with software version 340 49x-02 (including service packs 01 up to 08) Controller unit CC 424(B) Axes with two encoders (motor and position encoder) Incremental motor encoder and incremental position encoder (this error does not occur if one of the two encoders is an Endat encoder) This error can only occur if all four conditions listed above are fulfilled. Corrective action: Please install service pack 09 starting immediately on all machines for initial delivery. HEIDENHAIN recommends retrofitting machines in the field with software version 02 (including service packs 01 up to 08). If you require support, please contact the HEIDENHAIN service department. As an immediate workaround for linear encoders with distance-coded reference marks, machine parameter MP 1350 can be set to 4. Four reference marks are then used to determine the reference point. The control detects that the reference point was not reproduced clearly, and displays the Ref mark <axis>: Incorrect spacing error message. The reference marks must be approached again.

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HEIDENHAIN Technical Manual iTNC 530

1 Update Information No. 19


1.1 Overview
1.1.1 Released Service Packs The following service packs were released for 340 422-14 and 340 423-14: Service pack 1: The following service packs were released for 340 480-14 and 340 481-14: Service pack 1: The following service packs were released for 340 490-03 and 340 491-03: Service pack 1: Service pack 2: Service pack 3: Service pack 4: Service pack 5: Service pack 6: Service pack 7: Service pack 1: Service pack 2: Service pack 3: Service pack 4: Service pack 5: Service pack 6: Service pack 7: 1.1.2 Released NC Software The following NC software was released: NC software 340 490-04 and 340 491-04 NC software 340 492-04 and 340 493-04 December 2007 December 2007 November 2006 January 2007 March 2007 May 2007 July 2007 September 2007 October 2007

The following service packs were released for 340 492-03 and 340 493-03: November 2006 January 2007 March 2007 May 2007 July 2007 September 2007 October 2007

December 2007

Overview

11

1.2 NC Software 340 49x-04


1.2.1 Important Notes Warning This NC software will only run on MC main computers with at least 256 MB of main memory! This applies to single-processor and dual-processor controls! You must upgrade the main memory of your control to at least 256 MB. Please contact your HEIDENHAIN service agency for this. Memory expansion for software option Python OEM Process #46 In order to use Option #46 Python OEM Process , you must increase the main memory of your control to at least 512 MB. Please contact your HEIDENHAIN service agency for this. You do not need to increase the main memory if you do not want to use Option #46. This does not impair any of the other features. If the MC being used has no more than 256 MB of main memory, it is not possible to start a Python process although Option #46 has been activated. Since May 2007, a main memory of 512 MB has been a standard feature of all MC 420 (index B), MC 422 C (index A) and MC 422B dual-processor version (index B) main computers. The RAM of the MC can be checked in the herosdiagnose.txt file. The RAM of the MC is listed in [kB] under the Total Memory heading. Proceed as follows to create the herosdiagnose.txt file:

While in the Programming and Editing operating mode, press the MOD key. Press the DIAGNOSIS soft key, and then the HEROS DIAGNOSIS soft key.

Discontinuation of USB cables The following USB cables will be discontinued and will be replaced by the new USB cables, ID 624 775-06 to ID 624 775-30. In the new cables the integrated amplifiers are arranged in a reduced interval of 5 m instead of 6 m, and ensure a high operational reliability up to a length of 30 m (see Cable Overview on page 113). Discontinuation as of June 2008: USB cable with ID 365 499-xx The USB cable with ID 365 499-36 (length 36 m) will not be replaced. USB cables from ID 354 770-06 to ID 354 770-12 The USB cables from ID 354 770-01 to ID 354 770-05 (lengths 1 m to 5 m) without amplifier will remain in the product program.

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HEIDENHAIN Technical Manual iTNC 530

New PUR cables for control components New connecting cables will be introduced to connect the control components TE 530B, TE 520, TE 535Q, MB 420, MB 520, PLC inputs and outputs as well as the PL 410B (only if servicing is necessary) to the MC 4xx (see Cable Overview on page 113). The properties of the new PUR cables were improved in order to make them particularly suitable for machine tool applications: Bending radius: >40 mm for rigid configuration, >150 mm for frequent flexing Torsion: Clamping length >1200 mm, rotation angle 180 Suited for drag chains (improved) Previous ID (until June 2008) 244 005-xx 263 954-xx 263 955-xx 289 111-xx 317 788-xx New ID Intended use (starting Dec ember 2007) 635 876-xx 635 877-xx 635 878-xx 635 879-xx 635 880-xx PLC I/O; cable with one connector for OEM MB PLC I/O; cable with connectors at both ends (for TE, MB, PLC I/O) PLC I/O; extension cable for ID 635 877-xx for TE, MB, PLC I/O Connection of PL 410B (cable, service) Connection of PL 410B (cable, service)

Window Manager With software version 340 49x-04, the XFCE Window Manager will be introduced on the iTNC 530 control in order to provide a better overview and to improve the ease of working with multiple windows. This will result in minor changes in the graphical interface of the iTNC. But the operation of the control remains the same.

December 2007

NC Software 340 49x-04

13

1.2.2 Description of the New Functions New options and upgrade functions The following options are enabled by entering a code number. HEIDENHAIN can give you the code number after having been informed of the SIK number. Option #41 Description Additional Languages The following languages are now available as additional dialog languages: Turkish Romanian #46 #48 Python OEM Process: Possibility to execute a Python process on the control KinematicsOpt: Performing an initial measurement and optimizing the active kinematics 530 184-08 530 184-09 579 650-01 630 916-01 ID

#101 to #130

OEM Option 1 to OEM Option 30: Possibility to 579 651-01 enable OEM applications for the end user via the to SIK from HEIDENHAIN. 579 651-30

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HEIDENHAIN Technical Manual iTNC 530

Machine parameters

Expanded: MP750 Hysteresis for the axes (backlash compensation) The input range was expanded from +/ 1.0000 [mm] or [] to +/ 9.9999 [mm] or []. Input: 9.9999 to +9.9999 [mm] or [] Expanded: MP1060.x, MP1061 and MP1070 Acceleration parameter The input range for the machine parameters MP1060.x, MP1061 and MP1070 was expanded. Input: 0.001 to 500 [m/s2] Expanded: MP1085.x, MP1086.x and MP1090.x Jerk parameter The input range for the machine parameters MP1085.x, MP1086 and MP1090 was expanded. Input: 0.0 to 9999.9 [m/s3] Expanded: MP1160 LIFTOFF at power failure The input range for MP1160 was expanded. Input: 0.0000 to 30.0000 [mm] Danger Limit switch monitoring is not active during LIFTOFF. Note Perform the LIFTOFF function on the machine to check whether the tool lifts off the complete distance defined in MP1160 without problems. Due to the dynamics of a machine, it may occur that the LIFTOFF (if values > 10 mm are defined in MP1160) cannot be executed completely and is aborted with an error message. Expanded: MP1515.x kv factor for velocity feedforward control (M 105) The input range for machine parameter MP1515.x was expanded. Input: 0.100 to 1000.000 [m/(min*mm)]

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MP1352 Activate the software limit switches before traversing the reference marks Controls with software version 340 49x-04 and higher save the last axis positions that were traversed before switch-off. These positions allow you to check the traverse ranges of the axes when traversing the reference marks. This can be activated for a specific axis in MP1352 and is switched on/off with the MONITOR SW LIMIT soft key. This soft key is available after the control has been switched on in the "reference mark traverse" operating mode. Input: %xxxxxxxxxxxxxx Danger When approaching the reference marks again (e.g. after switching the axis), this monitoring function is not active. If fatal error messages occur, the position at shutdown may not be exactly identical to the position at switch-on. Please inform your customers for which axes you have enabled the activation of the software limit switches in MP1352, and for which axes you have not enabled it. The MONITOR SW LIMIT soft key is available when MP1352 is set for at least one axis. The user, however, is not informed for which axes the software limit-switch monitoring function before reference-mark traverse is active. As of CC 424: MP2198.x Type of power supply module In MP2198.0 and MP 2198.1 you enter the types of power supply modules being used. This makes it possible to calculate the dc-link power for display in the oscilloscope. The entries in the SUPPLY.SPY table must be used for MP 2198.x. The table is stored in the PLC:\mp\ directory. In the MP editor a soft key in the second soft-key row is available for manually entering the name of the power supply module into the MP. Input: Name of the UV Default setting: (Empty string) As of CC 424: MP2199.x Assignment of the servo drive to the power supply module In MP2199.x you assign the respective axis/spindle to one of the two power supply modules defined in MP2198.x. Input: 0: The axis/spindle is assigned to the UV in MP2198.0 1: The axis/spindle is assigned to the UV in MP2198.1 As of CC 424: MP2221.x bit#7 Switch-on time of servo drive MP2221.x bit#7 enables you to deactivate the reduction of a drive's switch-on time when it is switched on with PLC module 9161. If spindles with wye/delta switchover but without evaluation of the status of the wye/ delta contactor are used, it may occur that the drive is switched on again before the contactor has switched over to the appropriate mode. If this occurs, the current controller sets the voltage to the maximum possible value. If the contactor is then closed, this may lead to overcurrent, and as a result, to a switch-off (e.g. due to error message 8B60) of the drive. The reduction of the switch-on time when a drive is switched on by PLC module 9161 was introduced with software 340 49x-03. In some cases, problems occurred after a software update. You can now deactivate the reduction of the switch-on time with bit#7 of MP2221.x. Input: 0: Reduction of the switch-on time is active 1: Reduction of the switch-on time is not active

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MP2222.x Reserved MP2222.x Reserved As of CC 424: MP2250.x Determining the field angle without moving the motor A new method was introduced for determining the field angle, which makes it possible to establish the relationship between the position of the incremental encoder and the position of the rotor magnets even if there is considerable noise in the encoder signals. (See New Functions as of CC 424 on page1 87) Input: 4: Method 4 (if there is a lot of noise in the encoder signals) As of CC 424: MP2195 bit#7, bit#8 Suppress the error messages from the HEIDENHAIN power supply units The SUPPLY.SPY table for the power supply modules contains the STATUS-SIG column for the status signals of the power supply module. This column informs you, among other things, whether the PF.PS.AC and PF.PS.DC is supported by the power supply module. This information in SUPPLY.SPY is evaluated by the CC 424 and higher. The new bits #7 and #8 of MP2195 enable you to deactivate the error messages that may be triggered by the evaluation of these signals (PF.PS.AC, PF.PS.DC). The introduction of the new bits enables you to do this without having to change the SUPPLY.SPY table. MP2195 bit#7 If MP2195 bit#7 is set, the error message triggering the PF.PS.AC signal is suppressed. 0: Previous behavior; Error message is not suppressed 1: Error message is suppressed MP2195 bit#8 If MP2195 bit#8 is set, the error message triggering the PF.PS.DC signal is suppressed. 0: Previous behavior; Error message is not suppressed 1: Error message is suppressed MP2309.x Controller parameters are adjusted to closed brake In MP2309.x you can define a time period in which the speed and position controller parameters are adjusted to values for controlling a closed brake when the drive is switched on. This parameter can be used to avoid oscillations in the drive during switch-on when the brake is still closed and the controller is already active. Input: 0: Previous behavior; not active 0.001 to 1.999 [s]

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MP4031 Monitoring of number of PLs In MP4031, you can enter the number of physically connected PLs in order to monitor the number of connected PLs (PL 4xxB, PL B510). When the control is started and every time the PLC is restarted, the entry in MP4031 is compared to the actual number of physical PLs. If the entry in MP4031 is not identical to the number of connected PLs, the PLC is not started and the error message PL: Configuration incorrect appears. Input: 1: Previous behavior; monitoring not active 0 to 4: Number of PLs is monitored MP4043 Delay for shutdown With MP4043, you can delay shutdown of the control (after pressing the SHUTDOWN soft key) to enable the PLC to execute final actions. When you press the SHUTDOWN soft key, the control starts shutting down, PLC marker M4179 is set and the delay time entered in MP4043 starts to elapse. The PLC program can execute final actions during the delay time. If the PLC marker M4179 is reset by the PLC program, the SHUTDOWN process will be continued before the time set in MP4043 has elapsed. The SHUTDOWN process is automatically continued at the latest after the expiration of the time in MP4043. Input: 0: Previous behavior; no delay 1 to 60 [s] If the following conditions apply, however, it cannot be guaranteed that final PLC actions (e.g. data backup of non-volatile memory ranges of the PLC) are executed: If no PLC program is active at the time the control is shut down, (e.g. PLC run time error has occurred, power interruption status), the shutdown time is not delayed. If a PLC run time error occurs during shutdown, the delay is canceled. Expanded: MP6010 Selecting the touch probe You can now select the battery-free TS 444 touch probe by entering the value 3 into MP6010. MP6600 KinematicsOpt: Amount of change In MP6600 you can enter the maximum permissible amount of change for the cycles used in KinematicsOpt. The amount of change prevents you from accidentally changing the machine kinematics too much with KinematicsOpt. Input: 0.010 to 1000 [mm] Default: 0.05 MP6601 KinematicsOpt: Radius deviation of the calibration ball In MP6601 you can enter the maximum permissible deviation of the calibration ball radius. The ball radius is measured and checked with KinematicsOpt. This monitoring feature also detects incorrect probing caused by contamination. Input: 0.010 to 0.100 [mm] Default: 0.02 Expanded: MP7230.x Conversational language MP7230.23 = Turkish (Option #41) MP7230.24 = Romanian (Option #41)

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MP7246 bit#4 ASCII file for machining time per NC block If MP7246 bit#4 is set, the calculation of the tool usage times is written to an ASCII file. This file contains the run time and the absolute end time of each NC block listed by NC block numbers. The name of the ASCII file is derived from the name of the NC program (e. g. NCPROG.H) and has the extension *.POS.DEP (e. g. NCPROG.H.POS.DEP). Input: 0: Do not create ASCII file for machining time per NC block 1: Create ASCII file for machining time per NC block MP7362.x Additional status display in the graphics window The input range was expanded by the MP7362.5, MP7362.6 and MP7362.7 indexes. This enables you to change the colors and the associated background colors for the actual override factor and the actual spindle load on the AFC tab. MP7362.5 = AFC tab Background color Default setting: $0ECECEC MP7362.6 = AFC tab Color of actual override factor Default setting: $000FF80 MP7362.7 = AFC tab Color of actual spindle factor Default setting: $000AAFF MP7444 Reserved Input: 0 MP7641 bit#4 Handwheel superimposition in the active tool-axis direction The VT axis (Virtual Tool Axis) can now be activated for handwheel superimposition in the active tool-axis direction by setting MP7641 bit#4. Input: 0: Previous behavior 1: VT axis can be selected MP7641 bit#5 Inactive behavior of HR 420 If MP7641 bit#5 is set, the keys of the HR 420 (PLC markers 4661 to 4668) are reported to the PLC even if the HR 420 is not active. This enables the PLC to make the keys of the HR 420 (e. g. NC stop, spindle stop) become effective even if the handwheel is not selected. Input: 0: Report the keys of the HR 420 to the PLC only when the HR is active 1: Report the keys of the HR 420 to the PLC even if the HR is not active MP7682 bit#10 Peripheral milling active/inactive You can switch off the peripheral milling function (3-D radius compensation with tool orientation) by setting MP7682 bit#10. As a result, only 2-D radius compensation is active even if M128 with RR/RL radius compensation is active. Input: 0: Peripheral milling allowed 1: Peripheral milling inactive

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PLC modules

Module 9063 Deactivate and activate collision monitoring With PLC module 9063, you can influence the status of DCM collision monitoring in the program run modes of operation. Condition: During program run, collision monitoring can only be deactivated during an NC strobe. PLC module 9064 enables you to interrogate the status of collision monitoring for the current operating mode. It may occur that more than one PLC cycle is executed between activation/ deactivation and feedback from the PLC module 9064. Call: PS PS B/W/D/K <Mode> 0: Collision monitoring active/inactive during program run B/W/D/K <Action> 0: Deactivate collision monitoring 1: Activate collision monitoring 9063

CM

Error code: Marker M4203 W1022 Value 0 1 1 8 21 45 Meaning Function was performed correctly Error code in W1022 Invalid value for mode/action Call was during manual operation mode or during reference run Call was during program run without strobe signal Collision monitoring has already been programmed

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Module 9067 Status of software settings PLC Module 9067 enables you to request status information about software settings. Module 9067 can currently be used to interrogate the software options set in the SIK. Call: PS PS CM PL B/W/D/K <Mode> 0: Interrogate whether SW option is set in the SIK B/W/D/K <Number> If mode is 0: Number of SIK option 9067 B/W/D <Status> Status of SIK option (if mode is 0): 0: Not set 1: Set

Error code: Marker M4203 W1022 Value 0 1 1 2 Meaning Function was performed correctly Error code in W1022 Invalid value for number Invalid value for mode

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Module 9150 Axis-specific reading of axis traverse limits PLC module 9150 enables you to read the axis traverse limits that can be defined (after pressing the MOD key) by the user. If the axis traverse limits are set by the user (after pressing the MOD key), marker 4624 is set. The marker must then be reset by the PLC program. Condition: The default values entered in MP91x.x are the maximum possible values for the axis traverse limits. Call: PS PS B/W/D/K <Axis> B/W/D/K <Traverse range> 0: Traverse range 1 1: Traverse range 2 2: Traverse range 3 1: Current traverse range B/W/D/K <Mode> 0: Axis traverse limits that were changed with the MOD key 9150 D <Positive axis traverse limit> D <Negative axis traverse limit>

PS CM PL PL

Error code: Marker M4203 W1022 Value 0 1 1 2 Meaning Axis traverse limit determined Error code in W1022 Invalid value for mode Invalid value for axis or traverse range

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Module 9188 Call a soft-key function Module 9188 enables you to simulate soft-key functions. The soft-key designation is used for programming. Conditions: For a soft-key function to be simulated the soft key must be contained in the soft-key row that is displayed on the screen or in one of the soft-key rows that are in the same level but on the following screen pages. The parameter Attribute defines whether a function should be activated although the soft key is not displayed in the soft-key row on the screen, but is contained in one of the following soft-key rows. As opposed to module 9186, the status can be determined with error code W1022 as soon as the module is called. The following soft keys can be simulated using the designators listed below: Soft key Soft-key designator SK_NC_Manual_operation_TOUCH_PROBE

SK_NC_Manual_operation_PRESET_TABLE

SK_NC_TOOL_TABLE

SK_NC_Manual_operation_INCREMENT_OFF

SK_NC_Manual_operation_INCREMENT_ON

SK_NC_Manual_operation_PASS_OVER_REFERENCE

SK_NC_Manual_operation_SET_DATUM

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Soft key

Soft-key designator SK_NC_Program_run_TOOL_USAGE_TEST

SK_NC_Program_run_F_MAX

SK_NC_Program_run_AUTOSTART

SK_NC_Program_run_AUTOSTART_ON

SK_NC_Program_run_AUTOSTART_OFF

SK_NC_Program_run_SLASHED_BLOCKS_NOT_ACTIVE

SK_NC_Program_run_SLASHED_BLOCKS_ACTIVE

SK_NC_Program_run_GLOBAL_SETTINGS

SK_NC_Program_run_AFC_ENTER_TABLES

SK_NC_Program_run_AFC_RESULTS

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Soft key

Soft-key designator SK_NC_Program_run_AFC_SETTINGS

SK_NC_Program_run_AFC_ON

SK_NC_Program_run_AFC_OFF

SK_NC_Program_run_GLOBAL_SETTINGS_SET_ STANDARD_VALUES

SK_NC_Program_run_GLOBAL_SETTINGS_SET_ INACTIVE

SK_NC_Program_run_GLOBAL_SETTINGS_UNDO

SK_NC_Program_run_INTERNAL_STOP

SK_NC_Program_run_RESTORE_POSITION

SK_NC_Program_run_MANUAL_TRAVERSE

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Call: PS PS PS

CM

B/W/D/K <Mode> 0 = Simulate the soft key using the soft-key designator B/W/D/K/S<Soft-key designator> B/W/D/K <Attribute> Bit 0: 0 = Soft-key is only simulated if it is in the main row 1 = Soft key is simulated regardless of whether it is in the main or subordinate row 9188

Error code: Marker M4203 W1022 Value 0 1 2 11 20 45 61 62 Meaning No error See error code Invalid value for mode String as a soft-key designator is invalid Call was not in a submit or spawn job Internal operating system error Soft key is neither available in the main soft key row nor in the following soft-key rows Programmed soft-key name does not exist

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Module 9312 Editing/Edited machine parameter in the current machine parameter file Module 9312 enables you to dynamically overwrite the values of the machine parameters in the active machine parameter file and the process memory, or only in the process memory. For machine parameters defined as numerical values, the new value can also be programmed as a string. Conditions: For numbers the values must be returned as an integer. The decimal point is shifted by the number of possible decimal places. For example, if MP910.0 is to be set to 100.12 mm, the transferred <MP value > must be equal to 1001200. (4 possible decimal places lead to a multiplication by 10000). For non-indexed machine parameters, zero must be programmed as the index. Once the NC program has started, the module operates only during the output of M/G/S/T/T2/Q change signals (strobe). Depending on the changed machine parameters type, the geometry is reinitialized. Not every MP can be changed by the PLC. If a new value for a machine parameter defined as a numerical value is programmed as a string, the value is converted to the decimal system (even if the new value is programmed in the "$0004" or "%0000011111" format, for example). If the new values are immediately transferred after the modification of the active machine-parameter file and the process memory (bits 1 and 2 not set in the parameter "Mode"), the marker 4174 (first run after MP was changed) is set. If the new machine parameters are not transferred immediately, the new values will become effective when the module is called again without bit 2 being set.

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Call: PS

B/W/D/K <Mode> Bit 0: 0 =Modify MP numerical value (MP is a number) 1 =Modify MP string (MP is a string) Bit 1: 0 = Modify parameter in the file and in the process memory (Bit 2 is then also relevant) 1 = Modify parameter in the process memory (Behavior like Module 9031) Bit 2: 0 = Change the file and the process memory and immediately tranfer value(s) into the NC 1 = Change the file and the process memory, do not immediately assume new value(s) in NC. Will be assumed at next call with bit 2 = 0 B/W/D/K/S<File name> not supported at present (a value must be transferred (e.g. S""), but the value is not evaluated yet) B/W/D/K <MP number> B/W/D/K <MP index> B/W/D/K/S<MP value> Depending on the mode, the MP value is interpreted as a PLC string number, PLC constant string or number 9312 B/W/D <Error code> 0: No error 1: Parameter does not exist or cannot be changed 2: New value for parameter is invalid 3: Error while saving 4: Call was not in a submit or spawn job 5: Call during running NC program without change signal 6: Invalid PLC string for file name or MP value 7: Parameter file does not exist

PS

PS PS PS

CM PL

Error code: Marker M4203 Value 0 1 Meaning No error See error code

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Expanded: Module 9036 (Writing status information) In Module 9036, you can now also use number 7 as the <number of the status information>. When number 7 is transferred, you can choose between three different handwheel feed rates. The following feed rates can be selected as <Value to be written>: 0 = Slow speed 1 = Medium speed 2 = Rapid speed Expanded: Module 9151 (Select traverse range and axis designation) The PLC module 9151 may now also be called when the user has stopped the machining process with External Stop, and has then activated the MANUAL TRAVERSE function with the appropriate soft key. When RESTORE POSITION is activated, the system checks whether the traverse range has been reset to the original value. If this is not the case, an error message is output and the RESTORE POSITION function is not executed. You can, however, cancel the machining process with External Stop or Emergency Stop. If the traverse range is switched when the MANUAL TRAVERSE function is active (activated by soft key), an active M128 function is automatically deactivated. After switching back with RESTORE POSITION, M128 is reactivated. Expanded: Module 9170 (Finding the current torque) Unlike the description in the Technical Manual, the PLC module 9170 up until now gave the current nominal torque value in percent instead of tenth of percent when Mode 0 was active. Module 9170 now allows you to read the current torque value in percent (Mode 0) or tenth of percent (Mode 1). <Mode> = 0: Torque value in percent of the nominal torque <Mode> = 1: Torque value in tenth of percent of the nominal torque Expanded: Module 9186 (Calling a soft-key function) Number 8 for the MANUAL TRAVERSE soft-key function was added to the module. <Number of soft-key function> = 8: MANUAL TRAVERSE Expanded: Module 9221 (PLC positioning movement) With module 9221, you can now deactivate collision monitoring for a specific PLC positioning movement. This means that it is also possible to position an axis when DCM is active and the reference marks have not yet been traversed in all axes. A PLC positioning command can only be executed if collision monitoring is deactivated for all axes involved in the positioning movement. The deactivation of collision monitoring for the PLC positioning movement does not affect the status information provided by Module 9064. In Module 9221, bit 3 is now available for <Mode>: Bit 3 = 0: Behavior as before (collision monitoring is active) Bit 3 = 1: Collision monitoring is deactivated

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Expanded: Module 9222 (Status request of PLC positioning movement) If PLC positioning movements are not started due to the collision monitoring function, Module 9222 now uses value 7 to report the status "Positioning not started due to collision monitoring". This information is bit-encoded and is provided for all axes. Expanded: Module 9223 (Free rotation) For auxiliary axes (e.g. rotary axes that are configured as auxiliary axes), the PLC module can now also be used without active strobe signal during a running NC program. Expanded: Module 9240 (Opening a file) Bit#3 is now available for <Mode>. Bit#3 is only evaluated in "record oriented" <Mode> (bit#2 = 0). If bit#2 is set, a file is created regardless of bit#3. Bit 3 = 0: Do not create file Bit 3 = 1: Create file if it does not exist Expanded: Module 9248 (copying, renaming or deleting files) For Module 9248, the values of marker W1022 were revised: Memory M4203 Value 0 1 W1022 2 3 7 Meaning Successful execution of module Error code in W1022 Module was called in an invalid mode setting Invalid source string or target string Error during file conversion, source file does not exist or an invalid source drive or target drive was specified Module was not called in a spawn or submit job Copying or renaming not allowed for the current file types Error during renaming or deletion. More information about the error can be requested with Module 9149, immediately after Module 9248 has been called. Or an error occurred during a copying process without conversion.

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Expanded: Module 9250 (Starting the PLC editor for tables) Bit#3 for <Mode> was added to the module. This results in a new error code for W1022. Value 6 in W1022 means that the write protection of a writeprotected file is respected (bit#3 = 1) and that the file cannot be opened. Bit 3 = 1: Write protection of the file to be opened is respected

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PLC programming

Number of SPAWN processes was increased The number of possible SPAWN processes in the PLC was increased from 8 to 16. M4188 Compilation status of the PLC Marker M4188 is set at the beginning of each compilation process in the PLC project. Marker M4188 is reset as soon as the initialization of all components involved in the compilation process has been completed and the PLC has been started. M4225 Activate an alternative error reaction You can now use marker M4225 to activate an alternative error reaction, provided that it is available in the PET table. The new column AE (Alternative error reaction E/C/S/F) was therefore added to the PET table. However, the error reactions that are active at the time an error message occurs will become effective. This means that error messages that were initiated before marker M4225 was set, but have not been displayed yet, will trigger the original error reactions. The following entries can be made in the AE column: E = EMER.STOP C = NC-CANCEL S = NC-STOP F = F-STOP M4680 Disable activation of the HR 420 The activation of the HR 420 can be disabled by PLC. If you set the marker M4680, the message HR not allowed appears in the handwheel's display. If the marker is set and the user presses the handwheel activation key, the error message Wrong operating mode for handwheel appears. If the marker M4680 is set when the handwheel is active, the marker has no effect. M4054 Battery voltage too low Marker M4054 was introduced for the new battery-free TS 444 (MP6010 = 3) touch probe. The marker is set when the the touch probe is ready for operation (M4050) and the supply voltage for the battery-free touch probe is too low. If no touch probe is connected, the value of marker M4054 is undefined. Power is supplied to the battery-free touch probe by compressed air driving an integrated air turbine generator. The capacitor in the touch probe stores energy for approx. two minutes of continuous operation. Evaluation of marker M4054 makes it possible to purposefully control the supply of compressed air. M4624 Changed axis-traverse limits If the axis traverse limits are changed by the user (after pressing the MOD key), marker M4624 is set. The marker can only be reset by the PLC program. M4625 Disable operation with following error / semifeedforward control If the marker M4625 is set, the start of an NC axis for which operation with following error or velocity semifeedforward control is active is prevented, and the error message Semifeedforward not permitted is displayed. The marker is only evaluated when an NC program is started or when the axes are traversed with axis-direction keys. W336 Setting of the AFC OFF/ON soft key The setting of the AFC OFF/ON soft key is mapped in PLC word W336. W336 = 0: Soft key is set to OFF W336 = 1: Soft key is set to ON

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W348 Current mode of AFC In PLC word W348 is now the current mode ( inactive = 0, learning phase = 1, controlling = 2) of the adaptive feed control AFC stored. W348 = 0: AFC inactive (OFF) W348 = 1: AFC in learning phase W348 = 2: AFC controlling W632 AFC control input value from W632 instead of spindle power For the AFC adaptive feed rate control, you can now use the value in PLC word W632 [value in tenths of percent] as control input variable, instead of using the spindle power in percent. A spindle power of 50% corresponds to the value 500 to be entered in W632 (0.1% corresponds to the value 1). This may be necessary for individual applications (e. g. pecking). The control input variable in W632 must be calculated in the PLC program, which can best be done with a fast PLC cycle (e. g. 15 ms). Also, when word W632 is used, no idle load for the spindle is determined and no transitional period for the tool entering or leaving the workpiece is considered. This function must be activated by entering AFC.PLCCONTROL = ON in the OEM.SYS. However, the function only works if a value is entered in W632. W766 % factor for feed rate override If the value 0 is entered in W766, the value 0 is now immediately transferred without smoothing. FN18 ID630 NR0 IDX<n> The new function FN 18: SYSREAD ID630 NR0 IDX<n> makes it possible to interrogate the status of the software options in the SIK. The number of the software option in the SIK must be entered in <n>. The result 1 is returned, when the option is set in the SIK. If the option is not set in the SIK, the result is 0. FN18 ID630 NR1 The new function FN 18: SYSREAD ID630 NR1 enables you to read out the FCL set in the SIK. FN18 ID630 NR2 The new function FN 18: SYSREAD ID630 NR2 enables you to read out the serial number of the SIK. If no valid SIK exists in the system (e. g. programming station), the function returns the result 1.

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System definitions available in the PLC soft-key project file The following system definitions that are already available in the PLC compiler are now also supported by the soft-key generator. They can thus be used in the PLC soft-key project file *.SPJ: $<variantbase>$ (e. g. #ifdef $340422$) $<variant>$ $<model>$ $<VARIANT>$ (e. g. #if $VARIANT$ < 34042210) $<VARIANTBASE>$ $<VARIANTINDEX>$ Environmental variable for conditional compilation The environmental variable %GraphicsResolution% in the PLC configuration file is now available for conditional compilation of the PLC program. The variable is set to the value 1024x768 or 1280x1024, depending on the screen resolution. The content of the environmental variable can be evaluated and used for conditional compilation. Example: define resolution=%GraphicsResolution% ... # if resolution=1024x768 ... #endif ... # if resolution=1024x768 ... #endif

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iTNC Operation and technology

AFC (Option #45) AFC OFF/ON soft key is saved for control reset The setting of the AFC OFF/ON soft key is saved and is not automatically set to AFC OFF when the control is reset or an emergency stop occurs. The setting of the soft key is also retained after switching off the machine with the main switch. AFC (Option #45) Changes during the learning phase The spindle reference power determined with the teach-in cut until this time is displayed in a pop-up window. The new PREF RESET soft key is displayed next to the EXIT LEARNING soft key. This soft key enables you to reset the spindle reference power determined by the teach-in cut until this moment, and to restart reference-value determination. AFC (Option #45) Line diagram display The actual values of the spindle power and override factor defined by AFC are recorded and displayed in a line diagram for diagnosis. Like the previous bar graph, the line diagram is available on the AFC tab. The diagram is generated from the same input data as the bar graph.

AFC (Option #45) Delete entries in the table for control settings The DELETE LINE soft key is now available in the Programming and Editing mode of operation. Only use this function if you specifically want to delete an incorrectly created line from the <NAME>.H.AFC.DEP table for control settings. This may be reasonable when lines were created in the table, which would not have been created during normal program run. Such lines might, for example, be produced when program run is canceled, or by a GOTO command to a previous beginning of a cut. You must confirm deletion in a confirmation request, because deleting a line moves up the following lines with their control parameters. Danger Please note that the control parameters will be assigned to the wrong cuts if you delete lines incorrectly. If you are not sure which line may be deleted, then perform the learning phase anew for the complete NC program. AFC (Option #45) Input area of column PLC expanded In the two tables of controll settings <NAME>.H.AFC.DEP and AFC.TAB the input area of column PLC is expanded from 2 figures to 3 figures.

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DCM (Option #40) Behavior of collision monitoring was changed The behavior of DCM collision monitoring in the Manual Operation mode was changed. The sequence of early warning (distance < 14 mm), warning (distance < 8 mm) and error (distance < 2 mm) is not used any longer. Now the axes are automatically stopped when two collision objects are at a distance of < approx. 4 mm from each other, and a corresponding error message is output. Example of error message: DCM: TOOL Tilting table However, the axes can now be moved again if the motion increases the distance between the collision objects (for example by pressing the axisdirection key for the opposite direction): First release the axis-direction key or stop the handwheel, and then press the appropriate axis-direction key or turn the handwheel in the appropriate direction. Confirming the error message with the CE key is then no longer necessary. If you want to execute a motion that reduces the distance between the two collision objects, you must deactivate DCM collision monitoring for the manual operating mode. DCM (Option #40) Exclude TT for tool measurement During tool measurement with a TT, the CMO protecting the TT can automatically be excluded from collision monitoring. A CMO that has been identified correspondingly will then automatically be excluded during the execution of touch probe cycles TCH PROBE 30/31/32/ 33 or 480/481/482/483. The CMO for the touch probe is identified by entering TT_ENABLE_PROBING in the DOC column of the kinematics table. The CMO identified in this way will be excluded from collision monitoring before the beginning of the touch probe cycle. At the end of the cycle or when the cycle is canceled, the CMO will automatically be included in collision monitoring again. Another possibility for excluding an identified CMO from collision monitoring is to use the function FN 17: SYSWRITE ID 990. The function FN 17: SYSWRITE ID 990 NR6 = 1 causes switching to input X13. The CMO is then excluded from collision monitoring for as long as X13 is active. The following must be kept in mind: You can use TT_ENABLE_PROBING for only one CMO.. If a touch probe cycle is canceled with the EXTERNAL STOP soft key, the tool (TT) should be retracted in the Manual Operation mode before pressing the INTERNAL STOP soft key. The INTERNAL STOP soft key results in the CMO being included in collision monitoring again, and the tool would then be immobilized by collision monitoring. DCM would trigger an error message reporting a distance < 2 mm. The tool (TT) can then not be retracted until collision monitoring has been switched off. After retraction from the measuring point, the tool (TT) must be located sufficiently far from the area for which protection is active again. After retraction, the distance must be > 5 mm. This safety clearance can be defined in MP6540.x.

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DCM (Option #40) Language-sensitive texts in DOC column The texts displayed for selecting the kinematics can now be created as language-sensitive texts. The window for selecting the kinematics is opened after the keyword KINEMATIC is entered. In the DOC column of the kinematics table, you enter a string that consists of the following elements: "#<line number of DIALOG.A>". Depending on MP7230.x, the texts is fetched from the specified line in DIALOG.A, and displayed in the selection window. The line numbers of DIALOG.A are identified by the preceding character #. At present, utf8 characters cannot be displayed in the selection window. If the entry in the DOC column is used as a keyword to make changes to the kinematics by using WRITE TO KINEMATIC, the "#<line number of DIALOG.A> can be entered as KEY. Example: WRITE TO KINEMATIC AT COLUMN "HEIGHT" CAPTURE "DOC" KEY "#143" = 22 DCM (Option #40) Monitoring of chucking fixtures KinematicsDesign mentions possibilities for creating chucking fixtures and chucking fixture templates for collision monitoring of chucking fixtures. These possibilities are preliminary measures for realizing this type of monitoring in the iTNC 530. For more information, please contact HEIDENHAIN. Handwheel superimposition and DCM (FCL 4 function) DCM can now also monitor handwheel superimposition (with M118 or Global Program Settings) for collisions. During program run, however, the handwheel is not active. Handwheel superimposition with active DCM is only possible when program run is stopped with External Stop or with the Single block operating mode. If an offset is defined for handwheel superimposition after the External Stop, this offset is considered by collision monitoring when the NC program run is continued. This behavior also applies to the virtual tool axis VT. 3-D graphics The 3-D graphics was improved. When you activate DISPLAY TOOLS, the improved 3-D graphics with the following new features will appear: Continuous zoom Machining of workpiece can be viewed from all sides Tool is displayed Profiles are displayed Bottom view of model possible

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Python OEM Process #46 software option The Python OEM Process option is an effective tool for you 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 and is well known by experts. "Python OEM Process" can be used for machine functions and complex calculations, as well as to display special information. It is especially useful for the implementation of user-specific or machine-specific solutions, regardless of whether special algorithms or interfaces for special functions have to be created. The applications created can be displayed by the PLC in the familiar PLC windows or in separate freely definable windows that can be expanded to the TNC's full screen size. The system requires 512 MB of RAM. A separate documentation will be prepared for Python OEM Process, which you can download free of charge from the HEIDENHAIN FileBase under "PC software > Python" together with simple examples and additional PC tools for debugging and for the development of user interfaces. Gear transmission or wye/delta switchover and Cycle 209 With software version 04, the RPM FACTOR function is available for Cycle 209 (Tapping with chip breaking). This function must not be used for machines with transmission or wye/delta switchover. Keep the following in mind: Warning On machines with transmission or wye/delta switchover, the RPM FACTOR (Q403) function of Cycle 209 (Tapping with chip breaking) must not be used with a value other than the default value. Switching the gear range or wye/delta switchover during retraction with the RPM FACTOR function may cause damage to the machine. Please inform the customers who are using these types of machines that the RPM FACTOR (Q403) function of Cycle 209 (Tapping with chip breaking) must not be used with a value other than the default value.

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Introduction of the table for the power supply modules The SUPPLY.SPY table was introduced in connection with MP2198.x and MP2199.x. The table contains information on the power supply modules and is evaluated by CC 424 and higher. The table is always stored in the SYS:\mp\ directory. It is also stored in the PLC:\mp\ directory after it has been edited by the user. The iTNC searches for a valid supply module table in the same way as it does with power stage tables. The table for power supply modules contains the following entries: Designation (NAME) Type of power supply module (E-R) 0: No regenerative module 1: Regenerative module Rated power output (P-N) in W Peak power (S6-40) (P-S6-40) in W Peak power for (0.2 s) (P-MAX02) in W DC-link voltage (UZ) in V Ratio of measuring voltage / UZ (UZ-AN) in V/V Ratio of measuring voltage / IZ (IZ-AN) in V/V Status signals (STATUS-SIG) Bit#0:AC-FAIL Bit#1:POWERFAIL Bit#2:TEMP Bit#3:READY Bit#4:Reserved Bit#5:Reserved Bit#6: Reserved Bit#7: Reserved Proportional factor of D controller (P-D) Integral factor of D controller (P-D) Proportional factor of Q controller (P-Q) Integral factor of Q controller (I-Q) PWM frequency (FREQ) in HZ HR 420 Activation possibility was added The HR 420 can now also be activated when probing was activated in the Manual Operation mode. This makes it possible to pre-select a probing cycle and pre-position the touch probe directly at the workpiece with the HR 420. Then the probing process can be started. Also, the HR 420 handwheel can now be activated after pressing the HELP soft key under MOD, and after pressing the 3-D ROT soft key in the Manual Operation mode.

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Integrated oscilloscope (as of CC 424) The integrated oscilloscope was expanded by the following signals: DC-link P If the machine parameters MP2198.x and MP2199.x are configured, the dc-link power of the power supply module for the respective axis can be displayed in the oscilloscope. Amplitude Amplitude of the position encoder Motor A: Signal A of the speed encoder Motor B: Signal B of the speed encoder CC DIAG The signal is axis-specific and connected with an additional input box on the right side of the oscilloscope screen. In the input box you can enter a number for selecting a channel of the DSP. The following channels and signals are available: Number 101 201 202 203 204 205 206 207 208 Meaning Status of emergency stop input (I32) Masking the reference pulse via W1054 Activating the fine interpolation filter (nominal position value filter is active) Position controller is closed W1040 Position control is fed forward (MP1392, MP 1392) Deactivation of monitoring functions via W1042 Position control in semifeedforward mode (MP1396) Rapid switch-off of speed controller (activated in MP4130) DC-link voltage monitoring can be activated via PLC module 9167. The current status can be read via this channel. Ready signal of power module (green LED on the power module) Error signal of power module (triggers an error message) Output for controlling the brake at the power module (X 344) UV ready signal of the inverter DC-link voltage too high DC-link current too high Excessive temperature of UV Leakage current detected by UV NC Software 340 49x-04 1 29

300 301 302 400 401 402 403 404 December 2007

Number 405 600 601 602 603 604

Meaning AC fail signal is active I2T early warning threshold of drive was exceeded Axis enabled (PLC module 9157) Axis is active (PLC module 9162) Commutation angle of motor was measured using the reference mark or EnDat TNCopt function is currently being performed

New column "Radius compensation allowed" in MFUNCT.TAB The new RC ("Radius compensation allowed") column in the MFUNCT.TAB table enables you to define with Y/N whether the macro for the M function is also executed when radius compensation is active (RR/RL). If you enter Y, the macro will also be run when radius compensation is active. Until now, the error message Cancel radius comp. before PLC pos. was displayed. A macro that can also be run during active radius compensation should only contain NC functions that do not influence radius compensation in the calling program. New column "R SENSOR" in INVERTER.INV The resistance of the current sensor is indicated in the new column R-SENSOR of the INVERTER.INV table for the power stages. The entries in this column are maintained by HEIDENHAIN and need not be changed by the machine tool builder. Compensation points of nonlinear axis-error compensation The maximum number of lines, and as a result, the maximum number of compensation points for nonlinear axis-error compensation was increased from 360 to 4000. IPC delays shutdown of the control The control detects if one or more industrial PCs (IPCs) are connected and delays shutdown until the connected IPCs have been shut down (max. delay time of 2 minutes). During the delay time the IP addresses of the connected IPCs are displayed. Automatic termination of LSV2 connections Network connections for LSV2 applications are now cyclically checked. If the remote station does no longer respond (e. g. because the connecting cable was disconnected), the LSV2 connection will automatically be terminated. In the default setting, the connection is checked four times within a ten-second cycle. If the remote station does not respond after the fourth attempt, the connection is automatically terminated. If you do not want a cycle of ten seconds, you can increase the cycle time to a maximum of 6000 seconds with the REMOTE.TIMEKEEPIDLE token in the OEM.SYS. Example of entry in the OEM.SYS: REMOTE.TIMEKEEPIDLE = 250

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Editing the tables for motors, power stages and power supply modules was improved Editing the tables for motors, power stages and power supply modules from the MP editor was improved. If the cursor is located on the respective entry in the machine parameter list (e. g. MP2100.x, 2198.x) in the MP editor, pressing the associated soft key opens the selection list at the corresponding line. If the highlighted entry is not found, the selection list is opened at the beginning of the list. When the selection list is open, two new soft keys are now available. Press the SHOW ACTIVE VALUE soft key to open the respective table (motor.mot, inverter.inv or supply.spy) in write-protected mode. The current values of an entry can then not be edited. No new file will be created on the PLC partition. The CHANGE ACTIVE VALUE soft key allows you to edit the current values in the same way as before. Rotary axes with a traverse range exceeding 360 If you are using encoders with distance-coded reference marks (MP1350), you can now define a traverse range of more than 360 for rotary axes with limit switches (e. g. +/ 190 degrees). When the machine is switched off, the position is stored by the control. This enables the control to ascertain whether the axis is, for example, at a position of 1 or +359 after the machine is switched back on. Log entries The following events are now entered in the log of the control: The event when a file is transmitted to the control via an LSV2 connection, or when a file is copied, renamed, deleted or its write protection is changed on the control by an LSV2 telegram. File extension for compensation files was changed The file extension .trc (derived from torque ripple compensation) was changed to .cmp. If, however, the file defined in MP2260 is not available as a file with the extension .cmp, the corresponding file with the extension .trc will continued to be used.

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Virtual Tool Axis (VT) With the iTNC 530, handwheel superimposed traverse in the active tool axis system (Virtual Tool Axis VT) is now possible when TCPM is active. This function is available in the Global Program Settings (Option#44). When the HR 420 is connected, the position of the virtual tool axis is displayed separately. It can be used in automatic mode when the HR 420/HR 410 is connected. Requirements that must be met for using the Virtual Tool Axis VT: TCPM (Tool Center Point Management) function must be active. DCM (Dynamic Collision Monitoring) must be deactivated. MP7641 bit#4 "Handwheel superimposition in the active tool-axis direction" must be set. MP7503 "Virtual tool axis" must be set. MP7682 bit#9 "Load tilted working plane" should be set for the tilting values to be loaded into the Manual Operation mode during a program interruption. Global Program Setting software option (Option #44) must be activated. In the Global Program Settings you must define the permissible traverse range for the VT axis (as with M118). Marker M4576 "Disable handwheel pulses" must not be set. Associated new functions: In the Global Program Settings for handwheel superimposition, the axis VT can also be activated for the active tool-axis direction. If an HR 420 is used, the axis VT can be selected in the axis menu. When an HR 410 handwheel is connected, the axis VT can be selected via PLC module 9036 (selection parameter 6 (handwheel axis); axis value -1). If parameter 10 (handwheel axis) is selected, the PLC module 9035 supplies a value of $8000000 (bit#31 is set) when the axis VT is active. If the handwheel traverses an offset in this axis, the tool length compensation will change (additional DL). This additional length compensation is retained after a tool change.

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KinematicsDesign available on the iTNC 530 The KinematicsDesign PC tool is now also available on the control. The KinematicsDesign version on the control supports you in optimizing, adjusting and changing the kinematics of your machine. The working space and the collision objects of the active kinematics can be displayed and edited. The version in the control contains almost all the functions of the PC version. The command "File Save as" was removed, because the active kinematics for editing is automatically saved when the KinematicsDesign version on the control is used. All other functions of the PC version that you find under "Edit," "View," "Paste," etc. have been implemented in the control version by using appropriate icons. HEIDENHAIN recommends using a mouse for operating KinematicsDesign. The documentation of the KinematicsDesign PC tool is stored in the PLC:\tncguide\ directory on the control. The operation of the KinematicsDesign PC tool described in the documentation substantially corresponds to that of the KinematicsDesign version stored in the control. To start the tool, switch to the PLC mode of operation. Press the ADVANCED SETUP soft key, and then the KINEMATICS soft key. To switch between KinematicsDesign and the screen of the control, press the screen switchover key. The corresponding icons provide you with the following functions:

Danger When you use the KinematicsDesign version on your control, you edit and change the active kinematics of your machine. The changes made immediately become effective in the active kinematics.

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Requirements on the control: If no valid kinematics is active on the control, or if the entry KINEMATIC = is missing from the OEM.SYS, the error message Kinematics table missing appears, and KinematicsDesign is not started. If you have created the kinematics description only with the KinematicsDesign version on the control and without the KinematicsDesign PC tool, then no .ini file (KineDesign.ini) of KinematicsDesign is available in the control. In this case, it may be necessary to create the file manually. If the machine configuration does not differ from the standard configuration (positive Z axis points up, and the positive X axis to the right) assumed by KinematicsDesign, you do not need to create the KineDesign.ini file. Also, if the kinematics description was transferred to the control by the KinematicsDesign PC tool, the .ini file is created automatically in the control and does not need to be created manually. However, if the configuration of your machine differs from the assumed standard configuration, you must manually create the KineDesign.ini file on the control. The file must be stored in the same directory as the KINELIST.tab file. The KineDesign.ini file must be an ASCII file with the two following entries: UpwardAxis = RightwarAxis = Example of KineDesign.ini: UpwardAxis = Z RightwarAxis = X

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Graphic simulation of the protected space or of collision objects (FCL 4 function) The Screen Layout key and the PROGRAM + KINEMATIC soft key enable you to display 3-D graphics of the collision objects defined in your machine in the Program Run operating modes. The viewer of the KinematicsDesign tool is used for this. However, the collision objects of the machine are only displayed and cannot be edited. A requirement for this to work is FCL 4 or higher and software option #40 (Dynamic Collision Monitoring). If no valid kinematics is active on the control, or if the entry KINEMATIC = is missing in the OEM.SYS, the error message Kinematic table missing appears, and the graphic simulation window remains empty. Whenever a threat of collision occurs, the collision objects concerned are shown in a red frame if DCM is active in the respective Program run mode of operation. Press the right mouse button to rotate the overall view of the collision objects.

New description added to the kinematics description table An input option in the KEY column was added to the kinematics description table: Column KEY Input MachBase Description Defines the stationary part of the machine (machine base) for the graphic simulation in KinematicsDesign. All movements of a machine are simulated around the stationary part of the machine. MachBase only affects graphic simulation in KinematicsDesign. However, HEIDENHAIN recommends entering "MachBase" at the respective position.

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Append 3-D basic rotation to kinematics (FCL-4) Software 340 49x-04 enables you to append a 3-D basic rotation to the end of the kinematics description, e.g. for chucking equipment. When a rotation is appended to the kinematics, the coordinate system of the machine table is rotated with respect to the coordinate system of the machine axes. The preset vector from the preset table is always interpreted as a vector of the coordinate system of the machine table. As a result, the rotations must first be appended to the kinematics, and then the reference point must be determined. The working plane must be correspondingly tilted for the determination of the reference point. The following entries must be appended to the end of the kinematics description (e. g. after the description of the rotary table): Trans C ... Trans B ... Trans A ... Then you can use the WRITE TO KINEMATIC function to enter the coordinates of the rotation in the kinematics table. The rotation becomes effective when the PLANE function is activated. Use Cycle 431 "Measure plane" to determine the spatial angles for the rotation. Then the coordinates of the rotation must be entered in the kinematics description in the sequence described above. The coordinates of the rotation only correspond to the spatial angles of the kinematics description if they have been entered in the described sequence. Please also note that the first two measurement results of Cycle 431 define the orientation of the principal axis (principal axis X if tool axis Z). It may be necessary to align the workpiece in the plane before determining the rotation with Cycle 431. To do this, use Touch Probe Cycle 403. Expansion of the unicode character sets The unicode character sets were completed for the "Latin Extended-A" code range. This makes it possible to display the special characters for Turkish and Romanian. Tool change macro for the simulation In the PLC:\NCMACRO.SYS file, you can now enter the name of a tool change macro using the keyword TCSIMU, which is called during a tool change in the Test Run mode of operation. Like with the TOOL CALL macro for the machine operating modes, a TOOL CALL block must be executed within a macro in order to activate the new tool. Tool types in the magazine rules The maximum number of tool types in the magazine rules (tooltype) was increased from 20 to 99. EnDat encoders Software 340 49x-04 supports EnDat encoders with a resolution of more than 31 bits. This applies both for the reference run and for determining the commutation angle. USB devices It is now possible to connect a mouse or touch pad (USB mouse device) to each of the two ports for USB devices (X141, X142), and to operate them simultaneously. If you want to use this possibility so as to operate the control with two USB mouse devices from two separate locations, the PLC must ensure that only one of the two devices is active at any one time. This could be realized by connecting USB hubs with switchable supply voltage, for example. Also, a USB mouse can be disconnected and reconnected again during operation when controls with software 340 49x-04 are used. The USB mouse is now automatically recognized without needing to reboot the control.

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1.2.3 Drive Name and User Group for USB Device You can now define the drive name and the authorized user group for USB devices. This requires that USBMOUNTS = <path\file> is entered in the OEM.SYS. This entry refers to a file containing one or more lines with the following syntax: <Volume>,<Mountpoint:>,<User> Example of entry in the file that is referred to, e. g. Stickconfig.a: KINGSTON,PLCSTICK:,OEM If the control detects a USB device during startup (only if it was switched on with the main switch), which has a VFAT partition with one of the specified volume names, the device is mounted and displayed with the name specified in <Mountpoint:>, and not with the name USBn:. If the device also has other partitions, the other partitions are ignored except if they are also mounted with a volume name. If a USB device with one of the indicated volume names is connected after the control has started up, the device is mounted with the name USBn: as usual. The new functionality does not become effective until the control is switched off and then back on again. The described function is not available on dual-processor controls with the MC 422B hardware. On dual-processor controls with the MC 422C, the new function only works for USB devices that are connected to a real-time processor (X143). The following settings can be defined in any ASCII file (e.g. Stickconfig.a): <Volume> Volume name of a USB device formatted with VFAT. If the name contains blank spaces, the complete name must be enclosed between quotation marks (" "). Also, the name must always be given in capital letters. <Mountpoint> Drive name under which the USB device is to be mounted (e. g. PLCSTICK:). The last character of the name must be a colon. The name can have up to 8 characters (without colon). <User> User group for which the USB device is mounted and displayed. The following user groups are possible: TNC: The USB device can be used by the machine operator. OEM: The USB device can only be used by the OEM (code number 807667, PLC program, NC cycles). SYS: The USB device can only be used by the HeROS system. Connecting more than one USB device with the same volume name may cause problems. When the control is started up, the first detected USB device with the new drive name is mounted. As a result, it may occur that each time the controls is started up, another device with the same volume name is mounted. HEIDENHAIN therefore recommends using unique volume names that cannot be confused (e.g. "JHK247G4"). On a PC with Windows operating system, the volume name can be defined in the properties of the USB device.

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1.2.4 Generation of Service Files A function has been introduced that enables you to save data relevant for service purposes in a .zip file. The appropriate data from the NC and PLC are saved in the file TNC:\service\service<xxxxxxxx>.zip. The name of the file is generated automatically, whereby <xxxxxxxx >is the system time shown as an unambiguous character string in hexadecimal code. You can generate a service file in the following ways: Press the ERR key and then the SAVE SERVICE FILES soft key. It can be provoked by certain configured errors. Here a 1 must be entered in the SF column (Create Servicefile) of the PET table. A service file is generated no more than once per minute. Crash of the NC software due to a fatal error Request via TNCremoNT The following data (and other information) is saved in the service file: Log PLC log Selected files (*.H/*.I/*.T/*.TCH/*.D) of all operating modes *.SYS files Machine parameters Information and log files of the operating system (can be partially activated via MP7691) Contents of PLC memory NC macros defined in PLC:\NCMACRO.SYS Information about the hardware Note HEIDENHAIN recommends that you encrypt your passwords in order to protect your passwords in *.SYS files when a service file is generated. When a service file is generated, the *.SYS files are also saved in the .zip file. As a result, however the passwords in the *.SYS files can be accessed by other persons. If you also want to protect your passwords from unauthorized access when the service file is generated, proceed as follows:

Open the *.SYS file in which you have stored passwords (e.g. OEM.SYS). Place the cursor on the line containing a password (e.g. PLCPASSWORD, MPPASSWORD). Press the ENCRYPT PASSWORD soft key. This encrypts the password and places it after the keyword.

In the default setting, the data are automatically converted to ASCII format when being saved to the .zip file. If however the conversion to ASCII fails, the binary version of the file is saved in the .zip file. Note Files that are saved on the encrypted PLC partition PLCE: cannot be written to the service file.

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You can also store your own control file PLC:\oemservicefiles.sys, in which you can enter additional files to be saved. In addition, your service agency can help the end user save another control file TNC:\service\userfiles.sys. Control files have the following syntax: FOLDER <folder> [<fmask>][-a=<n><u>][-s=<n><u>][-b] Saving all files of a directory. The effect of the command can be influenced by various parameters. The individual parameters must be entered in the described sequence. If more than one criterion is specified, all of the criteria must apply for the file to be saved. Event <folder> Function Directory that is to be searched for files to be saved. Only the specified directory is searched for files, and not the subdirectories. Optional parameter as a selection criterion for the file name. The wild cards * can be used for any number of characters, and the character ? can be used for exactly one character. Example: *.TXT, PGM12?.H If no parameter is entered, all files of the directory are saved. Optional parameter for specifying the age of the files to be saved. Files that are older than the specified period of time will not be saved. <n> for the time period: Input of a number <u> for the unit of time: s = seconds m = minutes h = hours d = days Examples: -a=30s, -a=7d, -a=24h

[<fmask>]

[-a=<n><u>]

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Event [-s=<n><u>]

Function Optional parameter for specifying the size of the files to be saved. Files exceeding the specified size will not be saved. The parameter is to prevent that an NC program with 1 GB is saved, for example. <n> for the size: Input of a number <u> for the unit of size: B = byte k = kilobyte m = megabyte Examples: -s=100k, -s=1m

[-b]

Binary files are not converted to ASCII files. All binary files are saved in binary format.

SETUPFILE <file> <token> [-a=<n><u>][-s=<n><u>][-b] Saving a file whose name is saved in a system file. You can use the same parameters that are used for FOLDER. Event <file> Function Specify one of the following keywords for the system files that are to be searched for the token: OEM (= PLC:\OEM.SYS) NCPATH (= SYS:\NCPATH.SYS) NCMACRO (= PLC:\NCMAKRO.SYS) <token> Enter the token under which the file to be saved is entered in the specified system file. Example: SETUPFILE OEM MPFILE, SETUPFILE NCMACRO PALETT

FILE <fname> [-a=<n><u>][-s=<n><u>][-b] Saving an individual file. You can use the same parameters that are used for FOLDER. Event <fname> Function Complete path and name of the file to be saved.

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INCLUDE <file> When a file is specified, it is evaluated as another control file. In order to avoid that a file is specified twice, the INCLUDE statement must not be nested more than three levels. Event <file> Function Complete path and name of the additional control file.

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1.2.5 Temporary Enabling of Software Options You now have the possibility of enabling software options with a temporary code number for a limited period of time. You can define a time between 10 to 90 days for enabling the software options. However, each option can only be enabled once with a temporary code number. If you want to enable a software option temporarily on the control via the temporary key, proceed in the same way as for the standard enabling of software options. Press the Set Option button or the SET OPTION soft key. This opens a window in which you can enter the code number for the desired software option in Enter Key Code. If the software option was enabled successfully, the expiration date of the temporary enabling is shown in the Expires column under SIK Options. After the defined period has expired, the entry in the Expires column will change to EXP standing for "expired." The software option is then no longer available. A software option can be enabled for an unlimited period at any time by means of the code number, which you will receive from HEIDENHAIN after stating the SIK number. HEIDENHAIN would like to point out that it is not possible to use the OEMspecific options with the SIKs of the first generation. If you encounter any problems in this respect, please contact your HEIDENHAIN service agency. You can generate the temporary code number with the TNCOEMOption tool for PCs. The tool is available for download free of charge from the HEIDENHAIN FileBase under PC Software > Special Tools. When you generate the code number, you must specify the number of the respective software option, the number of days you want to enable the option, and an optional OEM Key. The OEM Key provides protection against unauthorized persons generating code numbers for your machines with the help of the PC tool in order to enable software options without your approval. However, it is not essential to specify an OEM Key. The OEM Key for generating the code number must be identical to the OEM KEY on your control.

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The OEM Key was added to the display and management of the SIK options, Feature Content Level and General Key on the control. Press the MOD key and enter the code number SIK to display the input form for SIK functions: OEM Key The OEM Key on the control can only be used for enabling software options with a temporary code number if the same OEM Key was specified for the generation of the temporary code number. If the OEM Key on the control is not identical to the one used for generating the code number, the software option will not be enabled. Once the OEM Key has been set, it cannot be reset. Display OEM Key for temp. options Set OEM Key Meaning NONE SET OEM Key was not set OEM Key was set

Press the Set OEM Key button or the SET OEM KEY TEMP. OPT. soft key to open a window in which you can enter the OEM Key. Keep in mind that this process cannot be undone. The OEM Key may consist only of numbers. Confirm your entry by pressing the Apply button, or by pressing the SET OEM KEY TEMP. OPT. soft key again. If the OEM Key was set successfully, the message OEM Key has been set appears, and the status in OEM Key for temp. options changes to SET.

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1.2.6 Encrypted PLC Partition (PLCE:) The machine manufacturer now has the possibility to create an additional PLC partition, which is automatically encrypted. The PLCE: partition enables the machine manufacturer to protect his files and data from unauthorized access. The encrypted PLC partition PLCE: can only be accessed with a password that the OEM chooses. The password is stored in encrypted form either in the OEM.SYS file or in the SIK. Note HEIDENHAIN recommends: Storing the password in the SIK, because it provides a higher degree of security than the OEM.SYS. Using the PLCE partition generally only for specific files that are to be protected from unauthorized access. Against using the PLCE partition for system files (such as MP files, NCMACRO.SYS). Please keep in mind that HEIDENHAIN cannot access the data in the encrypted partition, even if servicing becomes necessary. When creating the PLCE: partition, you must specify the desired memory size (max. 100 MB) of the encrypted partition. Because the PLCE partition saved in the PLC:\PLCE.BIN file is a part of the PLC partition, the memory available on the PLC partition is reduced accordingly. Danger When you lose the password for the PLCE: partition, the data is permanently lost. Deleting the PLC:\PLCE.BIN binary file leads to loss of the data on PLCE: HEIDENHAIN does not have any possibility to access the data on the encrypted PLCE: partition. This also applies when servicing becomes necessary. The data of the encrypted PLCE: partition cannot be written to the service file. If the password is stored in the control, the NC software can access the data and files in the PLCE: partition at any time. The control can therefore run on the PLCE partition in the same way as on the standard PLC partition. The NC software automatically searches the PLC partition for files that it needs during run time. If the search is not successful and a PLCE partition exists, the search is continued in the PLCE partition. This does not apply to the OEM.SYS file itself, or to data and files that are called by using absolute paths (e.g. in PLC modules, OEM.SYS). The OEM.SYS file must always be stored in the PLC partition of the control. If data or files are called by using an absolute path, the NC software only searches the given path for the data or files. The search is not automatically continued in the other partition. Note Do not store the same files both in the PLC partition and the PLCE partition. 1 44 HEIDENHAIN Technical Manual iTNC 530

All data or files on the PLCE partition are automatically encrypted and are therefore protected from unauthorized access. The only exception is the active machine-parameter file. If the active MP file is stored in the PLCE partition, it can nevertheless be edited when you switch to the Machine Parameter Programming mode of operation. Backup/Restore and PLCE The control operator does not need to know the password to back up or restore the PLCE data. The encrypted content remains protected. When restoring a backup on a control, you must make sure that the password on the control (in the SIK or OEM.SYS) is identical to the password that was used for creating the PLCE.BIN file or the PLCE partition. To enable automatic updating of the PLCE partition through a restore process or software update, you must manually separate the PLCE partition before the restore process by using Unmount. You must keep the following in mind to ensure that the PLCE partition is successfully overwritten with the PLC:\PLCE.BIN file during a restore process or a software update: The password for the PLCE partition is stored in the SIK or OEM.SYS in the control. The password in the control matches the password in PLCE.BIN. The PLCE partition has been separated (Unmount). Enough memory capacity on the PLCE partition for new data available Software update and PLCE A software update can either contain the PLC:\PLCE.BIN file or the PLC:\_mpupdate\plce.zip file. If the software update contains a PLC:\PLCE.BIN file, the requirements described above under "Backup/Restore and PLCE" apply as well. If the software update contains a PLC:\_mpupdate\plce.zip file, the following requirements apply: The .zip file must be encrypted with the same password as the PLCE: drive. When the control is started up the next time, this file is unpacked and the corresponding files are copied to PLCE:. This .zip file can be created using PLCdesignNT with version 2.5 or later. Danger Please note that the encryption algorithm of this .zip file is less secure than encrypting the PLCE partition on the hard disk of the control. You must keep the following in mind to make sure that the data is transferred to the PLCE partition (with the PLC:\_mpupdate\plce.zip file) during a software update: The password for the PLCE partition is stored in the SIK or OEM.SYS in the control. The password in the control matches the password in plce.zip. The PLCE partition exists and is mounted (Mount). Enough memory capacity on the PLCE partition for new data available

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Automatic binary-to-ASCII conversion is not possible for the encrypted PLCE partition during a software update. This means that you must manually convert binary-coded files on the PLCE partition to ASCII format before a software update. After the software update, the files must be reconverted back to the binary format. To convert the files manually, proceed as follows:

Switch to the Machine Parameter Programming mode of operation. Press the MOD key and then the UPDATE DATA soft key. Use the CONVERT BIN -> ASC soft key to convert the files to ASCII format before a software update. Use the CONVERT ASC -> BIN soft key to convert the files back to binary format after the software update.

In order to avoid converting the files manually, you could also load the binarycoded files onto the PLCE partition after a software update. ENCCYC. ZIPNAME = The possibility of machining with or without preset tables in OEM cycles can also be used with the encrypted PLCE partition. A separate directory is created on the PLCE partition for each cycle project (PLCE:\OEMCYC_ZIP\, PLCE:\OEMCY2_ZIP\, etc.), just as is done on the PLC partition. In the OEM.SYS, enter after the code word the name of the *.ZIP file to be unpacked. For example, this is for the PLCE partition: ENCCYC.ZIPNAME = ABC.ZIP, ENCCY2.ZIPNAME = DEF.ZIP, etc. The *.ZIP files contain all information for the cycles, including the directory structure. When the control is started up, the appropriate *.ZIP files are unpacked in the folders. The documentation for CycleDesign contains more detailed information. Starting November 2007, HEIDENHAIN will offer the following new PC tools for working with the data of the encrypted partition: PLCdesignNT 2.5, PLCtext 4.2, CycleDesign 4.5 and TNCremoNT 2.6. The PLCE partition cannot be accessed until the correct password has been entered. Note At present it is not possible to create an encrypted PLCE: partition with the iTNC 530 programming station.

PC tools and PLCE

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In the PLC mode of operation, press the ADVANCED SETUP soft key and then the ENCRYPTED DRIVE soft key to call the settings of the encrypted partition. The following information and options are available on the Password tab:

Password State: Display No password Meaning Active if you have not yet assigned a password to the PLCE: partition. Active if the password for the PLCE: partition is saved in the OEM.SYS file. Active if the password for the PLCE: partition is saved in the SIK.

Password stored in OEM.SYS

Password stored in SIK

Password Actions: Button Set password Meaning Assign a password for access to the PLCE: partition. Delete the password for access to the PLCE: partition. Move the password for access to the PLCE: partition from the OEM.SYS file to the SIK.

Delete password

Move OEM.SYS -> SIK

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The following information and options are available on the Drive tab:

Drive State: Display No encrypted drive Encrypted drive, size = xxx MB Meaning Active if no PLCE: partition has been created yet. Active if PLCE: partition has been created. The size of the partition is indicated in [MB]. Active if PLCE: partition is mounted. Active if PLCE: partition is available, but not mounted. Active if the PLCE: partition cannot be used because it is formatted incorrectly, or because the password is incorrect.

Drive is mounted Drive is not mounted, but OK Drive is not formatted or wrong password

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Drive Actions: Button Create Drive Meaning The encrypted PLCE: partition is created and the size of the partition is indicated in [MB]. Only available if no PLCE: partition has been created yet. Maximum size: 100 MB Minimum size: 1 MB Delete the encrypted PLCE: partition. Only available if the PLCE: partition is not mounted. Change the size in [MB] of the PLCE: partition. Only available if the PLCE: partition is not mounted. Mount the PLCE: partition. Only available if the PLCE: partition is not mounted. Format the PLCE: partition. Only available if the PLCE: partition is not mounted. Unmount the PLCE: partition. Only available if the PLCE: partition is mounted.

Delete Drive

Change Size

Mount

Format

Unmount

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Create and mount the PLCE partition

1. To assign a password to the encrypted partition, proceed as follows:


While in the Programming and Editing operating mode, press the MOD key. Enter the code number 807 667 to switch to the PLC operating mode. Press the ADVANCED SETUP soft key. Press the ENCRYPTED DRIVE soft key. Press the Set Password button under Actions. In New Password: you enter a valid password for access to the encrypted partition. The password must be between 12 and 21 characters long. You can use numbers and special characters, but do not use any umlauts. The password is case sensitive. Repeat the selected password in Verification: In Store Password in you select whether the password is saved in the SIK or in the OEM.SYS. Confirm your entry with the OK button. Note When entering the password, keep in mind that the password is case sensitive. HEIDENHAIN recommends storing the password in the SIK.

The control confirms the password by displaying the message Password has been set, and under State it shows where the password is stored. 2. To create an encrypted partition, proceed as follows:

Select the Drive tab. Press the Create Drive button under Actions. In Size:, you enter the desired size for the encrypted partition in [MB]. Confirm your entry with the OK button.

The control confirms the creation of the PLCE: partition by displaying the message Encrypted drive has been created and changes the status under State to indicate that the partition has been created. The right column beneath State shows that the partition exists, but that it is not mounted. 3. To mount the encrypted partition, proceed as follows:

The newly created PLCE: partition must first be formatted: To perform the formatting process, press the Format button and then press the Apply button. Danger All data stored on the PLCE: partition are lost during the formatting process.

To mount the encrypted partition, press the Mount button and then press the Apply button.

The control confirms that the PLCE: partition has been mounted by displaying the message Encrypted drive has been mounted and changes the status under State to indicate that the partition has been mounted. 1 50 HEIDENHAIN Technical Manual iTNC 530

Access to PLCE: by the user

The control operator cannot access the mounted PLCE: partition until he has entered the correct password for the PLCE partition.

While in the Programming and Editing operating mode, press the MOD key. Enter the password for the encrypted PLCE: partition.

If you then press the PGM MGT key, the iTNC displays the PLCE: partition in the directory structure on the left side of the screen. If the PLCE partition is displayed in the File Management, files and data can be handled in the same way as in all other partitions (e.g. move, delete, rename). Encryption is automatic.

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1.2.7 SIK Options for the OEM With software 340 49x-04, the SIK options #101 to #130 are available as OEMspecific options. You can assign your own OEM-specific software options to these options. This makes it possible for you to enable your own applications (e.g. cycles) for the end user via the SIK from HEIDENHAIN. The options can be enabled by entering a code number. HEIDENHAIN can give you the code number after having been informed of the SIK number. You also have the possibility of creating a temporary key for these OEM-specific options in order to enable the options for a period of max. 90 days. HEIDENHAIN would like to point out that it is not possible to use the OEMspecific options with the SIKs of the first generation. If you encounter any problems in this respect, please contact your HEIDENHAIN service agency. The new PLC module 9067 enables you to request the status of the SIK options. Use this module to request information from the SIK about whether certain software options are enabled via the SIK. Depending on the response, you can activate the software option via the PLC program.

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1.2.8 Window Manager The Window Manager XFCE for the graphic interface of the control will be introduced with software version 04. The Window Manager XFCE is a standard Window Manager for UNIX-based operating systems. It provides the following functions: Optional taskbar for switching between various applications (user interfaces). Additional desktop on which the machine tool builder's applications can be run. Controlling the focus between NC-software applications and those of the machine tool builder. The size and position of pop-up windows can be changed. It is also possible to close, minimize and restore the pop-up windows. Basic configuration The Window Manager is supplied with two default configurations (FULL and SIMPLE). The configuration of the Window Manager can be changed at any time by using the XFCE configuration dialog. The SIMPLE configuration neither has a taskbar, nor a background image for the 3rd desktop. As a result, the TNC software with Window Manager differs only very slightly from the NC software version without Window Manager. The FULL configuration has a taskbar, however. HEIDENHAIN recommends using the taskbar of the Window Manager only on controls equipped with a mouse or a touch pad. If a software version with Window Manager is installed on a control for the first time, the PLC:\WINDOWMANAGER directory does not exist. It is created when the NC software is started up for the first time, and the SIMPLE configuration is active. If you delete the PLC:\WINDOWMANAGER directory, the directory is created again during the next startup of the NC software and the SIMPLE configuration is active. If TNCRemoNT is used to transfer the PLC partition between the programming station and a single-processor or dual-processor version, the configuration of the Window Manager (PLC:\WINDOWMANAGER directory) is also transferred. The configuration is portable, except for the position of the XFCE taskbar (also called TNC taskbar). On a dual-processor control, the TNC taskbar is moved to the opposite side of the screen if it displayed at the same position as the Windows taskbar, which is usually at the bottom of the screen. If a Window Manager configuration exists, it is retained when the NC software is reinstalled (software update).

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To call the configuration of the Window Manager, press the ADVANCED SETUP soft key and then the CONFIGURE WINDOW-MANAGER soft key.

If you press the LOAD MINIMUM CONFIG soft key and confirm the following confirmation prompt, the current configuration of the Window Manager will be overwritten with the SIMPLE configuration. If you press the LOAD MAXIMUM CONFIG soft key and confirm the following confirmation prompt, the current configuration of the Window Manager will be overwritten with the FULL configuration. If you do not want to load any configuration, press the LOAD CUSTOMIZED CONFIG soft key. This starts the XFCE configuration dialog in which you can edit the current configuration. Configuration with XFCE If you want to create your own configuration containing the TNC taskbar, you should first activate the FULL configuration. If you do not want your configuration to contain the TNC taskbar, first select the SIMPLE configuration. Do not start the XFCE configuration until you have activated the respective basic configuration. The two supplied basic configurations SIMPLE and FULL are only changed temporarily when you configure the Window Manager using the LOAD CUSTOMIZED CONFIG soft key. The files containing the two basic configurations are stored in the control and remain unchanged. This means that you can call the basic configurations at any time by pressing the LOAD MINIMUM CONFIG soft key or the LOAD MAXIMUM CONFIG soft key. Direct saving of your own configurations is not possible. However, you can save your own configurations by saving the complete PLC:\WINDOWMANAGER

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directory via TNCremoNT, for example. If you copy the PLC:\WINDOWMANAGER directory to other controls, the configuration saved in the directory will become active.

The XFCE configuration dialog provides the following configuration options: Desktop Appearance The DESKTOP button and the Appearance tab of the XFCE configuration dialog enable you to define a background color and background images, which do only become effective on the 3rd desktop (machine tool builder) or the desktops after the 3rd one. The background image from OEM.SYS is shown on the first two desktops (Edit, Machine). Note Additional background images (i.e. images that are not supplied) should always be saved in the PLC:\WINDOWMANGER\BACKDROPS directory. Saving the background images in this directory ensures that the path of the selected background image is adjusted to the configuration when backup/ restore functions are executed between the programming station and dualprocessor or single-processor controls. Desktop Behavior This function is not yet supported. In the future, the DESKTOP button and the Behavior tab of the XFCE configuration dialog will enable you to change the size of the desktop icons. Window Manager Style The Windows Manager button and the Style tab of the XFCE configuration dialog enable you to influence the layout of the windows. You can edit the font size of the window titles, the orientation of the window headers, the design of the window frames, etc. Window Manager Advanced The Windows Manager button and the Advanced tab of the XFCE configuration dialog enable you to influence the behavior of the windows.

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Workspaces and Margins To define the number of possible desktops and their names, use the Workspaces and the Margin buttons of the XFCE configuration dialog. Note A minimum of two desktops (Edit and Machine) must be defined in Number of Workspaces. Configuration of the TNC taskbar The TNC taskbar appears when you move the mouse pointer to the position of the taskbar (standard setting: at bottom of screen). When the mouse pointer is located over the TNC taskbar, press the right mouse key to open the context menu for the configuration.

When the FULL configuration is active, the TNC taskbar contains the following element buttons (from left to right): 1: Show desktop button 2: Pager for switching between the desktops and for moving windows between the desktops with "drag and drop". 3: Task list (shows all open windows) 4: Context menu for configuring the TNC taskbar 5: Time To configure the TNC taskbar, proceed as follows:

Press the ADVANCED SETUP soft key in the PLC operating mode. Press the CONFIGURE WINDOW MANAGER soft key. Move the mouse pointer over the position of the TNC taskbar until it appears. Place the mouse pointer over the TNC taskbar and press the right mouse key. To edit the properties of an element in the taskbar, place the mouse pointer over the respective button in the taskbar. This opens the context menu for configuring the TNC taskbar and the selected element.

The context menu provides the following configuration options: Properties Change the properties of the selected element. Move Change the sequence of the buttons in the taskbar. Customize Panel Change the properties of the complete TNC taskbar.

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1.2.9 KinematicsOpt Accuracy requirements are becoming increasingly stringent, particularly in the area of 5-axis machining. Complex parts are required to be manufactured with precision and reproducible accuracy even over long periods. The new TNC function KinematicsOpt is an important component that helps you meet these complex requirements: A 3-D touch probe cycle measures the rotary axes on your machine fully automatically, regardless of whether they are used in rotary-table or head configurations. A calibration ball is fixed at any position on the machine table, and measured with a resolution that you define. In the cycle definition, you only have to define for each rotary axis the area that you want to measure. From the measured values, the TNC calculates the static tilting accuracy. The software minimizes the spatial error arising from the tilting movement and, at the end of the measurement process, automatically saves the machine geometry in the respective machine constants of the kinematics table. Functions Testing the static tilting accuracy by probing different points on a calibration ball with a 3-D workpiece touch probe. Optimizing the static tilting accuracy by adjusting the kinematics description. Backing up and restoring the kinematics data that can be changed with this software. Prerequisites The software options #48 (KinematicsOpt) and #8 (software option 1) must be enabled. Feature Content Level (FCL) 3 or higher must be enabled. The 3-D touch probe used for the measurement must be calibrated. A calibration ball with an exactly known radius and sufficient rigidity must be attached to the machine table. The kinematics must be described in the new table format (columns: KEY, AXIS, COORD, ...) The kinematics description of the machine must be complete and correct. The transformation values must be entered with an accuracy of approx. 1 mm. All machine axes involved must have adequate positioning accuracy. The geometry of the machine must have been measured. The machine datum (MP960.x) must be defined for the rotary axes (is not measured in the cycle). The machine parameters MP6600 and MP6601 must be defined.

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Kinematics description

In the optimizing mode, the linear offsets (compensation translations) are adjusted to the kinematics description. Please note that two compensation transformations defining the position (not the angular position) of the rotary axis must be defined for every rotary axis. The definitions of the two translations required for the position of the rotary axis must directly precede the definition of the machine axis. KinematicsOpt searches the last three translations defined before the rotary axis for two suitable compensation translations. However, the search is automatically canceled if another rotary axis is defined between the three last translations. Example of a correct kinematics description with a B head and C table: NR xx xx xx xx xx xx xx KEY Trans Trans MachAxis Trans Trans Trans MachAxis AXIS COORD X Z B Z X Y C -600.142 +300.021 -251.191 Search range for two suitable translations for the C axis +100.014 +299.951 Search range for two suitable translations for the B axis

Example of an incorrect kinematics description with a B head and C table: Incorrect position for the Y translation of the C axis: NR xx xx xx xx xx xx xx KEY Trans Trans Trans MachAxis Trans Trans MachAxis AXIS COORD X Y Z B Z X C -600.142 +300.021 Search range for two suitable translations for the C axis +100.014 -251.191 Errors +299.951 Search range for two suitable translations for the B axis

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Example of changes in the kinematics description with a B head and optional C table: NR 0 2 3 4 6 7 8 9 10 11 12 KEY TOOLFILE CMO Trans Trans Trans MachAxis MachAxis MachAxis MachAxis SUBFILE1 Trans X Y Z B Z Y X X X +0 +0.01 +0 +250.02 AXIS COORD --> --> --> --> --> --> --> --> --> --> --> COORD (compensations) No changes No changes +0.006 +0 +250.034 No changes No changes No changes No changes No changes No changes

[END] SUBFILE1: NR 0 1 2 3 4 5 KEY Trans Trans Trans CMO MachAxis CMO C AXIS COORD Z X Y -655.045 --> +440.01 +250.02 --> --> --> --> --> COORD (compensations) No changes +440.006 +250.034 No changes No changes No changes

[END] Tolerance limit The tolerance limit prevents you from accidentally making major changes to the kinematics description. Whenever optimization requires a major change, a message appears and the change must be confirmed with NC start. The tolerance limit must be permanently defined in MP6600.

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Ball radius

The measured probe radius is checked. The permissible deviation is defined in MP6601. This monitoring feature also detects incorrect probing caused by contamination.

Danger After optimization the position of the presets relative to the workpiece may have changed. It is essential that you check or reset the datum points. Touch probe cycle 450 (SAVE KINEMATICS) Use this cycle to save the values of the active kinematics description in order to be able to restore the active kinematics description if required. For a detailed description of Cycle 450 SAVE KINEMATICS, refer to the Touch Probe Cycles User's Manual. Note As a machine tool builder, you can save the shipping data for example. You enter the standard PLC code number (807667) and save the data to any memory location. When the software 340 49x-04 is reinstalled, the backup file of the kinematics description that was created with Cycle 450 is overwritten. After installing the software, you must save the kinematics description again with Cycle 450 if required.

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Touch probe cycle 451 (MEASURE KINEMATICS)

The MEASURE KINEMATICS cycle enables you to check and, if required, optimize the kinematics of your machine. Use the 3-D TS touch probe to measure any calibration ball that you have attached to the machine table. For a detailed description of Cycle 451 MEASURE KINEMATICS, refer to the Touch Probe Cycles User's Manual. Backlash: The Touch Probe Cycles User's Manual provides more detailed information. Depending on the value defined in machine parameter MP110.x, the backlash of the axis is measured in Test mode. The value 0 in MP110.x defines that backlash is to be measured. Protocol function: The Touch Probe Cycles User's Manual provides more detailed information. In addition, the cycle creates axis-specific protocols in tabular format. The files are saved as TCHPR451_<axis name>.A in PLC:. The columns created may vary depending on the conditions for measurement. For example, if the Optimize mode was selected in Cycle 451, only optimized values are output. If the following designations are used, the measured data are referenced to the coordinate system tilted at the axis angle: PA = primary axis SA = secondary axis TA = tool axis (spindle axis) If the designation contains the expression "REF", the values are referenced to the machine-coordinate system. This data can be imported for evaluation (e.g. in TNCscope, Excel). TNCscope: Open the file in TNCscope by selecting:

File Import Table. Then select the file to be opened. The Import Table dialog box opens. Select Fixed sampling interval and enter the value 1 ms in the Time unit field. Select "/" as the column separator and confirm your entry with OK.

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Measured and optimized deviations (simulated measured data / displayed with TNCscope):

Optimized deviations as a function of the position of the rotary axis (simulated measured data / displayed with TNCscope):

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Positioning direction: The positioning direction of the rotary axis to be measured is determined from the start angle and the end angle. Because +270 is identical to 90 for example, the same angles can result in different measuring positions. Example: Start angle = 90 End angle = +90 Measuring points = 4 Stepping angle = (end angle start angle) / (measuring points 1) = (90 - 90) / 3 = +60 Therefore: P1 = 90; P2 = 30; P3 = +30; P4 = +90 Start angle = +270 End angle = +90 Measuring points = 4 Stepping angle = (end angle start angle) / (measuring points 1) = (90 - 270) / 3 = 60 Therefore: P1 = 90; P2 = 120; P3 = 210; P4 = 270

Hirth axes: The cycles use the value entered in MP420 or MP430 to determine whether the respective axis is a rotary axis or a Hirth axis. The Touch Probe Cycles User's Manual provides more detailed information.

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Programming station: The cycle recognizes whether a programming station is being used. Because it is not possible to measure real data on a programming station, the measured data are simulated. Simulated measured data as a function of the position of the measuring axis (C axis):

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1.2.10 Diagnostic Functions The diagnostic functions of the iTNC were completely revised. The iTNC 530 up to and including software version 340 49x-03 provided the following diagnostic functions for error diagnosis, which were available after pressing the DIAGNOSIS soft key. The following table compares the organization of the diagnostic functions in software 340 49x-03 and lower with the organization in software 340 49x-04 and higher. The majority of the known diagnostic functions has been implemented in the new diagnostic tool DriveDiag. DriveDiag significantly improves the performance range of diagnosis in the control. None of the known functions was removed, but some of them are only available outside the DriveDiag tool. Also, DriveDiag improves clarity and ease of use of the diagnostic functions.

Soft key

Soft key

Soft key

Function

Replaced by BUS DIAGNOSIS soft key Remains available The integrated oscilloscope is started Replaced by DRIVE DIAG

The following soft keys only appear if the Power Interrupted message was not acknowledged, and if the code number 688379 or 807667 was entered. The integrated oscilloscope for commissioning the current controller is started. For more detailed information, refer to the Technical Manual of your control. Replaced by DRIVE DIAG. Remains available (only after the code number has been entered).

The file TNC:\herosdiagnose.txt is created after pressing this soft key. HEIDENHAIN uses this file for diagnosis of the operating system.

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The iTNC 530 with software version 340 49x-04 and higher provides the following diagnostic functions for error diagnosis. To call the diagnostic functions:

While in the Programming and Editing operating mode, press the MOD key. Press the DIAGNOSIS soft key.

The following diagnostic functions are available: Soft key Soft key Soft key Function

After pressing this soft key, you can test various HSCI and Profibus settings, provided that you are using one of the two bus systems. After pressing this soft key, you can test various Profibus settings, provided that you are using a Profibus system. After pressing this soft key, you can test various HSCI settings, provided that you are using an HSCI system. Various drive diagnosis functions can be selected after pressing this soft key. Before selecting the diagnostic function, under Supply unit you must select the power supply unit being used, so that the signals present are not interpreted as errors. The integrated oscilloscope is started. The diagnosis tool DriveDiag is opened, see page 1 67. The following soft keys only appear if the Power Interrupted message was not acknowledged, and if the code number 688379 or 807667 was entered. The integrated oscilloscope for commissioning the current controller is opened. The file TNC:\herosdiagnose.txt is created after pressing this soft key. HEIDENHAIN uses this file for diagnosis of the operating system.

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DriveDiag

The diagnosis tool DriveDiag is available on iTNCs 530 with software version 340 49x-04 and higher. To start DriveDiag:

While in the Programming and Editing operating mode, press the MOD key. Press the DIAGNOSIS soft key. Press the DRIVE DIAGNOSTICS soft key. Press the DRIVE DIAG soft key.

This opens an additional task for the DriveDiag diagnosis tool. The structure of the drive system is displayed on the left side of the screen in a tree structure. Detailed information on the currently selected component is displayed on the right side of the screen. To navigate within the tree structure (left side of screen) and the tabs (right side of screen), use the arrow keys. Use the ENT key to move from the left side of the screen to the right side of the screen. Use the END key to move from the right side of the screen back to the left side of the screen. If the cursor is already located on the left side of the screen, you can exit DriveDiag with the END key.

To switch back to the screen of the control or to DriveDiag, press the screen switchover key.

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Icon

Icon Machine:

Icon

Function

Higher-level folder containing all components of the complete machine Connection: Internal IP address (127.0.0.1) Main computer, see page 1 69 Power supply unit, see page 1 74 Information about ID label and status Axis (e.g. X, Y, Z, etc.), see page 1 76 Higher-level folder containing all axis components

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Main computer Icon Icon Icon Function

Main computer Version tab: Control model: Type of control NC software: Installed NC software version PLC software: PLC software being used Main computer Status tab: Status information about various signals, see page 1 70 Drive control board x Version tab: Speed controller software: Installed speed-controller software version Current-controller software: Installed current-controller software version Hardware code: Additional information for identifying the hardware (only CC 422). Version of additional info: Date and time of installation Degree of support: Degree of support for controller software SG software available: Information about whether the installed software supports functional safety SG software active: Functional safety is activated/deactivated Drive control board x Voltages and currents tab: Supply voltage +5V: Current value of voltage in [V] DC-link voltage: Current value of voltage in [V] DC-link current: Current value of current in [A] DSP computer board temp.: Current temperature value on the DSP computer board in [C] Supply voltage +15V: Current value of voltage in [V] Supply voltage 15V: Current value of voltage in [V] Supply voltage +3.3V: Current value of voltage in [V] Auxiliary voltage UL: Current value of voltage in [V] Auxiliary voltage UH: Current value of voltage in [V] Drive control board x Status tab: Status information about various signals, see page 1 72

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Meanings of the signals under "main computer / status" Signal Acknowledgment: Control is ready (NE1) Meaning Colors

External enabling signals The NE1 signal (emergency stop input 1, Gray: No information about the signal available MC) is active if a 0 level is present (low active). For the iTNC 530 the Green: Signal is not active, corresponding input is at connector X42/ enabled I3 (PLC input), and is looped to the MC as Red: Signal is active, not enabled a hardware line. For more detailed information, refer to "Input: Spindle Reference Signal" in the Technical Manual. Gray: No information about the signal available Green: Signal is active Red: Signal is not active

External signals from MC Ref. signal of spindle (X30)

Trigger signal (X12) of TS touch probe Battery (X12) of TS touch probe

For more detailed information, refer to Gray: No information about the signal available "X12: Connecting the Touch Probe" in the Technical Manual. Green: Signal is active Red: Signal is not active For more detailed information, refer to Gray: No information about the signal available "X12: Connecting the Touch Probe" in the Technical Manual. Green: Signal is not active, warning Red: Signal is active, no warning For more detailed information, refer to Gray: No information about the signal available "X12: Connecting the Touch Probe" in the Technical Manual. Green: Signal is active Red: Signal is not active

TS touch probe is ready (X12)

Trigger signal For more detailed information, refer to Gray: No information about the signal available (X13) of TT probe "X13: Connecting the Touch Probe" in the Technical Manual. Green: Signal is active Red: Signal is not active TT touch probe ready (X13) For more detailed information, refer to Gray: No information about the signal available "X13: Connecting the Touch Probe" in the Technical Manual. Green: Signal is active Red: Signal is not active

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Signal Current ctrlr commissioning mode

Meaning

Colors

MC internal signals and status The signal is active if the control is in the Gray: No information about the signal available operating mode for adjusting the current controller. Green: Operating mode for adjusting the current controller is active Red: Operating mode for adjusting the current controller is not active The signal is active if the Power interrupted message has been acknowledged with the CE key. Gray: No information about the signal available Green: Power interruption was acknowledged Red: Power interruption was not acknowledged

Power interruption acknowledged

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Meanings of the signals under "drive control board / status" Signal Drive enable (NE2) Meaning Colors

External enabling signals The NE2 signal (emergency stop input 2, Gray: No information about the signal available CC) is active if a 0-level is present (low active). For the iTNC 530 the Green: Signal is not active, corresponding input is at connector X42/ enabled I32 (PLC input), and is looped to the CC as Red: Signal is active, not enabled a hardware line. The PF signal shows the status of the Gray: Information does not exist effective powerfail signal for the drive Green: Enabled, PF is inactive controller. The signal is the result of (1-level) gating the PF.PS.ZK (dc-link powerfail) Red: PF is active (0-level): the dcand PF.PS.AC (AC fail) signals. The gating link voltage has decreased below process can be defined in the machine a permissible (inverter-specific) level or the phase monitoring parameters and in the PLC. responded; not enabled No longer relevant in the current HEIDENHAIN controls. Gray: Information does not exist

Powerfail

X50 Machine On

MC is ready (WD) This signal shows that the MC is ready for Gray: Information does not exist control. This signal is a possible reason Green: Enabled: ME not active that the power module was switched off (1-level) via SH1. Red: Not enabled: WD1 is active (0-level), the MCs watchdog is not retriggered. This signal is relayed to the inverter as SH1 (SH1 also has other signal sources). Powerfail (DC) The signal is generated at the inverter, Gray: Information does not exist and is led via the supply bus to the drive Green: Enabled: Powerfail (DC) is controller. The input at the drive controller inactive (1-level) is displayed. Depending on the wiring, Red: Not enabled: Powerfail (DC) either this signal or Powerfail (AC) is is active (0-level): the dc-link relayed on the controller PCB to the voltage has decreased below a permissible (inverter-specific) powerfail signal. level. The signal is generated at the inverter, Gray: Information does not exist and is led via the supply bus to the drive Green: Enabled: Powerfail (DC) is controller. The input at the drive controller inactive (1-level) is displayed. Depending on the wiring, Red: Not enabled: Powerfail (AC) either this signal or Powerfail (DC) is is active (0-level), phase relayed on the controller PCB to the monitoring responded, at least powerfail signal. Powerfail one power supply phase failed (AC)Powerfail (AC) does not exist for all supply units (e.g. not for UV 130).

Powerfail (AC)

Internal enabling signals

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Signal Switch-off (speed 0)

Meaning

Colors

This signal causes all axes to be switched Gray: No information about the signal available off or locked at zero level. Thus the drives of all control boards are switched off or Green: Enabled: N0 inactive (1locked. level) Red: Not enabled: N0 active (0level); all drives are locked If no error is present in the drive controller Gray: No information about the signal available and the controller unit was started, ready for control is reported. Green: Enabled: CC is ready for control Red: Not enabled Clearable DSP errors are 2nd class errors Gray: No information about the signal available (such as motor temperature). The CC can only resume control after the error has Green: Enabled: There is no been cleared (by pressing the CE key). (clearable) 2nd class error Red: Not enabled: A 2nd class error is present This signal is activated by the current controllers watchdog. It affects SH2 on the power stage via the PWM interface. Gray: No information about the signal available Green: Enabled: Current controller watchdog OK Red: Not enabled: Current controller watchdog is active (0level). No pulse release from the current controller via the PWM interface

CC controller ready

Clearable DSP error

Watchdog current controller

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Power supply unit Icon Icon Icon Function

Power supply unit ID Label tab, see page 1 86: Plug and Play: Information about whether the device is Plug and Play capable Device: Designation of the device Model: Designation of the type of unit Serial number: Serial number of the unit ID number: HEIDENHAIN ID of the unit Power supply unit Status tab: Status information about various signals, see page 1 70 Meanings of the signals under "supply unit / status" Signal DC-link voltage DC-link current Powerfail Meaning Current value of voltage in [V] Current value of current in [A] The PF signal shows the status of the Gray: Information does not exist effective powerfail signal for the drive Green: Enabled, PF is inactive controller. The signal is the result of (1-level) gating the PF.PS.ZK (dc-link powerfail) Red: PF is active (0-level): the dcand PF.PS.AC (AC fail) signals. The gating link voltage has decreased below process can be defined in the machine a permissible (inverter-specific) level or the phase monitoring parameters and in the PLC. responded; not enabled The signal is generated at the inverter, Gray: Information does not exist and is led via the supply bus to the drive Green: Enabled: Powerfail (DC) is controller. The input at the drive controller inactive (1-level) is displayed. Depending on the wiring, Red: Not enabled: Powerfail (DC) either this signal or Powerfail (AC) is is active (0-level): the dc-link relayed on the controller PCB to the voltage has decreased below a powerfail signal. permissible (inverter-specific) level. The signal is generated at the inverter, Gray: Information does not exist and is led via the supply bus to the drive Green: Enabled: Powerfail (DC) is controller. The input at the drive controller inactive (1-level) is displayed. Depending on the wiring, Red: Not enabled: Powerfail (AC) either this signal or Powerfail (DC) is is active (0-level), phase relayed on the controller PCB to the monitoring responded, at least powerfail signal. Powerfail (AC) does not one power supply phase failed exist for all supply units (e.g. not for UV 130). Colors

Powerfail (DC)

Powerfail (AC)

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Signal

Meaning

Colors

DC-link voltage>> The signal reports the status of the dc-link Gray: No information about the signal available voltage: Either it is OK or too high. This signal also switches off all power Green: DC-link voltage OK modules (via the unit bus). Red: DC-link voltage too high Possible error causes: Missing or faulty braking resistor Excessive braking power Temperature The signal reports the status of the heat Gray: No information about the signal available sink temperature in the inverter: Either it is OK or too high. Green: Temperature OK Red: Temperature too high

DC-link current >> The signal reports the status of the dc-link Gray: No information about the signal available current: Either it is OK or too high. Both the positive and the negative dc-link Green: DC-link current OK currents are evaluated. Red: DC-link current too high Power supply unit ready The signal reports the ready status of the Gray: No information about the signal available supply unit: Supply unit OK, Main contactor on, or Supply unit not ready. Green: Supply unit OK, Main contactor on Red: Power supply unit not ready The signal reports the status of the Gray: No information about the signal available leakage current monitoring: Either it is OK or too high or there is a ground fault. Green: Leakage current is OK Red: Leakage current too high or ground fault Signal RES.LE. Reset from controller unit to supply module. Resets the error memory in the supply module. Gray: No information about the signal available Green: Reset signal is not active Red: Reset signal is active

Ground fault

Reset from CC to UV

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X, Y, Z, etc. (axis) Icon Icon Icon Function

X, Y, Z, etc. (axis) Higher-level folder containing all axis components Status Speed Controller tab: Status information about various signals, see page 1 79 Status Position Controller tab: Status information about various signals, see page 1 82 Status PLC tab: Status information about various signals, see page 1 83 Motor ID Label tab, see page 1 86: Plug and Play: Information about whether the device is Plug and Play capable Device: Designation of the device Model: Designation of the type of unit Serial number: Serial number of the unit ID number: HEIDENHAIN ID of the unit Brake present: Information about whether the motor has a brake Motor Motor Data tab: Information about motor-specific data from the motor table Motor Result tab: Information about motor data derived from the motor table or from the machine-parameter file Motor constant [Nm/A]: Internal reference value that indicates the ratio of torque to current (= torque constant). Voltage constant: Internal reference value that indicates the ratio of no-load voltage to rated speed. Field angle []: Value converted to [] for the corresponding entry from the MP file (MP2256.x).

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Icon

Icon

Icon

Function

Power stage ID Label tab, see page 1 86: Plug and Play: Information about whether the device is Plug and Play capable Device: Designation of the device Model: Designation of the type of unit Serial number: Serial number of the unit ID number: HEIDENHAIN ID of the unit Power stage Status tab: Status information about various signals, see page 1 85 EnDat rotational speed encoder Depending on the functions provided by the encoder, the submenus status, diagnosis and temperature are available. EnDat rotational speed encoder Depending on the functions provided by the encoder, the submenus status, diagnosis and temperature are available. EnDat position encoder Depending on the functions provided by the encoder, the submenus status, diagnosis and temperature are available. EnDat 2.2 position encoder Depending on the functions provided by the encoder, the submenus status, diagnosis and temperature are available. Status Status information about various signals, see page 1 84 Diagnostics The function reserves are evaluated, which provide an exact overview of the current status of the encoder. The three values displayed inform the user at a glance of the encoder performance. In the yellow range, fault-free operation is no longer guaranteed. The encoder should be checked. If required, assistance can be provided by your HEIDENHAIN service agency. Temperature The temperature information provided by the temperature sensors in the encoder and the motor is displayed.

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Icon

Icon

Icon

Function

Motor encoder test (available only after the code number 688379 or 807667 has been entered) Diagram tab: After the test has been completed, the result is displayed in a diagram. Two green lines in the diagram mark the minimum and maximum height of the speed encoder signals. The red line shows the measured signals. Motor encoder test Overview tab: Begin the test by pressing the START MEASUREMENT button. Status information about various signals, see page 1 85 The plain text displayed in the lower part of the screen provides additional information about the test results. Position encoder test Diagram tab: After the test has been completed, the result is displayed in a diagram. Two green lines in the diagram mark the minimum and maximum height of the speed encoder signals. The red line shows the measured signals. Position encoder test Overview tab: Begin the test by pressing the START MEASUREMENT button. Status information about various signals, see page 1 85 The plain text displayed in the lower part of the screen provides additional information about the test results. Drive test (available only after the code number 688379 or 807667 has been entered) Test tab: Begin the test by pressing the START MEASUREMENT button. Status information about various signals, see page 1 86 The plain text displayed in the lower part of the screen provides additional information about the test results.

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Meanings of the signals under "status / speed controller" Signal MC enabling marker Meaning Colors

The MC can accelerate the switch-off via Gray: No information about the signal available this marker. Green: Enabled Red: Not enabled The signal shows the enabling status for Gray: No information about the signal available the X150/X151 switch-off. The signal is formed from the status of the inputs Green: Enabled: There is currently no switch-off via X150/X151 and the setting in MP2040.x. X150/X151 Red: Not enabled: The drive is currently switched off or locked via X150/X151 This signal is a group signal for all hardware enabling signals from the speed controller. This signal is a group signal for all hardware enabling signals from the software. Gating of all ready signals (external, internal and software) Gray: No information about the signal available Green: Enabled Red: Not enabled Gray: No information about the signal available Green: Enabled Red: Not enabled Gray: No information about the signal available Green: Enabled Red: Not enabled Gray: No information about the signal available Green: Enabled: The SH2 signal is inactive Red: Not enabled: The SH2 signal is active Gray: No information about the signal available Green: Enabled: Current controller is on (in control) Red: Not enabled: Current controller is off

X150/X151 Drive enabling

Drive enabling from speed controller

Drive enabled by software

Internal drive status

Power module active (SH2)

The signal shows the status of the SH2 line to the power module. The CC activates/deactivates this line for switching off the power module.

Current controller active

The signal shows the status of the current controller. The current controller is either switched on (in control) or switched off.

Speed controller active The signal shows the status of the speed Gray: No information about the signal available controller. The speed controller is either switched on (in control) or switched off. Green: Enabled: Speed controller is on (in control) Red: Not enabled: Speed controller is off

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Signal

Meaning

Colors

Rotor position captured This signal gives information about determining the field angle: Drive is not oriented:

Gray: No information about the signal available Green: Field angle has been determined Motor with rotary encoder without Z1 Yellow: Field angle has track (incl. linear motors) before the been roughly determined first Drive on status Non-aligned rotary encoder with EnDat Dark gray: Field angle has not been determined interface (incl. linear motors), if the field angle has not yet been determined Drive is roughly oriented: Motor with rotary encoder without Z1 track (incl. linear motors) after the first Drive on status Motor with rotary encoder with Z1 track after it has been read Drive is oriented: Motor with rotary encoder with Z1 track after traversing the reference mark Aligned rotary encoder with EnDat interface immediately after switch-on Non-aligned rotary encoder with EnDat interface immediately if the field angle has already been determined Motor with rotary encoder without Z1 track after traversing the reference mark if the field angle has already been determined

Switching on speed controller

This signal indicates whether the speed Gray: No information about the signal available encoder has been switched on since the last time the Power interrupted Dark gray: Speed controller has not been switched on message was active. Status changes are yet (since power saved. interruption) Green: Speed controller is currently being switched on Yellow: Speed controller was switched on once (this does not mean, however, that the speed controller is currently on)

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Signal Switching off speed controller

Meaning

Colors

This signal indicates whether the speed Gray: No information about the signal available encoder has been switched off since the last time the Power interrupted Dark gray: Speed controller message was active. Status changes are has not been switched off yet (since power saved. interruption) Green: Speed controller is currently being switched off Yellow: Speed controller was switched off once (this does not mean, however, that the speed controller is currently off) This signal shows the status of the motor Gray: No information about the signal available brake signal on the PWM bus. This signal is led on the power module via a relay to Green: Brake released the motor. Red: Brake active This signal shows the current and stored Gray: No information about the signal available status of the I2t monitoring. Green: No I2t warning up to now Yellow: There was already (since switch-on) an I2t warning, but there is no current warning Orange: There is a current I2t warning The signal indicates the status of torque- Gray: No information about the signal available ripple compensation. Green: Compensation is active Red: Compensation is not active The signal shows the status of acceleration feedforward control (MP1392 or 1391.1, depending on the selected mode of operation). Gray: No information about the signal available Green: Feedforward control is active Red: Feedforward control is not active

Brake released

I2t warning

Torque ripple

Acceleration feedforward control

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Meanings of the signals under "status / position controller" Signal Position control loop closed Meaning Corresponds to PLC word W1024 for a specific axis. Information about whether the position control loop is closed or open. Colors Gray: No information about the signal available Green: Position control loop closed Red: Position control loop open Gray: No information about the signal available Green: Axis is operated with position feedback control Red: Axis is operated with speed feedback control

Position looped

The signal indicates whether the axis is operated with position feedback control or speed feedback control.

Nominal position value filter

The signal indicates whether the nominal Gray: No information about the signal available position value filters are active. Green: Nominal position value filter is active Red: Nominal position value filter is not active The signal indicates whether "eliminate following error" is active. Gray: No information about the signal available Green: Output limit is active Red: Output limit is not active Gray: No information about the signal available Green: Following-error monitoring is active Red: Following-error monitoring is not active Gray: No information about the signal available Green: Probing is active Red: Probing is not active Gray: No information about the signal available Green: Expectation of reference pulse is active Red: Expectation of reference pulse is not active

Position controller limit

CC monitoring active

The signal indicates whether followingerror monitoring is active (can be deactivated by PLC, W1042).

Touch probe active

The signal indicates whether probing is active.

Reference pulse active

The signal indicates whether the MC expects a reference pulse (host command).

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Signal Velocity feedforward control

Meaning

Colors

The signal indicates whether the position Gray: No information about the signal available controller is working with feedforward control or with following error. Green: Operation with feedforward control Acceleration feedforward control can be Red: Operation with switched on/off cyclically by the MC. following error Corresponds to parameter MP 1392 or MP1391.0 in the MP file, depending on the current mode of operation.

Meanings of the signals under status/PLC Signal Axis in position (PLC) Meaning If the axes have reached the positioning window after a movement, the status is shown in W1026. Colors Green: Axis in position Yellow: Axis not in position

Position control loop closed (PLC)

Position control loop closed (W1040 Green: Position control loop closed inverted). By setting W1040 in the PLC, the position control loop is opened by the Yellow: Position control PLC program. loop open W1024 shows if the position control loop Green: Axis not enabled is open or closed, and if the axis has been Yellow: Axis enabled enabled. During axis movement, the NC sets the bits in W1026. Green: Axis in motion Yellow: Axis at standstill

Axis enabled (PLC)

Axis in motion (PLC)

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Meanings of the signals under "EnDat/status" Signal Encoder model Device name Data width Resolution Meaning Designation of the encoder model Name of the encoder Number of bits of position value Speed encoder Number of signal periods per revolution Linear encoder: Signal period in nanometers Value 0: The encoder is a pure serial encoder. Distinguishable revolutions Information about multiturn encoders. Number of max. distinguishable revolutions. Colors

Resolution of abs. track Speed encoder Number of measuring steps per revolution Linear encoder: Number of measuring steps per nanometer Serial number Absolute value EnDat 2.2 Alarms Serial number of encoder Current absolute value Information about whether the encoder is EnDat 2.2-compatible. Evaluation of different types of error information from the encoder. If the encoder reports an encoder error, fault-free encoder function is no longer guaranteed. The encoder must be checked and replaced if necessary. If required, assistance can be provided by your HEIDENHAIN service agency. Warnings Evaluation of different types of status information from the encoder. Green: No error Red: Encoder reports an error

Green: No warning. Yellow: Encoder issues a warning If the encoder issues a warning, it means that the encoder still functions properly, but one of the functions is operating at its limits. The encoder must be checked and replaced if necessary. If required, assistance can be provided by your HEIDENHAIN service agency.

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Meanings of the signals under "power module / status" Signal Meaning Colors Gray: No information about the signal available Green: Power module is ready Red: Power module reports not ready Gray: No information about the signal available Green: No power module switch-off (IGBT) Red: Power module switchoff (IGBT) Gray: No information about the signal available Green: Temperature of power module OK Red: Temperature of power module too high

Power module ready (LT- The power module is ready: RDY) Safety relay has picked up Main contactor is on SH1 (MC) is High No error from the power module Switch-off power module (IGBT) The signal shows that the IGBT in the power module has been switched off.

Power module temperature

The signal reports the status of the heat sink temperature in the power module: Either it is OK or too high.

Meanings of the signals under "speed controller / overview"

Information Direction (only available in motor encoder test)

Meaning Results of the test for the direction of rotation.

Colors Green: Direction of counting and rotation are the same (OK) Red: Direction of counting and rotation differ (error) Green: Signal amplitude within the tolerance (OK) Red: Signal amplitude outside the tolerance (error)

Amplitude

Result of the test of the speed encoders signals

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Automated testing of drives Information Meaning Colors Green: Phase is OK Red: Phase error Phase 1, Phase 2, Status of the phases in the Phase 3 motor and the supply line Leakage current

Information on a short circuit Green: No ground fault to ground in the motor, the rot: Ground fault power module or in the detected supply line Status of the power module Green: Power module is OK Red: Power module error Status of the supply unit Status of the connection control power module Green: Supply unit OK Red: Supply unit error Green: Connection is OK Red: Connection error

Power module

Supply unit Connection

Electronic ID label

HEIDENHAIN inverter components of type D, as well as HEIDENHAIN synchronous motors with absolute encoders with EnDat interface, are equipped with an electronic ID label. The product name, the ID number and the serial number are saved in this ID label. These devices are automatically detected when the control is started.

Load the displayed component to the corresponding machine parameter automatically with the SELECT soft key.

During every further control restart, the control checks whether the connected units with electronic ID label match the entries in MP2100.x or MP2200.x. If not, an error message might appear and the connected encoder must be transferred to the corresponding machine parameters by soft key. In exceptional cases, the evaluation of the electronic ID label can be deactivated with MP7690. MP_7690 Input: Evaluation of the electronic ID labels %xx Bit 0 HEIDENHAIN power modules 0: Active 1: Inactive Bit 1 HEIDENHAIN synchronous motors 0: Active 1: Inactive

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1.2.11 New Functions as of CC 424 Reduced load on the brakes for vertical axes When axes are switched off, the current is no longer switched off immediately, but it is reduced to zero within 50 ms. This prevents an abrupt load on the mechanical brakes for vertical axes. The time between the switch-off of the drive controllers by Module 9161 and the acknowledgement by Module 9162 is therefore prolonged by 50 ms. The time required for the brake to engage is called overlap time. Should there be cases where you do not want an additional overlap time of 50 ms, you can change the time required for the controllers to switch off by entering a value in MP2308.x. Measuring the rotor position for spindles and torque motors with incremental encoders If you are using linear, synchronous or torque motors with incremental encoders (not EnDat encoders), you must determine the field angle every time after rebooting the control in order to establish the relationship between the encoder and the rotor magnets. Noisy encoder signals may sometimes cause problems and a corresponding error message. Noisy signals are frequently caused by external interpolation of the measured signals. The introduction of a new type of field orientation makes it possible to establish the relationship between the encoder and the rotor magnets even if the encoder signals carry a lot of noise. This new function is activated with MP2250.x = 4. When this function is active, an additional filter is applied to the encoder signals. This has the disadvantage of a delayed detection of movements. The time during which the filter is active is defined in MP2252.x (relevant input range: 0.0002 to 0.5 s) if MP2250.x = 4. Small values in MP2252.x cause a low suppression of the noise component, and large values a strong suppression. Note HEIDENHAIN recommends entering the value 0 in MP2252.x, which activates the default time constant. Adjusting gantry axes with TNCopt TNCopt with version 3.0 and higher now supports the adjustment of gantry axes in such a way that two separate machine-parameter blocks for master axis and slave axis can be optimized and transferred. This applies to the adjustment of the current controller, the feedforward adjustment, the IPC adjustment and the circular interpolation test.

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1.3 Hardware
1.3.1 CML 110 Capacitor Module The capacity of the CML 110 capacitor module was increased from 5 F to 8.3 F. As a result, power is maintained for a considerably longer time after a power failure. Due to the increase in capacity, the new model can replace the previous model, but not vice versa. Like with the old model, the two terminals ++ and of the new CML 110 with 8.3 F are internally connected with each other. This makes it possible to connect several CMLs 110 in parallel without needing to use additional external terminals. CML 110 capacitor module for 24-V power supply Specifications Power supply: Capacity: Max. charging current: Internal resistance (discharge) Maximum: Typical: Discharging current ID 574 087-02 CML 110 156 mOhm 65 mOhm 30 A 24 V 8.3 F 2.4 A

Danger Before service or maintenance work, you must ensure that the CML 110 has been completely discharged.

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1.3.2 HR 150 Handwheel For the iTNC 530, the HR 150 is available in conjunction with the HRA 110. The HRA 110 permits the connection of three HR 150 handwheels (see iTNC 530 Technical Manual). The HR 150 was improved. The cable outlet can now be used radially or axially. An additional version with mechanical detent was developed. The most important characteristics of the HR 150 are: 11 App signals, line count 5000 1 m cable, connector (male), 9-pin Cable outlet for axial and radial use Ergonomic knurled control knob Version with mechanical detent, 100 positions / 360 for ID 540 940-xx The following HR 150 versions are available: ID 540 940-06, HR 150 with mechanical detent ID 540 940-07, HR 150 without mechanical detent The HR 150 replaces the following handwheels which were removed from the sales program in May 2007: ID 257 061-08 ID 257 061-09 ID 257 061-10

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1.3.3 MC 422C DP There is a new, more powerful MC 422C DP hardware for the dual-processor versions of the iTNC 530. As of fall 2007, this hardware replaces the dualprocessor version of the MC422B DP. Properties of the MC 422C DP: Real-time computer: Pentium III with 800 MHz Windows computer: Pentium M with 1.8 GHz Main memory of real-time computer: 512 MB RAM Main memory of Windows computer: 512 MB RAM Same dimension as the MC 422B DP

Main computer (standard version) MC 422C DP

Signal inputs

ID of the MC for BF 150 monitor 631 209-01 631 215-01 631 217-01

Replaces ID

Without position encoder inputs (for CC 424) 5 position encoder inputs Position: 1 VPP/EnDat 10 position encoder inputs HDR hard disk for iTNC 530 with Windows XP Export version with Windows XP (MC 422C DP) Standard version with Windows XP (MC 422C DP)

387 175-01 387 183-01 387 191-01

ID 617 969-51 617 969-01

Other accessories (e.g. SIK) for the new MC 422C DP hardware are identical to those for the MC 422B DP. Please note that the iTNC 530 software can only run on the MC 422C DP if the following software versions and higher are installed: ID 340 492/493-04: Available as of November 2007

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The essential differences of the MC 422C DP from the MC 422B DP: The connection of the PL 51x is equipped with a triple-row connector (X147) instead of a double-row connector (X47). You should use the connection cable with ID 371 046-xx for the connection to X147. If required, HEIDENHAIN will deliver an adapter cable for X147 (ID 587 789-A5). This makes it possible to connect the PL 51x over the previous cable 371 045-xx as well. However, HEIDENHAIN does not recommend connecting the PL 51x with the connecting cable with ID 371 045-xx for a longer period of time. Connector X9 for additional analog outputs is missing. Only connector X8 with 6 analog outputs is present. If this presents you with difficulties, please contact HEIDENHAIN. A second USB connection (X144) is located on the bottom of the MC 422C's housing. X143, X144 are only displayed on the HeROS operating-system level and can only be used on the HeROS operating-system level. They have the same properties as the USB ports of an MC 422C single-processor version. X141, X142 are available in Windows and HeROS. The properties of these two USB ports cannot be influenced with a settings file of the HeROS system. MC 422C DP requires the additional 5V supply via X74 of the CC 42x. Important notes about the MC 422C DP Warning In regard to the MC 422C DP hardware, please note the following: The new MC 422C DP hardware only runs on software version 340 492/493-04 or higher. If you accidentally install a lower software version in connection with the MC 422C DP, then a corresponding error message appears when the control is booted. The boot procedure is aborted. If you have difficulties rebuilding or starting your control, or if you want to exchange a defective MC 422B DP for an MC 422C DP, please contact your HEIDENHAIN service agency. Note On the MC 422C DP, X 129 and X 126 must be connected with each other via an RJ 45 cable (Ethernet cable). If this connection is missing or was removed during operation, the main computer must be shut down and switched off with the main switch to ensure that it is not under power. The HeROS computer cannot be rebooted until the connection between X 129 and X 126 has been restored.

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When exchanging an MC 422B DP for an MC 422C DP, please proceed as follows:

Use the TNCremoNT software for PCs to create a full backup of the PLC partition and the TNC partition of the MC 422B DP. Completely switch off your machine after you have created the backup. Warning Do not engage or disengage any connecting elements while the unit is under power! Do not in any case exchange the hard disk of an MC 422B DP for that of an MC 422C DP, or vice versa. Because of the different Windows operating systems, this causes faulty configurations that cannot be fixed.

Remove the MC 422B DP hardware. Please refer to the notes in the Technical Manual. Install the MC 422C DP with the appropriate new HDR and reconnect all connecting elements. Refer to the connection overview of the MC 422C DP. Completely boot the MC 422C DP until the control application is running. The boot process for the control application ("iTNC Control Panel") may take somewhat longer than that of the MC 422B DP. Restore the full backup of the PLC partition and the TNC partition to the new HDR of the MC 422C DP. Reboot the control.

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Connection overview of MC 422C DP / without position encoder inputs and CC 424 with 6 control loops X1 to X5 X35 to X38
X15 X17 X19 X45

Vacant Vacant Encoder for speed PWM output Nominal value output, analog TS touch trigger probe TT 130 touch trigger probe

X15 to X20
X143 X126

X16 X18 X20

X149 X129 X26

X51 to X60 X8 X12 X13

X51 X53 X55

X141 X127

X142

X128 X52 X54 X56 X145 X14

X23 Handwheel X26 Ethernet data interface X27 RS-232-C/V.24 data interface X28 RS-422/V.11 data interface X127 RS-232-C/V.24 (only for Windows 2000) X128 RS-422/V.11 (only for Windows) X141 to X142 USB interface X30 X34 X41 X42 X44 X45 X46 X147 X48 X149 X126, X129 X69 X121 X165 X145, X14 X74 X150 B 24 V reference signal for spindle 24 V for control-is-ready output PLC output PLC input 24 V PLC supply voltage Keyboard unit Machine operating panel PLC expansion PLC analog input BF 150 monitor Ethernet reserved Power supply Reserved Reserved Reserved 5-V power supply Axis-specific drive enabling Signal ground Equipment ground (YL/GN)

0V 5V X69 X201 X203 X205

X202 X204 X206

X147

X150, X142 at bottom of housing

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Warning Do not engage or disengage any connecting elements while the unit is under power! Mating dimensions of MC 422C DP/ 5 position encoder inputs and CC 422 with 6 control loops Note All dimensions are in millimeters [mm].

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1.3.4 iTNC 530 with Windows XP General information Note When the control is put into service, the end user accepts the Microsoft license conditions. which are printed in the User's Manual. Keep the following in mind when installing Windows applications: HEIDENHAIN offers no support for the installation of non-HEIDENHAIN software and cannot guarantee the function of Windows applications. HEIDENHAIN is not liable for faulty hard disk contents caused by installing updates to non-HEIDENHAIN software or additional application software. If such changes to programs or data require a service visit from HEIDENHAIN, the costs for this visit are paid by the user. Microsoft service packs and patches Warning Service packs and patches from Microsoft may only be installed if they have been approved by HEIDENHAIN! HEIDENHAIN does not assume any liability for the compatibility of these service packs and patches with other installed Windows applications. Note HEIDENHAIN recommends deactivating the screens energy saver for existing installations. Drives in PGM MGT The same conditions apply as described in Chapter 11 of the Technical Manual for the iTNC 530 with Windows 2000. The same conditions apply as described in Chapter 11 of the Technical Manual for the iTNC 530 with Windows 2000.

Serial interfaces

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Hard disk

The MC 422C supports the following partition sizes (approx.): Partition MC 422C C: TNC: PLC: SYS: 25 GB 1 GB 2 GB MC 422C (with Windows XP) 17 GB 17 GB 1.95 GB 1.3 GB

The partitions of the hard disk can be displayed through Start/Settings/ Control Panel/Administrative Tools/Computer Management/Storage/ Disk Management. System time The same conditions apply as described in Chapter 11 of the Technical Manual for the iTNC 530 with Windows 2000. Module 9133 for determining the temperature of the second processor is not available on controls with Windows XP. The same conditions apply as described in Chapter 11 of the Technical Manual for the iTNC 530 with Windows 2000. The same conditions apply as described in Chapter 11 of the Technical Manual for the iTNC 530 with Windows 2000. In general, the usual Windows operating properties are valid for the iTNC 530 software! Setting the Windows language Hard disks with Windows XP support a multi-language version. In the version you can select the language of the operating system under Start/Settings/ Control Panel/Regional Settings. This new function cannot be retrofitted.

Processor temperature Set PLC output after shutdown Operation

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1.3.4.1 Starting and Shutting Down the iTNC On the MC 422C DP, X 129 and X 126 must be connected with each other via an RJ 45 cable (Ethernet cable). This is the connection between the HeROS computer and the Windows computer. If this connection is missing, the following Windows error messages of the Tftpd32 are displayed when you start the control application ("iTNC Control Panel").

If you receive this error message, the main computer must be shut down and switched off with the main switch to ensure that it is no longer under power. The HeROS computer cannot be rebooted until the connection between X 129 and X 126 has been restored. Otherwise, the same conditions apply as described in Chapter 11 of the Technical Manual for the iTNC 530 with Windows 2000. 1.3.4.2 The iTNC Control Panel The same conditions apply as described in Chapter 11 of the Technical Manual for the iTNC 530 with Windows 2000. 1.3.4.3 Network Settings The same conditions apply as described in Chapter 11 of the Technical Manual for the iTNC 530 with Windows 2000.

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1.3.4.4 Windows Settings Two network adapters are integrated in Windows: Local Area Connection: Connection of the Windows computer to the Windows network (Intel(R) 8255xER PCI adapter) iTNC Internal Connection: Connection between the HeROS computer and the Windows computer (Intel(R) PRO/100 VE Network Connection) Start/Settings/Network and Dial-up Connections displays an overview of the network connections:

Ask your network specialists for the network settings in your company network. Note Administrator rights are required for all network settings! Warning The network settings of the internal connection (iTNC Internal Connection) should not be changed! Otherwise, the same conditions apply as described in Chapter 11 of the Technical Manual for the iTNC 530 with Windows 2000.

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Registered users

Under Windows XP, the following users are already registered by HEIDENHAIN: User group Users Power Users Administrators Administrators Administrators Editable Description

User name TNC TNCP OEM

Password (Without password) SYS095148 SYS807667

Yes, can also be Example user name for the deleted end usera Yes, can also be Example user name for the deleted end usera Yes, password can be changed No No Administrator for the machine tool builder Only for HEIDENHAIN Serviceb User for access by the HeROS computer to the Windows computerc

Administrator (not disclosed here) SYS_TNC

a. The end user must not be assigned to the Administrators group because otherwise he would have access through Windows to the PLC and SYS partition. b. The Administrator must not be changed because otherwise HEIDENHAIN cannot offer any service. c. The user SYS_TNC must not be changed because otherwise the control will not operate. Note When entering the password, pay attention to capitalization. The Windows Help contains general information about user groups. If the control is not in a domain, under Windows XP, users can be entered who are logged on automatically. Please refer to the online help of Windows XP.

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In the factory default setting, the MC 422C DP displays the two user options TNC User and TNC Power User on the screen when you log onto Windows XP. The user TNC User corresponds to the user TNC, and the user TNC Power User corresponds to the user TNCP of the table shown above.

Press the key combination ALT+CTRL+Del twice to switch from the displayed logon screen to the same logon window as in Windows 2000, which enables you to use all users listed in the table shown above after entering the user and the appropriate password from the table. Note for administrators The same conditions apply as described in Chapter 11 of the Technical Manual for the iTNC 530 with Windows 2000.

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1.3.5 TE 535Q General information The NC keys of the new operating panel are identical to those of the TE 530B. In addition, machine operating keys were integrated.

Technical characteristics: NC operating panel: Same as TE 530B Machine operating panel: 6 axis-direction keys 16 function keys Keys for NC start and NC stop (illuminated) Keys for spindle start and spindle stop All keys in the machine operating panel are snap-on keys. EMERGENCY STOP button Key for control voltage ON (RAFI key, illuminated) Two bore holes (22 mm) for additional RAFI buttons (shipped blocked with a cover) or keylock switches

ID 547 577-xx

TE 535Q

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X3: to MC 4xx/X46

Connecting cable ID 263 954-xx: X3 D-sub, 37-pin male Pin no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 PLC input Meaning of the keys SN/Signal

I128 I129 I130 I131 I132 I133 I134 I135 I136 I137 I138 I139 I140 I141 I142 I143 I144 I145 I146 I147 I148 I149 I150

X minus Y minus Z minus IV minus V minus X plus Y plus Z plus IV plus V plus Select tool change Unclamp tool Chip conveyor back Unlock working space Chip conveyor Spindle start Spindle stop Coolant (external) (M08) NC start NC stop Rapid traverse Retract axis Coolant (internal) (M07)

S14 S27 S28 S29 S30 S16 S3 S2 S1 S4 S7 S8 S25 S38 S12 S34 S33 S11 STRT from terminal strip X15 STP from terminal strip X14 S15 S17 S24

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X3 D-sub, 37-pin male Pin no. 24 25 26 27 28

PLC input

Meaning of the keys

SN/Signal

I151 I152 O0 O1 O2

Machine control voltage ON Additional coolant NC start lamp NC Stop lamp Machine control voltage ON lamp Vacant Vacant Vacant Vacant Vacant

STSP from terminal strip X13 S37 From terminal strip X15 From terminal strip X14 From terminal strip X13

29 30 31 32 33 34 35 36 36

O3 O4 O5 O6 O7 0V 0V +24 V +24 V

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X10: to transfer unit

Connecting cable ID 629 663-xx: X10 D-sub, 15-pin male Pin no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 PLC input Meaning of the keys SN/Signal

Vacant Vacant Vacant Vacant Vacant Vacant Vacant Vacant Vacant Vacant Vacant Vacant Vacant Vacant Vacant

VI plus VI minus Jog spindle to left Jog spindle to right Permissive mode FN1 FN2 FN3 Not assigned Not assigned Not assigned Not assigned Not assigned Not assigned Not assigned

S5 S31 S20 S21 S18 S10 S23 S36 Vacant input X12/1 Vacant input X12/2 Vacant input X12/3 Vacant input X12/4 Vacant input X12/5 Vacant input X12/6 Vacant input X12/7

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X11: Vacant outputs X11 1 2 3 PLC operand O0 O1 O2 Meaning NC start lamp NC stop lamp Machine control voltage ON lamp Vacant Vacant Vacant Vacant Vacant Signal From terminal strip X15 From terminal strip X14 From terminal strip X13 Vacant output X3 Vacant output X3 Vacant output X3 Vacant output X3 Vacant output X3

4 5 6 7 8 9 10 X12: Vacant inputs X12 1 2 3 4 5 6 7 8

O3 O4 O5 O6 O7 0V +24 V

PLC operand Ixxx Ixxx Ixxx Ixxx Ixxx Ixxx Ixxx

Meaning Vacant Vacant Vacant Vacant Vacant Vacant Vacant +24 V

Signal Vacant input to X10/1 Vacant input to X10/2 Vacant input to X10/3 Vacant input to X10/4 Vacant input to X10/5 Vacant input to X10/6 Vacant input to X10/7

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X13, X14, X15

X13, X14 and X15 are terminal strips that are already wired when shipped: X13: Terminal strip for the 'machine control voltage ON' key X14: Terminal strip for the 'NC stop' key X14: Terminal strip for the 'NC start' key

Machine operating panel: Key assignment


S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S12 S13

S14

S15

S16

S17

S18

S19

S20

S21

S22

S23

S24

S25

S26

S27

S28

S29

S30

S31

S32

S33

S34

S35

S36

S37

S38

S39

Dimensions
400 12 0 3760.2 8 51.8 +1 0 44.6 +1 0

M5

3540.2 294.5 339 X

370

8 +1 0

76.50

5.5

1 4

M5

3540.2

354 +1 0

11x45 2.2 +0.4 0

X (2x) 2:1
+0.4

3760.2
+1 f 384 0

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HEIDENHAIN Technical Manual iTNC 530

24.1 +0.4 0

10
2.3 0

1.3.6 MB 520 General information With End of 2007 the new machine operating panel MB 520 is avaliable. The new operating panel is identical to the one integrated in the TE 535Q. The operting panel MB 420 will still be available as an replacement for simple machines. Technical characteristics: Machine operating panel: 6 axis-direction keys 16 function keys Keys for NC start and NC stop (illuminated) Keys for spindle start and spindle stop All keys in the machine operating panel are snap-on keys. EMERGENCY STOP button Key for control voltage ON (RAFI key, illuminated) Two bore holes (22 mm) for additional RAFI buttons (shipped blocked with a cover) or keylock switches ID 628 040-xx MB 520

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X3: to MC 4xx/X46

Connecting cable ID 263 954-xx: X3 D-sub, 37-pin male Pin no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 PLC input Meaning of the keys SN/Signal

I128 I129 I130 I131 I132 I133 I134 I135 I136 I137 I138 I139 I140 I141 I142 I143 I144 I145 I146 I147 I148 I149 I150

X minus Y minus Z minus IV minus V minus X plus Y plus Z plus IV plus V plus Select tool change Unclamp tool Chip conveyor back Unlock working space Chip conveyor Spindle start Spindle stop Coolant (external) (M08) NC start NC stop Rapid traverse Retract axis Coolant (internal) (M07)

S14 S27 S28 S29 S30 S16 S3 S2 S1 S4 S7 S8 S25 S38 S12 S34 S33 S11 STRT from terminal strip X15 STP from terminal strip X14 S15 S17 S24

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X3 D-sub, 37-pin male Pin no. 24 25 26 27 28

PLC input

Meaning of the keys

SN/Signal

I151 I152 O0 O1 O2

Machine control voltage ON Additional coolant NC start lamp NC Stop lamp Machine control voltage ON lamp Vacant Vacant Vacant Vacant Vacant

STSP from terminal strip X13 S37 From terminal strip X15 From terminal strip X14 From terminal strip X13

29 30 31 32 33 34 35 36 36

O3 O4 O5 O6 O7 0V 0V +24 V +24 V

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X10: to transfer unit

Connecting cable ID 629 663-xx: X10 D-sub, 15-pin male Pin no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 PLC input Meaning of the keys SN/Signal

Vacant Vacant Vacant Vacant Vacant Vacant Vacant Vacant Vacant Vacant Vacant Vacant Vacant Vacant Vacant

VI plus VI minus Jog spindle to left Jog spindle to right Permissive mode FN1 FN2 FN3 Not assigned Not assigned Not assigned Not assigned Not assigned Not assigned Not assigned

S5 S31 S20 S21 S18 S10 S23 S36 Vacant input X12/1 Vacant input X12/2 Vacant input X12/3 Vacant input X12/4 Vacant input X12/5 Vacant input X12/6 Vacant input X12/7

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X11: Vacant outputs X11 1 2 3 PLC operand O0 O1 O2 Meaning NC start lamp NC stop lamp Machine control voltage ON lamp Vacant Vacant Vacant Vacant Vacant Signal From terminal strip X15 From terminal strip X14 From terminal strip X13 Vacant output X3 Vacant output X3 Vacant output X3 Vacant output X3 Vacant output X3

4 5 6 7 8 9 10 X12: Vacant inputs X12 1 2 3 4 5 6 7 8

O3 O4 O5 O6 O7 0V +24 V

PLC operand Ixxx Ixxx Ixxx Ixxx Ixxx Ixxx Ixxx

Meaning Vacant Vacant Vacant Vacant Vacant Vacant Vacant +24 V

Signal Vacant input to X10/1 Vacant input to X10/2 Vacant input to X10/3 Vacant input to X10/4 Vacant input to X10/5 Vacant input to X10/6 Vacant input to X10/7

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X13, X14, X15

X13, X14 and X15 are terminal strips that are already wired when shipped: X13: Terminal strip for the 'machine control voltage ON' key X14: Terminal strip for the 'NC stop' key X14: Terminal strip for the 'NC start' key

Machine operating panel: Key assignment


S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S12 S13

S14

S15

S16

S17

S18

S19

S20

S21

S22

S23

S24

S25

S26

S27

S28

S29

S30

S31

S32

S33

S34

S35

S36

S37

S38

S39

Dimensions

400 12 0 940.2 34.5 79 X 3760.2 8 M5

52 +1 0 45 +1 0

110

8 +1 0

5.5 76.50 M5

1 4

940.2

94 +0.5 0

12x45 2.2 +0.4 0

X (2x) 2:1
+0.4

3760.2

384 +0.5 0

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24.1 +0.4 0

10

2.3 0

Basic configuration
TE 535Q 630 960-xx

15-pin female connector 315 650-04 15-pin male connector 315 650-03 20m 290 110-xx
Housing must be mounted 40m

VL: Extension cable for separation points with connecting cable for extending existing connecting cable

20m MB 420 293 757-xx

40m 1)

Speed inputs

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290 109-xx
Terminal box 251 249 01

BF 150 353 522-xx

TE 520 B 535 835-xx TE 530 BX 519 441-xx

21.11.2007

635 877-xx
629 663-xx

1.3.7 Cable Overview

37-pin male connector 315 650-07 40m 635 877-xx 635 876-xx

Included with visual display unit

USB touchpad TE 530 354 770-xx: 5m 365 499-xx: 6m...30m 635 877-xx VL 635 878-xx 635 876-xx 298 429-xx 298 430-xx

12m

353 545-xx

VL 635 878-xx 310 199-xx

1 VPP

60m

1 VPP

1) with 1x BTS 150 353 544-01

X149
X45 X46

X141 X142 X8 X41/X42 PLC I/0


Position inputs

309 783-xx Analog output

1 VPP

2) Adapter connector 544 703-01 for spindle (if necessary)

Hardware
X51 ... X62 X1 ... X5 X6, X35 ... X38 1) X201 ... X212 2)

3) only for connection of the KTY

MC 420 MC 422 C CC 42x


1) 2)

558 714-xx

LC x83
30m

X69
X15 ... X20 X80 ... X83

only MC 422 C only CC 424 B 1m

60m RCN 729 RCN 226 RCN 228

1 VPP 2) 289 440-xx

332 115-xx

Axes + spindle: 30m

VL 336 847-xx

VL 323 897-xx

533 631-xx max. 6m

LC x83

Axes + spindle: 60m 2)

VL (max. 6m) 336 847-xx 289 440-xx

60m 509 667-xx Voltage controller 5 V 368 210-01 3) 1m RCN 729 RCN 226 RCN 228

Voltage controller 5 V 370 226-01 Axes: 15m

336 376-xx

VL 323 897-xx

533 631-xx max. 6m KTY


289 440-xx Voltage controller 5 V 383 951-01 max. 9m KTY 1 VPP 60m LB/LS

LC x83

EnDat 2.1 interface VL (max. 6m) 340 302-xx

Voltage controller 5 V 370 224-01 VL 340 302-xx

336 376-xx

1 113

Axes: 60m

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HEIDENHAIN Technical Manual iTNC 530

2 Introduction
2.1 General Information......................................................................... 2 3 2.2 Meaning of the Symbols Used in this Manual .............................. 2 4 2.3 Overview of Components................................................................ 2 5 2.3.1 Main Computer, Hard Disk and SIK ........................................... 2 5 2.3.2 CC Controller Units .................................................................. 2 11 2.3.3 UV 106B Power Supply Unit .................................................... 2 13 2.3.4 UV 105B (Non-HEIDENHAIN Inverter Systems) ...................... 2 14 2.3.5 UV 105 Power Supply Unit ...................................................... 2 15 2.3.6 Keyboard Units and Monitors .................................................. 2 16 2.3.7 Handwheels ............................................................................. 2 20 2.3.8 Key Symbols ............................................................................ 2 23 2.3.9 Touch Probe Systems .............................................................. 2 28 2.3.10 Other Accessories ................................................................. 2 30 2.3.11 Documentation ...................................................................... 2 31 2.4 Brief Description............................................................................. 2 32 2.5 Software.......................................................................................... 2 43 2.5.1 Designation of the Software .................................................... 2 43 2.5.2 PLC Software ........................................................................... 2 44 2.5.3 Additional Control Loops or Software Options ........................ 2 44 2.5.4 Upgrade Functions (Feature Content Level) ............................ 2 47 2.5.5 NC Software Exchange on the iTNC 530 ................................. 2 48 2.5.6 Installing a Service Pack .......................................................... 2 63 2.5.7 Data Backup ............................................................................. 2 64 2.6 Software Releases.......................................................................... 2 65 2.6.1 NC Software 320 420-xx .......................................................... 2 65 2.6.2 NC Software 340 422-xx .......................................................... 2 70 2.6.3 NC Software 340 480-xx .......................................................... 2 81

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HEIDENHAIN Technical Manual iTNC 530

2 Introduction
2.1 General Information
HEIDENHAIN contouring controls are designed for use with milling, drilling and boring machines as well as machining centers. The iTNC 530 features integral digital drive control and controls the power stages via PWM signals. Integration of the drive controllers in the iTNC 530 offers the following advantages: All the software is contained centrally in the NC; this means that the individual components of the NC, such as feed axes, spindle, NC or PLC, are optimally matched. High control quality, because the position control, speed control and current control are combined into one unit. The same functions are available for commissioning, optimizing and diagnosing feed drives as well as spindles.

The iTNC 530 offers digital control for up to 14 axes and 2 spindles at spindle speeds up to 40 000 rpm. The iTNC 530 is designed for connection of a compact or modular inverter system. Thus, together with HEIDENHAIN motors, a complete control package including servo drives can be supplied (see the Inverter Systems and Motors Technical Manual).

September 2006

General Information

23

2.2 Meaning of the Symbols Used in this Manual


Danger Failure to comply with this information could result in most serious or fatal injuries or in substantial material damage. Warning Failure to comply with this information could result in injuries and interruptions of operation, including material damage. Note Tips and tricks for operation as well as important information, for example about standards and regulations as well as for better understanding of the document.

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HEIDENHAIN Technical Manual iTNC 530

2.3 Overview of Components


2.3.1 Main Computer, Hard Disk and SIK

MC main computer The iTNC 530 comprises 2 components: MC 42x(B) main computer (MC = main computer) CC 42x controller unit (CC = controller computer) The MC 42x(B) main computer is available in two versions: Standard version MC 422B Basic version MC 420 with 5 position encoder inputs and reduced performance range. However, these functions can be activated with two code numbers. See page 2 41 for the performance range.

MC 422 B

MC 420

The main computer consists of three components: MC 42x(B) main computer HDR hard disk SIK system identification key

HDR

SIK

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Overview of Components

25

Main computer (standard version) MC 422 B

Signal inputs

Id. Nr. of MC for BF 120 Id. Nr. of MC for display unit BF 150 display unit 387 171-xx (discontinued as of software 340 490-xx) 387 172-xx (discontinued as of software 340 490-xx) 387 173-xx 387 181-xx

Without position encoder inputs (for CC 424) 5 position encoder inputs Position: 1 VPP/ EnDat 10 position encoder inputs MC 422 B (with Windows 2000) Without position encoder inputs (for CC 424) 5 position encoder inputs Position: 1 VPP/ EnDat 10 position encoder inputs Main computer (Basic version) MC 420 5 position encoder inputs Position: 1 VPP/ EnDat Signal inputs

387 189-xx

387 175-xx 387 183-xx 387 191-xx

Id. Nr. of MC for BF 120 Id. Nr. of MC for display unit BF 150 display unit 515 929-01

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HEIDENHAIN Technical Manual iTNC 530

HDR hard disk for iTNC 530 Export version (MC 422B, MC 420) Standard version (MC 422B, MC 420) Export version with Windows 2000 (MC 422B) Standard version with Windows 2000 (MC 422B) SIK with NC software license for standard version with MC 422 B iTNC 530 For 4 control loops for CC 4xx with 6/8 control loops For 7 control loops for CC 4xx with 10/12/14 control loops For 5 control loops for CC 4xx with 6/8 control loops For 8 control loops for CC 4xx with 10/12/14 control loops For 6 control loops for CC 4xx with 6/8 control loops For 9 control loops for CC 4xx with 10/12/14 control loops For 10 control loops for CC 4xx with 10/12/14 control loops For 11 control loops for CC 4xx with 12/14 control loops iTNC 530 with Windows 2000 For 4 control loops for CC 4xx with 6/8 control loops For 7 control loops for CC 4xx with 10/12/14 control loops For 5 control loops for CC 4xx with 6/8 control loops For 8 control loops for CC 4xx with 10/12/14 control loops For 6 control loops for CC 4xx with 6/8 control loops For 9 control loops for CC 4xx with 10/12/14 control loops For 10 control loops for CC 4xx with 10/12/14 control loops For 11 control loops for CC 4xx with 12/14 control loops SIK with NC software license for basic version with MC 420 iTNC 530 4 control loops without software options 1 + 2 5 control loops without software options 1 + 2 6 control loops without software options 1 + 2

Id. Nr. 387 546-51 387 546-01 387 545-51 387 545-01 Id. Nr. (standard) 389 764-01 389 764-02 389 764-03 389 764-04 389 764-05 389 769-01 389 769-02 389 769-03 389 769-04 389 769-05 Id. Nr. (standard) Id. Nr. (export) 389 764-51 389 764-52 389 764-53 389 764-54 389 764-55 389 769-51 389 769-52 389 769-53 389 769-54 389 769-55 Id. Nr. (export)

510 085-01 510 085-51 510 085-02 510 085-52 510 085-03 510 085-53

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Overview of Components

27

Main computer (standard version)

Signal inputs

Id. Nr. of MC for BF 120 display unit 359 629-0x Export: 359 629-5x 359 632-0x Export: 359 632-5x 367 224-0x Export: 367 224-5x

Id. Nr. of MC for BF 150 display unit 369 947-0x Export: 369 947-5x 359 630-0x Export 359 630-5x 359 633-0x Export: 359 633-5x 367 225-0x Export: 367 225-5x 377 274-0x Export: 377 274-5x 372 037-0x Export: 372 037-5x 369 717-0x Export: 369 717-5x Id. Nr. 372 171-01 372 171-51

MC 422 (E) (discontinued as of software 340 49x) Without position encoder inputs (for CC 424) 5 position encoder inputs Position: 1 VPP/EnDat 10 position encoder inputs 5 position encoder inputs Position: 1 VPP/EnDat

MC 422 (E) (basic version) (discontinued as of software 340 49x)

MC 422 (E) (with Windows 2000) (discontinued as of software 340 49x) Without position encoder inputs (for CC 424) 5 position encoder inputs Position: 1 VPP/EnDat 10 position encoder inputs

SIK (for MC 422) (discontinued as of software 340 49x) SIK for standard software (basic version) SIK for export software (basic version)

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HEIDENHAIN Technical Manual iTNC 530

Controller unit CC 422 Max. 6 digital speed control loops Max. 10 digital speed control loops Max. 12 digital speed control loops Controller unit CC 424 Max. 6 digital control loops Max. 8 digital control loops Max. 10 digital control loops Max. 12 digital control loops Max. 14 digital control loops

Signal inputs 1 VPP/ EnDat

Enabled control loops Depends on SIK

Possible analog control loops 6 additional 5 additional 3 additional

Id. Nr. of CC 422

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

Signal inputs 1 VPP/ EnDat

Enabled control loops Depends on SIK

Possible analog control loops 6 additionala 6 additionala 5 additionala 3 additionala 1 additionala

Id. Nr. of CC 424

366 376-xx 521 755-xx 366 377-xx 533 569-xx 541 579-xx

a. In the CC 424, analog control loops can be realized only in connection with an MC 42x(B) with position encoder inputs. In addition to the digital control loops of the corresponding SIK, further control loops can be enabled. The enabling can be used for digital and for analog control loops (as of NC software 340 420-04). Option #0: 1st additional control loop #1: 2nd additional control loop #2: 3rd additional control loop #3: 4th additional control loop #4: 5th additional control loop #5: 6th additional control loop #6: 7th additional control loop #7: 8th additional control loop Id. Nr. 354 540-01 353 904-01 353 905-01 367 867-01 367 868-01 370 291-01 370 292-01 370 293-01

September 2006

Overview of Components

29

Designation of MC 42x(B) and CC 42x

ID numbers of MC 42x (B) and CC 42x:

359 632-01
BasicIDnumber Variant

The basic ID number indicates hardware differences. This first digit of the variant number indicates hardware changes. Variant xxx xxx-y1 xxx xxx-y2 Changes to MC 422 Initial version Main computer revised (not for dual-processor version) Changes to MC 420 Initial version Changes to the MC 422B Initial version Changes to CC 422 Initial version (speed controller SH1, current controller SH2) Modified controller (MC SH1, speed controller SH2) Changes to CC 424 Initial version

Variant xxx xxx-01 Variant xxx xxx-01 Variant xxx xxx-01 xxx xxx-02

Variant xxx xxx-01

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2.3.2 CC Controller Units

CC 422 controller unit CC 422 with 6 control loops It is equipped with: - 6 PWM outputs - 6 speed encoder inputs CC 422 with 10 (12) control loops It is equipped with: - 10 (12) PWM outputs - 10 (12) speed encoder inputs

CC 424 controller unit CC 424 with 6 control loops It is equipped with: - 6 PWM outputs - 6 speed encoder inputs - 6 position encoder inputs CC 424 with 8 control loops (as of software 340 49x) It is equipped with: - 8 PWM outputs - 8 speed encoder inputs - 8 position encoder inputs

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CC 424 with 10 control loops It is equipped with: - 10 PWM outputs - 10 speed encoder inputs - 10 position encoder inputs

CC 424 with 12 control loops (as of software 340 49x) It is equipped with: - 12 PWM outputs - 12 speed encoder inputs - 12 position encoder inputs

CC 424 with 14 control loops (as of software 340 49x-02) It is equipped with: - 14 PWM outputs - 14 speed encoder inputs - 12 position encoder inputs An image was not available at press time.

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HEIDENHAIN Technical Manual iTNC 530

2.3.3 UV 106 B Power Supply Unit General information UV 106 B power supply unit for analog HEIDENHAIN contouring controls The UV 106 B power supply unit was designed so that the iTNC 530 could be used with a compact, coordinated system for analog nominal shaft-speed interfaces (+/ 10 V). It supplies the iTNC 530 with the supply voltages necessary for operation. The UV 106 B (Id. Nr. 546 581-01) is being introduced as a replacement for the UV 106 (Id. Nr. 366 572-11).

Id. Nr. 546 581-01 UV 106 B UV 106 B Specifications Specifications Power supply (at X31) Protection Load capacity (5 V) Power consumption Degree of protection Module width Weight ID number UV 106 B 400 Vac 10 %a 50 Hz 6.3 A (gR) Siemens SITOR type 6.3 A (gRL) SIBA type 20 A Max. 400 W IP 20 159 mm 4 kg 546 581-xx

a. An isolating transformer is not necessary for connecting the UV 106 B

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2.3.4 UV 105 B (Non-HEIDENHAIN Inverter Systems) General information The UV 105 B (Id. Nr. 532 581-01) was designed solely for the use of HEIDENHAIN controls in connection with non-HEIDENHAIN inverter systems. It is essential for the supply voltages of the HEIDENHAIN control units. UV 105 B power supply unit for the operation of HEIDENHAIN controls with non-HEIDENHAIN inverter systems An LED showing the readiness of the supply voltage is located on the front of the UV 105 B.

UV 105 B Id. Nr. 532 581-01 UV 105 B

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2.3.5 UV 105 Power Supply Unit

UV 105 power supply unit The UV 105 serves to supply the power to the CC 42x if a non-HEIDENHAIN inverter is used, or, if required, to supply additional power if HEIDENHAIN inverter components are used (see Power Supply for the iTNC 530 on page 3 19). If a non-HEIDENHAIN inverter system is used, the adapter connector is connected to X69 of the UV 105. The cover for the UV 105 and the adapter connector for X69 are included in the items supplied. Id. Nr. 344 980-xx Id. Nr. 349 211-01 UV 105 Adapter connector for X69

Variant xxx xxx-01 xxx xxx-02 xxx xxx-12 xxx xxx-13 xxx xxx-14

Changes to UV 105 Initial version Modification for double-row configuration Version only for HEIDENHAIN inverters Version for HEIDENHAIN and non-HEIDENHAIN inverters Leads and ribbon cables elongated

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2.3.6 Keyboard Units and Monitors

TE 530 operating panel with touchpad TE 530 Id. Nr. 359 906-01

TE 530B operating panel with touchpad Function keys for the new smarT.NC operating mode, as well as the new SPEC FCT key for calling special TNC functions. TE 530B for smarT.NC and SPEC FCT key Id. Nr. 519 441-11

The IV and V keys are snap-ons, and can be switched (see Key Symbols on page 2 23).

Note Please note the following limitations caused by the touchpad when using a TE 530(B): The length of the required USB cable is limited to 36 m When using two operating panels, which are switched with the BTS 1xx, only one touchpad can be active (touchpad at X142 of the MC). The TE 520B operating panel should be used in these cases.

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HEIDENHAIN Technical Manual iTNC 530

TE 520 B operating panel with function keys for the new smarT.NC operating mode, as well as the new SPEC FCT key for calling special TNC functions. This operating panel corresponds to the TE 530B, but without the touchpad. Id. Nr. 535 835-01 TE 520B

The IV and V keys are snap-ons, and can be switched (see Key Symbols on page 2 23).

TE 420 operating panel Id. Nr. 313 038-12 The IV and V keys are snap-ons, and can be switched (see Key Symbols on page 2 23). Horizontal rows to match the design of the flatpanel display Id. Nr. 316 343-01

BF 150 visual display unit 15.1-inch color flat panel display (1024 x 768 pixels) with the following keys: 1 x 8 soft keys, 1 x 6 soft keys for PLC 3 soft keys for switching soft-key rows Screen layout Operating-mode switchover Id. Nr. 352 522-04 Horizontal rows depending on design Id. Nr. 339 516-02 (at bottom) Id. Nr. 339 516-04 (at top)

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BF 120 visual display unit (discontinued as of software 340 49x) 10.4-inch color flat panel display (640 x 480 pixels) with the following keys: 8 soft keys 2 soft keys for switching soft-key rows Screen layout Operating-mode switchover Id. Nr. 313 506-02

Variant xxx xxx-01 xxx xxx-02 xxx xxx-03 xxx xxx-04 BTS 1x0 screen-keyboard switching unit

Changes to BF 150 Initial version New housing front New display model (compatible to previous versions) New display model (compatible to previous versions)

With the BTS 1x0, it is possible to connect two monitors and two operating panels to an MC 42x(B). Id. Nr. 353 544-01 Id. Nr. 329 965-02 BTS 150 (2 x BF 150) BTS 120 (2 x BF 120)

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HEIDENHAIN Technical Manual iTNC 530

MB 420 machine operating panel Machine operating panel with snap-on (switchable) keys (see Key Symbols on page 2 23). Key assignment: Emergency stop Machine control voltage NC start, NC stop Direction keys for 5 axes Rapid traverse Coolant Spindle start Spindle stop 7 keys for machine functions FN 1 to FN 5 (standard assignment) Retract axis, tool change, unlock tool, menu selection, unlock door, rinse water jet, chip removal (assignment for HEIDENHAIN basic PLC program) Id. Nr. 283 757-33 Id. Nr. 293 757-45 Standard assignment Machine key assignment for HEIDENHAIN basic PLC program

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2.3.7 Handwheels All handwheels are available with and without detent. For handwheels with detent, the cogging torque prevents movements of the handwheel due to motions or vibrations of the machine. On handwheels without detent, this is prevented by a defined holding torque. Handwheels with detent feature 100 detent positions per revolution, i.e. every 3.6. The increment per step is specified as follows: HR 130: By the user via conversational programming on the control HR 410: By the user on the HR 410 via 3 different step increments predefined by the machine manufacturer HR 420: By the user on the HR 420 Handwheels with detent are supported as of software versions 340 422-09, 340 423-09, 340 480-09, 340 481-09 and 340 49x-01 HR 410 handwheel Portable electronic handwheel with snap-on (switchable) keys (see Key Symbols on page 2 23). Keys for selection of 5 axes Keys for traverse direction Keys for preset feeds Actual-position-capture key Three keys for machine functions (definable via PLC) Spindle right/left/stop NC start/stop, spindle start; for HEIDENHAIN basic PLC program Two permissive buttons (24 V) Emergency-stop key (24 V) Magnetic holding pads Id. Nr. 296 469-54 Id. Nr. 296 469-55 Id. Nr. 535 220-05 HR 410 handwheel (spindle right/left/stop) HR 410 handwheel (NC start/stop, spindle start) HR 410 handwheel (NC start/stop, spindle start) with detent

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HEIDENHAIN Technical Manual iTNC 530

HR 420 handwheel Portable electronic handwheel with Display for operating mode, actual position value, programmed feed rate and spindle speed, error messages Spindle speed and feed-rate override Axis selection via keys and soft keys Actual-to-nominal value transfer NC start/stop Spindle start/stop Keys for traverse direction Two permissive buttons (24 V) Emergency-stop key (24 V) Magnetic holding pads Mount for attaching the handwheel to the machine Id. Nr. 375 239-01 Id. Nr. 512 367-01 Id. Nr. 312 879-01 Id. Nr. 296 467-xx Id. Nr. 296 687-xx Id. Nr. 296 466-xx Id. Nr. 281 429-xx Id. Nr. 271 958-03 HR 130 handwheel Panel-mounted handwheel Id. Nr. 254 040-05 With ergonomic knob, radial cable outlet Same as above, but with detent HR 420 Handwheel HR 420 handwheel with detent Connecting cable to cable adapter (spiral cable 3 m) Connecting cable to cable adapter (normal cable) Connecting cable to cable adapter (with metal armor) Adapter cable to MC 42x(B) Extension to adapter cable Dummy plug for emergency

Id. Nr. 540 940-01

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HRA 110 handwheel adapter For connecting up to three HR 150 handwheels with the TNC. The axes and the subdivision factor are selected via rotary switch. Id. Nr. 261 097-03 Id. Nr. 257 061-09 HRA 110 HR 150 radial cable outlet Handwheel selection switch

Id. Nr. 270 908-01

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HEIDENHAIN Technical Manual iTNC 530

2.3.8 Key Symbols Key symbols for the spindle Key Designation Print/Background Id. Nr. Spindle stop White/Red 330 816-08 Spindle direction left Black/Gray 330 816-40 Spindle stop White/Red 330 816-47 Clamp the axis Black/Gray 330 816-48 Key symbols with axis designations Key Designation Print/Background Id. Nr. X Black/Orange 330 816-24 Z Black/Orange 330 816-25 B Black/Orange 330 816-26 U Black/Orange 330 816-43 W Black/Orange 330 816-45 Key Designation Print/Background Id. Nr. Y Black/Orange 330 816-36 A Black/Orange 330 816-42 C Black/Orange 330 816-23 V Black/Orange 330 816-38 IV Black/Orange 330 816-37 Key Designation Print/Background Id. Nr. Spindle start White/Green 330 816-09 Spindle direction right Black/Gray 330 816-41 Spindle start White/Green 330 816-46

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Axis direction keys for the principle axes

Key

Designation Print/Background Id. Nr. X Black/Gray 330 816-63 X < Black/Gray 330 816-18 X > Black/Gray 330 816-0W X < Black/Gray 330 816-0N Y Black/Gray 330 816-67 Y > Black/Gray 330 816-21 Y < Black/Gray 330 816-0P

Key

Designation Print/Background Id. Nr. X+ Black/Gray 330 816-64 X+ > Black/Gray 330 816-17 X+ < Black/Gray 330 816-0V X+ > Black/Gray 330 816-0M Y+ Black/Gray 330 816-68 Y+ < Black/Gray 330 816-20 Y+ > Black/Gray 330 816-0R

Y > Black/Gray 330 816-0D Z Black/Gray 330 816-65 Z < Black/Gray 330 816-19 Z > Black/Gray 330 816-0L

Y+ < Black/Gray 330 816-0E Z+ Black/Gray 330 816-66 Z+ > Black/Gray 330 816-16 Z < Black/Gray 330 816-0K

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HEIDENHAIN Technical Manual iTNC 530

Key symbols for axis-direction keys for rotary and secondary linear axes

Key

Designation Print/Background Id. Nr. A Black/Gray 330 816-95 B Black/Gray 330 816-97 C Black/Gray 330 816-99 U Black/Gray 330 816-0B V Black/Gray 330 816-70 W Black/Gray 330 816-0G IV Black/Gray 330 816-71

Key

Designation Print/Background Id. Nr. A+ Black/Gray 330 816-96 B+ Black/Gray 330 816-98 C+ Black/Gray 330 816-0A U+ Black/Gray 330 816-0C V+ Black/Gray 330 816-69 W+ Black/Gray 330 816-0H IV + Black/Gray 330 816-72

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Key symbols for machine functions Key Designation Print/Background Id. Nr. Special function Black/Gray 330 816-0X Function B White/Black 330 816-31 Function 1 Black/Gray 330 816-73 Function 3 Black/Gray 330 816-75 Function 5 Black/Gray 330 816-77 Unlock door Black/Gray 330 816-79 Coolant (internal) Black/Gray 330 816-0S Rinse water jet Black/Gray 330 816-81 Chip removal Black/Gray 330 816-83 Tool change Black/Gray 330 816-89 Tool changer right Black/Gray 330 816-86 Unlock tool Black/Gray 330 816-88 Lock tool Black/Gray 330 816-0U Key Designation Print/Background Id. Nr. Function A White/Black 330 816-30 Function C White/Black 330 816-32 Function 2 Black/Gray 330 816-74 Function 4 Black/Gray 330 816-76 Unlock door Black/Gray 330 816-78 Coolant Black/Gray 330 816-80 Coolant (external) Black/Gray 330 816-0T Spotlight Black/Gray 330 816-82 Chip conveyor Black/Gray 330 816-84 Tool changer left Black/Gray 330 816-85 Unlock tool Black/Gray 330 816-87 Lock tool Black/Gray 330 816-94 Retract axis Black/Gray 330 816-91

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HEIDENHAIN Technical Manual iTNC 530

Other key symbols Key Designation Print/Background Id. Nr. No symbol /Black 330 816-01 NC start White/Green 330 816-11 NC start White/Green 330 816-49 Feed rate 1 Black/Gray 330 816-33 Rapid traverse Black/Gray 330 816-35 Permissive key Black/Gray 330 816-90 White/Black 330 816-28 Menu selection > Black/Gray 330 816-92 0 Black/Gray 330 816-0Y Key Designation Print/Background Id. Nr. No symbol /Gray 330 816-61 NC stop White/Red 330 816-12 NC stop White/Red 330 816-50 Feed rate 2 Black/Gray 330 816-34 Permissive key White/Green 330 816-22 Actual position capture White/Black 330 816-27 + WH/BK 330 816-29 Menu selection < Black/Gray 330 816-93

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2.3.9 Touch Probe Systems

TT 130 tool touch probe Touch-trigger probe for measuring tools. Id. Nr. 296 537-xx Id. Nr. 335 332-xx TT 130 Adapter cable for connection to the MC 42x(B)

TT 140 tool touch probe Triggering touch probe with rated break point of the connection pin for the probe head and optical deflection display. An additional connection pin is delivered with the touch probe. Id. Nr. 527 797-03 Id. Nr. 559 758-01 Id. Nr. 335 332-xx TT 140 Connection pin Adapter cable for connection to the MC 42x(B)

TS 220 touch probe Touch-trigger probe with cable connection for workpiece setup and measurement during machining. Id. Nr. 293 488-xx Id. Nr. 274 543-xx TS 220 Adapter cable for connection to the MC 42x(B)

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HEIDENHAIN Technical Manual iTNC 530

TS 640, TS 440 touch probe Touch-trigger probe with infrared transmission, for workpiece setup and measurement during machining. Id. Nr. 359 575-xx Id. Nr. 372 401-xx Id. Nr. 377 686-xx TS 640 TS 440 SE 640 transmitterreceiver unit SE 540 transmitterreceiver unit

Id. Nr. 517 518-xx

TS 640

TS 440

SE 640

SE 540

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2.3.10 Other Accessories

PL 410 B PLC input/output unit For the expansion of PLC inputs and outputs Id. Nr. 263 371-12 64 inputs 31 outputs 64 inputs 31 outputs 4 analog inputs 10 V 4 inputs for Pt 100 thermistors

Id. Nr. 263 371-02

PL 405 B PLC input/output unit Id. Nr. 263 371-22 32 inputs 15 outputs

PL 510 PLC input/output unit This is a modular I/O system for the expansion of PLC inputs and outputs. The PL 510 consists of the PLB 510 basic module and the following components: PLD 16-8 I/O module with 16 digital inputs and 8 digital outputs PLA 4-4 analog module with 4 analog inputs for Pt 100 thermistors and 4 10 V analog inputs Empty housing for partial assembly The PL 510 can be mounted on a top hat rail (NS 35 EN 50022). The PL 510 equipped (completely or partially) with PLD 16-8 is compatible with PL 410 B/ PL 405 B. 358 849-01 PLB 510 basic module

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360 916-01 366 423-01 383 022-01

PLD 16-8 input/output module PLA 4-4 analog module Empty housing

PLD 16-8

PLA 4-4

Further components Adapters for encoder signals TTL (HEIDENHAIN layout)/1 VPP TTL (SIEMENS layout)/1 VPP 11 APP to MC 42x(B) 11 APP /1 VPP

Id. Nr. 317 505-01 317 505-02 317 505-05 313 119-01

2.3.11 Documentation Items supplied with the control include: 1 Users Manual for conversational programming 1 Users Manual for ISO programming 1 Pilot (brief users programming guide) The HEIDENHAIN inverters and motors for the iTNC 530 are described in the Inverter Systems and Motors Technical Manual. The components required for operating the iTNC 530 with non-HEIDENHAIN inverter systems are described in Technical Information for Operation of SIMODRIVE and POWER DRIVE Inverter Systems.

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2.4 Brief Description


Technical data MC 422 B Processor: Pentium III with 800 MHz 128 MB SDRAM Bus frequency: 133 MHz 5 or 10 position encoder inputs 1 VPP or EnDat, or without position encoder inputs (for CC 424) Unambiguous identification of MC 422B through SIK (System Identification Key) MC 422 B (with Windows 2000) Two processors: Pentium III with 800 MHz 128 MB SDRAM for the control 256 MB SDRAM for Windows 2000 Bus frequency: 133 MHz 2 x USB 5 or 10 position encoder inputs 1 VPP or EnDat, or without position encoder inputs (for CC 424) Unambiguous identification of MC 422B through SIK (System Identification Key) MC 420 Processor: Celeron with 400 MHz 128 MB SDRAM Bus frequency: 100 MHz Five position encoder inputs 1 VPP or EnDat Unambiguous identification of MC 420 through SIK (System Identification Key) CC 422 All speed encoder inputs 1 VPP or EnDat 6 speed encoder inputs with 1 VPP or EnDat for axes and spindles Basic version: 4 speed control loops 10 speed encoder inputs with 1 VPP or EnDat for axes and spindles Basic version: 7 speed control loops 12 speed encoder inputs with 1 VPP or EnDat for axes and spindles Basic version: 7 speed control loops CC 424 All position and speed encoder inputs 1 VPP or EnDat 6 position and 6 speed encoder inputs with 1 VPP or EnDat for axes and spindle(s) Basic version: 4 speed control loops 10 position and 10 speed encoder inputs with 1 VPP or EnDat for axes and spindle(s) Basic version: 7 speed control loops iTNC 530

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Technical data Options

iTNC 530 Additional control loops or software options can be enabled by entering a code number.

Display 15.1-inch TFT color flat-panel display 10.4-inch TFT color flat-panel display Program memory Hard disk with > 6 gigabytes Input resolution and display step Up to 0.1 m for linear axes Up to 0.0001 for angular axes Interpolation Straight line
a

5 of 14 axes 2 of 14 axes 3 of 14 axes with tilted working plane Superimposition of circular and linear paths Cubic splines can be executed 0.5 ms Basic version: 3.6 ms (0.5 ms with software option 2) a. Export version

Straight lines (with MC 42x(B) E ) 4 of 14 axes Circle Helix Spline (software option 2) Block processing time

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Machine interfacing Feedback control with CC 422/CC 424 Position loop resolution

iTNC 530

Signal period 1024 CC 422: 1.8 ms CC 424: 3 ms CC 422: CC 424: 200 s/100 sa CC 422: 1.8 ms CC 424: 200 s (100 s)b CC 422: 600 s CC 424: 200 s/100 sa PWM frequency 3333 Hz 4166 Hz 5000 Hz 6666 Hz 8333 Hz 10000 Hz Maximum feed rate: 60000 No. of pole pairs Cycle time 150 s 120 s 100 s 75 s 60 s 50 s

Path interpolation Fine interpolation Cycle time, position controller Cycle time, speed controller Cycle time, current controller

Feed rate

Ballscrew pitch

at fPWM = 5000 Hz Up to approx. 40 m/min (33 kHz) or approx. 420 m/min (350 kHz) for encoders with 20 m grating period Up to approx. 200 m/min (33 kHz) or approx. 2100 m/ min (350 kHz) for encoders with 100 m grating period Minimum feed rate: (Cycle time of speed controller)1 Line count of motor encoder 1024 Rotational speed Maximum revolutions per minute: n max
1 f PWM 60000 min = --------------------------------------p 5000 Hz

Ballscrew pitch

nmax: Maximum spindle speed [rpm] fPWM: PWM frequency [Hz] p: Number of pole pairs The following PWM frequencies are available: 3333 Hz 4166 Hz (CC 424: 4000 Hz) 5000 Hz 6666 Hz 8333 Hz (CC 424: 8000 Hz) 10000 Hz a. Single-speed/double-speed b. Double-speed without position encoder

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Machine Integration Error compensation

iTNC 530 Linear and nonlinear axis error Backlash Reversal spikes during circular movements Reversal error Thermal expansion Stiction Sliding friction

Monitoring functions Amplitude of encoder signals Edge separation of encoder signals Absolute position for encoders with distance-coded reference marks Following error Movement monitoring Standstill monitoring Nominal speed value Checksum of safety-related functions Power supply Buffer battery Operating temperature Cycle time of the PLC program Motor current Motor temperature Temperature of power stage DC-link voltage Integral PLC PLC memory Program format Main memory (RAM) PLC cycle time PLC inputs 24 Vdc PLC outputs 24 Vdc Analog inputs 10 V Analog outputs 10 V Inputs for thermistors 2 GB on hard disk Statement list 512 KB 10.8 ms (can be set) 56 (additional inputs as option) 31 (additional outputs as option) 3 (additional analog inputs as option) 13 3 (additional inputs as option)

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Machine Integration Commissioning aids

iTNC 530 Oscilloscope Trace function Table function Logic diagram Log TNCopt software for PCs

Interfaces One RS-232-C/V.24 and one RS-422/V.11, each with max. 115 Kbps Expanded interface with LSV-2 protocol for external operation of the iTNC over the interface with HEIDENHAIN software TNCremo. Fast Ethernet interface 100 BaseT Permissible temperature range Operation: 0 to +40 C Storage: 35 C to +65 C

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HEIDENHAIN Technical Manual iTNC 530

User functions User functions Program entry Fixed cycles iTNC 530 HEIDENHAIN conversational and ISO Drilling/boring cycles for drilling, peck drilling, reaming, boring, counterboring, tapping with or without floating tap holder Cycles for milling internal and external threads Roughing and finishing rectangular and circular pockets Cycles for face milling plane and oblique surfaces Cycles for milling linear and circular slots Hole patterns on circle and line Contour pockets also contour parallel Contour train OEM cycles (special cycles developed by the machine tool builder) can also be integrated Touch probe calibration Compensating workpiece tilt manually and automatically Setting the datum manually and automatically Automatic workpiece measurement Cycles for automatic tool measurement Straight line Chamfer Circular path Circle center Circle radius Tangentially connected arc Corner rounding

Touch probe cycles

Contour elements

Contour approach and departure Via straight line: tangential or perpendicular Via circle FK free contour programming FK free contour programming in HEIDENHAIN conversational format with graphic support for workpiece drawings not dimensioned for NC Creating a program with graphical support while another program is being run Feed rate reduction during plunging (M103) Jerk-free path control HSC filter and advanced HSC filter 3-D tool compensation through surface-normal vectors Automatic compensation of machine geometry when working with tilted axes (M114, M115, M128, M129, M130) Changing the angle of the tilting head with the electronic handwheel during program run. The position of the tool tip does not change. Tool perpendicular to contour Tool radius compensation perpendicular to traversing and tool direction Spline interpolation

Background programming 3-D machining

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User Functions Rotary table machining Q parameters programming with variables

iTNC 530 Programming a contour on a cylindrical surface as if on a plane Feed rate in mm/min (M116) Mathematical functions =, +, , *, /, sin , cos , angle from sin and cos , a, a +b
2 2

Logical comparisons (=, =/, <, >) Parentheses tan , arc sin, arc cos, arc tan, an, en, ln, log, absolute value of a number, constant , negation, truncation before or after decimal point Functions for calculating a circle Programming aids Pocket calculator Context-sensitive help function for error messages Graphic support for the programming of cycles Comment blocks in the NC program Nominal positions for straight lines and circles in Cartesian or polar coordinates Absolute or incremental dimensional data Display and input in mm or inches Display of handwheel path during machining with handwheel superpositioning Tool radius in the working plane and tool length Radius compensated contour look ahead for up to 99 blocks (M120) Three-dimensional tool radius compensation for editing tool data at a later date without a renewed program computation Multiple tool tables with any number of tools For automatic calculation of spindle speed and feed rate from toolspecific data (cutting speed, feed rate per tooth) With respect to the path of the tool center With respect to the tool cutting edge (M109, M110, M111) Subprograms Program-section repeat Any desired program as subroutine Datum shift, rotation, mirroring Scaling factor (axis specific) Tilting the working plane Actual positions can be transferred directly into the part program Graphical simulation before a program run, also while another program is being run Plan view, view in three planes, 3-D view Magnification of details

Position data

Tool compensation

Tool tables Cutting-data tables Constant contour speed Program jumps

Coordinate transformation

Actual position capture Test graphics

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HEIDENHAIN Technical Manual iTNC 530

User Functions Programming graphics

iTNC 530 In the Programming and Editing operating mode, the contours of the NC blocks are drawn (2-D pencil-trace graphics), also while another program is being run Graphical simulation of executed program in plan view, three planes and 3-D view Calculation of machining time in the Test Run mode of operation Display of the current machining time in the Program Run modes of operation Mid-program startup in any block in the program, returning the tool to the calculated nominal position to continue machining Program interruption, contour departure and return Multiple datum tables Tool-oriented or workpiece-oriented execution of pallet tables with any number of entries for selection of pallets, part programs and datums

Machining graphics Machining time

Returning to the contour

Datum tables Pallet tables

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Accessories Accessories Electronic handwheels iTNC 530 One portable HR 410 handwheel, or One portable HR 420 handwheel with display, or One panel-mounted HR 130 handwheel, or Up to three panel-mounted HR 150 handwheels via the HRA 110 handwheel adapter TS 220 triggering 3-D touch probe with cable connection, or TS 440, TS 640 triggering 3-D touch probe with infrared transmission, or TT 130 triggering 3-D touch probe for tool measurement TNCremoNT, TNCremo PLCdesignNT CycleDesign TeleService TNCopt TNCdiag Up to four PL 410B/PL 510 or one PL 405B PL 410B version 1: Additional 64 PLC inputs and 31 PLC outputs per PL PL 410B version 2: Additional 64 PLC inputs and 31 PLC outputs as well as 4 analog inputs 10 V and 4 inputs for thermistors per PL PL 405B: Additional 32 PLC inputs and 15 PLC outputs per PL PL 510: Four slots for PLD 16-8 (16 PLC inputs and 8 PLC outputs) and PLA 4-4 (four 10 V analog inputs and 4 inputs for thermistors)

Touch probe systems

Data transfer software PLC development software Software for generating cycle structure Software for remote diagnosis Software for putting digital control loops into operation Software for diagnosis of digital drive systems PLC input/output unit

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HEIDENHAIN Technical Manual iTNC 530

Software options Software options #8: Software option 1 Id. Nr. 367 591-01 iTNC 530 Cylinder surface interpolation Feed rate in mm/min Tilting the working plane Circular interpolation in 3 axes with tilted working plane HSC path control: Special position value filters for optimal path control (HSC filter and advanced HSC filter) Cycle 32: Additional options in Cycle 32 for roughing and finishing mode, and tolerances for rotary axes 3-D compensation of the tool length and diameter via surface normal vectors (DL/DR in the tool table) via radius compensation perpendicular to the tool direction (RL/RR in the NC program) Programming with LN blocks (machine-neutral 3-D programming with various options) 3-D machining TCPM: Tool Center Point Management Maintain position of the tool tip when positioning with tilting axes (via M128 in the NC program) and with additional options (via Function TCPM in the NC program) M114: Automatic correction of machine geometry when positioning tilting axes M144: Compensating the machines kinematics configuration for ACTUAL/NOMINAL positions at end of block Tool perpendicular to contour Straight-line interpolation in 5 axes (permit required for export) Spline interpolation: Execution of splines (third-degree polynomials) 0.5-ms block processing time #18: HEIDENHAIN DNC Id. Nr. 526 451-01 All functions of HEIDENHAIN DNC become available (see Remo Tools SDK documentation) The following functions of the LSV2 ActiveX control become available (all other options do not require option #18): OpenChatWindow RunProgram SetOverride SetPreset TransmitChatText TransmitPLCCommand TransmitPLCString HostFunction EventReceived NCMsgReceived PLCMsgReceived

#9: Software option 2 Id. Nr. 367 590-01

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Software options #40: DCM Dynamic Collision Monitoring Id. Nr. 526 452-01 #41: Additional Language: Slovenian Id. Nr. 530 184-01 #42: DXF Converter Id. Nr. 526 450-01

iTNC 530 Dynamic collision monitoring of defined machine components

Additional dialog language Slovenian

Conversion of DXF files (also just parts of files) for editing in HEIDENHAIN conversational programming or with smarT.NC (see iTNC 530 Users Manual)

#53: Upgrade functions (Feature Enabling of expanded, useful functions in updates of NC software. However, these are available without option #53 for Content Level) the initial installation (see iTNC 530 Users Manual) Id. Nr. 529 969-01

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2.5 Software
2.5.1 Designation of the Software The iTNC 530 features a separate software for the NC and the PLC. The NC software is identified with an eight-digit number. If you press the MOD key in any operating mode, you can display the ID numbers of the NC software, the DSP software (DSP1, DSP2) and the current-controller software (ICTL1, ICTL2). An installed service pack is shown by SPx after the ID number of the NC software.

Type

The iTNC 530 is shipped with the following NC software versions: Standard 340 420-xx 340 422-xx 340 500-xx 340 480-xx 340 502-xx Export 340 421-xx 340 423-xx 340 501-xx 340 481-xx 340 503-xx Note iTNC 530 iTNC 530 Service pack for 340 480-xx or 340 481-xx iTNC 530 with Windows 2000 Service pack for 340 480-xx or 340 481-xx

Due to restrictions on the export of the iTNC 530, HEIDENHAIN can also supply a special export version. This export version differs from the standard control though the installed NC software type. HEIDENHAIN releases a new NC software type whenever it introduces extensive new functions.

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2.5.2 PLC Software The PLC software is stored on the hard disk of the iTNC. You can order a PLC basic program directly from HEIDENHAIN. With the PLC development software PLCdesignNT, the PLC program can very easily be adapted to the requirements of the machine. 2.5.3 Additional Control Loops or Software Options For each MC 42x(B), only the minimum number of control loops is enabled. If you need additional control loops, you must enable them by entering a code number. These additional control loops are not bound to a certain machine parameter index. The definition as to whether a control loop is used is entered as a value 0 in MP120.x (nominal speed value outputs to the axes) and MP121.x (nominal speed value outputs to the spindles). Up to two software options can be enabled on the basic version of the MC 42x. This is also done by entering a code number. Each MC 42x(B) can clearly be identified by the SIK (System Identification Key). You will find the SIK number on the outside of the MC 42x(B) housing (below the ID label) and on the SIK board. To install the SIK, see Handling of the HDR Hard Disk and the SIK on page 3 5. If you wish to enable additional control loops or software options, please contact HEIDENHAIN for the code number. After you have informed us of the SIK number, we can give you the required code number. Note If you replace the MC 42x(B), you must also replace the SIK in order to ensure that the enabled control loops will also be enabled on the new MC 42x(B). To enable additional control loops, proceed as follows:
8 8

While in the Programming and Editing operating mode, press the MOD key. Enter the code number SIK and confirm your entry with the ENT key.

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The following display will appear: Display SIK ID: Control Type: General Key: Meaning SIK number Control model (=iTNC 530) Enter the master code number 65535 to enable all options for the duration of two weeks. NONE: Master code number has not been entered yet. dd.mm.yyyy: Date up to which all options will be enabled. It is not possible to enable the control loops again by entering the master code number. EXPIRED: The two weeks since the master code number was entered have expired. Enter Option #: Key: In the list: Option column Active column Description of the individual options YES: Option is enabled NO: Option is not enabled Enter the number of the option to be enabled (the option number is shown in the list) Code number for the option to be enabled

In Enter option #: you enter the number for the option you want to enable. Options that have not been enabled yet are identified by the entry NO in the Active column. Enter the code number for enabling the option under Key: and confirm your entry by pressing the ENT key. HEIDENHAIN can give you the code number after having been informed of the SIK number.

The message Option <number> has been set appears.


8

Press the END soft key. The iTNC performs a reset.

If the code number is correct, the enabled option is identified by the entry YES in the Active column. To display the corresponding number of machine-parameter indexes:
8

In OEM.SYS, enter the code word PWMPARAMETER = followed by the required number of machine-parameter indexes MP2xxx.y for the current and speed controller. In OEM.SYS, enter the code word AXISNUMBER = followed by the required number of remaining machine-parameter indexes.

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Displaying the status of an option

The status of an option (enabled or not) can be displayed either as a menu by entering the code number SIK (see previous page), or bit-encoded after pressing the MOD key in the OPT line. Each bit has the following meaning: OPT: %xxxxxxxxxxxxxxxx Bit 0: 1st additional control loop to Bit 7: 8th additional control loop Bit 8: Software option 1 Bit 9: Software option 2 Bit 10: Reserved to Bit 15: Reserved

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2.5.4 Upgrade Functions (Feature Content Level) Until now, each new NC software version contained error fixes as well as expanded functions. Users who wanted only the NC software update to eliminate the errors often felt bothered by the expanded functions. For this reason, error fixes and expanded functions will now be handled separately within the software. If a new NC software is later loaded as an update onto a machine with NC software 340 490-01, then as the default setting only the error fixes contained will be effective. The upgrade functions will at first remain inactive. The upgrade functions can then be enabled by entering a code number. HEIDENHAIN can give you the code number after having been informed of the SIK number and NC software version. The upgrade functions are defined as feature content level (FCL) in the SIK under option #53. The first time an NC software with upgrade functionality is installed on a control (i.e. no FCL has been set in the SIK), then the entire scope of functions can be used (including the upgrade functions.). The FCL is then automatically set after 100 restarts, or by entry of the code number 0 under option #53 (see Additional Control Loops or Software Options on page 2 44), and all upgrade functions belonging to this software version are enabled as well. A note appears asking to confirm the installed NC software as the initial version, or if another initial software version is to be installed. If the FCL has already been set in the SIK of a control, then after an update (e.g. from software 340 490-02 to -03), the new upgrade functions of the newer software version can only be used after entry of a code number from HEIDENHAIN under option #53 (see Additional Control Loops or Software Options on page 2 44). After pressing the MOD key, the current status of the FCL is displayed in addition to the software versions. The FCL is incremented with each new version of the NC software. If the upgrade functions are enabled via the FCL for a software version, then all upgrade functions of this software version and all its predecessors are available. For example, if the FCL for version 340 490-03 is set, then all upgrade functions from version 340 490-02 are also available immediately.

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If a newer software version, e.g. 340 490-06, is simply loaded onto a control, then the already existing upgrade functions remain available, but the upgrade functions of the newer version cannot be used. They must be enabled by entering a new code number.

2.5.5 NC Software Exchange on the iTNC 530 Note The NC software must be exchanged only by trained personnel. For exchanging the NC software, HEIDENHAIN provides packed files (*.zip) with the NC software. The packed files are transferred to the hard disk of the control or to a network drive and are unpacked. There have been some format changes to the software update. Please refer to the notes about Update to SW 340 490-02 on page 7 (digital Version) in Update Information 14.

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General information

The following files are necessary for an update, and must be located in the same directory: - setup.zip - setup.omf (setup.exe in Windows) - setup.ini (this is to be created by the OEM, and is only necessary if the update is to occur according to a specific sequence) Please note that this currently means that the version of the software to be installed is not displayed in advance. Note You can download the two files necessary for the update (setup.zip and setup.omf) from the HEIDENHAIN FileBase under NC Milling iTNC530 > Software as a single ZIP file, e.g. 340490_002.zip, and unzip them in your Update directory. Software updates and service packs are loaded in the same manner. Automated updating is possible. If your directories are structured appropriately and you use a setup.ini control file, this method makes it possible to update the control automatically when it is booted (see Automated update (setup.ini) on page 2 50). Copying of the update files (setup.omf/exe and setup.zip) to the system partition occurs automatically as part of the update program in directories with the following naming convention: iTNC without Windows - Software update: SYS:\zip\<Id.Nr.>_<ver> - Service pack: SYS:\zip\<Id.Nr.>_<ver>_SP<n> iTNC with Windows - Software update: C:\Program Files\install\<Id.Nr.>_<ver> - Service pack: C:\Program Files\install\<Id.Nr.>_<ver>_SP<n> Warning No manual changes may be made to these directories, since they might be required for restoring earlier software versions. Before the update, a query appears asking whether the necessary binary to ASCII conversion should be performed. HEIDENHAIN recommends always performing this conversion. Only files whose binary version has changed are converted. Immediately thereafter a query appears asking for the recommended procedure if there is not enough memory space: - Cancel if not enough memory - Delete largest or oldest files first After successful installation, these ASCII files are automatically reconverted to binary format. This procedure can be automated in the control file mentioned above.

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The NC software has been prepared in such a manner that when an update is performed or a service pack loaded as of software 340 490-02, the PLC program and PLC partition can be updated as well, according to the requirements of the OEM. When the NC software is updated, the OEM uses the HEIDENHAIN PC software PLCdesignNT to add all necessary files to the setup.zip archive. These files are copied to the appropriate locations during an update. Note The support necessary for this in PLCdesignNT will be available starting from version 2.3. It is not possible to update only the PLC data but not the NC software. Automated update (setup.ini) Automated updating is possible with the iTNC 530. In order to automate an update as much as possible, a control file with the name setup.ini is necessary in addition to the setup.zip and setup.omf (.exe with Windows control) files. If your directories are structured appropriately and you use this setup.ini control file, this method makes it possible to update the control automatically when it is booted. If there is a certain install directory on your iTNC containing a setup.ini control file in addition to the update files, an update is performed automatically according to the instructions in this control file. The following directories are checked during booting for the presence of a control file: iTNC without Windows - TNC:\install\ or, if a USB memory device is connected - USB0:\install\ (USB0: first partition of the first USB memory device) iTNC with Windows - D:\install\ or, if a USB memory device is connected - G:\install\ (G: corresponds to the drive letter of the USB memory device network drives are not permitted!) The setup.ini file can be created with a simple text editor. An example of a setup.ini file: Interactive=1 Confirm=1 Language=GERMAN SavePlc=TNC:\backup\340490_002.zip

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The following settings are selectable: Parameters Interactive=[0,1] Description Deletion of the NC software archive (old software versions) and binary to ASCII conversion must be confirmed by the user. 0: No 1: Yes [default] Start of update and reboot process must be confirmed by the user 0: No 1: Yes [default] A service request is triggered after an update (only if remote diagnosis is active) 0: No [default] 1: Yes Binary to ASCII conversion with automated update process (not with service pack) 0: No 1: Yes [default] The setup archive to be installed is copied to the directory SYS:\zip (iTNC with Windows: C:\Program Files\install). This makes it possible to return to this software version later. 0: No 1: Yes [default] Procedure during binary to ASCII conversion during automated update if there is not enough memory available on the TNC or PLC partition DATE: Delete oldest files first SIZE: Delete largest files first CANCEL: Cancel the update [default] Procedure is there is not enough room on the SYS partition for the update DATE: Delete oldest archive first SIZE: Delete largest archive first CANCEL: Cancel the update [default] Language for the dialog guidance during the update if no user activities are required for starting the update and rebooting (Confirm=0) GERMAN: German dialog text ENGLISH: English dialog text [default] Delete the source files (setup.zip, setup.ini, setup.omf/exe) once the update has completed successfully 0: No [default] 1: Yes Delete the setup.ini file after a successful update. 0: No [default] 1: Yes

Confirm=[0,1]

ServiceRequest=[0,1]

ConvertToAscii=[0,1] (only if Interactive=0)

CopyToSys=[0,1]

DeleteFiles= [DATE,SIZE,CANCEL] (only if Interactive=0)

DeleteArchives= [DATE,SIZE,CANCEL] (only if Interactive=0)

Language=[ENGLISH, GERMAN] (only if Confirm=0)

DelSource=[0,1]

DeleteIni=[0,1]

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Parameters SavePlc=<name>

Description If the software is updated from 340 49x-02 or higher to a newer version, then the entire PLC partition can be stored as a ZIP file in binary format. This makes it possible to restore this software state including the PLC files. Here you enter the path and file name for the ZIP file in which the entire PLC partition is saved in binary format. Please consider the software version when assigning the file name. The Restore function is used to restore the PLC data to a certain software state. Here you enter the path and file name for the ZIP file containing the PLC data state (in binary format) appropriate to the NC software version to be installed. This should be the ZIP file which was saved with the SavePlc function, containing the corresponding PLC state and saved on the PLC partition.

RestorePlc=<name>

Automated updating of machine parameters

If a PLC:\_mpupdate directory is created, then files that automatically update or expand the active and selected MP or OEM.SYS files when the control is started can be saved here. Files containing the name merge.* (merge.mp and merge.oem.sys) expand the MP and OEM.SYS files by the entries contained in them. Files containing the name overwrite.* (overwrite.mp and overwrite.oem.sys) contain updated entries for the corresponding files, and overwrite entries with the same names in the MP and OEM.SYS files. This means that MP subfiles cannot be considered.

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Information about the OEM cycles

Keep the following information in mind if you switch from software 340 422-xx to 340 490-xx or when you use OEM cycles in the HEIDENHAIN cycle tree instead of in an OEM cycle tree:
8 8 8 8 8 8 8

Download and install the current CycleDesign software version from the HEIDENHAIN FileBase Open the existing CycleDesign project with the current CycleDesign version and adapt it if necessary Menu item File > Change variant... In the New variant pull-down menu, select the entry with the newest version of the NC software and confirm with OK Confirm also the subsequent Update Information with OK Menu item File > Save Then transfer the file (*.cdf) to the control, start the software update and check its functions. Warning Without this procedure, after a software update to the version 34049x the error message Key nonfunctional will appear when you press the CYCL DEF key The iTNC also does not recognize these cycles, and so ERROR blocks are inserted in the NC program. These ERROR blocks must be deleted manually!

Your *.cdf file and the appropriate *.cdc for the HEIDENHAIN cycles are still in the folder PLC:\JH\ on the control after the NC software exchange. You can find more information in the Users Manual or in the online help for CycleDesign.

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Manual NC software exchange as of software 340 490-02

Manual update The following procedure is used to perform a manual update (without a setup.ini file in the setup directory) or an installation of a service pack:
8 8

HEIDENHAIN recommends using the PC program TNCremoNT from HEIDENHAIN to make a backup for the control. Please check whether cycle projects (HEIDENHAIN or OEM cycles) must be adapted and transferred before the update! See Information about the OEM cycles on page 53. Connect the appropriate network drive or USB memory medium containing the files necessary for the update (setup.zip, setup.omf). If the network drive is not displayed, please proceed as follows: Enter the code number 95148 and confirm your entry with the ENT key. While in the Machine-parameter programming mode, press the PGM MGT key. Press the NETWORK soft key. Select the PC to be connected with the cursor keys and press the MOUNT DEVICE soft key. To exit the list of network drives, press the END soft key. To exit the program management, press the END soft key. Press the END key to exit the Machine-parameter programming mode.

8 8 8

In the Programming and Editing mode, press the MOD key Enter the code number SETUP and confirm your entry with the ENT key. In the upper part of the window, select the folder containing the setup files for the new NC software, and confirm with the ENT key. The file to be called for the installation (setup.omf) is displayed in the lower part of the window. To switch to the lower part of the window, press the FILES soft key. (Press the PATH soft key to return to the top part of the window.) In the lower part of the window, select the *.omf file of the new NC software with the cursor keys and press ENT. Following that, the NC software exchange will start. Use the cursor keys to select the language desired for the update guidance, and confirm your entry with the ENT key.

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Choose the desired action for the event that there is not enough memory available on the TNC or PLC partition for the binary to ASCII conversion: - Cancel if not enough space: The update procedure is cancelled if there is not enough space available, and a message to this effect appears. In this case you must save the files (*.h, *.i, and tables) externally, if they are needed, and then remove them manually in order to make space for the conversion. - Delete largest files first: The largest files (*.h, *.i, and tables) are deleted until there is enough space for the conversion. - Delete oldest files first: The oldest files (*.h, *.i, and tables on the PLC and TNC partitions) are deleted until there is enough space for the conversion. If there is not enough space on the SYS partition, select deletion of the oldest setup files. This procedure is repeated until there is enough memory space available. Confirm the update actions listed and that are to be performed. After the update has finished successfully, confirm the restart of the control. Read-in files which you had saved to a PC using TNCremoNT. With the COPY SAMPLE FILES soft key, the HEIDENHAIN standard tables for cutting data, the tilting-axis geometry, and the M-function macros as well as a prototype for a freely definable table (contains only the column Name) can be copied into the corresponding directories. The NC software exchange is completed. Note If a setup.ini file exists in the setup directory when you update manually, then the update is performed according to the instructions in this file. See Automated update (setup.ini) on page 50.

8 8 8 8

Automated software exchange as of version 340 490-02

Automated update An automated update is usually a part of a manual update. In addition, this means that you can use the control file to reduce the number of user actions necessary for the update to a minimum, and at the same time make a backup of the PLC partition. However, before you perform the automated update, please check whether cycle projects (HEIDENHAIN or OEM cycles) must be adapted and transferred before the update! See Information about the OEM cycles on page 53. If one of the following directories exists when an iTNC is booted, - TNC:\install\ or, if a USB memory device is connected - USB0:\install\ (USB0: first partition of the first USB memory device) and if a setup.ini control file is saved in this directory, then an automated update is performed according to the instructions in this control file (see Automated update (setup.ini) on page 2 50). Note Please note that if automated updating is selected, the update program may start with a delay due to the file size.

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Software exchange via remote operation

Update via remote operation How to perform an update via remote operation:
8 8

In the Programming and Editing mode of the iTNC, press the MOD key On the iTNC, activate remote maintenance by pressing the Service ON soft key. A service request is triggered and a connection is established. Transmit the setup.omf and setup.zip files to a suitable directory on the control (e.g. TNC:\update) Continue the update via remote operation as described under Manual update

8 8

Notes on updating via remote operation If remote maintenance is active when the update is started, the remote maintenance is deactivated (this does not affect the current remote operation). After the reboot or after the update was cancelled due to an error, a service request is triggered. The service request information indicates whether the update was successful. If the control does not boot due to missing or incorrect machine parameters, a service request is triggered until the power interrupt stage of the boot process is reached. Procedure for exchanging the NC software up to and including 340 422-12 Before exchanging the NC software, ensure that the free space on the hard disk of the MC 42x(B) is at least 50% the size of the occupied space. If that is not the case, you must save the files to a PC, e.g., with the TNCremoNT datatransfer software for PCs.

Note When the control starts, it checks whether there is enough space on the hard disk for system files. If not, the error message Too many setup files appears. In this event, delete any unnecessary setup files from the hard disk (see Deleting the packed files of existing NC software on page 2 61.)
8 8 8

While in the Programming and Editing operating mode, press the MOD key. Enter the code number 95148 and confirm your entry with the ENT key. If you want to use the Ethernet interface for transferring the NC software from a PC, proceed as follows: While in the Machine-parameter programming mode, press the PGM MGT key. Press the NETWORK soft key. Select the PC to be connected with the cursor keys and press the MOUNT DEVICE soft key. To exit the list of network drives, press the END soft key. To exit the program management, press the END soft key.

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8 8 8 8

While in the Machine-parameter programming mode, press the MOD key. Press the UPDATE DATA soft key. The name and path of a log file can be entered after Path = in the header. Press the BINASC soft key to convert the files on the hard disk from binary to ASCII format.

Soft keys for update functions Soft key Function Convert the files on the hard disk from binary format to ASCII format and save nonvolatile markers in the PLCMEM.A file. Convert the files on the hard disk from ASCII format to binary format and save nonvolatile markers in the PLCMEM.A file. Copy cutting-data tables, tables for tilting-axis geometry, and the table of M-function macros from the SYS partition into the corresponding directories of the TNC or PLC partition, and create prototypes of the tables. Activate or delete existing NC software. Exchange the NC software.

Equivalent file name extensions in binary and ASCII format .H .TCH .PNT
8 8

.H% .TC% .PN%

.I .D .COM

.I% .D% .CO%

.T .P .CMA

.T% .P% .CM%

Press the NCV iTNC soft key. In the upper part of the window, you select the folder containing the *.zip file of the new NC software. The folder contents are displayed in the lower part of the window. To switch to the lower part of the window, press the FILES soft key. To return to the upper part of the window, use the PATH soft key. In the lower part of the window, select the *.zip file of the new NC software with the cursor keys and press ENT. Following that, the NC software exchange will start. All NC software versions that exist in the control are shown in the following list box.

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Select the new NC software with the arrow keys and press the SELECT soft key. The selected NC software is marked with an asterisk (*) in the Sel column. Confirm your selection with the YES soft key. The control activates the selected NC software and performs a reset. With the END key, the NO soft key or the END soft key, you exit the list box without making a new selection. If required, complete or delete the machine parameters. While in the Programming and Editing operating mode, press the MOD key. Enter the code number 95148 and confirm your entry with the ENT key. While in the Machine-parameter programming mode, press the MOD key. Press the UPDATE DATA soft key. Press the ASCBIN soft key to reconvert the files on the hard disk from ASCII to binary format. Read-in files which you had saved to a PC. The NC software exchange is completed. With the COPY SAMPLE FILES soft key, the HEIDENHAIN standard tables for cutting data, the tilting-axis geometry, and the M-function macros as well as a prototype for a freely definable table (contains only the column Name) can be copied into the corresponding directories.

8 8 8 8 8 8 8 8 8

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NC software exchange from standard version to export version (and vice versa)

The control version (iTNC 530 or iTNC 530 E) is saved in the SIK. If the NC software is exchanged on a software version different from that stored on the SIK, after the control starts up a message appears that the control can be operated only as a programming station. This message must be acknowledged. Procedure for exchanging the NC software:
8

Exchange the NC software as described above.

After the control powers up, Incorrect software version or Falsche Softwareversion appears.
8 8

Switch off the control. Exchange the SIK for a new, appropriate SIK (for Id. Nr., see page 2 5); for the location of the SIK in the MC 42x(B), see Additional Control Loops or Software Options on page 2 44. Switch on the control.

Since the new SIK has another SIK number, the options that are enabled on the old SIK must be re-enabled on the new SIK. After informing HEIDENHAIN of the SIK number, HEIDENHAIN can give you the code number for enabling the functions. To make it possible to identify the control from outside, after you indicate the ID and serial number of the control, you will receive a new ID label with the new data.
8

Stick the new ID label with the new control designation on the MC 42x(B) (E). Warning After you have changed the NC software from the standard version to the export version, you must delete the packed files of the standard version from the hard disk, since the packed files are also subject to export authorization. After the export version has been started, a prompt appears, asking if the compressed files of the standard version are to be deleted from the hard disk. If you answer with YES, all compressed files with the names of the standard version are deleted from the hard disk. The procedure for deleting compressed files in on page 2 61.

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Activating existing NC software

Before activating existing NC software, ensure that the free space on the hard disk of the MC 42x(B) is at least 50% the size of the occupied space. If that is not the case, you must save the files to a PC, e.g., with the TNCremoNT datatransfer software for PCs.
8 8 8 8 8 8

While in the Programming and Editing operating mode, press the MOD key. Enter the code number 95148 and confirm your entry with the ENT key. While in the Machine-parameter programming mode, press the MOD key. Press the UPDATE DATA soft key. The name and path of a log file can be entered after Path = in the header. Press the BINASC soft key to convert the files on the hard disk from binary to ASCII format.

Equivalent file name extensions in binary and ASCII format .H .TCH .PNT
8 8 8

.H% .TC% .PN%

.I .D .COM

.I% .D% .CO%

.T .P .CMA

.T% .P% .CM%

Press the NCVer soft key. All NC software versions that exist in the control are shown in the selection window that appears. Select the NC software to be activated with the arrow keys and press the SELECT soft key. The selected NC software is marked with an asterisk (*) in the Sel column. Confirm your selection with the YES soft key. The control activates the selected NC software and performs a reset. With the END key, the NO soft key or the END soft key, you exit the list box without making a new selection. If required, complete or delete the machine parameters. While in the Programming and Editing operating mode, press the MOD key. Enter the code number 95148 and confirm your entry with the ENT key. While in the Machine-parameter programming mode, press the MOD key. Press the UPDATE DATA soft key. Press the ASCBIN soft key to reconvert the files on the hard disk from ASCII to binary format. The activation of the NC software is completed. With the COPY SAMPLE FILES soft key, the HEIDENHAIN standard tables for cutting data, the tilting-axis geometry, and the M-function macros as well as a prototype for a freely definable table (contains only the column Name) can be copied into the corresponding directories.

8 8 8 8 8 8 8 8

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Deleting the packed files of existing NC software

8 8 8 8 8 8 8

While in the Programming and Editing operating mode, press the MOD key. Enter the code number 95148 and confirm your entry with the ENT key. While in the Machine-parameter programming mode, press the MOD key. Press the UPDATE DATA soft key. Press the NCVer soft key. All NC software versions that exist in the control are shown in the following options display. Select the NC software to be deleted with the arrow keys and press the DELETE soft key to delete all packed NC software files. The currently active NC software is marked with an asterisk (*) in the Sel column. Confirm your selection with the YES soft key. With the NO soft key or the END soft key, you exit the list box without deleting an NC software. Note If the packed files of an NC software, including the currently active software, are deleted, the respective software cannot be activated via the selection window any longer. The software concerned must then again be transferred to the control (see Procedure for exchanging the NC software up to and including 340 422-12 on page 2 56). The deletion of the packed files of the currently active NC software has no other effects.

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Entries in the log file

If errors occur during conversion, the TNC will display error messages and log them in the log file. During the NC software switch, the name and path of a log file can be entered in the header after Path =; the extension .A must be used. If no entry is made in this line, the file TNC:\CVREPORT.A is created. Each error message contains Error message Error number Error cause File concerned Example: ================================================== ERROR ERRNO ERROR MESSAGE FILE :REMANENT PLC DATA NOT RESTORED :2 :Program name not found :PLCMEM.A

================================================== Error message CANNOT OPEN DIRECTORY REMANENT PLC DATA NOT RESTORED NOT ENOUGH SPACE CONVERSION BIN ASC FAILED Meaning File could not be opened No access to the file PLCMEM.A Too little free memory on the hard disk A binary file has an incorrect format (e.g., binary format from an old NC software) An ASCII file on the hard disk is incorrect

CONVERSION ASC BIN FAILED

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2.5.6 Installing a Service Pack When needed, HEIDENHAIN prepares service packs for certain NC software versions. A service pack is loaded in addition to an already completely installed NC software. When the control is started, a note regarding the installed service pack is shown. This can be replaced by a special logo (see Powering Up and Shutting Down the Control on page 8 65). The latest service pack always includes all changes from earlier service packs. HEIDENHAIN recommends installing all released service packs. Soft key Function Installing a service pack

Warning If a service pack has already been installed, it will not be possible to install a service pack with a lower index. Up to software 340 490-01, the person installing the service pack must check this. As of software 340 490-02, the software will check this during the installation of a service pack, and a message will be displayed if an error is found. Note A service pack may only be loaded onto completely installed NC software (files in binary format), and may only be done by trained personnel. The service pack consists of packed files (*.zip). The packed files are transferred to the hard disk of the control and unpacked. It is not necessary to convert from binary format to ASCII format.
8

If you want to use the Ethernet interface for transferring the service pack from a PC, proceed as follows: While in the Programming and Editing operating mode, press the PGM MGT key. Press the NETWORK soft key. Select the PC to be connected with the cursor keys and press the MOUNT DEVICE soft key. To exit the list of network drives, press the END soft key. To exit the program management, press the END soft key.

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8 8 8

While in the Programming and Editing operating mode, press the MOD key. Press the SP iTNC soft key. In the upper part of the window, you select the folder containing the *.zip file of the service pack. The folder contents are displayed in the lower part of the window. To switch to the lower part of the window, press the FILES soft key. To return to the upper part of the window, use the PATH soft key. In the lower part of the window, select the *.zip file of the service pack with the cursor keys and press ENT. The installation of the service pack starts. End of service pack installation Note When installing a service pack, it is not necessary to convert the binary format to ASCII format or vice versa, or to make a back-up of the remanent operands.

2.5.7 Data Backup HEIDENHAIN provides a data backup program called TNCBACK.EXE free of charge. HEIDENHAIN recommends that the machine manufacturer use the software TNCBACK.EXE to save all his machine-specific data to a floppy disk, and that he supply the disk with the machine. The disk must also contain the program TNCBACK.EXE. The customer, too, can save his TNC data before exchanging the control. It is also advisable that the customer save all of the files and programs created on the iTNC at regular intervals. Data backup is described in detail in the Readme file, which is included on the disk.

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2.6 Software Releases


2.6.1 NC Software 320 420-xx NC software 320 420-01 (export 340 421-01) NC software 320 420-02 (export 340 421-02) Release: 10/2001 Initial version Release: 12/2001 MP1086.x: Maximum permissible jerk during single-axis movements at rapid traverse MP7365.x: Color settings for the oscilloscope The path acceleration is calculated from the axis proportions. New signals in the oscilloscope (I2t monitoring of the motor and power module, utilization of the motor, position difference for gantry axes) 6 channels in the oscilloscope Reference the signals of the oscilloscope to the datum line and adjust Starting and ending times for the log FAILTEST code number for testing an internal EMERGENCY STOP Power Fail Interrupt is entered if POWERFAIL is used to switch off Error message No measured value saved <axis> if no value is saved during probing Expanded ranges for PLC operands (M0 to M9999, B0 to B9999, T0 to T999, C0 to C143) Write data to the PLC partition with FN15: PRINT and FN16: F-PRINT Connect Windows computers as network drives Entry of an ASCII file (with IP addresses and computer names) in the column DOMAIN of the network settings Negative spindle angle in Q336 for Cycles 202, 204 and 209 New, expanded search function At startup, inspect the file system in case the control was not shut down properly Release: 01/2002 MP4040, MP4041, MP4042: Set PLC output after shutting down the control The error message <Number> cannot be displayed is displayed if more than 4 channels from the current/speed controller are to be displayed Display of progress during field orientation Display of progress while the log file is created with the code number LOGBOOK The results of evaluation of the soft-key resource file are saved in the ASCII file called <Name of the soft-key resource file>.SYS.LOG When the pocket table TOOL_P.TCH is reset, the data is taken over from the file PLC:\PROTO\PROTOTYP.TCH if it exists. Module 9279: Mode 2: Control shut down depending on MP4040, MP4041 and MP4042 A, B and C axes as helical axes

NC software 320 420-03 (export 340 421-03)

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NC software 320 420-04 (export 340 421-04) NC software 320 420-05 (export 340 421-05)

Release: 03/2002

Release: 05/2002 MP1011: Limit of rapid traverse on the path MP1061: Limitation of the path acceleration MP1146: Permissible difference between the position at shutdown and the position read in via the EnDat interface MP1355: Double reference run MP1356.x: Distance between speed and position encoder for double reference run MP2202.x: Overwrite Line count of the encoder in the motor table MP2204.x: Overwrite Counting direction in the motor table MP2206.x: Overwrite Type of encoder in the motor table MP7370.x: Color settings of the small PLC window MP7691: Size of a log file with messages from the operating system New code number KINEMATIC, for choosing a kinematic from a selection list. The name from the new column DOC in the assignment table is used. Message window before simulating an internal emergency stop via the code number FAILTEST Soft key RESTORE SCREEN in the oscilloscope, in order to read in *.DTA files FN18: SYSREAD ID56 to receive file information Module 9035: New status information 28 (tool or pocket table in editing mode) Module 9163: New error codes W1022 = 1 and W1022 = 2 Support graphics for cycles for the BF 150 revised Maximum input value is 3.2767 for the column LBREAK in the tool table After pressing MOD, the Id. Nr. of the setup is no longer displayed Cycle 403: Q337 (Set to zero after alignment) Status window with program section repeats and subprograms Zoom function for 3-D graphics in the Program Test mode Status of the soft key Machining time ON/OFF remains in effect after a power interruption Message window if the NC software in the SIK does not match the NC software being used Two-line display of NC error messages with more then 32 characters

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NC software 320 420-06 (export 340 421-06)

Release: 07/2002 MP110.x, MP111.x: Error message for position encoder inputs that do not exist MP960.x: Input range expanded to +/ 1.79769313486E+308 MP2160.x: Axis-specific and 2 as new input value for HEIDENHAIN EcoDyn synchronous motors MP2195: Suppress error messages of the HEIDENHAIN supply units MP2220: Monitoring of the direction of rotation for synchronous motors cannot be switched off. Bit 3: Suppress vibrations when switching off the drive with applied motor brakes. MP2304.x: Reference value for I2t monitoring of power module MP2308.x: Time between the braking signal and switch-off of the controller MP7263 bit 1: Output of the columns in the pocket table for file functions MP7357.x: Colors for inactive and active soft-key row in the Machine operating mode MP7358.x: Colors for inactive and active soft-key row in the Programming operating mode MP7370.15: Color 15 of the small PLC window MP7481.x: Sequence for new and returned tool when changing tools MP7482: Magazine with variable or fixed pocket coding MP7684 bit 7: Reserved Switch-on of the current controller delayed by 50 ms after switching on the controller (Module 9161) Entry MACEND (end of an NC macro) in the log file Error message and limitation to 999 error messages in the *.PET table Screen switchover key active after M or S function has been started M4185: Internal stop performed New entries for the soft-key resource file *.SPJ: VROOT, HROOT, EMODE, MMOD, ENABLE, STATUS, POPUPMENU, CLOSEPOPUPMENU, LARGEWINDOW, SMALLWINDOW, CLOSEPLCWINDOW, FirstInGroup WATCH LIST in the PLC main menu FN18: SYSREAD ID52 NR2 IDX<tool number> finds the corresponding tool magazine. Module 9136: Switching the touch probe on/off Module 9148: Use nominal value as actual value Module 9157: Status information 4 (spindle in operating mode 0 or 1) Module 9321: Ascertain current block number Module 9305, 9306: Error code 6 Module 9342: Find magazine and pocket number

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Error message when a Tolerance for rotary axes is programmed when the HSC filter is not active Display *.A ASCII files in the Save machine parameters mode of operation M140 MB<Retraction value> F<Feed rate> with optimized feed rate Network ping in the network settings Message window if the NC software in the SIK does not match the NC software being used. In this case it can only be operated as a programming station. After changing the NC software from the standard to the export version, compressed files can automatically be deleted Display of progress when loading new controllers for hardware components New NC block CYCLE CALL POS NC software 320 420-07 (export 340 421-07) NC software 320 420-08 (export 340 421-08) Release: 08/2002

Release: 10/2002 MP2230.x: Factor for rated current during test of motor brake MP2232.x: Maximum permissible path during test of motor brake MP4000.x: Indexes expanded from 16 to 32 MP4045: Switch off outputs that cannot be switched off by emergency stop after 250-ms delay MP7310: Bits 5 and 6 can no longer be activated MP7246 bit 1: Confirm deletion of input with DEL MP7680 bit 14: Behavior of NC start after NC stop and internal stop MP7682 bit 6: Accuracy during TOOL DEF MP7682 bit 7: Sorted run of block elements in ISO Monitoring of the 5 V supply voltage Additional entries in log when the PLC shuts down or restarts the control Expansion of the PLC modules 9092, 9093 and 9094 for new elements The network can be configured in the Machine-parameter programming mode. New soft keys in the Machine-parameter programming mode for deleting and restoring individual entries. Character set of BF 150 revised Maximum input value for the jog increment limited to 10 mm. In Cycles 21 to 25, climb milling (with M3) is standard. The code number VERSION generates an ASCII file with system information.

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NC software 320 420-09 (export 340 421-09)

Release: 10/2002 MP2220.x: Bits 7 to 15 reserved MP2254.x: Determining the field angle MP2560.x: Only CC 424: Filter order of the low-pass filter The combination of Cycle 12 with Cycle 220 or 221 results in the error message No fixed cycle defined. Release: 04/2003 Cycle 215: Approach behavior optimized

NC software 320 420-10 (export 340 421-10)

NC software 320 420-11 (export 340 421-11)

Release: 11/2003 NC software 340 420-11 contains all of the functions of NC software 340 422-09. In the standard setting, datum management via preset tables is deactivated.

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2.6.2 NC Software 340 422-xx NC software 320 422-01 (export 340 423-01) Release: 08/2002 Initial version Expansions since NC software 340 420-07: Presets are managed with the preset table TNC:\PRESET.PR. Presets are recalculated using the defined tilting-axis geometry. MP7294: Disable axis-specific datum setting in the preset table New prototypes for pallet tables (PROTOPR.P and PROTO_TOPR.P) with the column PRESET Cycle structure of the machining structures revised. Error message Use preset table! appears when MP7475 = 1 and Cycle 7 is programmed. Cycle 205: Parameter Q379 (START POINT) Cycle 220: Parameter Q365 (TYPE OF TRAVERSE) Cycle 247: Entry of the preset number from the preset table Cycles 400, 401, 402: Parameter Q305 (NO. IN TABLE) Cycles 410 to 418: Parameter Q303 (MEAS. VALUE TRANSFER) Cycles 414, 415: Parameter Q305 (NO. IN TABLE) for datum and basic rotation Cycle 419: DATUM IN ONE AXIS Cycles 420 to 430: Take active rotation into account NC software 320 422-02 (export 340 423-02) Release: 10/2002 MP2230.x: Factor for rated current during test of motor brake MP2232.x: Maximum permissible path during test of motor brake MP4000.x: Indexes expanded from 16 to 32 MP4045: Switch off outputs that cannot be switched off by emergency stop after 250-ms delay MP7310: Bits 5 and 6 can no longer be activated MP7246 bit 1: Confirm deletion of input with DEL MP7680 bit 14: Behavior of NC start after NC stop and internal stop MP7682 bit 6: Accuracy during TOOL DEF MP7682 bit 7: Sorted run of block elements in ISO Monitoring of the 5 V supply voltage Additional entries in log when the PLC shuts down or restarts the control Expansion of the modules 9092, 9093 and 9094 for new elements The network can be configured in the Machine-parameter programming mode. New soft keys in the Machine-parameter programming mode for deleting and restoring individual entries. Character set of BF 150 revised Maximum input value for the jog increment limited to 10 mm.

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In Cycles 21 to 25, climb milling (with M3) is standard. Cycle 251: RECTANGULAR POCKET Cycle 252: CIRCULAR POCKET Cycle 253: SLOT MILLING Cycle 254: CIRCULAR SLOT The code number VERSION generates an ASCII file with system information. NC software 320 422-03 (export 340 423-03) Release: 01/2003 With the keyword PWMPARAMETER = in OEM.SYS you can activate 30 y indexes of MP2xxx.y. MP2620.x: Maximum input value was increased from 30.000 [A] to 100.000 [A]. MP6550: Maximum input value was increased from 20 000 [mm/min] to 300 000 [mm/min]. MP1120.x: Maximum motion of an axis while determining the field angle MP2220.x: Bits 7 to 15 reserved MP2250.x: Only CC 424: Determining the field angle MP2252.x: Only CC 424: Path for motion detection for determining the field angle according to method 1 (MP2250.x = 1) MP2254.x: Determining the field angle MP2256.x: Determined field angle MP2257.x: Control or encoder identification for the field angle from MP2256.x MP2560.x: Only CC 424: Filter order of the low-pass filter MP2607.x: Damping factor for active damping MP2608.x: Damping time factor for active damping MP7160 bit 4: Interpolate tool axis and spindle during tapping MP7246 bit 2: Create tool-usage file MP7266.32: Maximum shaft speed [rpm] (NMAX) MP7492.x: Number of axis in which the same datum is to be set during datum setting (with active preset table) MP7600.x removed (only CC 424) MP7602: Only CC 424: PLC cycle time Comments and unused machine parameters are displayed with the color from MP7355.x. Maximum 20 commands per auxiliary axis per scan of the PLC program TNCOPT.LOCKSOFTKEYVISIBLE = YES entry in OEM.SYS, to start the control with TNCopt Lines of the kinematics table can be overwritten with WRITE TO KINEMATIC AT COLUMN Circular test in the oscilloscope X/Y display of two channels in the oscilloscope New tilting-axis combination: Swivel head and rotary table (tool axis Z): C fixed, A fixed, B fixed 90, A variable, B fixed +90, A fixed, C fixed, C variable

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The entry PRESETTABLE = OFF in OEM.SYS deactivates the function of the preset tables. The entries OEMCYC.ZIPNAME =, OEMCY2.ZIPNAME = etc., unpack *.ZIP files with the cycle information while the control is starting up After entry of the code number KINEMATIC more than 15 entries are available. Additional information in the log when an NC program is terminated by an error message The entry PR.LINESLOCKED = in OEM.SYS sets write protection for lines of the preset table. NMAX column in the tool table for tool-specific rotational speed limit Graphics of the PLC window in BMP or BMX format In the *.TCR file the search sequence must be defined for each magazine FN17: SYSWRITE ID1020 NR1 = <value> for activating machine parameter subfiles defined in OEM.SYS through MPFRAGMENT<value> = FN17: SYSWRITE ID590 NR1 IDX<1 to 9> = <value> and FN18: SYSREAD ID590 NR1 IDX<1 to 9> to save machine conditions from NC macros and upload them again FN18: SYSREAD ID20 NR17 to find the current traverse range FN18: SYSREAD ID530 NR2 IDX<line> to ask whether a line of the preset table is write-protected FN18: SYSREAD ID1000 NR410 IDX<3 or 4> to read the ASCII value of the axis designation defined in MP410.3 or MP410.4 FN18: SYSREAD ID320 NR1 IDX0 to read the system time of the control in seconds FN17: SYSWRITE ID50 and FN18: SYSREAD ID50 has been expanded by NR24 (touch probe center offset in reference axis), NR25 (touch probe center offset in minor axis), NR26 (spindle angle during calibration), NR27 (tool type for pocket table) and NR28 (maximum rotational speed) The entry NUMBERMP4230 = in OEM.SYS for the number of indexes of MP4230.x If the NC macro defined under RESETINIT = in NCMACRO.SYS is not run completely, the error message Machine not initialized and the INIT soft key appear The entry FNERROR = in OEM.SYS for an ASCII file containing the error messages for FN14: ERROR = Extension of the modules 9092, 9093 and 9094 by element number 31 Module 9186: Transfer value 7 (soft-key function for feed-rate limiting) Module 9217: Display a pop-up window for messages Error message if 24 V is missing on X44 Text file jh_error.txt in all languages with all NC error messages on the PLC partition New soft keys DSP DIAGNOSIS and HEROS DIAGNOSIS with the corresponding diagnostic functions Faster zoom function of the graphics PLANE function for the definition of the position of the working plane

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Error message if during a touch probe cycle call the current angles of the tilting axes do not match the defined angles PLC window and PLC pop-up window evaluate keystrokes through the LSV2 protocol After COPY SAMPLE FILE the prototype PLC:\PROTO\EXAMPLE.TAB is created Exchange touch probe battery no longer cancels the probing process Before an NC program starts, any existing tool-usage file is examined Information window during datum setting from a touch probe cycle into the active line of the preset table With CYCLE CALL in connection with SL cycles, no error message is issued during active automatic programming graphics if the contour is incompletely defined. Revised screen mask during datum setting in the touch probe cycles The combination of Cycle 12 with Cycle 220 or 221 results in the error message No fixed cycle defined. Cycle 2: Automatically assume probe radius as tool radius if MP7411 bit 1 = 1. Cycle 9: CALIBRATE TS LENGTH Cycles 210 and 211: Parameter Q206 (FEED RATE FOR PLUNGING) Cycle 215: Approach behavior optimized Cycle 403: Parameter Q303 (MEAS. VALUE TRANSFER), Q305 (NUMBER IN TABLE), Q380 (REFERENCE ANGLE) Cycle 431: The tool-axis coordinates of the three touch points are saved in Q173 to Q175. NC software 320 422-04 (export 340 423-04) NC software 320 422-05 (export 340 423-05) Release: 02/2003

Release: 04/2003 MP1357.x: Behavior of W1032 during double reference run Bits in MP7500 depend on the (in)active preset table

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NC software 320 422-06 (export 340 423-06)

Release: 06/2003 MP2220.x bit 3: CC 422 and CC 424: Switching off the controller when the motor brakes are activated MP2220.x bit 5: CC 424: Monitoring for insufficient temperature MP2220.x bit 7: CC 424: Monitoring of encoder input frequency MP2220.x bit 8: CC 424: Compensate the mechanical offset during switchon by gradually increasing the kV factor MP2234.x: Internal triggering of the motor brakes via the PWM interface MP7266.33: Retract tool (LIFTOFF) MP7351.x: Colors for the error classes error, warning and information of the error messages from the *.PET table. MP7492.x: Maximum input value reduced to 9 MP7354.3, MP7355.3, MP7367.0: New standard color settings MP7494: Rotary axes for which an exact stop is to occur after positioning (M134) MP7500 bit 9: Reserved MP7620 bit 7: Reserved MP7641 bit 1: Reserved MP7684 bit 8: Reserved MP7690: Evaluation of the electronic ID labels of HEIDENHAIN synchronous motors and power modules New tilting axis combination: Double swivel head 45 and rotary table: Axis sequence A fixed; C variable; A fixed; B variable (tool axis Y) Traverse does not begin during tapping until after M4030 or M4031 has been set and after a cyclic PLC program scan. CC 424: The exchange of milling heads is also possible for encoders with EnDat interface. With MP2392.x you can set a power limit for the spindle when the ERR.IZ.GR signal is active. FN18: SYSREAD ID61 NR0 IDX<tool number> finds the corresponding toolchange sequence. In the PET table the strings S4 to S15 can be used. New columns MANLOCK and NONESTED in MFUNCT.TAB. Support of the electronic ID labels of HEIDENHAIN synchronous motors and power modules A tool change by M101 is transmitted delayed by at least one block and by no more than one minute. In the log, the source of the key inputs is registered. The contents of the machine parameters MP1054.x and MP7530.x can be read with FN18: SYSREAD ID1000 if they do not contain any formulas. RESTART PLC soft key for restarting the PLC program. Column headings of the TRACE IN-CODE function were revised. The compiled PLC program is stored on the control. W1016: Number of the last faulty processed PLC module

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Module 9035: Status information for the tool change Modules 9092, 9093, 9094: Expanded by element number 32 for tool retraction (LIFTOFF). Module 9072: Copying a byte block into a string Module 9140: Setting axis-specific feed-rate limitations Module 9141: Reading axis-specific feed-rate limitations The ERR key shows a list of current error messages Search function expanded by the REPLACE ALL soft key. After the PLANE function the position of the angular axes can be transferred with M114 OEM.SYS is reevaluated during activation of the machine-parameter programming operating mode and before downloading a machine parameter file. Additional information is shown in the help window. Cycles 253 and 254: Parameters Q385 (FEED RATE FOR FINISHING) and Q366 (PLUNGING) Cycles 1, 17 and 18 were shifted in the cycle structure Cycles 410 to 416 and 418: Parameters Q381 (PROBE IN TS AXIS), Q382 (1st CO. FOR TS AXIS), Q383 (2nd CO. FOR TS AXIS), Q384 (3rd CO. FOR TS AXIS), and Q333 (DATUM) Cycles 251 and 252: Parameters Q366 (PLUNGING) and Q385 (FEED RATE FOR FINISHING) With M116 swivel-head axes are ignored. Cycle 32: Tolerance for rotary axes is also active for single and double filters Cycle 3: Input field REFERENCE SYSTEM Soft key UPPERCASE/LOWERCASE OFF/ON for the search function in the ASCII editor Manually set datum in line 0 of the preset table Menu for FN functions rearranged Text output in a pop-up window with FN16: F-PRINT. Soft key SP iTNC for installing service packs Tool usage file generated through an LSV2 command. Point of interruption saved if program cancelled New FUNCTION TCPM function CONVERT PGM soft key for resolving FK programming or to generate two NC programs that only contain lines and circular arcs and can be run in the programmed sequence or the opposite sequence.

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NC software 320 422-07 (export 340 423-07)

Release: 08/2003 MP3142 and MP13242: Maximum input value increased from 9999 to 30000. MP4043: Switch off outputs O0 to O15 with delay MP4044: Switch off outputs O16 to O23 with delay MP7224.2: Disable the EDIT ON/OFF soft key MP7235 causes a reset MP7237.x, MP7238.x: Support of PLC operating times 9 to 13 The integrated oscilloscope can be called from within the diagnostics menu with the code number. Maximum input range for the number of pole pairs in the motor table expanded from 99 to 999. TOOL USAGE TEST soft key for comparing the data in the tool usage file with the data in the tool table. For each soft key pressed, an entry is made in the log file, including the path to the appropriate image file. DIAGNOSIS soft key also in the PLC Programming mode Cyclic monitoring by the NC of the supply voltage and short circuits of the PLC outputs of the PL 510. Diagnostic function as option to be enabled Preset table for every traverse range Maximum number of dependencies for non-linear axis-error compensation is 15. Markers M4800 through M4999 are deleted before the first run of the PLC program Soft keys and the user interface revised in the PLC Programming mode Module 9133 was expanded by code 3 (voltage of the buffer battery [mV]). Module 9203: Call with <number of soft key menu> < 0 supplies the current resource handle Modules 9246 or 9256: If a cell that does not yet exist in a table is written to, the line is filled with blank spaces up to the defined cell. If 1 is given as the line number, the next empty line is used. Module 9073: Copying a string to a byte block Module 9350: Read data from the tool table Module 9351: Write data to tool table Cycle 232: FACE MILLING Cycles 25x can be used with an inactive tool table Cycle 251: Error message if Q220 is less than the tool radius Probe cycle in the Manual operating mode finds the distance between two points, as well as the mid-point. In the touch probe cycles the trigger signal can be initiated by pressing the actual-position-capture key. Rather than entering a feed rate, you can also program a time over which the programmed block is to be traversed. TURN tilting possibility in the PLANE function Normal and tool directional vectors of LN blocks no longer need to be given standardized to the value 1. Progress indicator for sorting block numbers of an ISO machining program. Display of options upon entry of the SIK keyword revised. Autorepeat function for the PAGE and PAGE soft keys. HEIDENHAIN Technical Manual iTNC 530

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NC software 320 422-08 (export 340 423-08)

Release: 10/2003 Module 9133: Measurement of the CPU temperature is not possible for the MC 422B for the time being. If a service pack is installed, a corresponding informational text appears during a power interruption. A logo can be defined via a LOGOSP = entry in OEM.SYS. Release: 11/2003 MP4043, MP4044 and MP4045 removed MP4060.x: Outputs that are to be switched off with the delay from MP4061.x when all outputs are switched off MP4061.x: Delay time for switching off the outputs in MP4060.x MP7230.x: Input value 15 (Chinese dialog text) for MC 422B (with BF 150) MP7261: Reserved MP7640: Input value 11 activates HR 420 MP7641 bit 1: Stepped rotation of HR 420 MP7641 bit 2: Axis direction key and rapid traverse on the HR 420 MP7641 bit 3: NC start / NC stop on the HR 420 During the automatic test of the motor brakes the sum of MP1110.x and MP2232.x applies to standstill monitoring. Nonlinear axis error compensation revised Diagnosis functions are no longer an option Diagnosis functions expanded ((Motor)-i, (Motor)-TEST) In the log, the acknowledgment of an error message is registered. M4660 to M4668: New markers for the HR 420 M4057: Touch probe cycle active (depending on FN17: SYSWRITE ID990 Nr2) Number of strings increased from 16 to 100 (S0 to S99) FN17: SYSWRITE ID503 NR<line> IDX<column> for entering a value in the preset table. M4753: Enter errors from PLC modules in PLCDEBUG.LOG New log: PLC:\PLCDEBUG.LOG for PLC events Symbolic operands can be used in the mask files for PLC windows. The configuration file for conditional compilation can be selected with the SELECT + COMPILE and SELECT COMPILER CONFIG. soft keys. New partition sizes of the hard disk for newly supplied MC 422B Module 9007 supports the PL 510 when determining the number of connected PLs Module 9137 expanded by information 12 (number of connected PL 510) Module 9221 expanded by error code 6 (PLC positioning of axis already started). Module 9084: Displaying PLC error messages with additional data Module 9277: Writing data into the OEM log Module 9322: Information of the current NC program Improved graphics with the MC 422 B Four soft keys are available for setting the speed for graphic simulation in the Test Run mode.

NC software 320 422-09 (export 340 423-09)

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With the projection in three planes in Test Run mode, the horizontal plane of section starts at the top edge of the workpiece. After you have pressed the MOD key in the Programming and Editing mode of operation, the soft key for installing the service pack will be displayed. The ERR key also shows current PLC error messages Cycle 8: Rotary axes can be programmed as mirror axes REPLACE ONLY EMPTY LINES soft key for only overwriting those lines in TOOL.T that do not contain any data when copying an externally prepared table. Pressing the GOTO key in a DIN/ISO program no longer results in GOTO line xxx jumped yyy appearing Service pack 340 500-01 for NC software 320-422-09 (340-501-01 for 340 423-09) Service pack 340 500-02 for NC software 320 422-09 (340 501-02 for 340 423-09) NC software 320 422-10 (export 340 423-10) Release: 12/2003 Marking of multiple entries of error messages in the log Priority of External EMERGENCY STOP and PLC error messages with emergency stop increased Resetting of Cycle 32 (TOLERANCE) depends on MP7300 Release: 03/2004

Release: 05/2004 The PLC can change MP10 while an NC program is running. MP331.x, MP332.x: Maximum input value expanded to +/ +1.797693135E+308 MP1096.1: Tolerance at corners at rapid traverse MP1522: Feed-rate smoothing MP2195 bit 0: Handling of status signals from HEIDENHAIN power supply units which are already active during control start-up. MP2542.x to MP2546.x: Input range increased to 0 to 99.0 [dB]. MP2552.x to MP2556.x: Input range increased to 0 to 30 000.0 [Hz]. MP2562.x to MP2566.x: Filters can be assigned to the speed or position controller MP2572.x to MP2576.x: Input range increased to 0 to 30 000.0 [Hz]. MP5000: Input value 3 disables the serial interfaces MP5020.3, MP5030.3: Operating mode EXT4 (PLC) added MP5040.x: Data transfer rate for operating mode EXT3 or EXT4 MP7230.x: New dialog languages: Input value 14 (Russian with Cyrillic character set), input value 15 (Chinese/simplified), input value 16 (Chinese/ traditional); languages only for MC 422B (with BF 150) MP7363.5: Color for rapid traverse movements in the programming graphics MP7460.x, MP7461.x: Reserved MP7680 bit 15: Suppress NC Start if the program is aborted

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In master-slave torque control, switch the axes to single-axis operation Resetting of Cycle 32 (TOLERANCE) depends on MP7300 PLC positioning without nominal position value filter Maximum braking power MP2390.x can be greater then the power limitation MP2392.x Braking time during powerfail extended New I2t monitoring (2nd order) with new columns in the motor table (Tth1, Rth1, Tth2, Rth2) Step response on the integrated oscilloscope only after the code number is entered New F TCPM and int. Diagn. signals in the integrated oscilloscope: Trigger conditions for the integrated oscilloscope revised CC 424 supports backlash compensation via MP750.x and MP752.x. Disabled PLC soft keys are shown as inactive Using the LSV-2 TELEGRAM ON/OFF soft key, LSV-2 telegrams can be entered in the log for test purposes. Marking of multiple entries of error messages in the log M4754: Internal diagnostic information entered in the log MYDEBUG.LOG. Diagnostic functions expanded (automatic speed encoder test, analog signals shown with control loop name) New control commands in the print masks for the measurement log in the manual touch probe cycles (mm_display, inch_display, all_display) M4622: Delay NC macro (RESETINIT = from NCMACRO.SYS) after traversing the reference marks Priority of External EMERGENCY STOP and PLC error messages with emergency stop increased M4223: Error from PET table with NC cancel active M4227: PLC error message with priority 0 (error) M4228: PLC error message with priority 1 (warning) M4229: PLC error message with priority 2 (info) TRACE IN-CODE also possible with PLCdesignNT Search function of the TRACE function improved ADD TO WATCH LIST assumes selected operands from the TRACE or TABLE function into the WATCH LIST GOTO <symbolic name> possible in the TABLE function WATCH LIST function expanded: Put operands into the logic diagram, search function, switch number representation FN18: SYSREAD ID51 expanded: NR6: Type of tool (PTYP) NR7 to NR11: Value 1 (P1) to value 5 (P5) NR12: Pocket reserved (RSV) NR13: Pocket above locked (LOCKED_ABOVE) NR14: Pocket below locked (LOCKED_BELOW) NR15: Pocket at left locked (LOCKED_LEFT) NR16: Pocket at right locked (LOCKED_RIGHT)

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Module 9217: New error code W1022 = 36 Module 9217: Close window with Event $010000 via Module 9261 Module 9100: Transfer parameter 2 added Module 9179: Status information about spindle(s) Module 9282: Tool usage test for pallet table Module 9343: Compilation and activation of magazine rules TOOL USAGE TEST soft key also for pallet tables Error message if the time programmed in AUTOSTART is in the past Czech dialog language for the measuring logs of the touch probe cycles Management of multiple ID addresses for the control If desired, progress display when inserting new lines in a table Hide/show block numbers in the programming graphics Soft keys of the search function improved Last speed set for the graphic simulation in Program Test is remembered For some entry functions RETURN can also be used (not just ENT) List of the PLC operands with brief descriptions under PLC:\JH\ English instead of Russian dialogs in the freely definable tables M114 effective locally in cycles Rotary axes can be programmed within an M120 sequence. Status display: Maximum of eight datum shifts, maximum of six scaling factors, mirrored axes in sequence Paging with ENT or NO ENT during entry in screen masks Error message if during a touch probe cycle call the current tilting angles do not match the angles in Tilt working plane. With PROBING ROT the warning can be acknowledged and the cycle can be executed. Enter information into the log with FN38: SEND. Cycle 8 (MIRROR IMAGE): Maximum of three axes Cycle 22 (ROUGH-OUT): Parameter Q208 added (FEED RATE FOR RETRACTION). Cycle 28 (CYLINDER SURFACE): Parameter Q21 (TOLERANCE) Cycle 29 CYLINDER SURFACE RIDGE Cycle 39 CYLINDER SURFACE CONTOUR

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HEIDENHAIN Technical Manual iTNC 530

2.6.3 NC Software 340 480-xx NC software 320 480-02 (export 340 481-02) Release: 10/2002 Initial version Functions correspond to NC software 340 422-02 NC software 320 480-03 (export 340 481-03) Release: 01/2003 Functions correspond to NC software 340 422-03 Additional improvements: MP7235 removed: Time difference is assumed by the Windows PC NC software 320 480-04 (export 340 481-04) NC software 320 480-05 (export 340 481-05) NC software 320 480-06 (export 340 481-06) Release: 02/2003 Functions correspond to NC software 340 422-04 Release: 04/2003 Functions correspond to NC software 340 422-05 Release: 06/2003 Functions correspond to NC software 340 422-06 Additional improvements: Module 9133 expanded by code 2 (temperature of 2nd CPU) MP7225: Disable Windows drives in the TNC file manager New hard disks support Windows 2000 multi-language version The HeROS real-time operating system cyclically tests the internal communication. If this is not possible for more than 5 seconds, M4600 is set. If this is not possible for more than 10 seconds, the control is shut down. NC software 320 480-07 (export 340 481-07) NC software 320 480-08 (export 340 481-08) NC software 320 480-09 (export 340 481-09) Service pack 340 502-01 for NC software 320 480-09 (340 503-01 for 340 481-09) Release: 08/2003 Functions correspond to NC software 340 422-07 Release: 10/2003 Functions correspond to NC software 340 422-08 Release: 11/2003 Functions correspond to NC software 340 422-09 Release: 12/2003 Functions correspond to NC software 340 500-01

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Software Releases

2 81

Service pack 340 502-02 for NC software 320 480-09 (340 503-02 for 340 481-09) NC software 320 480-10 (export 340 481-10)

Release: 03/2004

Release: 05/2004 Functions correspond to NC software 340 422-10 Additional improvements: New hard disks contain Microsoft service pack 4 for Windows 2000 and Microsoft patch KB835732. Soft keys can be selected and soft-key rows switched by clicking the mouse. Log Files button on the iTNC Control Panel (reserved for HEIDENHAIN) The start and shut-down of the control software is recorded in a log for internal diagnostic purposes.

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September 2006

Software Releases

2 83

2 84

HEIDENHAIN Technical Manual iTNC 530

3 Mounting and Electrical Installation


3.1 General Information......................................................................... 3 3 3.1.1 Safety Precautions ..................................................................... 3 3 3.1.2 Degrees of Protection ................................................................ 3 4 3.1.3 Electromagnetic Compatibility ................................................... 3 4 3.2 Handling of the HDR Hard Disk and the SIK .................................. 3 5 3.3 Environmental Conditions............................................................... 3 7 3.3.1 Heat Generation and Cooling ..................................................... 3 7 3.3.2 Humidity .................................................................................... 3 8 3.3.3 Mounting Elevation .................................................................... 3 8 3.3.4 Mechanical Vibration .................................................................. 3 8 3.3.5 Mounting Attitude of MC 42x(B), CC 42x, UV xxx, UM xxx, UE 2xx B ... 3 9 3.3.6 Mounting Position of Screen ................................................... 3 10 3.4 Connection Overview for iTNC 530 ............................................ 3 11 3.5 Power Supply for the iTNC 530..................................................... 3 19 3.5.1 UV 105 Power Supply Unit ...................................................... 3 21 3.5.2 UV 105B (Non-HEIDENHAIN Inverter Systems) ...................... 3 24 3.5.3 UV 106B Power Supply Unit .................................................... 3 29 3.6 Power Supply for PLC Outputs ..................................................... 3 33 3.6.1 Power Supply for PL 4xxB ....................................................... 3 35 3.6.2 Power Supply for PL 510 ......................................................... 3 36 3.7 Power Supply for Control-Is-Ready Signal .................................. 3 37 3.8 Power Supply for the Display Units ............................................. 3 37 3.9 Buffer Battery ................................................................................. 3 38 3.10 Drive Controller Enable................................................................ 3 40 3.11 Encoder Connections .................................................................. 3 42 3.11.1 General Information ............................................................... 3 42 3.11.2 Input for Position Encoder .................................................... 3 43 3.11.3 Input of Speed Encoder ....................................................... 3 45 3.12 Adapters for Encoder Signals ..................................................... 3 49 3.13 Motor Power Stage Connection ................................................ 3 53 3.14 Analog Input ................................................................................. 3 54 3.15 Analog Nominal Value Output.................................................... 3 58 3.15.1 Nominal Value Output ............................................................ 3 58 3.16 Touch Probe Systems .................................................................. 3 63 3.16.1 Triggering Touch Probe for Workpiece Measurement .......... 3 63 3.16.2 Triggering Touch Probe for Tool Measurement ..................... 3 65 3.17 Data Interfaces.............................................................................. 3 67 3.18 Handwheel Input .......................................................................... 3 71 3.18.1 HR 4xx Portable Handwheel .................................................. 3 72 3.18.2 HR 130 Panel-Mounted Handwheel ...................................... 3 74 3.18.3 HRA 110 Handwheel Adapter ................................................ 3 74 3.19 Input: Spindle Reference Signal.................................................. 3 76 3.20 Switching Inputs 24 Vdc (PLC).................................................... 3 77 3.20.1 Input Signals and Addresses ................................................. 3 77 3.20.2 PLC Inputs on the PL 410B ................................................... 3 80 3.20.3 PLC Inputs on the PL 405B ................................................... 3 82 3.20.4 PLC Inputs on the PL 510 ...................................................... 3 83 3.21 Switching Outputs 24 Vdc (PLC) ................................................ 3 85

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31

3.22 PLC Input/Output Units............................................................... 3 91 3.22.1 PL 4xxB ................................................................................. 3 91 3.22.2 PL 510 ................................................................................... 3 94 3.23 Machine Operating Panel ............................................................ 3 98 3.24 iTNC Keyboard Unit .................................................................. 3 101 3.25 Flat-Panel Display....................................................................... 3 103 3.26 BTS 1x0 Monitor/Keyboard Switch Unit ................................ 3 107 3.27 USB Interface.............................................................................. 3 109 3.28 Cable Specifications................................................................... 3 110 3.29 Dimensions ................................................................................. 3 111 3.29.1 MC 422B / 5 Position Encoder Inputs and CC 422 with 6 Control Loops ............................................................ 3 111 3.29.2 MC 422B / 10 Position Encoder Inputs and CC 422 with 10 or 12 Control Loops ................................................. 3 112 3.29.3 MC 420 and CC 422 with 6 Control Loops .......................... 3 113 3.29.4 Dimensions for MC 422B/CC 424 with 6 Control Loops ..... 3 114 3.29.5 Dimensions for MC 422B/CC 424 with 8 Control Loops ..... 3 115 3.29.6 Dimensions for MC 422B/CC 424 with 10 Control Loops ... 3 116 3.29.7 Dimensions for MC 422B/CC 424 with 12 and 14 Control Loops . 3 117 3.29.8 UV 105 ................................................................................. 3 118 3.29.9 TE 420 ................................................................................. 3 119 3.29.10 TE 520B / TE 530 / TE 530B .............................................. 3 120 3.29.11 MB 420 .............................................................................. 3 121 3.29.12 BF 120 ............................................................................... 3 122 3.29.13 BF 150 ............................................................................... 3 123 3.29.14 BTS 120/BTS 150 .............................................................. 3 124 3.29.15 PL 4xxB ............................................................................. 3 125 3.29.16 PL 510 ............................................................................... 3 126 3.29.17 Adapter Block for the Data Interface ................................. 3 127 3.29.18 USB Hub ............................................................................ 3 128 3.29.19 Line-Drop Compensator .................................................... 3 129 3.29.20 Handwheels ....................................................................... 3 130 3.29.21 Touch Probe Systems ....................................................... 3 137 3.30 Grounding Diagrams.................................................................. 3 145 3.30.1 Grounding Diagram for iTNC 530 with Modular Non-Regenerative HEIDENHAIN Inverter System . 3 145 3.30.2 Grounding Diagram for iTNC 530 with Modular Regenerative HEIDENHAIN Inverter System ......... 3 146 3.30.3 Grounding Diagram for iTNC 530 with UE 2xxB Non-Regenerative HEIDENHAIN Compact Inverter ............. 3 147 3.30.4 Grounding Diagram for iTNC 530 with UR 2xx Regenerative HEIDENHAIN Compact Inverter ..................... 3 148 3.31 Basic Circuit Diagrams............................................................... 3 149 3.31.1 Availability ............................................................................ 3 149 3.32 Cable Overviews......................................................................... 3 150 3.32.1 Cable Overview for iTNC 530 Basic Configuration ........... 3 150 3.32.2 Cable Overview for iTNC 530 with HEIDENHAIN Inverter Systems ............................................ 3 151 3.32.3 Cable Overview for iTNC 530 with SIMODRIVE or POWER DRIVE Inverter Systems ................ 3 152 3.32.4 Cable Overview for iTNC 530 Accessories ....................... 3 153

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HEIDENHAIN Technical Manual iTNC 530

3 Mounting and Electrical Installation


3.1 General Information
Warning Keep the following in mind during mounting and electrical installation: National regulations for power installations Interference and noise immunity Conditions of operation Mounting attitude 3.1.1 Safety Precautions Danger Ensure that the main switch of the control or machine is switched off when you engage or disengage connecting elements or connection clamps. Danger Ensure that the equipment grounding conductor is continuous. Interruptions in the equipment grounding conductor may cause damage to persons or property. Danger Incorrect or not optimized input values may lead to malfunction of the machine and may thus cause damage to persons or property. Modifications of the machine parameters should be done with caution and uncontrolled axis motions should be taken into account. Warning In order to be able to judge the behavior of an NC controlled machine, you need to have fundamental knowledge about drives, inverters, controls and encoders. Inappropriate use may cause considerable damage to persons or property. HEIDENHAIN does not accept any responsibility for direct or indirect damage caused to persons or property through incorrect use or operation of the machine.

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General Information

33

Danger The interfaces for the PLC inputs/outputs, machine operating panel and PL connection comply with the requirements for basic insulation in accordance with IEC 742 EN 50 178. Only units that comply with the requirements of IEC 742 EN 50 178 for basic insulation may be connected, otherwise damage to persons or property may be caused. The maximum dc voltage mean value of the PLC inputs is 31 V. 3.1.2 Degrees of Protection The following components fulfill the requirements for IP54 (dust and splashproof protection). Visual display unit (when properly installed) Keyboard unit (when properly installed) Machine operating panel (when properly installed) Handwheel 3.1.3 Electromagnetic Compatibility This unit fulfills the requirements for Class A according to EN 55022 and is intended for operation in industrially zoned areas. Protect your equipment from interference by observing the following rules and recommendations. Likely sources of interference Interference is mainly produced by capacitive and inductive coupling from electrical conductors or from device inputs/outputs, such as: Strong magnetic fields from transformers or electric motors Relays, contactors and solenoid valves High-frequency equipment, pulse equipment and stray magnetic fields from switch-mode power supplies Power lines and leads to the above equipment Protective measures Keep a minimum distance of 20 cm from the MC 42x(B), CC 42x and its leads to interfering equipment. Keep a minimum distance of 10 cm from the MC 42x(B), CC 42x 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 IEC 61800-5-1. Use potential compensating lines with 6 mm2 cross-sections Use only genuine HEIDENHAIN cables, connectors and couplings

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HEIDENHAIN Technical Manual iTNC 530

3.2 Handling of the HDR Hard Disk and the SIK


Shipping brace of the hard disk The HDR hard disks of the MC 42x(B) are fitted with a shipping brace. Before putting the iTNC 530 into service, the shipping brace of the hard disk must be removed. Warning Do not transport the HDR with the MC 42x(B) after you have installed the HDR. If the entire machine is being transported, or the MC is being transported inside the electrical cabinet, the shipping brace for the hard disk is usually not required. However, if the possibility exists that the hard disk could be subject to increased shock or vibration loads, then you must remove the hard disk from the MC for transport, reinstall the shipping brace in the HDR, and send the HDR separately in the original packaging. Should servicing become necessary (i.e. the HDR is being shipped on its own), the hard disk must be secured with the shipping brace.

Festplatte entriegeln . Unlocking the hard disk 2. Lasche nach hinten drcken. 1. Sicherung anheben. Press tab down. Lift the catch.

Festplatte verriegeln . Locking the hard disk 1. hineindrcken, nach vorne schieben. (Click) Press hard disk down, slide it forwards. (click) 2. nach hinten schieben. (Click) Slide it backwards. (click)

1.

2.

Grifflaschen bentzen. Use holding tabs.

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Handling of the HDR Hard Disk and the SIK

35

HDR and SIK removal/insertion

Festplatteneinschub HDR HDR plug-in hard-disk module

SIK-Einbau Integration of SIK


CLICK

MC 420 MC 422 B

SIK
Achtung: Im Servicefall Festplatte verriegeln, SIK entnehmen und aufbewahren. Note: Should servicing become necessary, lock the hard disk, remove the SIK and keep it in a safe place.

HDR-Einbau . Installation of HDR

1. SIK einbauen Integrate SIK. 2. HDR einschieben, auf Verriegelung achten. (Click) Insert HDR. (click)

3. Bgel umlegen und gegen Lasche andrcken. (Click) Turn the bracket over and press it against the tab until it "clicks" in place.

Bgel Bracket

Lasche Tab

Andrcken, auf Verriegelung achten Pull bracket down, ensure that it is locked in place.

HDR-Ausbau in umgekehrter Reihenfolge . To remove the HDR, proceed in reverse order


1. Bgel entriegeln (Click) und aufstellen. 2. Lasche drcken und HDR rausziehen. 3. SIK entnehmen. Unlock the bracket so that it "unclicks" and pull it up. Press the tab and pull out the HDR. Remove the SIK.

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HEIDENHAIN Technical Manual iTNC 530

3.3 Environmental Conditions


3.3.1 Heat Generation and Cooling Danger The permissible ambient temperature in operation is between 0 C and 40 C. Any deviation from this will impair the operating safety of the machine. A heat exchanger or a cooling unit is preferable for controlling the internal temperature of the electrical cabinet. If filtered air is blown into the electrical cabinet for cooling purposes, the standard IEC 61800-5-1 applies, which permits contamination level 2. Danger Be sure to take the measures required for preventing dust from entering the electrical cabinet. Dust depositing inside electrical devices may cause them to fail and impair the safety of the system.

Incorrec

Correct

Blocking elements Elements with considerable heat generation

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Environmental Conditions

37

3.3.2 Humidity Permissible humidity: Maximum 75% in continuous operation Maximum 95% for not more than 30 days a year (randomly distributed) In tropical areas it is recommended that the iTNC 530 not be switched off, so as to avoid dew deposition on the circuit boards. 3.3.3 Mounting Elevation The maximum elevation for mounting is 3000 m above sea level. 3.3.4 Mechanical Vibration Permissible vibration: 0.075 mm, 10 to 41 Hz 5 m/s2, 41 Hz to 500 Hz Permissible shock: 50 m/s2, 11 ms Permissible shock with shipping brace for hard disk: 300 m/s2, 11 ms

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HEIDENHAIN Technical Manual iTNC 530

3.3.5 Mounting Attitude of MC 42x(B), CC 42x, UV xxx, UM xxx, UE 2xx B Warning When mounting, please observe proper minimum clearance, space requirements, length and position of the connecting cables.

Air outlet

Leave space for air circulation! Temperatures of > 150 C are possible with UE 21xB with integral braking resistor; Do not mount any temperaturesensitive components!

Leave space for servicing!

Air inlet

Leave space for air circulation and servicing!

*) Space for removing the HDR hard disk

Leave space for servicing and connecting cable!

UV(R), UE, UM

CC 42x, MC 42x(B)

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39

3.3.6 Mounting Position of Screen BF 120, BF 150 The BF 120 and BF 150 flat-panel displays must be viewed with a slight backward slant.
8

During installation, ensure a viewing angle of 150 > > 90.

BF 120 BF 150

TE

MB

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HEIDENHAIN Technical Manual iTNC 530

3.4 Connection Overview for iTNC 530


MC 422B / 5 position encoder inputs and CC 422 with 6 control loops X1 to X5 X35 to X38 X15 to X20
X127 X128

Encoder for position Vacant Encoder for speed PWM output Nominal value output, analog TS touch trigger probe TT 130 touch trigger probe Handwheel Ethernet data interface RS-232-C/V.24 data interface RS-422/V.11 data interface RS-232-C/V.24 (only for Windows 2000) RS-422/V.11 (only for Windows 2000) USB interface 24 V reference signal for spindle 24 V for "control-is-ready" output PLC output PLC input 24 V PLC supply voltage Keyboard unit Machine operating panel PLC expansion PLC analog input BF 150 (BF 120) visual display unit Reserved Power supply Reserved Reserved

X51 to X60 X8, X9 X12 X13 X23 X26 X27 X28 X127 X128 X141, X142 X30 X34 X41 X42 X44 X45 X46 X47 X48 X149 (X49) X131 X69 X121, X125 X165, X166

X150 at bottom of housing

X74 X150 B

5-V power supply Axis-specific drive release Signal ground Equipment ground (YL/GN)

Warning Do not engage or disengage any connecting elements while the unit is under power!

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Connection Overview for iTNC 530

3 11

MC 422B/10 position encoder inputs and CC 422 with 10 or 12 control loops X1 to X6 X35 to X38 X15 to X20 X80 to X83 X84, X85 X51 to X60 X61, X62 X8, X9 X12 X13 X23 X26 X27 X28 X127 X128 X141, X142 X30 X34 X41 X42 X44 X45 X46 X47 X48 X149 (X49) X131 X69 Encoder for position Encoder for position Encoder for speed Encoder for speed Encoder for speed (12 control loops) PWM output PWM output (12 control loops) Nominal value output, analog TS touch trigger probe TT 130 touch trigger probe Handwheel Ethernet data interface RS-232-C/V.24 data interface RS-422/V.11 data interface RS-232-C/V.24 (only for Windows 2000) RS-422/V.11 (only for Windows 2000) USB interface 24 V reference signal for spindle 24 V for "control-is-ready" output PLC output PLC input 24 V PLC supply voltage Keyboard unit Machine operating panel PLC expansion PLC analog input BF 150 (BF 120) visual display unit Reserved Power supply Reserved Reserved

X127 X128

X150, X151 at bottom of housing

X121, X125 X165, X166, X167 X74 X150/X151 B

5-V power supply Axis-specific drive release Signal ground Equipment ground (YL/GN)

Warning Do not engage or disengage any connecting elements while the unit is under power!

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HEIDENHAIN Technical Manual iTNC 530

MC 422B and CC 424 with max. 6 control loops X201 to X206


X15 X17 X19

Encoder for position Encoder for speed PWM output Nominal value output, analog TS touch trigger probe TT 130 touch trigger probe Handwheel Ethernet data interface RS-232-C/V.24 data interface RS-422/V.11 data interface RS-232-C/V.24 (only for Windows 2000) RS-422/V.11 (only for Windows 2000) USB interface 24 V reference signal for spindle 24 V for "control-is-ready" output PLC output PLC input 24 V PLC supply voltage Keyboard unit Machine operating panel PLC expansion PLC analog input BF 150 (BF 120) visual display unit Reserved Power supply Reserved

X15 to X20 X51 to X56

X16 X18 X20

X51 X53 X55

X8, X9 X12 X13 X23 X26 X27 X28 X127 X128 X141, X142 X30 X34 X41 X42 X44 X45 X46 X47 X48 X149 (X49) X131 X69

X52 X54 X56

0V 5V X69 X201 X203 X205

X202 X204 X206

X150 at bottom of housing

X121, X125, X165 X74 X150 B

5-V power supply Axis-specific drive release Signal ground Equipment ground (YL/GN)

Warning Do not engage or disengage any connecting elements while the unit is under power!

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Connection Overview for iTNC 530

3 13

MC 422B and CC 424 with max. 8 control loops X201 to X208


X15 X17X19 X80

Encoder for position Encoder for speed Encoder for speed PWM output Nominal value output, analog TS touch trigger probe TT 130 touch trigger probe Handwheel Ethernet data interface RS-232-C/V.24 data interface RS-422/V.11 data interface RS-232-C/V.24 (only for Windows 2000) RS-422/V.11 (only for Windows 2000) USB interface 24 V reference signal for spindle 24 V for control-is-ready output PLC output PLC input 24 V PLC supply voltage Keyboard unit Machine operating panel PLC expansion PLC analog input BF 150 monitor Reserved Power supply Reserved

X15 to X20 X80 to X81 X51 to X58 X8, X9 X12 X13 X23 X26 X27 X28 X127 X128 X141, X142 X30 X34 X41 X42 X44 X45 X46 X47 X48 X149 X131 X69

X16 X18X20 X81

X51 X53 X55 X57

X52 X54 X56

X58

X74 X69 X201X203 X205 X202X204 X208 X207

X206

X150 at bottom of housing

X121, X125, X165 X74 X150 B

5-V power supply Axis-specific drive release Signal ground Equipment ground (YL/GN)

Warning Do not engage or disengage any connecting elements while the unit is under power!

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HEIDENHAIN Technical Manual iTNC 530

MC 422B and CC 424 with max. 10 control loops X201 to X210


X15 X17X19 X80 X82

Encoder for position Encoder for speed Encoder for speed PWM output Nominal value output, analog TS touch trigger probe TT 130 touch trigger probe Handwheel Ethernet data interface RS-232-C/V.24 data interface RS-422/V.11 data interface RS-232-C/V.24 (only for Windows 2000) RS-422/V.11 (only for Windows 2000) USB interface 24 V reference signal for spindle 24 V for "control-is-ready" output PLC output PLC input 24 V PLC supply voltage Keyboard unit Machine operating panel PLC expansion PLC analog input BF 150 (BF 120) visual display unit Reserved Power supply Reserved

X15 to X20 X80 to X83 X51 to X60 X8, X9 X12 X13 X23 X26 X27 X28 X127 X128 X141, X142 X30 X34 X41 X42 X44 X45 X46 X47 X48 X149 (X49) X131 X69, X169

X16 X18X20 X81 X83

X51 X53 X55 X57 X59

X52 X54 X56

X58 X60

0V 5V X69 X201X203 X169 X207 X209

X205 X202X204 X208 X210

X206

X150, X151 at bottom of housing

X121, X125, X165 X74 X150/X151 B

5-V power supply Axis-specific drive release Signal ground Equipment ground (YL/GN)

Warning Do not engage or disengage any connecting elements while the unit is under power! September 2006 Connection Overview for iTNC 530 3 15

MC 422B and CC 424 with max. 12 control loops X201 to X206 X209 to X214 X15 to X20 X82 to X87 X51 to X56 X59 to X64 X8, X9 X12 X13
X52 X54 X56 X60 X62 X64

X15 X17X19

X82 X84 X86

Encoder for position Encoder for position Encoder for speed Encoder for speed PWM output PWM output Nominal value output, analog TS touch trigger probe TT 130 touch trigger probe Handwheel Ethernet data interface RS-232-C/V.24 data interface RS-422/V.11 data interface RS-232-C/V.24 (only for Windows 2000) RS-422/V.11 (only for Windows 2000) USB interface 24 V reference signal for spindle 24 V for control-is-ready output PLC output PLC input 24 V PLC supply voltage Keyboard unit Machine operating panel PLC expansion PLC analog input BF 150 monitor Reserved Power supply Reserved

X16 X18X20

X83 X85 X87

X51 X53 X55

X59 X61 X63

X74 X69 X201X203 X205 X169 X209 X213

X211 X202X204 X206 X210 X214

X23 X26 X27 X28 X127 X128 X141, X142 X30 X34 X41 X42 X44 X45 X46 X47 X48 X149 X131 X69, X169

X212

X150, X151 at bottom of housing

X121, X125, X165 X74 X150, X151 B

5-V power supply Axis-specific drive release Signal ground Equipment ground (YL/GN)

Warning Do not engage or disengage any connecting elements while the unit is under power!

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HEIDENHAIN Technical Manual iTNC 530

MC 422B and CC 424 with max. 14 control loops X201 to X208 X209 to X214 X15 to X20 X80 to X87 X51 to X58 X59 to X64 X8, X9 X12 X13
X52 X54 X56 X58 X60 X62 X64

X15 X17X19 X80 X82 X84 X86

Encoder for position Encoder for position Encoder for speed Encoder for speed PWM output PWM output Nominal value output, analog TS touch trigger probe TT 130 touch trigger probe Handwheel Ethernet data interface RS-232-C/V.24 data interface RS-422/V.11 data interface RS-232-C/V.24 (only for Windows 2000) RS-422/V.11 (only for Windows 2000) USB interface 24 V reference signal for spindle 24 V for control-is-ready output PLC output PLC input 24 V PLC supply voltage Keyboard unit Machine operating panel PLC expansion PLC analog input BF 150 monitor Reserved Power supply Reserved

X16 X18X20 X81 X83 X85 X87

X51 X53 X55 X57 X59 X61 X63

X74 X69 X201 X205 X207 X169 X209 X213

X203 X202

X211 X210 X214

X23 X26 X27 X28 X127 X128 X141, X142 X30 X34 X41 X42 X44 X45 X46 X47 X48 X149 X131 X69, X169

X206 X208

X204

X212

X150, X151 at bottom of housing

X121, X125, X165 X74 X150, X151 B

5-V power supply Axis-specific drive release Signal ground Equipment ground (YL/GN)

Warning Do not engage or disengage any connecting elements while the unit is under power!

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Connection Overview for iTNC 530

3 17

MC 420 and CC 422 with max. 6 control loops X1 to X5 Encoder for position

X15 to X20 X51 to X56 X8 X12 X13 X23 X26 X27 X28

Encoder for speed PWM output Nominal value output, analog TS touch trigger probe TT 130 touch trigger probe Handwheel Ethernet data interface RS-232-C/V.24 data interface RS-422/V.11 data interface

X10

X141
X48

USB interface 24 V reference signal for spindle 24 V for "control-is-ready" output PLC output PLC input 24 V PLC supply voltage Keyboard unit Machine operating panel PLC expansion PLC analog input BF 150 monitor

X30 X34
X147

X41 X42 X44 X45 X46 X147 X48 X149

X150 at bottom of housing

X69 X10 X121 X165, X166 X74 X150 B

Power supply Reserved Reserved Reserved 5-V power supply Axis-specific drive release Signal ground Equipment ground (YL/GN)

Warning Do not engage or disengage any connecting elements while the unit is under power!

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HEIDENHAIN Technical Manual iTNC 530

3.5 Power Supply for the iTNC 530


The UV 1x0 or UV 105 power supply unit supplies the iTNC 530 with power. Power is supplied through X69/X169 and possibly in addition through a 5-V terminal on the CC 42x. The control monitors the 5-V supply voltage. If it falls below 4.75 V, the error message 5-V power supply too low appears. If it rises above 5.4 V, 5-V power supply too high appears. For information on the UV 1x0 supply units, refer to the Inverter Systems and Motors Technical Manual. Whether the UV 1x0 supply unit is sufficient or whether a UV 105 is needed as additional equipment depends on the current consumption of the used units. Device UV 1x0, UE 2xx B UV 105, UV 105 B, UV 106 B, UVR 150 Device MC 420 MC 422 B MC 422B (with 2 processors) USB components CC 422 / 6 control loops CC 422/10 or 12 control loops CC 424 / 6 control loops CC 424 / 10 control loops LS, LB ERN, ROD, RON Absolute rotary encoders Absolute angle encoders LC Load capacity 8.50 A 20.00 A

Current consumption of the 5-V supply 4.8 A 5.20 A 7.40 A Max. 2 x 0.5 Aa 1.50 A 3.00 A 2.50 A 4.60 A 0.15 A 0.20 A 0.25 A (+0.085 A with line drop compensator)b 0.35 A (+0.085 A with line drop compensator)b 0.30 A (+0.085 A with line drop compensator)b

a. If USB components require more than 0.5 A, a separate power supply becomes necessary for these components. One possibility is the USB hub from HEIDENHAIN (368 735-01). b. For cable lengths > 10 m between the logic unit and the encoders with EnDat interfaces, a line drop compensator is required (efficiency = 75 %).

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Power Supply for the iTNC 530

3 19

Example: Device MC 422 B CC 422 / 6 control loops 3 x LS for X, Y, Z 1 x ROD for C 4 x ERN for X, Y, Z, C, spindle Total Current consumption 5.20 A 1.50 A 0.45 A 0.2 A 1.0 A 8.35 A < 8.50 A

A UV 105 unit is not needed for this application.

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HEIDENHAIN Technical Manual iTNC 530

3.5.1 UV 105 Power Supply Unit Connection overview

Conductor bar

Power supply with UZ

+5 V 0 V

X74 Free ribbon cable

5-V power supply for CC 42x Power supply for CC 42x (to X69 on CC 42x) Status signals from UV 1x0

X69

X31

Power supply

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Power Supply for the iTNC 530

3 21

Warning Do not engage or disengage any connecting elements while the unit is under power! X69, X169: NC supply voltage and control signals Note For the NC to be able to evaluate the status signals of the power supply units, connector X69 of the CC 4xx must be connected by ribbon cable with X69 of the UV 105. Since non-HEIDENHAIN inverters do not send any status signals, an adapter connector (Id. Nr. 349 211-01) must be connected to X69 on the UV 105. This connector is delivered with the UV 105. Pin layout: 50-pin ribbon connector 1a to 5b 6a to 7b 8a 8b 9a 9b Assignment +5 V +12 V 50-pin ribbon connector 16b 17a Assignment GND RDY.PS GND ERR.ILEAK GND PF.PS.AC (only UV 120, UV 140, UV 150, UR 2xx) GND Do not assign GND Do not assign GND Do not assign GND Reserved (SDA) GND Reserved (SLC) GND RES.LE GND

+5 V (low-voltage 17b separation) 0 V (low-voltage separation) +15 V 15 V 18a 18b 19a

10a 10b 11a 11b 12a 12b 13a 13b 14a 14b 15a 15b 16a

UZAN 0V IZAN 0V RES.PS 0V PF.PS.ZK GND ERR.UZ.GR GND ERR.IZ.GR GND ERR.TMP

19b 20a 20b 21a 21b 22a 22b 23a 23b 24a 24b 25a 25b

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HEIDENHAIN Technical Manual iTNC 530

X74: 5-V power supply

Pin layout: Wire color of 5-V connection BK RD 5-V terminal on CC 42x 0V +5 V

X31: Supply voltage for UV 105

Supply voltage: 400 V 10 % Pin layout: Connecting terminal U V Assignment Ua Va Equipment ground (YL/GY), 10 mm2 a. Connecting cable: 1.5 mm2 Note The supply voltage at terminals U and V must: be supplied via an isolating transformer (300 VA, basic insulation in accordance with EN 50 178 or VDE 0550) for non-HEIDENHAIN inverters and regenerative HEIDENHAIN inverter systems (UV 120, UV 140, UV 150, UR 2xx). There is no need for an isolating transformer if non-regenerative HEIDENHAIN inverter systems are used. Warning When using an isolating transformer, do not ground this isolating transformer on the secondary side! The isolating transformer decouples the dc-link voltage from ground. Grounding the isolating transformer on the secondary side leads to an addition of the dc-link voltage and the supply voltage. This overloads the UV 105, thereby destroying it! Please keep this in mind in your circuit diagrams.

Power supply of the UV 105 with UZ

The UV 105 is powered with dc-link voltage UZ through the conductor bars (for HEIDENHAIN inverter systems). a cable which is connected instead of the conductor bar (for nonHEIDENHAIN inverter systems). The dc-link voltage is monitored by the control (see Monitoring of the Power Supply Unit on page 6 247).

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3.5.2 UV 105 B (Non-HEIDENHAIN Inverter Systems) General information The UV 105 B (Id. Nr. 532 581-01) was designed solely for the use of HEIDENHAIN controls in connection with non-HEIDENHAIN inverter systems. It is essential for the supply voltages of the HEIDENHAIN control units. UV 105 B power supply unit for the operation of HEIDENHAIN controls with non-HEIDENHAIN inverter systems

Id. Nr. 532 581-01 UV 105 B

UV 105 B

Specifications Specifications Power supply (at X31) Protection Load capacity (5 V) Power consumption Degree of protection Module width Weight ID number Warning The UV 105 B is not compatible with the UV 105 (Id. Nr. 344 980-xx), and no HEIDENHAIN inverter components can be operated with this supply voltage. UV 105 B 400 Vac 10 % 50 Hz 6.3 A / gRL 20 A Max. 400 W IP 20 159 mm 3 kg 532 556-01

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HEIDENHAIN Technical Manual iTNC 530

Connection overview

DO NOT CONNECT WITH LINE POWER

X31

U V +UDC UDC

X31 X31

U/V +Uz / -Uz

400-V supply voltage Supply voltage from dc link

X74

+5 V 0V

X74

5-V power supply for CC 42x

Free ribbon cable

Further power supply and status signals for CC 42x (to X69 on CC 42x)

READY UV

LED green

Operating display for UV 105 B

Equipment ground (YL/GN)

Warning Do not engage or disengage any connecting elements while the unit is under power!

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Power Supply for the iTNC 530

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Status signals via ribbon cable Note For the control to be able to evaluate the status signals of the power supply unit, the ribbon cable of the UV 105 must be connected with X69 of the control. Connection: 50-pin ribbon connector 1a to 5b 6a to 7b 8a 8b 9a 9b Assignment +5 V +12 V 50-pin ribbon connector 16b 17a Assignment GND RDY.PS GND ERR.ILEAK GND PF.PS.AC (only UV 120, UV 140, UV 150, UR 2xx) GND Do not assign GND Do not assign GND Do not assign GND Reserved (SDA) GND Reserved (SLC) GND RES.LE GND

+5 V (low-voltage 17b separation) 0 V (low-voltage separation) +15 V 15 V 18a 18b 19a

10a 10b 11a 11b 12a 12b 13a 13b 14a 14b 15a 15b 16a X74: 5-V connection of the UV 105 B Connection:

UZAN 0V IZAN 0V RES.PS 0V PF.PS.ZK GND ERR.UZ.GR GND ERR.IZ.GR GND ERR.TMP

19b 20a 20b 21a 21b 22a 22b 23a 23b 24a 24b 25a 25b

Wire color of 5-V connection BK RD

5-V terminal on CC 42x 0V +5 V

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HEIDENHAIN Technical Manual iTNC 530

X31: Supply voltage for UV 105 B

Supply voltage: 400 V 10 % Connection: Connecting terminal U V Assignment Phase 1 / 400 Vac 10 % / 50 Hz to 60 Hz Phase 2 / 400 Vac 10 % / 50 Hz to 60 Hz Equipment ground (YL/GY), 10 mm2 Cable: Wire cross section: 1.5 mm2 (AWG 16) Line fuse: 6.3 A (gRL) Siemens Sitor type +Uz Uz Positive dc-link voltage of the nonHEIDENHAIN inverter system Negative or reference potential of the dc-link voltage of the non-HEIDENHAIN inverter system Cable: Wire cross section: 1.5 mm2 (AWG 16) The dc-link connection of the UV 105B is protected by the additional PCB on the non-HEIDENHAIN inverter system (4 A) Tightening torque: for the connecting terminals 0.7 Nm (6.5 - 7 lbs/in) Grounding terminal: 10 mm2 (AWG 6) Strain relief: Ensure that the connecting cables are not subject to excessive strain Note If you are using non-HEIDENHAIN inverter systems, you must connect the supply voltage to the terminals U and V via an isolating transformer (300 VA, basic insulation as per EN 50 178 or VDE 0550). Warning When using an isolating transformer, do not ground this isolating transformer on the secondary side! The isolating transformer decouples the line voltage from ground. Grounding the isolating transformer on the secondary side leads to an addition of the dc-link voltage and the supply voltage. This could destroy the UV 105 B! Please keep this in mind in your circuit diagrams.

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Power Supply for the iTNC 530

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UZ: Supply of the UV 105 B with UZ

Since the power to the UV 105 B is supplied through the dc-link, the voltage fed into the dc-link by the motors that are still running can be used during line voltage failures. The UV 105B uses this voltage to maintain the power supply to the control until the non-HEIDENHAIN inverter system has been shut down properly by the control. Connecting terminals UZ +UZ Assignment DC-link voltage DC-link voltage +

Dimensions for UV 105 B

M5 M4 5.5 50

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HEIDENHAIN Technical Manual iTNC 530

3.5.3 UV 106 B Power Supply Unit General information UV 106 B power supply unit for analog HEIDENHAIN contouring controls The UV 106 B power supply unit was designed so that the iTNC 530 could be used with a compact, coordinated system for analog nominal shaft-speed interfaces (+/ 10 V). It supplies the iTNC 530 with the supply voltages necessary for operation. The UV 106 B (Id. Nr. 546 581-01) is being introduced as a replacement for the UV 106 (Id. Nr. 366 572-11).

Id. Nr. 546 581-01 UV 106 B UV 106 B Specifications Specifications Power supply (at X31) Protection Load capacity (5 V) Power consumption Degree of protection Module width Weight ID number UV 106 B 400 Vac 10 %a 50 Hz 6.3 A (gR) Siemens Sitor type or 6.3 A (gRL) Siba type 20 A Max. 400 W IP 20 159 mm 4 kg 546 581-xx

a. An isolating transformer is not necessary when the UV 106B is connected.

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Power Supply for the iTNC 530

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Connection overview

X31

U V

X31

U/V

400-V supply voltage

READY UV

Green LED

Operational status indicator

Equipment ground (YL/GN)

Warning Do not engage or disengage any connecting elements while the unit is under power!

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HEIDENHAIN Technical Manual iTNC 530

X31: Supply voltage for UV 106 B

Supply voltage: 400 V 10 % Connection: Connecting terminal U V Assignment Phase 1 / 400 Vac 10 % / 50 Hz to 60 Hz Phase 2 / 400 Vac 10 % / 50 Hz to 60 Hz Protective ground (YL/GN), 10 mm2 Connecting leads Wire cross section: 1.5 mm2 (AWG 16) Tightening torque: for the connecting terminals 0.7 Nm (6.5 - 7 lbs/in) Grounding terminal: 10 mm2 (AWG 6) Strain relief: Ensure that the connecting cables are not subject to excessive strain

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Power Supply for the iTNC 530

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Power connection
UV 106B MC 4xx *)

L1 L2 X31

PE

PE

400V 10% 50HZ

Fuse Typ: Siemens Sitor 6,3A gR

L1 L2 L3 N PE
*) Connections to MC4xx: See Technical Manual

Dimensions for UV 106 B

M5

24.5+0.2 158.25+0.75

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HEIDENHAIN Technical Manual iTNC 530

3.6 Power Supply for PLC Outputs


The PLC of the iTNC 530 as well as the PL 410B/PL 405B/PL 510 are powered by the 24 Vdc control voltage of the machine (in accordance with VDE 0551). The control voltage must be smoothed with a minimum 1000 F at a rated current capacity of 150 F/A. At a current load of 15 A, for example, this corresponds to a capacity of 2250 F. EN 61 131-2:1994 permits: 5% alternating voltage component is permissible Minimum absolute value: 20.4 Vdc Maximum absolute value: 28.8 Vdc Danger Use only original replacement fuses. Power consumption If half of the outputs are switched at the same time, the following are the values for power consumption: MC 422(B): PL 410B: PL 405B: PL 510: Nominal operating current per output MC 422(B): PL 410B: PL 405B: PLD 16-8: 48 W Approx. 460 W Approx. 235 W Approx. 485 W 0.150 A 2 A (with max. current consumption of 20 A) 2 A (with max. current consumption of 20 A) 2A Simultaneity 2 outputs with 2 A each 4 outputs with 1 A each 8 outputs with 0.5 A each Total current: Out0 to Out7: 4 A Out0 to Out3: 2 A Out4 to Out7: 2 A

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Power Supply for PLC Outputs

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X44: PLC supply voltage

Pin layout on the MC 422(B): Connection terminal 1 2 3 4 Note If the +24-V power supply (which cannot be shut off via emergency stop) is missing at X44, the error message Supply voltage missing at X44 appears. Assignment PLC outputs

+24 V can not be switched O24 to O30 off via EMERGENCY STOP control-is-ready signal +24 V can be switched off via EMERGENCY STOP 0V O16 to O23 O0 to O15

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HEIDENHAIN Technical Manual iTNC 530

3.6.1 Power Supply for PL 4xxB Connection overview

X9 to X14: Supply voltage

Pin layout on the PL 410 B: Terminal X9 X10 X11 Assignment 0V +24 Vdc logic power supply and for control-is-ready signala +24 Vdc power supply for outputsa +24 Vdc power supply for outputsa +24 Vdc power supply for outputsa +24 Vdc power supply for outputsa O32 O39 O40 O47 O48 O55 O56 O62 O64 O71 O72 O79 O80 O87 O88 O94 O128 O135 O136 O143 O144 O151 O152 O158 O160 O167 O168 O175 O176 O183 O184 O190 PL 1 PL 2 PL 3 PL 4

X12

X13

X14

a. 20.4 V to 28.8 V

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Pin layout on the PL 405 B: Terminal X9 X10 X13 Assignment 0V +24 Vdc logic power supply and for control-is-ready signala +24 Vdc power supply for outputsa +24 Vdc power supply for outputsa O48 O55 O56 O62 O80 O87 O88 O94 O144 O151 O152 O158 O176 O183 O184 O190 PL 1 PL 2 PL 3 PL 4

X14

a. 20.4 V to 28.8 V X23: Power supply for the analog inputs on the PL 410B The PL 410 B input/output unit is also available with additional analog inputs and inputs for PT 100 thermistors.

Danger The power supply must correspond to a safety extra-low voltage (SELV) as per EN 61800-5-1. Terminal 1 2 3.6.2 Power Supply for PL 510 Note The iTNC 530 cyclically monitors the supply voltage of the PL 510. PLB 510 basic module Pin layout for X3 (power supply for logic circuit): Terminal 1 2 PLD 16-8 input/ output module Assignment +24 Vdc (20.4 V to 28.8 V) +0 V Assignment +24 Vdc (safety extra-low voltage as per EN 61800-5-1) +0 V

Pin layout at X6 (power supply for PLC outputs): Terminal 9 10 Assignment +24 Vdc (20.4 V to 28.8 V) for group 1 +24 Vdc (20.4 V to 28.8 V) for group 2

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HEIDENHAIN Technical Manual iTNC 530

3.7 Power Supply for Control-Is-Ready Signal


X34: Power supply for control-is-ready signal The control-is-ready signal output is powered by 24 Vdc provided by the UE 2xx B inverter or the UV1xx power supply unit. The voltage is connected with terminal X34. Pin layout: Connecting terminal X34 1 2 Assignment +24 V 0V Connection when using a HEIDENHAIN inverter X72/1 X72/2

3.8 Power Supply for the Display Units


Connecting terminal X1 1 2 Power consumption: BF 120: 15 W BF 150: 45 W Danger The power supply must have basic insulation as per EN 61800-5-1. Assignment +24 V 0V

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Power Supply for Control-Is-Ready Signal

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3.9 Buffer Battery


Note Make a data backup before changing the buffer battery. Danger When exchanging the buffer battery, remember: Switch off the machine and the iTNC 530. The buffer battery may be exchanged only by trained personnel. Battery type: 1 lithium battery, type CR 2450N (Renata), Id. Nr. 315 878-01 The lifetime of the buffer battery is between 2 and 5 years. If the voltage of the buffer battery falls below 2.6 V the error message Exchange buffer battery appears. If the voltage does not exceed 2.6 V, the error message is reactivated after 30 minutes. Notes on exchanging the buffer battery:
8 8

The buffer battery is located on the rear side of the MC 422(B). Exchange the battery; the new battery can be inserted in only one position.

Buffer battery

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HEIDENHAIN Technical Manual iTNC 530

The following information is stored in the battery-buffered memory: Remanent PLC operands Most recent log entries Information about the trace function Information about program interruption Information from absolute encoders with EnDat interface Information about the boot process Information about errors

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Buffer Battery

3 39

3.10 Drive Controller Enable


A drive controller can be enabled by the NC software only if the controller is enabled with 24 V on X150/X151 and on X42, pin 33. X150, X151: Drive controller enabling for axis groups The connecting terminals X150 and X151 are located on the bottom of the CC 42x. X150 controls drive enabling for the axis groups on the first controller board (PWM outputs X51 to X56). X151 controls drive enabling for the axis groups on the second controller board (PWM outputs X57 to X60 or X62). Note The pin of an axis group must always be wired to the connector on whose PCB the control loop is located. If an axis group contains control loops located on both PCBs, then the pins of both connectors must be wired. Pin layout: Terminal Assignment of X150 X150/X151 1 +24 Va drive controller enabling for axis group 1 +24 Va; drive controller enabling for axis group 2 +24 Va; drive controller enabling for axis group 3 Only CC 424: +24 Va; drive controller enabling for axis group 4 Only CC 424: +24 Va; drive controller enabling for axis group 5 Only CC 424: +24 Va; drive controller enabling for axis group 6 Reserved, do not assign Reserved, do not assign 0V a. maximum current consumption 10 mA Assignment of X151 +24 Va; drive controller enabling for axis group 1 +24 Va; drive controller enabling for axis group 2 +24 Va; drive controller enabling for axis group 3 Only CC 424: +24 Va; drive controller enabling for axis group 4 Only CC 424: +24 Va; drive controller enabling for axis group 5 Only CC 424: +24 Va; drive controller enabling for axis group 6 Reserved, do not assign Reserved, do not assign 0V

2 3 4

7 8 9

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HEIDENHAIN Technical Manual iTNC 530

X42/33: Global drive controller enable

Pin layout: D-sub connctn. (male) 37-pin Assignment .. 33 .. .. +24 V (drive controller enable) ..

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Drive Controller Enable

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3.11 Encoder Connections


3.11.1 General Information HEIDENHAIN contouring controls are designed for use with incremental or absolute linear and angular encoders as measuring systems. The encoder signals are interpolated 1024-fold. Encoders with one reference mark or distance-coded reference marks and with EnDat interface are permissible. HEIDENHAIN recommends the use of absolute encoders with EnDat interface or the use of encoders with distance-coded reference marks because they greatly reduce the traverse distance required to establish the absolute position. Please use only HEIDENHAIN encoder cables, connectors and couplings. For maximum cable lengths, see Cable Overview at the end of this chapter. Position encoder Signal amplitude Input frequency 1 VPP EnDat, 1 VPP Speed encoder EnDat, 1 VPP

MC 42x (B): CC 422: 350 kHz 27 kHz/400 kHz (can be CC 424: 400 kHz set via MP115.x) CC 424: 27 kHz/400 kHz (can be set via MP116.x)

11 APP encoders can be connected through the adapter plug with the Id. Nr. 317 505-05. Note Keep in mind the line count of the speed encoders when choosing the motors: f 60 1000 x = -----------------------------n x: line count of the speed encoder f: maximum input frequency n: maximum speed Example: f = 350 kHz; n = 10 000 rpm 350 60 1000 - 2048 x = -------------------------------------10000

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HEIDENHAIN Technical Manual iTNC 530

3.11.2 Input for Position Encoder X1 to X6, X35 to X38, X201 to X214: Position encoder 1 VPP MC 42x(B), CC 424 Male 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Hsg. Assignment +5 V (UP) 0 V (UN) A+ A Do not assign B+ B Do not assign +5 V (sensor) R+ 0 V (sensor) R 0V Do not assign Do not assign External shield Pin layout:

Adapter cable 309 783-xx Adapter cable 310 199-xx Female 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Hsg. Note External shield Hsg. VI 7 BL RD WH BK 2 3 11 4 GY PK 8 1 Color BN/GN WH/GN BN GN Female 12 10 5 6

Encoder Male 12 10 5 6 8 1 2 3 11 4 7 Hsg. Color BN/GN WH/GN BN GN GY PK BL RD WH BK VI External shield

The interface complies with the requirements of EN 61800-5-1 for protective extra-low voltage (PELV).

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Encoder Connections

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X1 to X6, X35 to X38, X201 to X214: Position encoder with EnDat interface MC 42x(B), CC 424 Male Assign. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Hsg.

Pin layout:

Adapter cable 332 115-xx Female Color BN/GN

Conn. cable 323 897-xx Fem. 7 WH/GN 10 GN/BK 15 YL/BK Line drop compensator 336 697-02, if required 16 GY BL/BK 14 12 RD/BK 13 PK BL RD WH BK 17 1 3 4 2 BN/GN

Adapter cable 313 791-xx Male Color BN/GN 7 WH/GN 10 GN/BK 15 YL/BK 16 14 12 RD/BK 13 17 1 3 4 2 11 8 9 Hsg. Internal shield VI YL External shield 4a 4b WH 6b PK BL 1b 3a 5a GY BL/BK 1a 2b 3b 2a 6a 5b Fem.

Female Male Color 7 7 10 15 16 14 12 13 17 1 3 4 2 11 8 9

+5 V (UP) 1 WH/GN 0 V (UN) A+ A Data B+ B Data +5 V (sensor) Free 0V (sensor) Free Internal shield Clock Clock Housing 2 GN/BK 3 YL/BK 4 5 6 RD/BK 7 8 9 10 11 12 13 14 15 Hsg. Internal shield VI YL WH PK BL GY BL/BK

10 15 16 14 12 13 17 1 3 4 2 11 8 9

Internal shield 11 VI YL Externa l shield 8 9

External shield Hsg. Note

The interface complies with the requirements of EN 61800-5-1 for protective extra-low voltage (PELV).

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HEIDENHAIN Technical Manual iTNC 530

3.11.3 Input of Speed Encoder Warning If you connect angle or linear encoders from HEIDENHAIN to the speed encoders (such as for torque motors), you must pay attention to the different connector layouts! HEIDENHAIN offers special cables and line-drop compensators for such applications. More information is in the Cable Overviews. X15 to X20, X80 to X87: Speed encoder 1 VPP CC 42x Male Assignment 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Hsg. +5 V (UP) 0 V (UN) A+ A 0V B+ B 0V Do not assign Do not assign Do not assign Do not assign Temperature + +5 V (sensor) Do not assign 0 V (sensor) R+ R C+ C D+ D Do not assign 0V Temperature Housing 25 Hsg. Note The interface complies with the requirements of EN 61800-5-1 for protective extra-low voltage (PELV). VI 9 9 VI 9 Hsg. External shield Hsg. Hsg. Ext. shield 16 17 18 19 20 21 22 WH RD BK GN BN GY PK 15 3 13 5 6 14 4 13 14 YL BL 8 16 6 7 8 BL/BK RD/BK Internal shield 11 17 Line drop compensator 370 226-01, if required 12 11 12 17 BL/BK RD/BK 11 12 Pin layout:

Adapter cable 289 440-xx Female Color 1 2 3 4 BN/GN WH/GN GN/BK YL/BK Female 10 7 1 2

Conn. cable 336 847-xx Male Color 10 7 1 2 BN/GN WH/GN GN/BK YL/BK Female 10 7 1 2

Internal shield 17

8 16 15 3 13 5 6 14 4

YL BL WH RD BK GN BN GY PK

8 16 15 3 13 5 6 14 4

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X15 to X20, X80 to X85: Speed encoder with EnDat interface CC 42x Male Assignment 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Hsg. +5 V (UP) 0 V (UN) A+ A 0V B+ B 0V Do not assign Clock Do not assign Clock Temperature + +5 V (sensor) Data 0 V (sensor) Do not assign Do not assign Do not assign Do not assign Do not assign Do not assign Data 0V Temperature Housing

Pin layout:

Adapter cable 336 376-xx Female Color 1 2 3 4 6 7 8 BN/GN WH/GN GN/BK YL/BK BL/BK RD/BK Internal shield Female 10 7 1 2 11 17 Line drop compensator 370 224-01, if required 12

Conn. cable 340 302-xx Male Color 10 7 1 2 11 12 17 BN/GN WH/GN GN/BK YL/BK BL/BK RD/BK Internal shield GN BN YL BL RD WH Female 10 7 1 2 11 12 17

10 12 13 14 15 16

GN BN YL BL RD WH

5 14 8 16 3 15

5 14 8 16 3 15

5 14 8 16 3 15

23 25 Hsg.

BK VI

13 9

13 9 Hsg.

BK VI External shield

13 9 Hsg.

External shield Hsg.

Note The interface complies with the requirements of EN 61800-5-1 for protective extra-low voltage (PELV). Danger Only units that comply with the requirements of EN 61800-5-1 for protective extra-low voltage (PELV) may be connected.

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HEIDENHAIN Technical Manual iTNC 530

Pin layout (for the LC or RCN):

CC 42x Male Assignment 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Hsg. +5 V (UP) 0 V (UN) A+ A 0V B+ B 0V Do not assign Clock Do not assign Clock +5 V (sensor) Data 0 V (sensor) Do not assign Do not assign Do not assign Do not assign Do not assign Do not assign Data 0V Temperature Housing

Adapter cable 336 376-xx Female 1 2 3 4 6 7 8 10 12 14 15 16 Color BN/GN WH/GN GN/BK YL/BK BL/BK RD/BK Internal shield GN BN YL BL RD WH Female 10 7 1 2 11 12 17 5 14 8 16 3 15 Line drop compensator 368 210-02

Adapter cable 369 124-xx Adapter cable 369 129-xx Male 7 10 15 16 12 13 11 8 9 1 14 4 Color BN/GN WH/GN GN/BK YL/BK BL/BK RD/BK Internal shield VI YL BL GY WH

Temperature + 13

23 25 Hsg.

BK VI

13 9

17

PK

External shield Hsg. 1 2 temperature+ 3 temperature+ 4

Hsg.

External shield

Note The interface complies with the requirements of EN 61800-5-1 for protective extra-low voltage (PELV).

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Pin layout (for the LC or RCN):

CC 42x

Adapter cable 509 667-xx

Adapter cable 369 124-xx Adapter cable 369 129-xx or RCN 7 10 15 16 12 13 11 BN/GN WH/GN GN/BK YL/BK BL/BK RD/BK Internal shield VI YL BL GY WH

Male Assignment 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 +5 V (UP) 0 V (UN) A+ A 0V B+ B 0V Do not assign Clock Do not assign Clock Temperature + +5 V (sensor) Data 0 V (sensor) Do not assign Do not assign Do not assign Do not assign Do not assign Do not assign Data 0V Temperature

Female Color 1 2 3 4 6 7 8 BN/GN WH/GN GN/BK YL/BK BL/BK RD/BK Internal shield GN BN YL BL RD WH

Female Male Color 7 10 15 16 12 13 11

10 12 13 14 15 16

8 9 5 1 14 4

8 9 1 14 4

23 25 Hsg.

BK VI External shield

17 6 Hsg.

17

PK

Hsg. Housing

Hsg.

External shield

Note The interface complies with the requirements of EN 61800-5-1 for protective extra-low voltage (PELV).

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HEIDENHAIN Technical Manual iTNC 530

3.12 Adapters for Encoder Signals


Encoder signals with 11 APP or TTL levels can be adapted to the 1 VPP interface with HEIDENHAIN adapter connectors.

4 ... 9 VPP Id.-Nr. 317 505-01

1V

MCLE 42x(B)

4 ... 9 VPP Id.-Nr. 317 505-02

1V

SIEMENS

MC LE 42x(B)

11A

Id.-Nr. 313 119-01

U0

1V

MC LE 42x(B)

Note Please note: The adapters adjust only the levels, not the signal shape. The contamination signal of the square-wave encoder cannot be evaluated. A square-wave signal can be subdivided no more than 4-fold.

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Adapters for Encoder Signals

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Adapter connector TTL (HEIDENHAIN)/ 1 VPP

Pin layout of D-sub connector (female) and D-sub connector (male): D-sub connector Assignment (female) 15-pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 +5 V (UP) 0 V (UN) A+ A 0V B+ B 0V +5 V R+ 0V R 0V UaS Not assigned D-sub connection (male) 15-pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Assignment

+5 V (UP) 0 V (UN) Ua1 Ua1 0V Ua2 Ua2 0V +5 V Ua0 0V Ua0 0V UaS Not assigned

Adapter connector TTL (SIEMENS)/ 1 VPP

Pin layout of D-sub connector (female) and D-sub connector (male): D-sub connector Assignment (female) 15-pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Not assigned 0V A+ A Not assigned B+ B Not assigned Not assigned R+ Not assigned R Not assigned Not assigned Not assigned D-sub connection (male) 15-pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Assignment Not assigned 0V Ua1 Ua1 Not assigned Ua2 Ua2 Not assigned Not assigned Not assigned Not assigned Ua0 Ua0 Not assigned Not assigned

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HEIDENHAIN Technical Manual iTNC 530

Adapter connector 11 APP / 1 VPP

Pin layout of D-sub connector (female) and D-sub connector (male): D-sub connector Assignment (female) 15-pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 +5 V (UP) 0 V (UN) A+ A 0V B+ B 0V +5 V R+ 0V R 0V Not assigned Not assigned D-sub connection Assignment (male) 15-pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 +5 V (UP) 0 V (UN) 0+ 0 0V 90+ 90 0V +5 V R+ 0V R 0V Not assigned Not assigned

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Adapters for Encoder Signals

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HEIDENHAIN Technical Manual iTNC 530

3.13 Motor Power Stage Connection


The iTNC 530 is connected with HEIDENHAIN or non-HEIDENHAIN inverters through a PWM interface. For a description of the HEIDENHAIN inverter systems, refer to the Technical Manual Inverter Systems and Motors. The components required for operation of the iTNC 530 with non-HEIDENHAIN inverter systems are described in the manual Technical Information for the Operation of SIMODRIVE and POWER DRIVE Inverter Systems. The individual PWM outputs of the CC 422 are assigned to different controller groups (see Maximum spindle speed on page 6 15 and PWM Frequencies of the CC 422 on page 326). The following applies to the output signals to the power stage: Logic level: Analog signals IACTL: PWM frequency: 5V 7.5 V MP2180.x can be used to set it at 3333 Hz, 4166 Hz, 5000 Hz, 6666 Hz, 8166 Hz and 10000 Hz

X51 to X64: PWM output

Pin layout: Ribbon connector, 20-pin 1a 1b 2a 2b 3a 3b 4a 4b 5a 5b 6a 6b 7a 7b 8a 8b 9a 9b 10a 10b Note The interface complies with the requirements of EN 61800-5-1 for protective extra-low voltage (PELV). Assignment PWM U1 0 V U1 PWM U2 0 V U2 PWM U3 0 V U3 SH2 0 V (SH2) SH1 0 V (SH1) +IIST 1 IIST 1 0 V (analog) +IIST 2 IIST 2 0 V (analog) BRK Do not assign ERR RDY

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3.14 Analog Input


The MC 42x(B), the PL 410B PLC I/O unit, and the PLA 4-4 (for PL 510) have analog inputs and inputs for Pt 100 thermistors. The PL 410 B is available with and without analog inputs. Analog inputs (10 V) MC 42x(B), X48 PL 405 B PL 410 B (263 371-02) PLA 4-4 (PLB 510) Analog inputs 3 4 4 Inputs for Pt 100 thermistors 3 4 4

Voltage range: Input resistance: Resolution (W480, W482, W484): Resolution (Module 9003, 9138):

Internal value range:

10 V to +10 V > 250 k 100 mV 10 mV (MC 42x(B)) 100 mV (PL 410B) 4.9 mV (PLA 4-4) 100 to +100, approx. resolution 100 mV 1000 to +1000, approx. resolution 10 mV 2040 to +2040, approx. resolution 4.9

mV Inputs for Pt 100 thermistors Constant current: Temperature range: Resolution (W486, W488, W490): Resolution (Module 9003, 9138): 5 mA 0 C to 100 C 0.5 C 0.1 C (MC 42x(B)) 0.5 C (PL 410B) 0.03 C (PLA 4-4) 0 to 200, at a resolution of 0.5 C 0 to 1000, at a resolution of 0.1 C 0 to 3333, at a resolution of 0.03 C

Internal value range:

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X48: Analog input (PLC) on the MC 42x(B)

Pin layout:

Warning Remember to connect the analog inputs with the correct polarity! D-sub connection (female) 25-pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 to 25 Housing Note The interface complies with the requirements of EN 61800-5-1 for protective extra-low voltage (PELV). Assignment I1+ Constant current for Pt 100 I1 Constant current for Pt 100 U1+ Measuring input for Pt 100 U1 Measuring input for Pt 100 I2+ Constant current for Pt 100 I2 Constant current for Pt 100 U2+ Measuring input for Pt 100 U2 Measuring input for Pt 100 I3+ Constant current for Pt 100 I3 Constant current for Pt 100 U3+ Measuring input for Pt 100 U3 Measuring input for Pt 100 Do not assign Analog input 1: 10 V to +10 V Analog input 1: 0 V (reference potential) Analog input 2: 10 V to +10 V Analog input 2: 0 V (reference potential) Analog input 3: 10 V to +10 V Analog input 3: 0 V (reference potential) Do not assign External shield

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Connection overview for the PL 410B

X15 to X18: Analog input on the PL 410 B

Pin layout Connecting terminals Assignment 1 2 3 Note The interfaces comply with the requirements of EN 61800-5-1 for protective extra-low voltage (PELV). 10 V to +10 V 0 V (reference potential) Shield

X19 to X22: Connection for Pt 100 on the PL 410B

Pin layout: Connecting terminals 1 2 3 4 5 Note The interfaces comply with the requirements of EN 61800-5-1 for protective extra-low voltage (PELV). Assignment I+ Constant current for Pt 100 U+ Measuring input for Pt 100 U Measuring input for Pt 100 I Constant current for Pt 100 Shield

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X15 to X18: Analog input on the PLA 4-4 analog module

Pin layout Connecting terminals Assignment 1 2 3 Note The interfaces comply with the requirements of EN 61800-5-1 for protective extra-low voltage (PELV). 10 V to +10 V 0 V (reference potential) Shield

X19 to X22: Connection for Pt 100 on the PLA 4-4 analog module

Pin layout: Connecting terminals 1 2 3 4 5 Note The interfaces comply with the requirements of EN 61800-5-1 for protective extra-low voltage (PELV). Assignment I+ Constant current for Pt 100 U+ Measuring input for Pt 100 U Measuring input for Pt 100 I Constant current for Pt 100 Shield

Connection of analog voltage

Characteristics of the connecting cable: Shielding 2 conductors with 0.14 mm Maximum length 50 meters
8

Connection of the Pt 100 thermistors

Configure the thermistor connection as a four-conductor circuit:

1 2 3 4 5

Measuring input Measuring input I

Pt100

Customer's cable 4 x 0.14 mm2 screened, max 30 m

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3.15 Analog Nominal Value Output


Output: Maximum load of outputs: Maximum capacity: 13 analog outputs are available: Connection X8: Analog outputs 1 to 6 Connection X9: Analog outputs 7 to 13 PLC analog output The PLC analog outputs can be controlled through Module 9130. 10 V 2 mA 2 nF

3.15.1 Nominal Value Output Please note: For analog axes and analog spindle, use MP120.x and MP121.x to assign the corresponding analog outputs on terminal X8 or X9 to the nominal speed outputs. The connecting cables to the nominal value outputs must not have more than one intermediate terminal. If you must branch to physically separate servo inputs, the connection must be made in a grounded terminal box, e.g. Id. Nr. 251 249-01 from HEIDENHAIN. The housing of the terminal box must be electrically connected with the frame of the machine. The 0-V connections of the nominal-value-difference inputs must be connected with the signal ground. Cross section 6 mm2 Use only original HEIDENHAIN cables and connecting elements.

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The following wiring plan is suggested for shielding the terminal box:

MC 42x(B) LE

Insulated from housing

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Lines are provided with end sleeves for strands

IV

Cable shielding is led to insulated wire of 0.14 mm by means of crimping rings.

Example for pin assignment in the terminal box: Connecting terminals 1 2 3 4 5 6 7 8 9 10 11 12 13 to 16 Shield connection Spindle nominal value Nominal value in axis 5 Nominal value in axis 4 Nominal value in Z axis Axis/Spindle Assignment 0V Nominal value in Y axis 10 V 0V 10 V 0V 10 V 0V 10 V 0V 10 V 0V

Nominal value in X axis 10 V

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X8: Analog output 1 to 6

For connecting cables, see Cable Overview at the end of this chapter. Pin layout on the MC 42x(B) and connecting cables: MC 42x(B) D-sub connctn. (female) 15-pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Housing Assignment Connecting cable D-sub connctr. (male) 15-pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Housing GY BL BK External shield Color

Analog output 1: 10 V Do not assign Analog output 2: 10 V Analog output 5: 10 V Analog output 3: 10 V Analog output 5: 0 V Analog output 4: 10 V Analog output 6: 10 V Analog output 1: 0 V Do not assign Analog output 2: 0 V Do not assign Analog output 3: 0 V Analog output 4: 0 V Analog output 6: 0 V External shield

BN BN/GN YL RD/BL PK GY/PK RD VI WH WH/GY GN

Note The interface complies with the requirements of EN 61800-5-1 for protective extra-low voltage (PELV). Danger Only units that comply with the requirements of EN 61800-5-1 for protective extra-low voltage (PELV) may be connected.

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X9: Analog outputs 7 to 13

For connecting cables, see Cable Overview at the end of this chapter. Pin layout on the MC 422(B) and connecting cables: MC 42x(B) D-sub connctn. (female) 15-pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Housing Assignment Connecting cable D-sub connctr. (male) 15-pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Housing GY BL BK External shield
a:

Color

Analog output 7: 10 V Analog output 13 10 V Analog output 8: 10 V Analog output 11: 10 V Analog output 9: 10 V Analog output 11: 0 V Analog output 10: 10 V Analog output 12: 10 V Analog output 7: 0 V Analog output Do not assign Analog output 9: 0 V Analog output 10: 0 V Analog output 12: 0 V External shield 13a: 0V Analog output 8: 0 V

BN BN/GN YL RD/BL PK GY/PK RD VI WH WH/GY GN

a. Only for MC 422B, but not for MC 422 Note The interface complies with the requirements of EN 61800-5-1 for protective extra-low voltage (PELV). Danger Only units that comply with the requirements of EN 61800-5-1 for protective extra-low voltage (PELV) may be connected.

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3.16 Touch Probe Systems


The following touch probes can be connected to the iTNC 530: TS 220, a touch-trigger probe with cable connection for workpiece setup and measurement during machining TS 440, TS 640, touch-trigger probes with infrared transmission for workpiece setup and measurement during machining TT 130, a touch probe for workpiece measurement For suitable connecting cables, see Cable Overview at end of chapter. 3.16.1 Triggering Touch Probe for Workpiece Measurement X12: Touch probe connection Note The interface complies with the requirements of EN 61800-5-1 for protective extra-low voltage (PELV). Pin layout for TS 220: MC 42x(B) Female 1 2 3 4 5 6 7 8 9 10 11 to 15 Hsg. Assignment 0 V (internal shield) Do not assign Ready Start +15 V 10% (UP), max. 100 mA +5 V 5% (UP), max. 100 mA Battery warning 0 V (UN) Trigger signal Trigger signala Do not assign External shield Adapter cable 274 543-xx Male 1 2 3 4 5 6 7 8 9 10 11 to 15 External shield Hsg. Hsg. a. Stylus at rest means logic level HIGH. GY BN/GN GY WH/GN GN YL 1 5 6 1 5 6 WH GN YL 3 2 3 2 BN PK 4 4 Color Pin TS 220 Pin Color

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Pin layout for TS 440, TS 640 with SE 640: MC 42x(B) Female 1 2 3 4 5 6 7 8 9 10 Assignment 0 V (internal shield) Do not assign Ready Start +5 V 5% (UP), max. 100 mA Battery warning 0 V (UN) Trigger signal Trigger signala 10 GN External shield 4 4 GN 7 8 BL WH 6 1 6 1 BL WH 3 4 GY YL BN 5 3 2 5 3 2 BN GY Adapter cable 310 197-xx Male Color 1 WH/BN 7 SE 640 TS 440, TS 640

Female Male Color

+15 V 10% (UP), max. 100 mA 5

11 to 15 Do not assign Hsg. External shield Hsg. Hsg. Hsg.

a. Stylus at rest means logic level HIGH. Pin layout for TS 440, TS 640 with SE 540: MC 42x(B) Female 1 2 3 4 5 6 7 8 9 10 Assignment Adapter cable 310 197-xx Male Color WH/BN 7 Adapter cable 517 375-xx Color Internal shield GY YL BN Female 7 TS 440, TS 640 7 SE 540

Female Male

0 V (internal shield) 1 Do not assign Ready Start 3 4

GY YL BN

5 3 2

5 3 2

5 3 2

+15 V 10% (UP), 5 max. 100 mA +5 V 5% (UP), max. 100 mA Battery warning 0 V (UN) Trigger signal Trigger signala 10 7 8

BL WH GN External shield

6 1 4

6 1 4

BL WH GN External shield

6 1 4

11 to 15 Do not assign Hsg. External shield Hsg. Hsg. Hsg. Hsg.

a. Stylus at rest means logic level HIGH.

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3.16.2 Triggering Touch Probe for Tool Measurement X13: Connection of the touch probe Pin layout on the MC 422(B):

Note The interface complies with the requirements of EN 61800-5-1 for protective extra-low voltage (PELV). Pin layout on adapter cable and touch probe: MC 42x(B) Female 1 2 3 4 5 6 7 8 9 Hsg. Assignment Ready 0 V (UN) Do not assign +15 V 5% (UP ) Do not assign Do not assign +5 V 5% (UP ) Trigger signal Trigger signal External shield
a

Adapter cable 335 332-xx Male 1 2 3 4 5 6 7 8 9 Hsg. BN GN External shield 3 4 7 Hsg. BN/GN 2 5 Color PK WH/GN Female 6 1

TT 130 296 537-xx Male Color 6 1 2 5 WH BN

3 4 7 Hsg.

GN YL

a. Stylus at rest means logic level HIGH.

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3.17 Data Interfaces


Please note: Maximum cable length with Ethernet 400 m (shielded), 100 m (unshielded) Maximum cable length with RS-232-C/V.24 is 20 meters. Maximum cable length with RS-422/V11 is 1000 meters. For connecting cables, see Cable Overview at the end of this chapter. General information Keep the following information in mind when connecting external peripheral devices to the data interfaces of the control: Wiring: The correct routing of the data cable is very important. The cable should not be located in the vicinity of power cables, except if appropriate protective measures are taken. Software: The use of non-HEIDENHAIN software may cause problems. The software supplier is responsible for the correct configuration of the control's data interfaces. Switch box: In many cases, a switch box is used to connect several control interfaces to a PC. The difference in potential of the machines may lead to fault currents causing damage to the interfaces. If you intend to install such a switch box, you should connect the interface of the control via a unit with electrical isolation to the switch box.

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X26: Ethernet interface RJ45 connection

Maximum data transfer rate: Approx. 2 to 5 Mbps (depending on file type and network utilization) Maximum cable length, shielded: 100 m RJ45 connection (female) 8-pin 1 2 3 4 5 6 7 8 Housing Face of the connector: Assignment TX+ TX REC+ Do not assign Do not assign REC Do not assign Do not assign External shield

Note The interface complies with the requirements of EN 61800-5-1 for protective extra-low voltage (PELV). Meanings of the LEDs on the Ethernet data interface X26: LED GN YL Status Blinks Off On Off Meaning Interface active Interface inactive 100-Mb network 10-Mb network

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X27, X127: RS-232-C/V.24 data interface

Pin layout:

Note The interface complies with the requirements of EN 61800-5-1 for protective extra-low voltage (PELV). 25-pin adapter block: MC 42x(B) Male 1 2 3 4 5 6 7 8 9 Hsg. Assignment Do not assign RXD TXD DTR Signal GND DSR RTS CTS Do not assign Conn. cable 365 725-xx Female 1 2 3 4 5 6 7 8 9 Extern al shield Hsg. Hsg. Hsg. Hsg. Externa Hsg. l shield YL GN BN RD BL GY PK Color Female 1 3 2 20 7 6 4 5 Adapter block Conn. cable 274 545-xx 310 085-01 Male Female Male 1 3 2 20 7 6 4 5 1 3 2 20 7 6 4 5 1 3 2 20 7 6 8 4 5 GY PK 5 4 Color YL GN BN RD VI Female 2 3 6 8 7 20 WH/BN 1

External shield Hsg.

9-pin adapter block: MC 42x(B) Male Assignment 1 2 3 4 5 6 7 8 9 Hsg. Do not assign RXD TXD DTR Signal GND DSR RTS CTS Do not assign Conn. cable 355 484-xx Female 1 2 3 4 5 6 7 8 9 Color RD YL WH BN BK VI GY WH/GN GN External shield Adapter block 363 987-02 Male 1 2 3 4 5 6 7 8 9 Hsg. 1 2 3 4 5 6 7 8 9 Hsg. Conn. cable 366 964-xx Female Color 1 2 3 4 5 6 7 8 9 Hsg. RD YL WH BN BK VI GY WH/GN GN External shield Female 1 3 2 6 5 4 8 7 9 Hsg.

Male Female 1 2 3 4 5 6 7 8 9 Hsg.

External shield Hsg.

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X28, X128: RS-422/V.11 data interface

Pin layout: MC 42x(B) Female 1 2 3 4 5 6 7 8 9 Hsg. Assignment RTS DTR RXD TxD 0V CTS DSR RxD TxD External shield Hsg. Note The interface complies with the requirements of EN 61800-5-1 for protective extra-low voltage (PELV). Conn. cable 355 484-xx Male 1 2 3 4 5 6 7 8 9 Color RD YL WH BN BK VI GY WH/GN GN External shield Female 1 2 3 4 5 6 7 8 9 Hsg. Adapter block 363 987-01 Male 1 2 3 4 5 6 7 8 9 Hsg. Female 1 2 3 4 5 6 7 8 9 Hsg.

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3.18 Handwheel Input


The following handwheels can be used with HEIDENHAIN contouring controls: HR 130 Panel-Mounted Handwheel HR 150 Panel-Mounted Handwheels via the HRA 110 handwheel adapter HR 410 or HR 420 portable handwheel X23: Handwheel input Pin layout: D-sub connection (female) 9-pin 1 2 3 4 5 6 7 8 9 Housing Note The interface complies with the requirements of EN 61800-5-1 for protective extra-low voltage (PELV). Assignment CTS 0V RTS +12 V Do not assign DTR TxD RxD DSR External shield

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3.18.1 HR 4xx Portable Handwheel The HR 4xx is a portable electronic handwheel. For the assignment of the keys of the HR 410 to the PLC inputs and outputs, see HR 410 Portable Handwheel on page 8 179. Pin layout Pin layout for the various extension cables, adapter cables, connecting cables, and the handwheel: Adapter cable Id. Nr. 296 466-xx Connecting cable see Chap. 2, Introduction." HR 4xx

Extension cable Id. Nr. 281 429-xx D-sub connector (male) 9-pin

D-sub D-sub connector cnnctr. (male) (female) 9-pin 9-pin

Cplg. on Cnnctr. (male) mntg. (5+7)-pin base (female) (5+7)pin


Housing Housing Shield

Cnnctr. Connector (female) (male) (5+7)(5+7)-pin pin

Housing

Shield

Housing

Housing

Shield

Housing

Housing Shield

2 4 6 7 8

WH BN YL GY GN

2 4 6 7 8

2 4 6 7 8

WH BN YL GY GN

E D B A C 6 7 5 4 2 3 1

E D B A C 6 7 5 4 2 3 1

WH BN YL GY GN BK RD/BL RD BL

E D B A C 6 7 5 4

E D B A C 6 7 5 4 2 3 1

WH/GN 2 BN/GN 3 GY/PK 1

WH/BN 3 WH/YL 2 WH/GN 1 WH/BL 1 WH/RD 2 YL/BK 3 WH/BK 4 Note

Contacts 1 + 2 Contact 2 (left) permissive button Contact 1 (right) Contact 1 Contact 1 EM. STOP Contact 2 Contact 2

The interfaces comply with the requirements of EN 61800-5-1 for protective extra-low voltage (PELV). Danger Only units that comply with the requirements of EN 61800-5-1 for protective extra-low voltage (PELV) may be connected.

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The adapter includes plug-in terminal strips for the contacts of the EMERGENCY STOP button and permissive button (max. load 24 Vdc, 1.2 A). The plug-in terminal strips are supplied together with the adapter cable. If you have an immediate need for these terminal strips, they can be ordered in advance. See the Additional components table below. Internal wiring of the contacts for the EMERGENCY STOP and permissive buttons:

Additional components Dummy plug for EMERGENCY STOP circuit Connecting cable Spiral cable Normal cable Metal armor tubing Plug-in terminal strips for advance ordering 3-pin terminal block 4-pin terminal block

Id. Nr. 271 958-03 312 879-01 296 467-xx 296 687-xx

266 364-06 266 364-12

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3.18.2 HR 130 Panel-Mounted Handwheel Standard cable length for the HR 130 is 1 meter. Pin layout for extension cable a