HEIDENHAIN MANUALplus 620 Manual
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HEIDENHAIN MANUALplus 620 Manual

The contouring control for cnc and cycle lathes
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MANUALplus 620
The Contouring Control for CNC
and Cycle Lathes
Information for the
Machine Tool Builder
April 2016

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Summary of Contents for HEIDENHAIN MANUALplus 620

  • Page 1 MANUALplus 620 The Contouring Control for CNC and Cycle Lathes Information for the Machine Tool Builder April 2016...

  • Page 2: Contouring Control With Drive System From Heidenhain

    In these cases, comprehensive tests of the complete system are required, irrespective of the specifications of the individual devices. In particular the following parts in controls from HEIDENHAIN are Expendable parts subject to wear: •...

  • Page 3: Table Of Contents

    Contents Contouring control with drive system from HEIDENHAIN Overview tables HSCI control components Accessories Cable overview Technical description Data transfer and communication Mounting information Overall dimensions General information Other HEIDENHAIN controls Subject index Please refer to the page references in the tables with the...

  • Page 4: Overview Tables

    ✓ Connecting cables For further information, refer to the Inverter Systems for HEIDENHAIN Controls brochure May be necessary depending on the configuration Please note: The MC main computer does not have any PLC inputs/outputs. Therefore one PL 6000 or one UEC is necessary for each...
  • Page 5 Accessories Accessories MANUALplus 620 Page • Electronic handwheels HR 180 panel-mounted handwheels for connection to position inputs, plus • HR 130 panel-mounted handwheel or • Up to three HR 150 via HRA 110 handwheel adapter, or • HR 510 portable handwheel •...

  • Page 6: Specifications

    Screw pitch [mm] No. of motor pole pairs at f = 5000 Hz ✓ Constant surface speed Input mm/min or mm/revolution For further information, refer to the MANUALplus 620 (ID 634865-xx) brochure As ordered On motors with two pole pairs...
  • Page 7 In electrical cabinet: 5 °C to 40 °C In operating panel: 0 °C to 50 °C Storage: –20 °C to 60 °C For further information, refer to the MANUALplus 620 (ID 634865-xx) brochure As ordered On motors with two pole pairs...
  • Page 8 Interfacing to the machine Interfacing to the machine MANUALplus 620 Page ✓ Error compensation ✓ Linear axis error ✓ Nonlinear axis error ✓ Backlash ✓ Hysteresis, reversal spikes ✓ Thermal expansion ✓ Integrated PLC Program format Statement list Program input at the control By external USB keyboard ✓...
  • Page 9 Interfacing to the machine MANUALplus 620 Page Commissioning and diagnostic aids DriveDiag Software for diagnosis of digital drive systems TNCopt Software for putting digital control loops into service ConfigDesign Software for creating the machine configuration ✓ Integrated oscilloscope ✓ Trace function ✓...
  • Page 10 User functions User function MANUALplus 620 ✓ Basic version: X and Z axis, spindle Short description Driven tool and auxiliary axes (U, V, W) 55+0-6 C axis and driven tool 70+0-6 Y axis 54+0-6 B axis 94+0-6 Parallel axes U, V, W (display function and compensation)
  • Page 11 User function MANUALplus 620 Interactive Contour Contour definition with linear and circular contour elements Immediate display of entered contour elements Programming (ICP) Calculation of missing coordinates, intersections, etc. Graphic display of all solutions for selection by the user if more than one solution is possible...
  • Page 12 User function MANUALplus 620 ✓ DIN PLUS Programming in DIN 66025 format ✓ Expanded command format (IF ... THEN ... ELSE ...) programming ✓ Simplified geometry programming (calculation of missing data) ✓ Powerful fixed cycles for area clearance, recessing, recess turning and thread machining...
  • Page 13 User function MANUALplus 620 ✓ Tool database For 250 tools For 999 tools ✓ Tool description can be entered for every tool ✓ Automatic inspection of tool-tip position with respect to the contour ✓ Compensation of tool-tip position in the X/Y/Z plane ✓...
  • Page 14 • Determining tool-setting dimensions with an optical gauge • Automatic workpiece measurement with a workpiece touch probe HEIDENHAIN DNC ID 526451-01 Communication with external PC applications over COM component Gantry axes ID 634621-01 Gantry axes in master-slave torque control...
  • Page 15 Option Option As of NC Comment Page number software 54843x- Parallel axes ID 679676-01 Support of parallel axes (U, V, W) Combined display of principal axes and secondary axes 101 - 130 OEM option ID 579651-01 Options of the machine tool builder ID 579651-30 Spindle ID 806270-01...

  • Page 16: Hsci Control Components

    CFR memory card with the NC software • The System Identification Key component(SIK) holds the NC software license for enabling control loops and software options. The following HSCI components are necessary for operation of the MANUALplus 620: • MC main computer • Controller unit •...
  • Page 17 Options The capabilities of the MANUALplus 620 can also be adapted retroactively with options to meet new requirements. These options are described on page 14. They are enabled by entering keywords based on the SIK number, and are saved in the SIK component.
  • Page 18 NC software There are always three control loops enabled in the basic version. The controller unit must be designed for the corresponding license and enabling of number of activated control loops. Maximum numbers: control loops • UEC 111: 4 control loops •...
  • Page 19 SIK for purely A special SIK is available for systems with purely analog drives on the basis of the HSCI platform. analog drive systems Please note: The SIK is functional as of NC software 548431-04. The following components are required: •...
  • Page 20 Controller unit Due to the very short cycle times of the position, speed and current controllers, the controller units from HEIDENHAIN are equally suited for conventional drives, for direct drives (linear motors, torque motors) and for HSC spindles. They permit a high...
  • Page 21 CC 61xx The CC 61xx controller units feature: • Position controller, speed controller, current controller • HSCI interfaces • PWM interfaces to the UM, UR, UE power modules • Interfaces to the speed and position encoders • Interfaces for power supply (via inverter)) •...
  • Page 22 UEC 11x The UEC 11x compact inverters not only include the inverter, but also a controller with PLC inputs and outputs and an integrated braking resistor. They form a complete solution for machines with a limited number of axes and low power demands. Controllers •...
  • Page 23 UEC 111/UEC 112/UEC 113 Controllers 4/5/6 digital control loops Speed inputs 4/5/6 x 1 V or EnDat 2.2 Position inputs 4/5/6 x 1 V or EnDat 2.2 Inverters 2/3/4 axes 1 axis Spindle Rated current I 3333 Hz 6.0/12.0 A 9.0/18.0 A 24.0/36.0 A Maximum current I...
  • Page 24 KTY adapter The adapter connector makes it possible for applications with connector purely serial EnDat 2.2 encoders to connect an external KTY temperature sensor (e.g. of linear and torque motors) and lead it to the speed encoder input of the controller unit. The adapter connector can also be used in conjunction with encoders with EnDat02 or 1 V interface.
  • Page 25 Machine operating panel • MB 720T Voltage supply: DC 24 V/≈ 4 W • 36 exchangeable snap-on keys with status LEDs, of which 16 are not labeled, freely definable via PLC • Operating elements: Keys preassigned through the PLC basic program: Control voltage on ;...
  • Page 26 PL 6000 PLC input/output systems with HSCI PL 6000 The PLC inputs and outputs are available via external modular PL 6000 PLC input/output systems. They consist of a basic module and one or more input/output modules. A total maximum of 1000 inputs/outputs is supported. The PL 6000 units are connected to the MC main computer via the HSCI interface.
  • Page 27 I/O modules for There are I/O modules with digital and analog inputs and outputs. HSCI For partially occupied basic modules, the unused slots must be occupied by an empty housing. PLD-H 16-08-00 I/O module with 16 digital inputs and ID 594243-xx 8 digital outputs I/O module with 8 digital inputs and ID 650891-xx...

  • Page 28: Accessories

    Power supply for HSCI components PSL 13x To power the HSCI components, HEIDENHAIN offers the PSL 13x power supply unit. Either line voltage and DC-link voltage or only line voltage is provided to the PSL 13x. The PSL 13x provides the safely separated DC 24 V NC power supply required for the HSCI components by EN 61 800-5-1.
  • Page 29 PLB 600x The PLB 600x HSCI adapter is required in order to connect an OEM-specific machine operating panel to the MANUALplus 620 The spindle-speed and feed-rate override potentiometers of the TE 7xx and the HR handwheel are also connected to these adapters.
  • Page 30 Additional modules Overview The additional modules are directly connected to the HSCI control system through a slot on the MC main computer. Module for analog Digital drive designs sometimes also require analog axes or axes spindles. The additional module CMA-H 04-04-00 (Controller Module Analog—HSCI) makes it possible to integrate analog servo drives in an HSCI system.
  • Page 31 Workpiece The TS touch trigger probes have a stylus for probing workpieces. measurement The HEIDENHAIN controls provide standard routines for datum setting and workpiece measurement and alignment. The touch probes are available with various taper shanks. Assorted styli are available as accessories.
  • Page 32 The measurement MANUALplus 620 has standard routines. The MANUALplus 620 automatically saves the results of measurement in a tool table. It is also possible to measure tool wear between two machining steps.
  • Page 33 Electronic handwheels Overview The standard MANUALplus 620 supports the use of electronic handwheels. • Up to two HR 180 panel-mounted handwheels for connection to the position inputs In addition, the MB machine operating panel or the PLB 6001 HSCI adapter can be connected with: •...
  • Page 34 HR 130 Panel-mounted handwheel with ergonomic control knob. It is attached to the MB 7x0 or the TE 7x5 either directly or via an extension cable. HR 130 Without detent ID 540940-03 With detent ID 540940-01 ≈ 0.7 kg Mass HR 130 HR 150 Panel-mounted handwheel with ergonomic control knob for...
  • Page 35 Snap-on keys for HR Snap-on keys The snap-on keys make it easy to replace the key symbols. In this way, the HR handwheel can be adapted to different requirements. The snap-on keys are available in packs of 5 keys. Overview for HR 410...
  • Page 36 Overview of HR 510...
  • Page 37 Snap-on keys for control Snap-on keys The snap-on keys make it easy to replace the key symbols. In this way, the keyboard can be adapted to different requirements. The snap-on keys are available in packs of 5 keys. Overview of control keys Keys Or an g e Gr ay...
  • Page 38 Spindle functions Gr een Gr een Other keys Bl ac k Bl ac k ID 679843-F4 Or an g e Bl ac k ID 679843-F5 Bl ac k ID 679843-F6 Gr een Special keys Snap-on keys with customized symbols for special applications can also be manufactured.

  • Page 39: Cable Overview

    Cable overview Control system with UEC...
  • Page 40 Control system with CC...
  • Page 41 Encoders...
  • Page 42 Inverter system...
  • Page 43 Accessories...

  • Page 44: Technical Description

    CC or UEC controller units, up to nine PL 6000 input/output modules, and an MB machine operating panel (e.g. MB 720 from HEIDENHAIN) can be connected to the serial HSCI bus of the MC main computer.  The HR handwheel is connected directly to the machine operating panel.
  • Page 45 The maximum permissible number of individual HSCI participants is listed below. HSCI components Maximum number HSCI master 1 in the system CC, UEC, UMC HSCI slave 4 controller motherboards (distributed to CC, UEC, UMC as desired) HSCI slave 2 in the system MB, PLB 6001 HSCI slave 7 in the system...
  • Page 46 Display of PDF files. Drawings, work instructions, etc. can be opened directly on the control. • Direct Internet access from the MANUALplus 620 thanks to the integrated browser. The browser can be run in a Sandbox to increase data security.
  • Page 47 Axes Overview The MANUALplus 620 is a contouring control for lathes with one spindle and a slide (X, Z and Y) for tool movement. For rear-face machining of the workpiece, an optional counter spindle can be operated in addition to the main spindle.
  • Page 48 Synchronized axes move in synchronism and are programmed with the same axis axes (option 24) designation. With HEIDENHAIN controls, parallel axis systems (gantry axes) such as on portal-type machines or tilting tables can be moved synchronously to each other through high-accuracy and dynamic position control. ...
  • Page 49 Position- The position of the spindle is monitored by the control. controlled spindle Encoder HEIDENHAIN rotary encoder with sinusoidal voltage signals (1 V or EnDat interface. C-axis machining For milling, drilling and boring cycles, either the spindle or counter (option 55) spindle is switched to C-axis operation, or a separate C-axis drive is activated.
  • Page 50 Constant shaft speed: 1 to 99  9 99 rpm • Constant surface speed: 1 to 9  9 99 m/min • Spindle speed limi- The MANUALplus 620 monitors the actual speed. • tation Speed limiting can be adjusted via parameter and in the feed- rate/spindle/tool menu (TSF menu).
  • Page 51 Additional incremental signals are output for highly dynamic control loops. EnDat interface The MANUALplus 620 features the serial EnDat 2.2 interface (includes EnDat 2.1) for the connection of absolute encoders. Note: The EnDat interface on HEIDENHAIN encoders differs in its pin assignment from the interface on Siemens motors with integrated absolute ECN/EQN rotary encoders.
  • Page 52 Position controllers, speed controllers, current controllers and inverters are integrated in the MANUALplus 620. HEIDENHAIN synchronous or asynchronous motors are connected to the MANUALplus 620. The MANUALplus 620 can be operated with following error or Axis feedback control feedforward control.
  • Page 53 Smoothed jerk The jerk is smoothed by nominal position value filters. The MANUALplus 620 therefore mills smooth surfaces at the highest possible feed rate and yet keeps the contour accurate. The operator programs the permissible tolerance in a cycle. Special filters for HSC machining (HSC filters) can specifically suppress the natural frequencies of an individual machine.
  • Page 54 Tool wear If the load and/or the load integral exceed the limit value for tool wear, the MANUALplus 620 marks the current tool as worn out. With active tool life monitoring the tool will automatically be replaced by a defined replacement tool the next time it is called.
  • Page 55 To compensate thermal expansion, the machine’s expansion expansion behavior must be known. The temperature can be recorded via thermistors connected to the analog inputs of the MANUALplus 620. The PLC evaluates the temperature information and transfers the compensation value to the NC. Load Adaptive...
  • Page 56 Optimization of the k factor (automatic) • Circular interpolation test, contour test The online monitor is a component part of the MANUALplus 620 Online Monitor (OLM) and is called over a code number. It supports commissioning and diagnosis of control components by: •...
  • Page 57 Oscilloscope The MANUALplus 620 features an integrated oscilloscope. Both X/t and X/Y graphs are possible. The following characteristic curves can be recorded and stored in six channels: • Actual value and nominal value of the axis feed rate • Contouring feed rate •...
  • Page 58 Integrated PLC Overview The PLC program is created by the machine manufacturer either at the control or with the PLC development software PLCdesign (accessory). Machine-specific functions are activated and monitored via the PLC inputs/outputs. The number of PLC inputs/ outputs required depends on the complexity of the machine. PLC inputs/ PLC inputs and outputs are available via the external PL 6000 PLC outputs...
  • Page 59 Python OEM The Python OEM Process option is an effective tool for the machine tool builder to use an object-oriented high-level process (option 46) 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.
  • Page 60 Touch probe All touch-probe data can be configured conveniently through a configuration table. All HEIDENHAIN touch probe systems are preconfigured and can be selected through a drop-down menu. Magazine The magazine management provides several functions for various...

  • Page 61: Data Transfer And Communication

    25-pin ID 310085-xx The MANUALplus 620 The TNC 640 features USB ports for the connection of standard USB devices, such as a mouse, drives, etc. On the back panel of the MC 7xxx there are 4 USB 3.0 ports. One easily accessible USB 2.0 port is on the front of the unit.
  • Page 62 USB hub If you need further USB ports or if the supply current is not sufficient, a USB hub is required. The USB hub from HEIDENHAIN offers four free USB 2.0 ports. USB hub ID 582884-xx Voltage supply: DC 24 V/max. 300 mA...
  • Page 63 (option 18) an external PC application can evaluate data from the control and, if required, influence the manufacturing process. To enable you to use HEIDENHAIN DNC effectively, HEIDENHAIN RemoTools SDK (accessory) offers the RemoTools SDK development package. It contains the COM components and the ActiveX control for integration of the DNC functions in development environments.

  • Page 64: Mounting Information

    IP54 (dust and splash-proof protection) in order to fulfill the requirements of contamination level 2.  All components of the OEM operating panel must also comply with protection class IP 54, just like the HEIDENHAIN operating panel components.
  • Page 65 • Shielding according to EN 50 178 • Use equipotential bonding conductors with a cross section of 6 mm • Use only genuine HEIDENHAIN cables and connecting elements...

  • Page 66: Overall Dimensions

    Overall dimensions Main computer MC 7410T Front panel opening Mounting surface Space for air circulation...
  • Page 67 Controller unit CC 6106...
  • Page 68 CC 6108, CC 6110 CC 6108: 8 control loops CC 6110: 10 control loops...
  • Page 69 UEC 111, UEC 112, UEC 113...
  • Page 70 Screen and keyboard MB 720T Front panel opening Mounting surface PLB 600x...
  • Page 71 PLC inputs and outputs PL 6000 (PLB 62xx, PLB 61xx) Space for air circulation...
  • Page 72 Power supply units PSL 130 PSL 135...
  • Page 73 Electronic handwheels HR 510 Adapter cable for HR 510 Mounting opening for wall thickness up to S = 4 Mounting opening for wall thickness from S = 4...
  • Page 74 HR 130, HR 150, HR 180 with control knob...
  • Page 75 HRA 110 Handwheel selection switch...
  • Page 76 Interface accessories Line-drop compensator for encoders with EnDat interface Connection to KTY USB hub Cover cap (accessory) Mounting surface...
  • Page 77 USB extension cable with hubs Ordering length KTY adapter connector Leave space for connecting cable!
  • Page 78 Touch probe TT 160 with cuboid probe contact...

  • Page 79: General Information

    General information Documentation • Technical MANUALplus 620 Technical Manual ID 747323-xx • documentation Inverter Systems and Motors Technical Manual ID 208962-xx • TS 260 Mounting Instructions ID 808652-9x • TS 460 Mounting Instructions ID 808653-9x • TS 444 Mounting Instructions ID 632757-9x •...
  • Page 80 HEIDENHAIN offers the machine manufacturer technical support to optimize the adaptation of the TNC to the machine, including on-site support. Replacement In the event of a fault, HEIDENHAIN guarantees the rapid supply of a replacement control system (usually within 24 hours in control system Europe).

  • Page 81: Other Heidenhain Controls

    Contouring control for milling/turning machines and machining centers • Up to 18 axes and closed-loop main spindle • HEIDENHAIN inverter systems and motors recommended • Uniformly digital with HSCI interface and EnDat interface • TFT color flat-panel display, 19-inch or 15-inch •...

  • Page 82: Subject Index

    Subject index Mounting and electrical installation..64 Absolute encoders......51 Feedforward control......52 Accessories........... 5 Field bus systems....... 30 Additional modules......30 following error........52 Nonlinear error........55 API DATA..........57 Axes........... 47 Axis feedback control......52 Gantry axes......... 48 Online Monitor........
  • Page 83 Spindle synchronism......50 Static friction........55 Synchronized axes....... 48 System PL.......... 26 Table function........57 TeleService ........57 Thermal expansion......55 TNCkeygen......... 17 TNCopt ..........56 TNCremoPlus ....... 62, 62 TNCscope .......... 57 Tool carriers......... 47 Tool measurement......32 Torque control....... 48, 48 Touch probes........
  • Page 84 Vollständige und weitere Adressen siehe www.heidenhain.de For complete and further addresses see www.heidenhain.de HEIDENHAIN Vertrieb Deutschland FARRESA ELECTRONICA S.A. 83301Traunreut, Deutschland 08028 Barcelona, Spain 02-384 Warszawa, Poland  08669 31-3132 www.farresa.es www.heidenhain.pl  08669 32-3132 E-Mail: hd@heidenhain.de HEIDENHAIN Scandinavia AB FARRESA ELECTRÓNICA, LDA.

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