Teach-in mode

Program run Setup functions 17 Programming Cycle programming 8 8+55 8+55 8+55 8+55 8+8+9 Interactive Contour Programming (ICP) 8/9 8/9 8/9 8/9 8/9 8/9 8/9

Standard

User functions

ICP (continued)

8/9+55 C-axis machining on face and lateral surface: Description of individual holes and hole patterns (only in smart.Turn) Description of gures and gure patterns for milling (only in smart.Turn) Creation of freely denable milling contours 9+70 Y-axis machining on the XY and ZY planes (only in smart.Turn): Description of individual holes and hole patterns Description of gures and gure patterns for milling Creation of freely denable milling contours 8/9+42 DXF import: Import of contours for lathe and milling operations The basis is the unit, which is the complete description of a machining block (geometry, technology and cycle data) Dialog boxes divided into overview and detail forms 9 Fast navigation between the llable forms and input groups via the smart keys 9 Context-sensitive help graphics 9 Start unit with global settings 9 Transfer of global values from the start unit 9 Transfer of cutting values from technology database 9 Units for all turning and recessing operations for simple contours and ICP contours 9 9+55/70 Units for boring, drilling and milling operations with the C and Y axes for simple holes, milling contours and drilling and milling patterns or those programmed with ICP 9+55 Special units for activating/deactivating the C axis, subprograms and section repeats Verication graphics for blank and nished part and for C and Y axis contours 9 Turret assignment and other setup information in the smart.Turn program 9 Parallel programming 9 Parallel simulation Programming in DIN 66025 format Extended command format (IF THEN. ELSE.). Simple geometry programming (calculation of missing data) Powerful machining cycles for turning, recessing, recess turning and thread machining Powerful machining cycles for boring, drilling and milling with the C axis Powerful machining cycles for boring, drilling and milling with the Y axis Subroutines Programming with variables Contour description with ICP Program verication graphic for workpiece blank and nished part Turret assignment and other setup information in the DIN PLUS program Conversion of smart.Turn units into DIN PLUS command sequences Parallel programming Parallel simulation Graphic simulation of the cycle process or of the cycle, smart.Turn or DIN PLUS program Display of the tool paths as wire-frame or cutting-path graphics, special identication of the rapid-traverse paths Machining simulation (2-D material-removal graphic) Side or face view, or 2-D view of cylindrical surface for verication of C-axis machining Display of programmed contours View of face and YZ plane for verication of Y-axis machining Three-dimensional display of the workpiece blank and nished part Shifting and magnifying functions Calculation of machining time and idle machine time Consideration of switching commands triggered by the CNC Representation of times per individual cycle or per tool change

smart.Turn programming

DIN PLUS programming
8/9 9 Program verication graphics Machining time analysis

Option 55 70

Standard

Tool database

For 250 tools 10 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 Precision path correction via handwheel, transferring compensation values to the tool table Automatic tool-tip and cutter radius compensation Tool monitoring for lifetime of the insert (tool tip) or the number of workpieces produced 10 Tool monitoring with automatic tool change after tool insert wear Management of multipoint tools (multiple inserts or reference points) 8/9 Access to cutting data after denition of workpiece material, cutting material and machining mode. The MANUALplus distinguishes between 16 machining modes. Each workpiecematerial/tool-material combination includes the cutting speed, the main and secondary feed rates, and the infeed for 16 machining modes. 8/9 Automatic determination of the machining modes from the cycle or the machining unit 8/9 The cutting data are entered in the cycle or in the unit as default values 8/workpiece-material/tool-material combinations (144 entries) workpiece-material/tool-material combinations (992 entries) Chinese (simplied), Chinese (traditional), Czech, Danish, Dutch, English, Finnish, French, German, Hungarian, Italian, Polish, Portuguese, Russian, Spanish, Swedish 41 For more conversational languages, see Option

Technology database

Conversational languages

Options

Option number

Comment

Additional axis
354 540-904-905-867-226-01
Additional control loops 1 to 4
Software option 1 Teach-in
Cycle programming Contour description with ICP Cycle programming Technology database with 9 workpiece-material/tool-material combinations smart.Turn Contour description with ICP Programming with smart.Turn Technology database with 9 workpiece-material/tool-material combinations Tools and technology Tool database expanded to 999 entries Technology database expanded to 62 workpiece-material/tool-material combinations Tool life monitoring with exchange tools Threads Thread recutting Handwheel superimposition during thread cutting Tool measurement and workpiece measurement Determining tool-setting dimensions with a tool touch probe Determining tool-setting dimensions with an optical gauge Automatic workpiece measurement with a touch probe Slovenian Slovak Latvian Norwegian Korean Estonian Turkish Romanian Lithuanian DXF import Import of DXF contours C-axis machining Y-axis machining Support of W axis
Software option 2 smart.Turn

632 227-01

Software option 3 Tools and technology

632 228-01

Software option 4 Thread cutting

632 229-01

HSCI MC main computer PLC inputs/ outputs PL

CC controller unit

Touch probe
HSCI Control System MANUALplus 620 Overview
The MANUALplus 620 contouring control consists of the following components:
Type MANUALplus 620 Main computer ,, with 12.1 screen Memory card MC 6110 T

Page 15

NC software license SIK component Power supply unit PSL 130 (as required) PSL 130 PSL 135 (for use with non-HEIDENHAIN inverter systems) Controller unit Control loops PLC inputs/ outputs System PL Expansion PL Connecting cables Accessories Machine operating MB 620 T panel Electronic handwheels Touch probes HR 410, HR 180, HR 130 or HR 150 UEC 1111) Max. 4 PL 6xxx series Integrated Max. 7 PLB 610x UEC 112 Max. 5
CC 6106 CC Max. 6 Max. 8 PL 6xxx series One PLB 620x Max. 7 PLB 610x 19
PL 6xxx series Integrated Max. 7 PLB 610x
TS 220 or TS 440 or TS 444 or TS 640 or TS 740 TT 140
Inverter and system PL integrated

Main Computer

Main computer
The MC 6110 T main computer consists of 1.0 GHz Celeron M processor 1 GB RAM memory MANUALplus control panel 12.1-inch TFT color at-panel display with soft keys, resolution: 1024 x 768 pixels HSCI interface to the controller unit and to other control components Further interfaces, such as Ethernet, USB, RS-232-C/V.24 To be ordered separately, and installed in the main computer by the OEM: CFR memory card with the NC software SIK component (System Identication Key) for enabling control loops and options The following HSCI components are necessary for operation of the MANUALplus 620: PL 62xx PLC input/output unit (system PL; integrated in UEC 11x)

MC 6110 T

Weight ID

5.6 kg 731 604-xx

Power supply
If a CC 610x controller unit is used, the PSL 130 supplies 24 V of power to the main computer and other HSCI components. If a UEC controller unit is used, a PSL 130 is only required if the current consumption is greater than 3.5 A.
The capabilities of the MANUALplus 620 can also be adapted retroactively with options to meet new requirements. These options are described on page 11. They are enabled by entering keywords based on the SIK number, and are saved in the SIK component. Please indicate your SIK number when ordering new options.

Axes: Spindle: 1st value: 2nd value:

0.2 s 10 s 40 % 4s

Cyclic duration factor for duty cycle time of 10 s with 70 % rated current preload Cyclic duration factor for duty cycle time of 60 s with 70 % rated current preload Cyclic duration factor for duty cycle time of 10 minutes (S6-40 %) Cyclic duration factor for duty cycle time of 20 s
PL 6xxx PLC Input/Output Systems with HSCI
The PLC inputs and outputs are available via external modular PL 6xxx PLC input/output systems. These consist of a basic module and one or more I/O modules, and are connected to the MC main computer via the HSCI interface. The PL 6xxx units are congured with the PC software IOcong. Basic modules There are basic modules with HSCI interface available for 4, 6 or 8 I/O modules. They are mounted on standard NS 35 rails (DIN or EN 50 022). Supply voltage 24 V Power consumption Approx. 20 W Weight 0.36 kg (bare) One required per control system Includes connections for TS touch probes (except with UEC) Safety-relevant inputs/outputs For 4 I/O modules For 6 I/O modules For 8 I/O modules ID 591 832-01 ID 630 054-01 ID 630 055-01 PL 62xx
PLB 6204 PLB 6206 PLB 6208 Expansion PL
For connection to the system PL to increase the number of PLC inputs/outputs For 4 I/O modules For 6 I/O modules For 8 I/O modules ID 591 828-01 ID 630 058-01 ID 630 059-01
PLB 6104 PLB 6106 PLB 6108
Up to eight PL 6xxx units can be connected to the control (one PLB 62xx or UEC 11x and up to seven PLB 61xx). The maximum cable length results from the maximum permissible length of the HSCI chain of 100 m. I/O modules With HSCI interface: There are I/O modules with digital and analog inputs and outputs. For partially occupied basic modules, the unused slots must be occupied by an empty housing. I/O module with 16 digital inputs and 8 digital outputs I/O module with 8 digital inputs and 16 digital outputs Total current Power output Weight PLD-H 16-08-00 PLD-H 08-16-00 PLA-H 08-04-04 Outputs 0 to 7: 8 A per output ( 8 A simultaneously) Max. 200 W 0.2 kg ID 594 243-01 ID 650 891-01

PL 61xx

PLD-H 16-08-00 PLD-H 08-16-00
Analog module for PL 6xxx with 8 analog inputs for 10 V 4 analog outputs for 10 V 4 analog inputs for PT 100 thermistors Weight ID 0.2 kg 675 572-01

Empty housing

For unused slots ID 383 022-01

IOcong (accessory)

PC software for conguring the PL 6xxx and PL 550 (PROFIBUS-DP) components
Power Supply for HSCI Components
To power the HSCI components HEIDENHAIN offers the PSL 13x power supply units. The PSL 13x is provided either with line and DC-link voltage or only with line voltage. The PSL 13x provides the safely separated +24 volt NC power supply required for the HSCI components by EN 61 800-5-1. The NC and PLC are powered by two separate, metallically isolated power supply units. Supply voltage Line voltage: 400 V~ 10 % 50 Hz, and DC-link voltage 400 V to 750 V Power consumption: Max. 1000 W NC: 24 V/ 20 A (double isolation) 5 V/ 16 A (only with PSL 135) electrically connected with 24 V NC 24 V/ 20 A (basic isolation) Max. 32 A/750 W

PSL 130

Outputs

PLC: Total:

The PSL 130 serves as a 24-V power supply unit for supplying the HSCI components. If a UEC controller unit is used, then the PSL 130 is not necessary if the total current consumption of the connected HSCI components does not exceed 3.5 A. HSCI component MC 6120 TE 615 QT PL 62xx PL 61xx (incl. TS and TT) 1.8 A 1.1 A 0.5 A 0.2 A

Current consumption

When a non-HEIDENHAIN inverter system is used (e.g. Siemens SIMODRIVE 611 D), the PSL 135 power supply unit is required for supplying the CC controller unit and the MC main computer. Module width Degree of protection PSL 130 PSL mm 50 mm IP 20 IP 20 Weight ID PSL 135 2.1 kg 2.5 kg 575 047-xx 627 032-xx

Conductor bars

For connecting the PSL 130 to the dc-link voltage. If the 24 V power supply unit PSL 130 is arranged to the left next to the UV(R) 1xx D or UE 2xx D/UR 2xx D, it can be connected directly to the DC link through special conductor bars. The conductor bars are insulated. The +Uz bar is red and the Uz bar is blue. The following lengths are available: Length 150 mm (UVR 120 D/130 D/UV 130) 200 mm (UVR 140 D/150 D/UE 21x D) 250 mm (UVR 160 D/UR 2xx D) Red 682 996-01 Blue 682 996-51

682 996-996-996-996-53

Accessories Machine Operating Panel
Machine operating panel MB 620 T 21 exchangeable snap-on keys, freely denable via PLC Operating elements: 12 axis keys, 16 function keys, NC start1), NC stop1), spindle start, spindle stop (all are snap-on keys; see Snap-On Keys); emergency stop button, control voltage on1); 2 holes for additional keys or detachable-key switch HSCI interface 8 PLC inputs and 8 PLC outputs Spindle-speed and feed-rate override potentiometers Weight ID 0.9 kg 737 610-01

MB 620 T

Power supply: 24 V, current consumption: 1 A Conguration of the PLC inputs/outputs with the IOcong PC software

Keys illuminated

HSCI adapter
For the OEM machine operating panel. The PLB 6001 HSCI adapter is required in order to connect an OEM-specic machine operating panel to the iTNC 620 HSCI. The override potentiometers of the TE 6xx and the HR xxx handwheel for spindle speed and feed rate are also connected to this adapter.

PLB 6001

HSCI interface Connection for HR xxx Terminal for 64 inputs and 32 outputs (inputs/outputs for keys/ key illumination) Connection for spindle speed override and feed-rate override Screw fastening or DIN-rail mounting Conguration of the PLC inputs/outputs with the IOcong PC software Weight ID Approx. 1.2 kg 668 792-01

Electronic Handwheels

The standard MANUALplus 620 supports the use of electronic handwheels. The following handwheels can be installed: For connection to the position inputs, up to two HR 180 panel-mounted handwheels For connection to the handwheel input of the MB machine operating panel or the PLB 6001 HSCI adapter, one HR 410 portable handwheel, or one HR 130 panel-mounted handwheel, or up to three HR 150 panel-mounted handwheels through the HRA 110 handwheel adapter Any combination is possible. Cycle machines, for example, typically use HR 180 andif requiredone HR 410, or if there are not enough position inputs, up to three HR 150 handwheels via the HRA 110 handwheel adapter. CNC machines usually require only one HR 130 or HR 410.

TS 220

TS 640

TS 740

TT 140

Cuboid probe contact

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

Axis keys Orange

ID 330 816-42 ID 330 816-26 ID 330 816-23
ID 330 816-24 ID 330 816-36 ID 330 816-25
ID 330 816-43 ID 330 816-38 ID 330 816-45

ID 330 816-37

ID 330 816-95 ID 330 816-96 ID 330 816-97 ID 330 816-98 ID 330 816-99 ID 330 816-0A ID 330 816-0B ID 330 816-0C ID 330 816-70 ID 330 816-69 ID 330 816-0G ID 330 816-0H ID 330 816-71 ID 330 816-72 ID 330 816-63 ID 330 816-64 ID 330 816-18 ID 330 816-17 ID 330 816-0W ID 330 816-0V ID 330 816-0N ID 330 816-0M ID 330 816-67 ID 330 816-68 ID 330 816-21 ID 330 816-20 ID 330 816-0P ID 330 816-0R
ID 330 816-0D ID 330 816-0E ID 330 816-65
ID 330 816-66 ID 330 816-19 ID 330 816-16 ID 330 816-0L ID 330 816-0K

Machine functions

ID 330 816-0X ID 330 816-1Y ID 330 816-30 ID 330 816-31 ID 330 816-32 ID 330 816-73 ID 330 816-74 ID 330 816-75 ID 330 816-76 ID 330 816-77 ID 330 816-78 ID 330 816-79 ID 330 816-80 ID 330 816-0S ID 330 816-0T ID 330 816-81 ID 330 816-82 ID 330 816-83 ID 330 816-84 ID 330 816-89 ID 330 816-85
ID 330 816-86 ID 330 816-87 ID 330 816-88 ID 330 816-94 ID 330 816-0U ID 330 816-91 ID 330 816-3L

Spindle functions

ID 330 816-08 ID 330 816-09 ID 330 816-40 ID 330 816-41

ID 330 816-47

(green)

ID 330 816-48

ID 330 816-46

Other keys

ID 330 816-01 ID 330 816-61
ID 330 816-50 ID 330 816-33 ID 330 816-34 ID 330 816-35 ID 330 816-22
ID 330 816-90 ID 330 816-27 ID 330 816-28 ID 330 816-29 ID 330 816-92

ID 330 816-93

ID 330 816-0Y ID 330 816-4M ID 330 816-3M ID 330 816-3N

ID 330 816-11

ID 330 816-12 ID 330 816-49

Speed inputs

VL: Extension cable for separation points with connecting cable for extending existing connecting cable

Cable Overview

07.06.2010

HSCI total length 100 m

HSCI 618 893-xx 12m X502
MB 620 T 739 545-xx 1 VPP

298 429-xx 298 430-xx

X199-xx 1 VPP
Control System with UEC 11x
HSCI 618 893-xx 309 783-xx
X201. X204 (UEC 111) X201. X205 (UEC 112) Position inputs 558 714-xx LC x83 30m 60m 1m RCN 729 RCN 226 RCN 631-xx max. 6m LC x83

PLC I/O

X15. X18 (UEC 111) X15. X19 (UEC 112) 332 115-xx VL 323 897-xx

38 inputs

23 outputs
1) Adapter connector 544 703-01 for spindle (if necessary) 1) 289 440-xx 509 667-xx Voltage controller 5 V 368 210-01 2) 2) Only for connection of the KTY
Axes + spindle: 30m 289 440-xx 336 376-xx

VL 336 847-xx

60m 1m RCN 729 RCN 226 RCN 228 VL 323 897-xx 533 631-xx max. 6m KTY Voltage controller 5 V 383 951-01 60m max. 9m 1 VPP KTY LB/LS 289 440-xx LC x83
Axes + spindle: 60m 1) Axes: 15m 336 376-xx

VL (max. 6m) 336 847-xx

Voltage controller 5 V 370 226-01
EnDat 2.1 interface VL (max. 6m) 340 302-xx
Voltage controller 5 V 370 224-01 VL 340 302-xx

Axes: 60m

X429-xx 298 430-xx X502
HSCI 618 893-xx MB 620 T 739 545-xx 310 199-xx 1 VPP

X502 X500

Control System with CC 610x

PL 610x 309 783-xx 1 VPP

HSCI 618 893-xx
X502 X201. X206 Position inputs 558 714-xx LC x83 30m 60m 1m RCN 729 RCN 226 RCN 631-xx max. 6m LC x83

PL 620x

HSCI 618 893-xx X15. X115-xx VL 323 897-xx

CC 6106

X51.X56
PWM out 1) Adapter connector 544 703-01 for spindle (if necessary) 1) 289 440-xx 509 667-xx Voltage controller 5 V 368 210-01 2) 2) Only for connection of the KTY
Axes + spindle: 30m 289 440-xx
60m 1m RCN 729 RCN 226 RCN 228 VL 323 897-xx 533 631-xx max. 6m KTY Voltage controller 5 V 383 951-440-xx 60m max. 9m 1 VPP KTY LB/LS LC x83
VL (max. 6m) 336 847-xx 336 376-xx
Compact inverter (nonregenerative)

KDR 120

(if needed)

L1 L2 L3

Compact inverter (regenerative) Uz Uz UR 2xx
250 479-07.-16 X51. X479-07.-16 X817-xx 325 816-xx X69
Uz UEC 11x Uz UM 111 UV 105 PSL 130
Uz CC 6106 CC 42x UM 111 CC 6106
250 479-07.-16 X51. X479-07.-16 X79 X816-xx X69 Line filter EPCOS 35 A X817-xx Three-phase ac capacitor 348 993-01

UE 2xx B

Inverter Systems

PW 210

15m L1 L2 L3
See Motors catalog for power cable to motor
Modular inverter (nonregenerative)
Modular inverter (regenerative) Uz Uz Uz Uz Uz Uz Uz CC 6106

250 479-07. -16 X51. X62

Line filter EPCOS xx
PSL 130 UV UM 1xx UM 1xx UM 1xx CC D 24V

X51. X62

PSL 130 UVR UM 1xx UM 1xx ZKF 1xx UM 1xx UP 110 (if needed) 1xx D 24V

250 479-07. -16 X79 X69

325 817-xx 325 816-xx

250 479-07.-16

X79 X69 (if needed) Three-phase ac capacitor 348 993-01

325 817-xx

325 816-xx

KDR 1xx

296 467-xx 296 466-xx 296 687-xx 312 879-01 VL 281 429-xx 3m HR 940-01 -03 max. 20 m HR 469-xx 535 220-xx 50m

50m X259-xx HRA 097-xx

3 inputs

HR 940-06 -07

Ethernet
355 484-xx 366 964-xx V.24/RS-232-C 274 545-xx PC

Adapter 9 pin 363 987-02

365 725-xx
Adapter 25 pin 310 085-01
X141 X142 USB hub 582 884-01

354 770-xx

624 775-xx

03.08.2007

SE 225-xx 633 611-xx 0.5m 633 608-xx 517 375-xx TS 189-xx

PL 62xx UEC 11x

633 613-xx

633 616-xx

TS 488-xx
X500 SE 001-xx 30m 50m TS 44x 588 008-xx

PLC PL 61xx 7 x max.

TT 797-xx
MANUALplus 620 The Contouring Control for CNC and Cycle Lathes
The MANUALplus 620 for cycle lathes Conceived for general repairs, thread repairs, single parts and short production runs Supports action-oriented machining Quickly learnedrequires minimum training time Supports boring, drilling and milling operations on the face and lateral surface Features a wide machining spectrum, from simple turned parts to complex workpieces
The MANUALplus 620 for CNC lathes Conceived for medium-sized and large production runs Programming via smart.Turn and/or DIN PLUS smart.Turn is quickly learned and requires very little training time Supports boring, drilling and milling operations on the face and lateral surface Features a wide machining spectrum, from simple turned parts to complex workpieces
Technical Description Axes
The MANUALplus 620 is a contouring control for lathes with one spindle and a slide (X, Z and Y) for tool movement. The control can also offset the display of movements in the Z axis with those of its secondary axis W. The MANUALplus supports both horizontal and vertical lathes. Display and programming Feed rate in mm/min mm/revolution Feed rate override: 0 to 150% Maximum feed rate at fPWM = Hz: min1 screw pitch [mm] No. of pole pairs in motor Traverse range 99 999.9999 to +99 999.9999 [mm] The machine tool builder denes the traverse range. It is also possible for the operator to limit the traverse range if he wishes to reduce the working space (with software limit switches). A protection zone for the spindle (Z) can also be specied. The MANUALplus 620 supports quick change tool posts (Multix) and tool turrets. The tool carriers can be located in front of or behind the workpiece.

C1(S4)

Tool carriers

Spindle

For machines featuring a higher level of automation, you can position the spindle or switch to C-axis operation. Display and programming Spindle speed: Constant shaft speed: 1 to rpm Constant surface speed: 1 to m/min Input resolution and display step: 0.to 150% nmax fPWM NPP Speed limiting = fPWM min1 NPP Hz
Spindle positioning Spindle override Maximum speed
= PWM frequency in Hz = number of pole pairs
The MANUALplus monitors the actual speed. Speed limiting can be adjusted via parameter and in the feed rate/spindle/tool menu. A specic parameter can be dened for each gear range. The gears are switched via the PLC. Up to 10 gear ranges are supported. For milling, drilling and boring cycles, either the spindle is switched to C-axis operation or a separate C-axis drive is activated. Input resolution and display step: 0.001

Gear ranges

C-axis operation

Driven Tool

The live (i.e. driven) tool is used for drilling and tapping holes as well as for milling in M19 or C-axis operation. Programs for a driven tool can be entered in manual operation, via cycles with smart.Turn or in the DIN editor. Display and programming Speed of the driven tool: Constant shaft speed: 1 to rpm Constant surface speed: 1 to m/min The MANUALplus monitors the actual speed. Speed limiting can be dened via parameter and in the feed-rate/ spindle/tool menu (TSF menu).

Speed limiting

Digital Control

Integrated inverter

Position controllers, speed controllers, current controllers and inverters are integrated in the control. HEIDENHAIN synchronous and asynchronous motors are connected to the MANUALplus 620.

Servo drive control

Velocity feedforward Acceleration feedforward

Inverter

Machine

Nominal velocity

Nominal acceleration

Position controller

Speed controller

Current controller

Power stage
Motor with rotary encoder for shaft speed and rotor position
Machine slide with linear or angle encoder

Nominal position

Nominal speed

Nominal current

Actual current Actual speed Actual position
Axis feedback control Operation with following error (servo lag)
The MANUALplus 620 operates with feedforward control.
The term following error denotes the distance between the momentary nominal position and the actual position of the axis. The velocity is calculated as follows: v = kv sa v kv sa = velocity = position loop gain = following error
Servo control with feedforward
Feedforward control means that a velocity and acceleration input is adapted to the machine while taking the jerk limiting into account. Together with the values calculated from the following error, it forms the nominal value. This greatly reduces the following error (to within a few m). The feedforward is adjustable from 0 to 100 % via a machine parameter.
Compensation of torque ripples
The torque of synchronous, torque and linear motors is subject to periodic oscillations, one cause of which can be permanent magnets. The amplitude of these oscillations depends on the motor design, and under certain circumstances can have an effect on the workpiece surface. After the axes have been commissioned with the TNCopt software, the Torque Ripple Compensation (TRC) of the CC 610x or UEC 11x can be used to compensate this torque ripple. The cycle time for path interpolation is dened as the time interval during which interpolation points on the path are calculated. The cycle time for ne interpolation is dened as the time interval during which interpolation points are calculated that lie between the interpolation points calculated for path interpolation. The cycle time for the position controller is dened as the time interval during which the actual position value is compared to the calculated nominal position value. The cycle time for the speed controller is dened as the time interval during which the actual speed value is compared to the calculated nominal speed value. The cycle time for the current controller is dened as the time interval during which the actual current value is compared to the calculated nominal current value. CC 6xxx/UEC 11x Path interpolation Fine interpolation Position controller Speed controller Current controller 3 ms 0.2 ms 0.2 ms 0.2 ms 0.1 ms at fPWM = Hz

Supply air

Protective measures
Overall Dimensions MC 6110 T
Dimensions in mm Tolerancing ISO 8015 ISO 2768 - m H < 6 mm: 0.2 mm

410 3860.12 98+1 5+1

3320.2

15x4x M5

2740.2

f 270+1

f = Cutout in machine panel m = Mounting surface

3860.2

f 400+1

0 940.2 34.X 3860.M5

56 +49 +1 0

8 +1 0

5.5 76.50 M5

94 +0.5 0.3

X (2x) 2:1 2.2 +0.4 0

0 22.3 +0. 4

3860.5

f 3940.2

24.1 +0.4 0
74.5+0.24.75 5.30 280.5 22.5+1

CC 6108

Dimensions in mm Tolerancing ISO 8015 ISO 2768 - m H < 6 mm: 0.2 mm CC 6108: 8 control loops CC 6110: 10 control loops
99.5+0.5 500.2 24.75 5.30 280.5 22.5+456+5 480

UEC 111, UEC 112

7 5.5 12
5.5 1000.2 149.5 24.75+0.5
300+1 280+1 M12 5.85.1 M5 5.5 24.234.9 1980.162 M6 B 10

PSL 135

12 5.30 280.5+1 M4 10

4560.2

170.9 420

5.5 24.75 50

PL 6xxx
PL 6x04: 139, PL 6x06: 183, PL6x08: 227

Dimensions in mm

Tolerancing ISO 8015 ISO 2768 - m H < 6 mm: 0.2 mm

6 109.5 288.4 2950.3 304

HR 130, HR 150, HR 180 with Control Knob

0.08 A 0.08 B

36.70.5 10

0.0.02 e

200.5 0.03 A

6 4.4 M3 x 5 3x 0.25 C

Selection Switch

24.1 8

20 max.

2.6+0.1 12.8+0.3

60.03

SW 14 2x M 2.5 x 5

10.1+0.1

Adapter Cable for HR 410

55 M5 32x23
Mounting opening for wall thickness S4
Mounting opening for wall thickness S>4
Line Drop Compensator for Encoders with EnDat Interface

12.5 9

*) Connection to KTY

RS-232-C/V.24 Adapter

Opening for mounting the adapter

USB Hub

17.5 MCover (accessory)

109 1000.2 A

3.4 68

500.2 2.5

3.42 600.2

93.2 A 180

m = Cutout for mounting
USB Extension Cable with Hubs
L 1000.5000 USBA n x USBB
n = 0. 4 L = Ordering length
Cuboid Probe Contact for TT 140

13.6 7.5 21.5

0.01 A 7.20

0.03 A 4.2 7.5

25 4.2 20

13.30 65

Documentation

Technical documentation

MANUALplus 620 Technical Manual in English or German Inverter Systems and Motors Technical Manual

ID 634 863-xx

ID 208 962-xx
User documentation MANUALplus 620 User's Manual MANUALplus 620 smart.Turn and DIN programming Miscellaneous TNCremo User's Manual TNCremoNT User's Manual TNCremoPlus User's Manual PLCdesign User's Manual IOcong User's Manual
ID 634 864-xx ID 685 556-xx
As integrated help and in PDF format As integrated help and in PDF format As integrated help and in PDF format As integrated help and in PDF format As integrated help and in PDF format

Other documentation

MANUALplus 620 brochure Touch Probes brochure Inverter Systems brochure Motors brochure Product Overview Remote Diagnosis with TeleService Touch Probes CD-ROM DataPilot MP/CP 620 CD-ROM Demo version
ID 634 865-xx ID 208 951-xx ID 622 420-xx ID 208 893-xx ID 348 236-xx ID 344 353-xx In preparation

HEIDENHAIN Service

Technical support
HEIDENHAIN offers the machine manufacturer technical support to optimize the adaptation of the MANUALplus to the machine including on-site support.
Replacement control system
In the event of a fault, HEIDENHAIN guarantees the rapid supply of a replacement control system (usually within 24 hours in Europe).

Hotline

Our service engineers are naturally at your disposal by telephone if you have any questions on the interfacing of the control or in the event of faults. { +31-3101 E-mail: service.nc-support@heidenhain.de PLC programming { +31-3102 E-mail: service.plc@heidenhain.de NC programming { +31-3103 E-mail: service.nc-pgm@heidenhain.de Measuring systems { +31-3104 E-mail: service.ms-support@heidenhain.de Lathe controls { +31-3105 E-mail: service.lathe-support@heidenhain.de TNC support

Seminars

HEIDENHAIN provides technical customer training in the following subjects: NC programming PLC Programming MANUALplus 620 mounting and commissioning MANUALplus 620 service Encoder service Special training for specic customers
For more information on dates, registration, etc. call in Germany: 08669 31-2293 or 31-1695 { | 08669 31-1999 E-mail: mtt@heidenhain.de www.heidenhain.de

Subject Index

Absolute encoders.. 36 Accessories.. 8 API DATA.. 40 Axes... 31
Incremental encoders.. Integral PLC.. IOcong software for PCs.. I/O modules.. 18 19

RS-232-C/V.24. 43

Secondary axes.. Seminars.. SIK component.. Snap-on keys.. Software for data transfer. Spindle.. System PL.. 19

Basic modules.. 19

Jerk... 35 Jerk limiting.. 35 Jerk, smoothed.. 35
Cable overview.. 26 C-axis operation.. 32 CC 610x... 17 CC 6106... , CC 6108... , CFR.. 16 CFR CompactFlash.. 16 Commissioning and diagnostic aids. 39 Compensation of torque ripples. 34 Conductor bars.. 20 Context sensitive help.. 38 Controller unit. 17

KinematicsDesign.. 38

Table function.. TeleService... TNCopt.. TNCremoNT.. TNCremoPlus. TNCscopeNT.. Tool carrier.. Touch probes.. Trace function.. TS 220.. TS 440.. TS 444.. TS 640.. TS 740.. TT 140.. 24
Log... 40 Look-ahead... 34
Machine conguration.. 35 Machine operating panel. 21 Main computer.. 15 MANUALplus 620.. 2, 14 Master keyword.. 16 MB 620T.. 21 MC 6110T.. 15, 46 Monitoring functions.. 38 Mounting instructions. 45
Data interfaces.. Digital control.. Digital Control Design. Documentation.. DriveDiag.. Driven tool.. 39 32

NC software license. 16

UEC 11x.. 18 UEC 111.. 18, 50 UEC 112.. 18, 50 Uniformly digital.. 13 USB.. 43 USB hub.. 43, 57 User functions.. 9
Electromagnetic compatibility. Electronic handwheels.. Encoders.. Error compensation.. Ethernet.. Expansion PL.. 43 19
Online monitor.. 39 Options... 12, 15 Oscilloscope.. 40
PL 6xxx... 19, 51 PLB 6001.. 21, 52 PLC basic program.. 42 PLCdesignNT.. 42 PLC input/output systems.. 19 PLC inputs/outputs.. 41 PLC Programming.. 41 Power supply for HSCI components. 20 Probe contact, cuboid. 24 PSL 130.. 20, 50 PSL 135.. 20, 51
Workpiece measurement. 24
HR 130... 22, 53 HR 150... 22, 53 HR 180... 22, 53 HR 410... 23, 55 HRA 110.. 22, 54 HSCI... 13 HSCI adapter.. 21
DR. JOHANNES HEIDENHAIN GmbH Dr.-Johannes-Heidenhain-Strae Traunreut, Germany { +31-0 | +5061 E-mail: info@heidenhain.de www.heidenhain.de
Vollstndige und weitere Adressen siehe www.heidenhain.de For complete and further addresses see www.heidenhain.de
HEIDENHAIN Technisches Bro Nord 12681 Berlin, Deutschland { 030 54705-240 HEIDENHAIN Technisches Bro Mitte 08468 Heinsdorfergrund, Deutschland { HEIDENHAIN Technisches Bro West 44379 Dortmund, Deutschland { 0231 618083-0 HEIDENHAIN Technisches Bro Sdwest 70771 Leinfelden-Echterdingen, Deutschland { 0711 993395-0 HEIDENHAIN Technisches Bro Sdost 83301 Traunreut, Deutschland { 08669 31-1345

mm/min or mm/revolution MC ms 3 ms CC 422 0.6 ms fPWM Hz Hz Hz Hz Hz Hz TINT 150 s 120 s 100 s 75 s 60 s 50 s

Power supply

Inverter with logic unit: 3 x 400 V~ Color at-panel display and PLC: 24 V Operation: 0 C to 40 C Storage: 35 C to +65 C
Permissible temperature range

Machine Interfacing

Error compensation Linear axis error Nonlinear axis errors Backlash Hysteresis, reversal peaks Thermal expansion Stick-slip friction Integrated PLC Program format Program input via the control Program input via PC PLC memory PLC cycle time PLC inputs, 24 V PLC outputs, 24 V Analog inputs, 10 V Analog outputs, 10 V Inputs for thermistors PLC soft keys PLC positioning PLC basic program Encoder inputs Position Incremental Absolute Spindle speed Incremental Absolute Commissioning and diagnostic aids Integrated oscilloscope
Statement list Via external USB keyboard
Hard disk 18 ms 56 (expandable by PL) 31 (expandable by PL) 3 (expandable by PL) 6 (expandable by PL) 3 (expandable by PL)
VPP EnDat 2.1 VPP EnDat 2.1
Machine Interfacing, Accessories
Trace function Logic diagram Table function OLM (online monitor) Log Data interfaces Ethernet (100BaseT) RS-232-C/V.24 RS-422/V.11 USB 1.1
Can only be controlled via PLC Can only be controlled via PLC 2

Accessories

Electronic handwheels
One HR 410, one HR 130, or up to three HR 150 via HRA 110 Up to two HR 180 One TT 140 tool touch probe Modular external input/output systems PL 510 or PL 550 consisting of Basic module with HEIDENHAIN PLC interface PLB 510: for 4 I/O modules PLB 511: for 6 I/O modules PLB 512: for 8 I/O modules PLB 550: for 4 I/O modules PLD 16-8: I/O module with 16 digital inputs and 8 digital outputs PLA 4-4: Analog module with 4 analog inputs for 10 V and inputs for PT 100 thermistors
Touch probes PLC input/output systems
USB hub PLC basic program1)
DataPilot MP 620 programming station Control software for PCs for programming, archiving, and training Software PLCdesignNT1) TNCremoNT1) TNCremoPlus TNCscopeNT1) DriveDiag1) TNCopt1) TeleService1) PLC software developing environment Data transfer software Data transfer software with live-screen function Software for data recording Software for diagnosis of digital drive systems Software for putting digital control loops into service Software for remote diagnostics, monitoring, and operation

Teach-in

Program run Setup functions Programming Cycle programming 8 8+55 8+55 8+55 8+55 8+8+9 Interactive Contour Programming (ICP) 8/9 8/9 8/9 8/9 8/9 8/9 8/9

Standard

User functions

ICP (continued)

8/9+55 C-axis machining on face and lateral surface: Description of individual holes and hole patterns (only in smart.Turn) Description of gures and gure patterns for milling (only in smart.Turn) Creation of freely denable milling contours 9+70 Y-axis machining on the XY and ZY planes (only in smart.Turn): Description of individual holes and hole patterns Description of gures and gure patterns for milling Creation of freely denable milling contours 8/9+42 DXF import: Import of contours for lathe and milling operations The basis is the unit, which is the complete description of a machining block (geometry, technology and cycle data) Dialog boxes divided into overview and detail forms 9 Fast navigation between the llable forms and input groups via the smart keys 9 Context-sensitive help graphics 9 Start unit with global settings 9 Transfer of global values from the start unit 9 Transfer of cutting values from technology database 9 Units for all turning and recessing operations for simple contours and ICP contours 9 9+55/70 Units for boring, drilling and milling operations with the C and Y axis for simple holes, milling contours and drilling and milling patterns or those programmed with ICP 9+55 Special units for activating/deactivating the C axis, subprograms and section repeats Verication graphics for blank and nished part and for C and Y axis contours 9 Turret assignment and other setup information in the smart.Turn program 9 Parallel programming 9 Parallel simulation 8/9 9 Programming in DIN 66025 format Extended command format (IF THEN. ELSE.). Simple geometry programming (calculation of missing data) Powerful machining cycles for area clearance, recessing, recess turning and thread machining Powerful machining cycles for boring, drilling and milling with the C axis Powerful machining cycles for boring drilling and milling with the Y axis Subprograms Programming with variables Contour description with ICP Program verication graphics for workpiece blank and nished part Turret assignment and other setup information in the DIN PLUS program Conversion of smart.Turn units into DIN PLUS command sequences Parallel programming Parallel simulation Graphic simulation of the cycle process or of the cycle, smart.Turn or DIN PLUS program Display of the tool paths as wire-frame or cutting-path graphics, special identication of the rapid-traverse paths Machining simulation (2-D material-removal graphic) Side or face view, or 2-D view of cylindrical surface for verication of C-axis machining Display of programmed contours View of face and YZ plane for verication of Y-axis machining Shifting and magnifying functions Calculation of machining time and idle machine time Consideration of switching commands triggered by the CNC Representation of time per cycle or per tool change

smart.Turn programming

DIN PLUS programming

Test run graphics

Machining time analysis

Standard

Tool database
For 250 tools 10 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 Precision path correction via handwheel, transferring compensation values to the tool table Automatic tool-tip and cutter radius compensation Tool monitoring for lifetime of the insert (tool tip) or the number of workpieces produced 10 Tool monitoring with automatic tool change after tool insert wear 10 Management of multipoint tools (multiple inserts or reference points) 8/9 Access to cutting data after denition of workpiece material, cutting material and machining mode. The MANUALplus distinguishes between 16 machining modes. Each workpiecematerial/tool-material combination includes the cutting speed, the main and secondary feed rates, and the infeed for 16 machining modes. 8/9 Automatic determination of the machining modes from the cycle or the machining unit 8/9 The cutting data are entered in the cycle or in the unit as default values 8/workpiece-material/tool-material combinations (144 entries) workpiece-material/tool-material combinations (992 entries) Chinese (simplied), Chinese (traditional), Czech, Danish, Dutch, English, Finnish, French, German, Hungarian, Italian, Polish, Portuguese, Russian, Spanish, Swedish 41 For more conversational languages, see Option

Technology database

Conversational languages

Overview Options

Option number

Comment

Additional axis

354 540-904-905-226-01

Additional control loops 1 to 3

Software option 1

Cycle programming Contour description with ICP Cycle programming Technology database with 9 workpiece-material/tool-material combinations smart.Turn Contour description with ICP Programming with smart.Turn Technology database with 9 workpiece-material/tool-material combinations Tools and technology Tool database expanded to 999 entries Technology database expanded to 62 workpiece-material/tool-material combinations Support of multipoint tools Tool life monitoring with exchange tools Threads Thread recutting Handwheel superimposition during thread cutting Tool measurement Determining tool-setting dimensions with a tool touch probe Determining tool-setting dimensions with an optical gauge Slovenian Slovak Latvian Norwegian Korean Estonian Turkish Romanian Lithuanian DXF import Loading of DXF contours C-axis machining

Software option 2

632 227-01

Software option 3

632 228-01

Software option 4

632 229-01
Software option TCH PROBE functions

632 230-01

Additional language
530 184-184-184-184-184-184-184-184-184-231-01
DXF import software option C-axis machining software option Y-axis machining W-axis machining

633 944-01

661 881-676-01
Y-axis machining Support of W axis
HEIDENHAIN Control Systems
The MANUALplus 620 lathe machine control from HEIDENHAIN includes various components, which can be selected and combined to t the application.
Model MANUALplus 620 Main computer Controller unit for digital servo control Power supply unit for analog servo control Operating panel Connecting cables Accessories Machine operating panel PLC inputs/outputs Electronic handwheels MB 420 PL 510 HR 410, HR 180, HR 130 or HR 150 TT 140 MC 420 CC 422

Page 13 15

UV 106 B

Tool touch probe

MC 420, CC 422 with compact inverter

Main Computer

Main computer
The MC 420 main computer includes: Processor (Celeron, 400 MHz) 512 MB RAM memory PLC Interface to the CC controller unit Interface to the control panel Interface to the handwheel Further interfaces (PLC expansion, Ethernet, USB, RS-232-C/V.24, RS-422/V.11) To be ordered separately: HDR hard disk with the NC software SIK component (System Identication Key) for enabling the control loops and software options
The main computer is powered over the CC controller unit.

MC 420

The MC 420 main computer features ve position encoder inputs.
Position inputs Weight ID
5 x 1 VPP or EnDat 2.1 4.2 kg 515 929-02 MC 420 with 5 position encoder inputs

HDR hard disk

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

HDR for MANUALplus 620

ID 628 935-51 HDR hard disk

SIK component

The SIK component contains the NC software license for enabling control loops and software options. It gives the main computer an unambiguous ID codethe SIK number. The SIK component is ordered and shipped separately. It must be inserted in a special slot in the HDR. Additional control loops and options can be enabled later by entering a keyword. HEIDENHAIN provides the keyword, which is based on the SIK number. When ordering, please indicate the SIK number of your control. When the keywords are entered in the control, they are saved in the SIK component. This enables and activates the options.

Master keyword

For commissioning the MANUALplus 620, a master keyword can be used that will unlock all options for a duration of two weeks. After this period, the control loop options will be active only through the correct keyword. Should service become necessary, the SIK component must be inserted in the replacement control to enable all required options.

NC software license

SIK with software license and enabling for: Three control loops and options Cycle programming (option 8) smart.Turn (Option 9) Thread (option 11) C axis (option 55)

530 005-53

Additional axes
Option number 1st additional axis (4th control loop) 2nd additional axis (5th control loop) 3rd additional axis (6th control loop) 2

354 540-904-905-01

Software options
The features of the MC 420 can also be adapted with options retroactively to meet new requirements. These options are described on page 11. They are enabled by entering keywords based on the SIK number, and are saved in the SIK component. Please indicate your SIK number when ordering new options.

Controller Unit

Digital control
The CC 422 controller unit serves for digital drive control. The components: Speed controller Current controller Interfaces to the UM 1xx, UR 2xx, UE 2xx power modules (PWM outputs) Interfaces to the shaft speed encoders Interfaces for power supply for controller unit and main computer (supply via UVR 1xx D, UE 2xx D, UR 2xx)

CC 422

The CC 422 can control up to 6 digital control loops. The number of enabled control loops is saved in the SIK (see Main Computer). The CC 422 controller unit is combined with the MC 420 main computer. The position controllers and position encoder inputs are located on the MC 420 main computer (version with 5 position encoder inputs).
CC 422 Speed inputs PWM outputs Weight ID
Max. 6 digital control loops 6 x 1 VPP or EnDat 2.4.0 kg 359 651-xx

Analog control

For analog drive control, a UV 106 B is required instead of the CC 422 to supply power to the main computer. In this case, the axes to be controlled are driven through the analog speed command interface of the MC 420 main computer. For further information on the UV 106 B, refer to the UV 106 B product information sheet on www.heidenhain.de/docu.

Operating Panel

BFT 131 operating panel

ID Weight (approx.)

583 683-kg
12.1-inch color at-panel display (1024 x 768) Operating mode keys Horizontal and vertical soft keys Numeric keypad Editing keys smart.Turn keys

TT 140

Cuboid probe contact

Snap-On Keys

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

Axis keys Orange

ID 330 816-42 ID 330 816-26 ID 330 816-23
ID 330 816-24 ID 330 816-36 ID 330 816-25
ID 330 816-43 ID 330 816-38 ID 330 816-45

ID 330 816-37

ID 330 816-95 ID 330 816-96 ID 330 816-97 ID 330 816-98 ID 330 816-99 ID 330 816-0A ID 330 816-0B ID 330 816-0C ID 330 816-70 ID 330 816-69 ID 330 816-0G ID 330 816-0H ID 330 816-71 ID 330 816-72 ID 330 816-63 ID 330 816-64 ID 330 816-18 ID 330 816-17 ID 330 816-0W ID 330 816-0V ID 330 816-0N ID 330 816-0M ID 330 816-67 ID 330 816-68 ID 330 816-21 ID 330 816-20 ID 330 816-0P ID 330 816-0R
ID 330 816-0D ID 330 816-0E ID 330 816-65
ID 330 816-66 ID 330 816-19 ID 330 816-16 ID 330 816-0L ID 330 816-0K

Machine functions

ID 330 816-0X ID 330 816-1Y ID 330 816-30 ID 330 816-31 ID 330 816-32 ID 330 816-73 ID 330 816-74 ID 330 816-75 ID 330 816-76 ID 330 816-77 ID 330 816-78 ID 330 816-79 ID 330 816-80 ID 330 816-0S ID 330 816-0T ID 330 816-81 ID 330 816-82 ID 330 816-83 ID 330 816-84 ID 330 816-89 ID 330 816-85
ID 330 816-86 ID 330 816-87 ID 330 816-88 ID 330 816-94 ID 330 816-0U ID 330 816-91

Spindle functions

ID 330 816-08 ID 330 816-09 ID 330 816-40 ID 330 816-41

ID 330 816-47

(green)

ID 330 816-48

ID 330 816-46

Other keys

ID 330 816-01 ID 330 816-61
ID 330 816-50 ID 330 816-33 ID 330 816-34 ID 330 816-35 ID 330 816-22
ID 330 816-90 ID 330 816-27 ID 330 816-28 ID 330 816-29 ID 330 816-92

ID 330 816-93

ID 330 816-0Y ID 330 816-4M

ID 330 816-11

ID 330 816-12 ID 330 816-49
40m Machine operating panel
20m 263 954-xx 290 109-xx

Terminal box 01

BFT 131 BFT 1xx 583 683-110-xx Housing must be mounted 28.06.2007

Control Systems

Cable Overview
15-pin male connector 315 650-03
VL: Extension cable for separation points with connecting cable for extending existing connecting cable
353 545-xx VL 263 955-xx 40m 263 954-xx 244 005-xx 9m

263 954-xx

37-pin male connector 315 650-07

244 005-xx

VL 263 955-xx 298 429-xx 298 430-xx

X149 X45 X783-xx

310 199-xx

Analog output

X51. X62 X1. X5 Position inputs

MC 420 CC 422

X41/X42

PLC I/0

X69 X15. X747-xx max.11m VL 323 897-xx RCN LC 15m 60m RCN Voltage controller 5 V 370 225-115-xx VL 323 897-xx 369 124-xx 369 129-xx

Technical Description Axes
The MANUALplus 620 is a contouring control for lathes with one spindle and a slide (X, Z and Y) for tool movement. The control can also offset the display of movements in the Z axis with those of its secondary axis W. The MANUALplus supports both horizontal and vertical lathes. Display and programming Feed rate in mm/min mm/revolution Feed rate override: 0 to 150% Maximum feed rate at fPWM = Hz: min1 screw pitch [mm] No. of pole pairs in motor Traverse range 99 999.9999 to +99 999.9999 [mm] The machine tool builder denes the traverse range. It is also possible for the operator to limit the traverse range if he wishes to reduce the working space (with software limit switches). A protection zone for the spindle (Z) can also be specied. The MANUALplus 620 supports quick change tool posts (Multix) and tool turrets. The tool carriers can be located in front of or behind the workpiece.

C1(S4)

Tool carriers

Spindle

For machines featuring a higher level of automation, you can position the spindle or switch to C-axis operation. Display and programming Spindle speed: Constant shaft speed: 1 to rpm Constant surface speed: 1 to m/min Input resolution and display step: 0.to 150% nmax fPWM NPP Speed limiting = fPWM min1 NPP Hz
Spindle positioning Spindle override Maximum speed
= PWM frequency in Hz = Number of pole pairs
The MANUALplus monitors the actual speed. Speed limiting can be adjusted via parameter and in the feedrate/spindle/tool menu. A specic parameter can be dened for each gear range. The gears are switched via the PLC. For milling, drilling and boring cycles, either the spindle is switched to C-axis operation or a separate C-axis drive is activated. Input resolution and display step: 0.001

Gear stages

C-axis operation

Live Tool

The live (i.e. driven) tool is used for drilling and tapping holes as well as for milling in M19 or C-axis operation. Programs for a driven tool can be entered in manual operation, via cycles with smart.Turn or in the DIN editor. Display and programming Speed of the driven tool: Constant shaft speed: 1 to rpm Constant surface speed: 1 to m/min The MANUALplus monitors the actual speed. Speed limiting can be adjusted via parameter and in the feedrate/spindle/tool menu.

Speed limiting

Analog Control
The MANUALplus 620 can be used for analog drive control (see the UV 106 B product information sheet on www.heidenhain.de/ docu).

Digital Control

Integrated inverters Position controllers, speed controllers, current controllers and inverters are integrated in the control. HEIDENHAIN synchronous and asynchronous motors are connected to the MANUALplus 620.

Servo drive control

Incremental encoders

Incremental encoders have as measuring standard a grating consisting of alternate lines and spaces. Relative movement between the scanning head and the scale causes output of sinusoidal scanning signals. The measured value is calculated by counting the signals. When the machine is switched on, the machine axes need to traverse a reference mark for an accurate reference to be established between measured value and machine position. For encoders with distance-coded reference marks, the maximum travel until automatic reference mark evaluation for linear encoders is only 20 mm or 80 mm, depending on the model, or 10 or 20 for angle encoders. Incremental encoders with sinusoidal output signals with 1 VPP levels are suitable for connection to HEIDENHAIN numerical controls.

Reference mark

Output signals

Absolute encoders

With absolute encoders, the position information is contained in several coded tracks. Thus, an absolute reference is available immediately after switch-on. Reference-mark traverse is not necessary. Additional incremental signals are output for highlydynamic control loops. The MANUALplus 620 is tted with the serial EnDat -2.1 interface for the connection of absolute encoders. Note: The EnDat interface on HEIDENHAIN encoders differs in its pin assignment from the interface on Siemens motors with integrated absolute ECN/EQN rotary encoders. Special adapter cables are available. Incremental and absolute linear, angle or rotary encoders from HEIDENHAIN can be connected to all position encoder inputs of the MC. Incremental and absolute rotary encoders from HEIDENHAIN can be connected to all speed encoder inputs of the CC 42x. Input frequency1) Position Incremental 1 VPP Absolute EnDat 2.VPP Spindle speed

EnDat interface

Encoder inputs

Inputs

Signal level/ 1) Interface
33 kHz/350 kHz 350 kHz 33 kHz/350 kHz 350 kHz

Switchable

Types of Error Compensation
The MANUALplus 620 features functions for automatic compensation of mechanical errors of the machine.

Linear error

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

Nonlinear error

The MANUALplus 620 compensates for axis errors and errors that result from other axes (spindle-pitch error, sagging, misaligned axes, etc.).

Backlash

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

Hysteresis

Mounting Instructions

Mounting attitude
When installing the MC 420, CC 422, UV(R) 1xx, UM xxx, UE 2xx B take note of the minimum spacing, space needed for servicing, and the appropriate length and location of the connecting cables.

Air out

Leave space for air circulation! Temperatures of > 150 C may occur with the UE 21x B with integrated braking resistor; do not mount any temperature-sensitive parts!
Leave space for servicing!
Leave space for air circulation and servicing! Air in *) Leave space for exchanging the HDR hard disk
Leave space for servicing and connecting cables!

UV(R), UE, UM

MC 42x, CC 42x
Mounting and electrical installation
Keep the following in mind during mounting and electrical installation: National regulations for power installations Interference and noise immunity Conditions of operation Mounting attitude The following components fulll the requirements for IP 54 (dust protection and splash-proof protection): Visual display unit (when properly installed) Keyboard unit (when properly installed) Handwheel

Degrees of protection

Electromagnetic compatibility Intended place of operation The unit fullls the requirements for a Class A device in accordance with the specications in EN 55 022, and is intended for use in industrially zoned areas. Protect your equipment from interference by observing the rules and recommendations specied in the Technical Manual. Likely sources of interference Noise is mainly produced by capacitive and inductive coupling from electrical conductors or from device inputs/outputs, such as: Strong magnetic elds from transformers or electric motors Relays, contactors and solenoid valves High-frequency equipment, pulse equipment and stray magnetic elds from switch-mode power supplies Power lines and leads to the above equipment Keep a minimum distance of 20 cm from the MC, CC and its leads to devices that carry interference signals. Keep a minimum distance of 10 cm from the MC, CC and its leads to cables that carry interference signals. For cables in metallic ducting, adequate decoupling can be achieved by using a grounded separation shield. Shielding according to EN Use potential compensating lines with a cross section of 6 mm2 Use only genuine HEIDENHAIN cables, connectors and couplings.

Protective measures

Overall Dimensions MC 420 CC 422
Dimensions in mm Tolerancing ISO 8015 ISO 2768 - m H < 6 mm: 0.2 mm MC 420 / 5 position encoder inputs CC 422 / 6 control loops
Dimensions in mm Tolerancing ISO 8015 ISO 2768 - m H < 6 mm: 0.2 mm

8 3860.76+1 5+1

2740.2
Space for air circulation

5.5 15x45 2

f 270+1

0.5 3860.2

f 400+1
f = Cutout in machine panel m = Mounting surface
HR 130, HR 150, HR 180 with Control Knob

0.08 A 0.08 B

36.70.5 10

0.0.02 e

200.5 0.03 A

6 4.4 M3 x 5 3x 0.25 C

Handwheel Selection Switch

24.1 8

20 max.

2.6+0.1 12.8+0.3

60.03

SW 14 2x M 2.5 x 5

10.1+0.1

Adapter Cable for HR 410

55 M5 32x23
Mounting opening for wall thickness S4
Mounting opening for wall thickness S>4
PL 510/550: 139, PL 511: 183, PL 512: 227 51
Tolerancing ISO 8015 ISO 2768 - m H < 6 mm: 0.2 mm

Dimensions in mm

Voltage Controller For Encoders with EnDat Interface

34 12.64 36

*) Connection to KTY

RS-422/RS-232-C Adapter

USB Hub

17.5 MCover (accessory)

109 1000.2 A

3.4 68

500.2 2.5

3.42 600.2

93.2 A 180

m = Cutout for mounting

USB Extension Cable with Hubs
L 1000.5000 USBA n x USBB
n = 0 to 4 L = Ordering length
Cuboid Probe Contact for TT 140

13.6 7.5 21.5

Documentation
Items supplied with the control include: One MANUALplus 620 Users Manual One MANUALplus 620, smart.Turn and DIN programming Users Manual This documentation must be ordered separately in the language required. Further documentation is available from HEIDENHAIN.

Technical documentation

Technical Manual for MANUALplus 620 in English or German Technical Manual for Inverters and Motors

ID 634 863-xx

ID 208 962-xx
User documentation Users Manual for MANUALplus 620 User's Manual for MANUALplus 620 smart.Turn and DIN programming Miscellaneous Users Manual for TNCremo Users Manual for TNCremoNT Users Manual for TNCremoPlus Users Manual for PLCdesign
ID 634 864-xx ID 685 556-xx
As integrated help and in PDF format As integrated help and in PDF format As integrated help and in PDF format As integrated help and in PDF format

Data interfaces... 36 Digital control.. 15, 26 Documentation.. 49 DriveDiag.. 34 Driven tool.. 26
Electronic handwheels.. 18 Encoders.. 29 Error compensation.. 30 Ethernet... 36 RS-422/RS-232-C adapter. 46
Selection switch.. 43 Seminars.. 50 SIK component.. 13 Snap-on keys.. 20 Software options.. 14 Spindle... 25
Hard disk.. 13 HR 130.. 18, 42 HR 150.. 18, 42 HR 180.. 18, 42 HR 410.. 19, 44 HRA 110.. 18, 43
TNCopt... 34 TNCremoNT.. 37 TNCremoPlus.. 37 TNCscopeNT.. 33 Tool carriers... 25 Tool touch probe.. 19 TT 140.. 19
Incremental encoders.. 29
Jerk... 28 Jerk limiting... 28 Jerk, smoothed.. 28

USB... 36 USB hub... 47

License,NC software. 14 Look-ahead.. 28
DR. JOHANNES HEIDENHAIN GmbH Dr.-Johannes-Heidenhain-Strae Traunreut, Germany { +31-0 | +5061 E-mail: info@heidenhain.de www.heidenhain.de
Vollstndige und weitere Adressen siehe www.heidenhain.de For complete and further addresses see www.heidenhain.de
HEIDENHAIN Technisches Bro Nord 12681 Berlin, Deutschland { 030 54705-240 HEIDENHAIN Technisches Bro Mitte 08468 Heinsdorfergrund, Deutschland { HEIDENHAIN Technisches Bro West 44379 Dortmund, Deutschland { 0231 618083-0 HEIDENHAIN Technisches Bro Sdwest 70771 Leinfelden-Echterdingen, Deutschland { 0711 993395-0 HEIDENHAIN Technisches Bro Sdost 83301 Traunreut, Deutschland { 08669 31-1345
FARRESA ELECTRONICA S.A. 08028 Barcelona, Spain www.farresa.es HEIDENHAIN Scandinavia AB 02770 Espoo, Finland www.heidenhain. HEIDENHAIN FRANCE sarl 92310 Svres, France www.heidenhain.fr HEIDENHAIN (G.B.) Limited Burgess Hill RH15 9RD, United Kingdom www.heidenhain.co.uk MB Milionis Vassilis 17341 Athens, Greece www.heidenhain.gr HEIDENHAIN LTD Kowloon, Hong Kong E-mail: service@heidenhain.com.hk Croatia SL HEIDENHAIN Kereskedelmi Kpviselet 1239 Budapest, Hungary www.heidenhain.hu PT Servitama Era Toolsindo Jakarta 13930, Indonesia E-mail: ptset@group.gts.co.id NEUMO VARGUS MARKETING LTD. Tel Aviv 61570, Israel E-mail: neumo@neumo-vargus.co.il HEIDENHAIN Optics & Electronics India Private Limited Chennai 600 031, India www.heidenhain.in HEIDENHAIN ITALIANA S.r.l. 20128 Milano, Italy www.heidenhain.it HEIDENHAIN K.K. Tokyo 102-0073, Japan www.heidenhain.co.jp HEIDENHAIN LTD. Gasan-Dong, Seoul, Korea 153-782 www.heidenhain.co.kr Montenegro SL Macedonia BG HEIDENHAIN CORPORATION MEXICO 20235 Aguascalientes, Ags., Mexico E-mail: info@heidenhain.com ISOSERVE Sdn. Bhd 56100 Kuala Lumpur, Malaysia E-mail: isoserve@po.jaring.my HEIDENHAIN NEDERLAND B.V. 6716 BM Ede, Netherlands www.heidenhain.nl HEIDENHAIN Scandinavia AB 7300 Orkanger, Norway www.heidenhain.no

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ME MK MX

634 867-10/2009 H Printed in Germany.5
Zum Abheften hier falzen! / Fold here for ling!