HEIDENHAIN iTNC 530 HSCI User manual

Technical Manual
iTNC 530 HSCI
NC Software
606 420-03
606 421-03
July 2013

2 HEIDENHAIN Technical Manual iTNC 530 HSCI

July 2013 3
Content
1 Update Information..................................19
1.1 General information..........................................................................19
1 Update Information No. 37
NC software 60642x-03 ............................21
1.1 Overview............................................................................................21
1.1.1 Released service packs.......................................................21
1.2 Important notes ................................................................................22
1.3 New software options......................................................................23
1.4 New machine parameters ................................................................24
1.5 New functions ...................................................................................29
1.6 Software option 144—Motion Adaptive Control (MAC) ...............41
1.7 DHCP server.......................................................................................43
1.8 VNC settings......................................................................................49
1.9 PLC functions.....................................................................................53
2 Introduction...............................................71
2.1 Meaning of the symbols used in this manual ................................71
2.2 Proper and intended operation........................................................71
2.3 Trained personnel .............................................................................71
2.4 General information..........................................................................72
2.4.1 HSCI interface .....................................................................75
2.5 Overview of components .................................................................76
2.5.1 MC 6xxx main computer, HDR or SSDR hard disk and SIK 76
2.5.2 CC 61xx controller unit........................................................84
2.5.3 UEC 11x, UMC 11x controller unit with integrated
inverter and PLC..................................................................86
2.5.4 PL 6xxx PLC input/output systems with HSCI interface.....89
2.5.5 SPI expansion modules.......................................................93
2.5.6 PSL 13x low-voltage power supply unit ..............................94
2.5.7 TE 6xx keyboard units .........................................................96
2.5.8 BF 2xx visual display units................................................101
2.5.9 MB 6xx machine operating panel......................................103
2.5.10 HSCI adapter for PLB 6001 OEM-specific machine
operating panel..................................................................105
2.5.11 HR 4xx(FS), HR 5xx(FS) handwheels ................................106
2.5.12 Industrial PC with Windows 7...........................................113
2.5.13 Key symbols......................................................................114
2.5.14 Touch probes.....................................................................119
2.5.15 MS 110 / MS 111 installation kit .......................................122
2.5.16 Other accessories .............................................................123
2.5.17 Documentation..................................................................126

4 HEIDENHAIN Technical Manual iTNC 530 HSCI
2.6 Brief description..............................................................................127
2.7 Software ..........................................................................................139
2.7.1 Designation of the software..............................................139
2.7.2 PLC software ....................................................................140
2.7.3 Additional control loops or software options.....................140
2.7.4 Upgrade functions (feature content level).........................150
2.7.5 NC software exchange on the iTNC 530...........................152
2.7.6 Availability of software versions, software options
and FCL .............................................................................164
2.7.7 Installing a service pack ....................................................167
2.7.8 Special features of the software .......................................169
2.7.9 HEROS 5 operating system ..............................................172
2.7.10 Functional safety (FS)........................................................174
2.7.11 Monitoring hardware changes ..........................................174
2.7.12 SELinux .............................................................................175
2.7.13 Data backup ......................................................................179
2.8 Released NC software ....................................................................180
3 Mounting and electrical installation .....181
3.1 General information........................................................................181
3.1.1 Safety precautions ............................................................181
3.1.2 Degrees of protection .......................................................182
3.1.3 Electromagnetic compatibility ...........................................182
3.1.4 ESD protection..................................................................183
3.2 Environmental conditions..............................................................185
3.2.1 Storage and operating temperatures ................................185
3.2.2 Heat generation and cooling .............................................187
3.2.3 Limit values for ambient conditions ..................................188
3.2.4 Installation elevation..........................................................188
3.2.5 Mounting attitude MC 6xxx, CC 61xx, UV xxx,
UM xxx, UE 2xx B .............................................................189
3.2.6 Mounting attitude of UMC 111 (FS)..................................190
3.2.7 Mounting attitude of UEC 11x (FS) ...................................191
3.2.8 Mounting attitude of MC 6222, MC 7222.........................192
3.2.9 Mounting attitude of CC 6106, UV xxx, UM xxx,
UE 2xx B(D).......................................................................193
3.2.10 Mounting attitude of PLB 6xxx .........................................194
3.3 Handling the HDR hard disk...........................................................195
3.4 Mounting the Solid State Disk (SSD)............................................196
3.5 Overview of components...............................................................197
3.6 HSCI..................................................................................................204
3.6.1 Introduction .......................................................................204
3.6.2 Topology............................................................................207
3.6.3 HSCI interface ...................................................................208

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3.7 iTNC 530 HSCI connection overview.............................................209
3.7.1 MC 6241............................................................................209
3.7.2 MC 6242............................................................................210
3.7.3 MC 6222............................................................................211
3.7.4 MC 7222............................................................................212
3.7.5 MC 6341............................................................................213
3.7.6 IPC 6341............................................................................214
3.7.7 CC 6106.............................................................................215
3.7.8 CC 6108.............................................................................216
3.7.9 CC 6110.............................................................................217
3.7.10 UMC 111FS.......................................................................218
3.7.11 UMC 111...........................................................................219
3.7.12 UEC 11x ............................................................................220
3.7.13 PLB 62xx ...........................................................................221
3.7.14 PLB 62xx FS......................................................................221
3.7.15 PLB 61xx ...........................................................................222
3.7.16 I/O modules PLD-H and PLA-H .........................................223
3.8 Supply voltages in the HSCI system .............................................226
3.8.1 Overview: Power supply for the iTNC...............................228
3.8.2 Current consumption of the HSCI components................229
3.8.3 X90: +24 V NC output of the UxC 11x (FS).......................230
3.8.4 X101: NC power supply.....................................................231
3.8.5 Power supply of the CC 61xx............................................232
3.8.6 PSL 13x low-voltage power supply unit ............................237
3.9 MS 110 / MS 111 installation kit for double-row configuration.247
3.9.1 General information...........................................................247
3.9.2 Double-row configuration..................................................248
3.9.3 Connection overview.........................................................250
3.10 UxC 11x (FS): Power supply and motor connection....................254
3.10.1 UMC 111 (FS)....................................................................254
3.10.2 UEC 11x (FS).....................................................................257
3.11 UxC 11x (FS): Meaning of the LEDs...............................................263
3.12 Power supply for PLC outputs .......................................................265
3.13 Power supply for PLB 6xxx (FS).....................................................267
3.14 Meaning of the LED on PLB 6xxx ..................................................268
3.15 Power supply for control-is-ready signal......................................268
3.16 Digital PLC inputs/outputs.............................................................269
3.16.1 UxC 11x (FS): Digital PLC inputs/outputs..........................278
3.17 Analog PLC inputs/outputs............................................................285
3.18 PROFIBUS connection ....................................................................288
3.19 PROFINET connection.....................................................................289
3.20 Configuring the PLC inputs/outputs with IOconfig.....................291
3.21 Buffer battery ..................................................................................294
3.22 Encoder connections .....................................................................296
3.22.1 General information...........................................................296
3.22.2 Position encoder input ......................................................297
3.22.3 Speed encoder input .......................................................300
3.23 Adapters for encoder signals.........................................................304
3.24 Connecting the motor power modules (only CC 61xx) ...............307

6 HEIDENHAIN Technical Manual iTNC 530 HSCI
3.25 Analog nominal value output ........................................................308
3.25.1 CMA-H 04-04-00—Pin layout ............................................310
3.26 Touch probes...................................................................................313
3.27 MB 620 machine operating panel..................................................317
3.28 Data interfaces ................................................................................325
3.28.1 USB interface (USB 2.0)....................................................328
3.28.2 HDL interface....................................................................329
3.29 MB 720 (FS) machine operating panel ..........................................330
3.30 HSCI adapter for PLB 6001 (FS) OEM-specific machine
operating panel ...............................................................................341
3.31 TE 620 keyboard unit......................................................................355
3.32 TE 630 keyboard unit......................................................................356
3.33 TE 635Q (FS) keyboard unit ...........................................................359
3.34 TE 645Q (FS) keyboard unit ...........................................................360
3.35 TE 730, TE 720 keyboard unit.........................................................364
3.36 TE 735 (FS) keyboard unit ..............................................................367
3.37 TE 740 keyboard unit......................................................................370
3.38 TE 745 (FS) keyboard unit ..............................................................373
3.39 BF 250 15-inch TFT screen..............................................................377
3.40 BF 260 19-inch TFT display unit.....................................................379
3.41 Handwheel input.............................................................................383
3.41.1 HR 4xx (FS) or HR 5xx (FS) portable handwheel...............383
3.41.2 HR 520FS, HR 410FS safety-oriented electronic
handwheels.......................................................................387
3.41.3 HR 550 handwheel with wireless transmission................393
3.41.4 HR 410 portable handwheel..............................................411
3.41.5 HR 130 panel-mounted handwheel...................................413
3.41.6 HRA 110 handwheel adapter ............................................414
3.42 CML 110 capacitor module.............................................................416
3.43 Connecting cables: Specifications.................................................418
3.44 Dimensions......................................................................................419
3.44.1 MC 6241 ...........................................................................420
3.44.2 MC 6341, MC 6x51, IPC 6341 ..........................................421
3.44.3 MC 6242 ...........................................................................422
3.44.4 MC 6222 ...........................................................................423
3.44.5 MC 7222 ...........................................................................424
3.44.6 MB 720 (FS) ......................................................................425
3.44.7 TE 635Q (FS) .....................................................................426
3.44.8 TE 645Q (FS) .....................................................................427
3.44.9 TE 720 ...............................................................................428
3.44.10 TE 730 ...............................................................................429
3.44.11 TE 735 (FS)........................................................................430
3.44.12 TE 630 ...............................................................................431
3.44.13 TE 620 ...............................................................................432
3.44.14 TE 740 ...............................................................................433
3.44.15 TE 745 ...............................................................................434
3.44.16 BF 250...............................................................................435
3.44.17 BF 750...............................................................................436
3.44.18 BF 260...............................................................................437

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3.44.19 BF 760...............................................................................439
3.44.20 CC 6106.............................................................................440
3.44.21 CC 6108 / CC 6110............................................................441
3.44.22 UMC 111 (FS)....................................................................442
3.44.23 UEC 11x (FS).....................................................................443
3.44.24 PL 6xxx (FS).......................................................................444
3.44.25 PLB 6001(FS).....................................................................445
3.44.26 PSL 130.............................................................................446
3.44.27 PSL 135.............................................................................447
3.44.28 MS 11x..............................................................................448
3.44.29 Adapter block for the data interface..................................449
3.44.30 USB hub ............................................................................450
3.44.31 Line-drop compensator .....................................................451
3.44.32 Handwheels ......................................................................451
3.44.33 Touch probes.....................................................................457
3.44.34 CML 110............................................................................464
3.44.35 USB hub for operating panel .............................................464
3.45 iTNC 530 HSCI grounding diagram with modular
HEIDENHAIN inverter system—External PSL 13x........................465
3.46 iTNC 530 HSCI grounding diagram with modular HEIDENHAIN
inverter system—Power supply unit integrated in UV(R) ..........466
3.47 iTNC 530 HSCI basic circuit diagram.............................................467
3.48 iTNC 530 HSCI cable overview—Basic configuration, MC in
electrical cabinet .............................................................................469
3.49 iTNC 530 HSCI cable overview—Basic configuration, MC in
operating panel ...............................................................................470
3.50 iTNC 530 HSCI cable overview—Basic configuration, MC in
electrical cabinet, UEC 1xx.............................................................471
3.51 iTNC 530 HSCI cable overview—Basic configuration, MC in
operating panel, UEC 1xx...............................................................472
3.52 Cable overview for iTNC 530 HSCI with HEIDENHAIN
inverter systems..............................................................................473
3.53 iTNC 530 HSCI cable overview—Accessories...............................474

8 HEIDENHAIN Technical Manual iTNC 530 HSCI
4 Machine parameters...............................475
4.1 What is a Machine Parameter?......................................................475
4.2 The Machine Parameter Programming mode of operation ........477
4.3 Input and output of machine parameters.....................................478
4.3.1 Input format ......................................................................478
4.3.2 Activating the machine parameter list...............................480
4.3.3 Changing the input values.................................................480
4.4 List of machine parameters ...........................................................494
4.4.1 Encoders and machines....................................................494
4.4.2 Positioning.........................................................................502
4.4.3 Operation with velocity feedforward control.....................510
4.4.4 Servo control with following error.....................................511
4.4.5 Integrated speed and current control................................512
4.4.6 Spindle ..............................................................................526
4.4.7 Integrated PLC ..................................................................530
4.4.8 Configuration of the data interface....................................533
4.4.9 3-D touch probe ................................................................535
4.4.10 Tool measurement with TT...............................................537
4.4.11 Tapping..............................................................................542
4.4.12 Display and operation........................................................543
4.4.13 Colors................................................................................553
4.4.14 Machining and program run ..............................................557
4.4.15 Hardware...........................................................................566
4.4.16 Second spindle..................................................................582
5 Modules, markers and words................583
5.1 Overview of modules......................................................................583
5.2 Overview of markers and words ...................................................591
6 Configuring the axes and spindle..........603
6.1 Control loops...................................................................................603
6.1.1 Selecting the axes.............................................................603
6.1.2 Axis designation................................................................604
6.1.3 Encoders ...........................................................................606
6.1.4 Assignment for axes .........................................................614
6.1.5 Assignment for spindles ...................................................616
6.1.6 Specifications of the controller unit:..................................618
6.1.7 Reading axis information...................................................621
6.1.8 Traverse ranges.................................................................623
6.1.9 Lubrication pulse...............................................................629
6.2 PLC axes...........................................................................................630
6.2.1 Coupling function for PLC axes or auxiliary axes ..............635
6.3 PLC positioning ...............................................................................640

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6.4 Axis-error compensation................................................................647
6.4.1 Backlash compensation.....................................................647
6.4.2 Linear axis error compensation .........................................651
6.4.3 Nonlinear axis error compensation....................................652
6.4.4 Compensation of thermal expansion.................................659
6.4.5 Compensation of reversal spikes during circular
traverse .............................................................................661
6.4.6 Compensation of stick-slip friction ....................................661
6.4.7 Compensation of sliding friction (only for digital axes)......662
6.4.8 Torsion compensation.......................................................663
6.4.9 KinematicsComp ...............................................................664
6.4.10 Software option 141—Cross Talk Compensation (CTC)....688
6.4.11 Software option 142—Position Adaptive Control (PAC)....693
6.4.12 Software option 143—Load Adaptive Control (LAC).........694
6.4.13 Software option 144—Motion Adaptive Control (MAC)....697
6.4.14 Software option 145—Active Chatter Control (ACC).........699
6.5 Tilting and swivel axes ...................................................................701
6.5.1 Determining the mechanical offset...................................701
6.5.2 Description of the kinematics configuration......................714
6.5.3 Temperature compensation with tilting axes....................741
6.5.4 Changing the milling heads ...............................................745
6.5.5 KinematicsOpt...................................................................746
6.5.6 “Tilt working plane” feature..............................................761
6.5.7 Automatic compensation of offset for tilting axes ............770
6.5.8 Virtual tool axis ..................................................................776
6.5.9 Tilting functions with open-loop rotary axes......................776
6.5.10 Cylindrical surface .............................................................777
6.6 Gantry/synchronized axes .............................................................778
6.6.1 Gantry axes .......................................................................778
6.6.2 Master-slave torque control ..............................................782
6.6.3 Brake test for synchronized axes ......................................792
6.7 Reference marks..............................................................................796
6.7.1 Definition...........................................................................796
6.7.2 Traversing the reference marks ........................................797
6.8 The control loop..............................................................................810
6.8.1 Relation between jerk, acceleration, velocity and
distance.............................................................................812
6.8.2 Interpolator........................................................................814
6.8.3 Position controller..............................................................832
6.8.4 Speed controller................................................................848
6.8.5 Switching drives on and off...............................................858
6.8.6 Current controller ..............................................................866
6.8.7 Braking the drives for an emergency stop and a
power failure .....................................................................870
6.8.8 Power and torque limiting .................................................873
6.8.9 Weakened field operation .................................................880
6.9 Offset adjustment ...........................................................................890
6.9.1 Offset adjustment with integral factor ..............................890
6.9.2 Offset adjustment by code number ..................................890

10 HEIDENHAIN Technical Manual iTNC 530 HSCI
6.10 Contouring behavior.......................................................................891
6.10.1 Radial acceleration ............................................................891
6.10.2 Contour velocity at corners ...............................................892
6.11 Monitoring functions......................................................................894
6.11.1 Position monitoring ...........................................................896
6.11.2 Nominal speed value monitoring.......................................898
6.11.3 Movement monitoring ......................................................899
6.11.4 Standstill monitoring .........................................................900
6.11.5 Positioning window...........................................................900
6.11.6 Monitoring of the power supply unit.................................902
6.11.7 Temperature monitoring ...................................................904
6.11.8 Internal power supply and housing fan .............................907
6.11.9 I2t monitoring ....................................................................908
6.11.10 Momentary utilization of drive motors ..............................918
6.11.11 Determining the current torque of a drive.........................920
6.11.12 Status of HEIDENHAIN power modules...........................922
6.11.13 Controlling the motor brakes.............................................925
6.11.14 Emergency stop monitoring..............................................930
6.11.15 EN 13849-1 on the iTNC 530 HSCI without
functional safety (FS).........................................................943
6.12 Spindle .............................................................................................944
6.12.1 Position encoder of the spindle.........................................945
6.12.2 Speed encoder of the spindle ...........................................950
6.12.3 Analog and digital closed-loop spindle control ..................952
6.12.4 Coded output of spindle speed.........................................965
6.12.5 Volts-per-hertz control mode.............................................967
6.12.6 Oriented spindle stop........................................................968
6.12.7 Tapping with floating tap holder and nominal speed
output................................................................................974
6.12.8 Tapping with floating tap holder and coded
spindle-speed output.........................................................976
6.12.9 Rigid tapping .....................................................................977
6.12.10 Switching the modes of operation ....................................980
6.12.11 Operating a second spindle...............................................985
6.12.12 C-axis operation.................................................................987
6.12.13 Software option 96—Advanced spindle interpolation .......991
6.13 Integrated oscilloscope ..................................................................992
6.14 Commissioning .............................................................................1004
6.14.1 Tables for power modules, supply modules and motors 1004
6.14.2 Field orientation...............................................................1019
6.14.3 Preparation ......................................................................1020
6.14.4 Commissioning digital control loops with TNCopt ..........1023
6.14.5 Commissioning of digital axes ........................................1026
6.14.6 Commissioning the digital spindle ..................................1055
6.14.7 Commissioning an analog axis ........................................1060
6.14.8 Commissioning the analog spindle .................................1064
6.15 Block diagram for iTNC 530 with CC 61xx..................................1065

July 2013 11
7 CC 61xx / UEC 1xx controller units....1067
7.1 Specifications ................................................................................1067
7.2 Connecting the encoders .............................................................1069
7.2.1 General information.........................................................1069
7.2.2 Position encoders............................................................1069
7.2.3 Speed encoders ..............................................................1070
7.3 Relationship between speed input, position input and
PWM output ..................................................................................1071
7.4 Single-speed, double-speed, PWM frequency............................1072
7.4.1 General information.........................................................1072
7.4.2 Single-speed and double-speed (software option 49) .....1074
7.4.3 Combination of several CC 61xx controller units ............1078
7.4.4 PWM frequency ..............................................................1082
7.5 PLC cycle time ...............................................................................1087
7.6 Monitoring functions ....................................................................1087
7.7 Special functions...........................................................................1088
7.7.1 Multifunction filter...........................................................1088
7.7.2 Filter order for separate low-pass filter in the speed
controller .........................................................................1093
7.7.3 Dynamic determination of load .......................................1093
7.7.4 LIFTOFF function.............................................................1098
7.7.5 TRC – Torque Ripple Compensation ...............................1101
7.7.6 Peculiarities in weakened-field operation........................1103
7.7.7 Crossover Position Filter (CPF)........................................1104
7.8 Stick-slip friction compensation at quadrant transitions .........1106
7.9 Field orientation............................................................................1108
7.9.1 Possibilities for determining the field angle ....................1110
7.9.2 Determination of the field angle without motor
motion (MP2254.x = 0) ...................................................1113
7.9.3 Determination of the field angle with motor motion
(MP2254.x = 2/3).............................................................1115
7.9.4 Reading or setting the field angle via the PLC ................1118
7.9.5 Saving the determined field angle...................................1120
7.9.6 Definition of the field angle .............................................1121
7.10 Adjustment of linear and torque motors....................................1122
7.10.1 General information.........................................................1122
7.10.2 Safety precautions for linear and torque motors.............1126
7.11 Commissioning linear and torque motors..................................1128
7.11.1 Machine parameters for linear motors............................1128
7.11.2 Machine parameters for torque motors ..........................1129
7.11.3 Adjustment of the current controller...............................1130
7.11.4 Adjustment of the speed controller.................................1133
7.12 Determining entries for motor tables .........................................1140
7.12.1 Determining data for linear motors .................................1140
7.12.2 Determining data for torque motors................................1143

12 HEIDENHAIN Technical Manual iTNC 530 HSCI
8 Machine interfacing..............................1147
8.1 Display and operation...................................................................1147
8.1.1 Position and status display..............................................1147
8.1.2 Operating modes ............................................................1165
8.1.3 Operating times ..............................................................1169
8.1.4 Error messages...............................................................1176
8.1.5 Service files.....................................................................1185
8.1.6 Help.................................................................................1189
8.1.7 PLC pop-up window........................................................1192
8.1.8 TNCguide – context-sensitive help system for the
iTNC 530 (user documentation) ......................................1195
8.1.9 Machine datum ...............................................................1205
8.1.10 NC program.....................................................................1210
8.1.11 Adaptive feed control (AFC) ............................................1218
8.1.12 Global program settings (PGM).......................................1236
8.1.13 Cycles..............................................................................1241
8.1.14 End of program run .........................................................1244
8.1.15 Returning to the contour.................................................1244
8.1.16 M functions.....................................................................1251
8.1.17 Powering up and shutting down the control ...................1260
8.1.18 Arc end-point tolerance ...................................................1263
8.1.19 Limit-switch tolerance for M140 / M150.........................1263
8.1.20 Radius compensation......................................................1264
8.1.21 User parameters .............................................................1264
8.1.22 Code numbers.................................................................1265
8.1.23 Programming station mode.............................................1267
8.1.24 Color settings..................................................................1267
8.1.25 Graphic display................................................................1275
8.1.26 Special characters ...........................................................1277
8.1.27 iTNC character set...........................................................1278
8.1.28 Conversational language .................................................1283
8.1.29 Logs ................................................................................1286
8.1.30 Diagnostic functions........................................................1298
8.1.31 BUS diagnosis.................................................................1320
8.1.32 Expanded PLC module interface for 18 axes ..................1329
8.1.33 Window manager............................................................1332
8.1.34 Software option 133—Remote Desktop Manager..........1338
8.2 PLC window ..................................................................................1354
8.2.1 Small PLC window..........................................................1354
8.2.2 Large PLC window .........................................................1358
8.3 PLC soft keys .................................................................................1372
8.3.1 Soft-key project file for screen ........................................1372
8.3.2 Soft-key project file for HR 420, HR 5xx .........................1385
8.3.3 Soft-key rows..................................................................1389
8.4 Keystroke simulation....................................................................1392
8.4.1 iTNC control panel...........................................................1392
8.4.2 Machine operating panel.................................................1404
8.4.3 Touchpad on USB port....................................................1405

July 2013 13
8.5 Files ................................................................................................1406
8.5.1 Datum tables (*.D) ..........................................................1409
8.5.2 Freely definable tables ....................................................1409
8.5.3 PLC files..........................................................................1419
8.6 DCM – Dynamic Collision Monitoring .........................................1424
8.6.1 DCM – monitoring the working space for collisions........1424
8.6.2 Fixture monitoring with DCM..........................................1453
8.6.3 Tool carrier kinematics and DCM ....................................1477
8.6.4 KinematicsDesign............................................................1488
8.7 Pallet management.......................................................................1490
8.8 Electronic handwheel ...................................................................1502
8.8.1 HR 130 panel-mounted handwheel.................................1510
8.8.2 HR 410 portable handwheel............................................1510
8.8.3 HR 420 portable handwheel............................................1513
8.8.4 HR 520 portable handwheel............................................1516
8.8.5 HR 550FS wireless handwheel .......................................1518
8.8.6 HR 150 panel-mounted handwheels with HRA 110
handwheel adapter..........................................................1524
8.9 PLC inputs/outputs.......................................................................1526
8.9.1 24 V– switching input/outputs ........................................1526
8.9.2 Analog inputs...................................................................1529
8.9.3 Analog outputs................................................................1529
8.10 Incremental jog positioning .........................................................1530
8.11 Hirth coupling................................................................................1532
8.12 Datum shift....................................................................................1534
8.13 Touch probe...................................................................................1535
8.13.1 Using the touch probes...................................................1536
8.13.2 Touch probe cycles .........................................................1539
8.13.3 Measurement log in manual touch probe cycles ............1546
8.13.4 Measurement log in the touch probe cycles for
probing from the NC program .........................................1549
8.13.5 Tool measurement .........................................................1552
8.14 Special functions for laser cutting machines .............................1561
8.14.1 Analog voltage output .....................................................1561
8.14.2 Graphic simulation (without TOOL CALL) .......................1563
8.14.3 Program stop for M functions and TOOL CALL S...........1564
8.15 Tool changer..................................................................................1565
8.15.1 Tool and pocket table......................................................1565
8.15.2 Tool-usage test................................................................1597
8.15.3 Automatic calculation of cutting data ..............................1601
8.15.4 Automatic tool recognition ..............................................1603
8.15.5 Controlling the tool changer ............................................1603
8.15.6 PLC programming example.............................................1629
8.15.7 Extended tool management............................................1641

14 HEIDENHAIN Technical Manual iTNC 530 HSCI
9 PLC Programming.................................1661
9.1 PLC Functions................................................................................1661
9.1.1 Selecting the PLC mode .................................................1667
9.1.2 PLC main menu...............................................................1667
9.1.3 File management ............................................................1670
9.1.4 The WATCH LIST function ..............................................1671
9.1.5 The I/O-FORCE LIST .......................................................1674
9.1.6 The TABLE function ........................................................1676
9.1.7 The TRACE function........................................................1678
9.1.8 The logic diagram............................................................1680
9.1.9 The COMPILE function ...................................................1682
9.1.10 ADVANCED SETUP.........................................................1683
9.2 Conditional Compilation ..............................................................1684
9.3 Hard-Disk Organization ................................................................1689
9.3.1 Encrypted PLC partition (PLCE:)......................................1690
9.4 System Files ..................................................................................1701
9.4.1 OEM.SYS ........................................................................1701
9.4.2 NCMACRO.SYS ..............................................................1709
9.4.3 MGROUPS.SYS ..............................................................1712
9.4.4 MSPLIT.SYS....................................................................1712
9.4.5 PLCSOFTK.SYS...............................................................1712
9.4.6 CYCLE.SYS .....................................................................1712
9.4.7 TNC.SYS..........................................................................1712
9.5 Data Transfer NC > PLC, PLC > NC ..............................................1713
9.5.1 Data transfer NC program > PLC (FN19: PLC =) .............1713
9.5.2 Data transfer PLC > NC program (Q-parameters) ...........1714
9.5.3 Data transfer NC program > NC (FN17: SYSWRITE) ......1716
9.5.4 Data transfer NC > NC program (FN18: SYSREAD)........1725
9.5.5 Data transfer of machine parameters > PLC...................1737
9.5.6 Interrogate PLC operands in the NC program (FN20:
WAIT FOR)......................................................................1740
9.5.7 Data transfer PLC operand <=> NC program .................1741
9.6 Operands........................................................................................1744
9.6.1 Overview of operands.....................................................1744
9.6.2 Operand addressing (byte, word and double word) ........1747
9.6.3 Timers .............................................................................1748
9.6.4 Counters..........................................................................1751
9.6.5 Fast PLC inputs ...............................................................1753
9.7 Program Creation..........................................................................1754
9.7.1 ASCII editor.....................................................................1755
9.7.2 Program format...............................................................1755
9.7.3 Program structure ...........................................................1756
9.7.4 Logical names for files ....................................................1757

July 2013 15
9.8 Command Set................................................................................1758
9.8.1 Overview.........................................................................1758
9.8.2 LOAD (L)..........................................................................1761
9.8.3 LOAD NOT (LN)...............................................................1763
9.8.4 LOAD TWO’S COMPLEMENT (L–).................................1765
9.8.5 LOAD BYTE (LB) .............................................................1766
9.8.6 LOAD WORD (LW)..........................................................1766
9.8.7 LOAD DOUBLE WORD (LD)...........................................1767
9.8.8 ASSIGN (=)......................................................................1767
9.8.9 ASSIGN BYTE (B=)..........................................................1768
9.8.10 ASSIGN WORD (W=)......................................................1769
9.8.11 ASSIGN DOUBLE WORD (D=) .......................................1769
9.8.12 ASSIGN NOT (=N)...........................................................1770
9.8.13 ASSIGN TWO’S COMPLEMENT (=–) .............................1770
9.8.14 SET (S).............................................................................1771
9.8.15 RESET (R)........................................................................1772
9.8.16 SET NOT (SN)..................................................................1773
9.8.17 RESET NOT (RN).............................................................1774
9.8.18 AND (A) ...........................................................................1775
9.8.19 AND NOT (AN) ................................................................1777
9.8.20 OR (O) .............................................................................1779
9.8.21 OR NOT (ON) ..................................................................1781
9.8.22 EXCLUSIVE OR (XO) .......................................................1783
9.8.23 EXCLUSIVE OR NOT (XON) ............................................1785
9.8.24 ADDITION (+)..................................................................1787
9.8.25 SUBTRACTION (–)...........................................................1788
9.8.26 MULTIPLICATION (X)......................................................1789
9.8.27 DIVISION (/).....................................................................1790
9.8.28 REMAINDER (MOD) .......................................................1791
9.8.29 INCREMENT (INC)...........................................................1792
9.8.30 DECREMENT (DEC) ........................................................1792
9.8.31 EQUAL TO (==)...............................................................1793
9.8.32 LESS THAN (<)................................................................1794
9.8.33 GREATER THAN (>) ........................................................1795
9.8.34 LESS THAN OR EQUAL TO (<=) ....................................1796
9.8.35 GREATER THAN OR EQUAL TO (>=).............................1797
9.8.36 NOT EQUAL (<>) ............................................................1798
9.8.37 AND [ ] (A[ ]) ....................................................................1799
9.8.38 AND NOT [ ] (AN[ ]) .........................................................1801
9.8.39 OR [ ] (O[ ]) ......................................................................1801
9.8.40 OR NOT [ ] (ON[ ]) ...........................................................1801
9.8.41 EXCLUSIVE OR [ ] (XO[ ]) ................................................1801
9.8.42 EXCLUSIVE OR NOT [ ] (XON[ ]) .....................................1801
9.8.43 ADDITION [ ] (+[ ])...........................................................1802
9.8.44 SUBTRACT [ ] (–[ ]) ..........................................................1803
9.8.45 MULTIPLY [ ] (x[ ])...........................................................1803
9.8.46 DIVIDE [ ] (/[ ])..................................................................1803
9.8.47 REMAINDER [ ] (MOD[ ]) ................................................1803
9.8.48 EQUAL TO [ ] (==[ ])........................................................1804
9.8.49 LESS THAN [ ] (<[ ]).........................................................1805
9.8.50 GREATER THAN [ ] (>[ ]).................................................1805
9.8.51 LESS THAN OR EQUAL TO [ ] (<=[ ]) .............................1805
9.8.52 GREATER THAN OR EQUAL TO [ ] (>=[ ])......................1805
9.8.53 NOT EQUAL [ ] (<>[ ]) .....................................................1805

16 HEIDENHAIN Technical Manual iTNC 530 HSCI
9.8.54 SHIFT LEFT (<<)..............................................................1806
9.8.55 SHIFT RIGHT (>>)...........................................................1807
9.8.56 BIT SET (BS)....................................................................1808
9.8.57 BIT CLEAR (BC)...............................................................1809
9.8.58 BIT TEST (BT)..................................................................1810
9.8.59 PUSH DATA ONTO THE DATA STACK (PS) ...................1811
9.8.60 PULL DATA FROM THE DATA STACK (PL)....................1812
9.8.61 PUSH LOGIC ACCUMULATOR ONTO THE DATA
STACK (PSL)....................................................................1812
9.8.62 PUSH WORD ACCUMULATOR ONTO THE DATA
STACK (PSW)..................................................................1813
9.8.63 PULL LOGIC ACCUMULATOR FROM THE DATA
STACK (PLL)....................................................................1813
9.8.64 PULL WORD ACCUMULATOR FROM THE DATA
STACK (PLW) ..................................................................1814
9.8.65 UNCONDITIONAL JUMP (JP).........................................1814
9.8.66 JUMP IF LOGIC ACCUMULATOR = 1 (JPT)...................1815
9.8.67 JUMP IF LOGIC ACCUMULATOR = 0 (JPF)...................1815
9.8.68 CALL MODULE (CM) ......................................................1816
9.8.69 CALL MODULE IF LOGIC ACCUMULATOR = 1 (CMT)..1816
9.8.70 CALL MODULE IF LOGIC ACCUMULATOR = 0 (CMF)..1817
9.8.71 END OF MODULE, END OF PROGRAM (EM) ...............1818
9.8.72 END OF MODULE IF LOGIC ACCUMULATOR = 1
(EMT)...............................................................................1818
9.8.73 END OF MODULE IF LOGIC ACCUMULATOR = 0
(EMF)...............................................................................1818
9.8.74 LABEL (LBL)....................................................................1818
9.9 INDEX register (X register)...........................................................1819
9.10 Commands for String Processing................................................1821
9.10.1 LOAD String (L)...............................................................1823
9.10.2 ADD String (+).................................................................1823
9.10.3 STORE String (=).............................................................1823
9.10.4 OVERWRITE String (OVWR) ...........................................1824
9.10.5 EQUAL TO Command for String Processing (==)...........1825
9.10.6 LESS THAN Command for String Processing (<)............1825
9.10.7 GREATER THAN Command for String Processing (>) ....1825
9.10.8 LESS THAN OR EQUAL TO Command for String
Processing (<=)...............................................................1826
9.10.9 GREATER THAN OR EQUAL TO Command for String
Processing (>=)...............................................................1826
9.10.10 NOT EQUAL Command for String Processing (<>) ........1827
9.10.11 Modules for string processing ........................................1828
9.11 Submit Programs..........................................................................1831
9.11.1 Calling the submit program (SUBM) ...............................1832
9.11.2 Interrogating the status of a submit program (RPLY)......1832
9.11.3 Canceling a submit program (CAN).................................1833
9.12 Cooperative multitasking.............................................................1835
9.12.1 Starting a parallel process (SPAWN) ...............................1835
9.12.2 Control of events.............................................................1836
9.13 Constants field (KF).......................................................................1841

July 2013 17
9.14 Program Structures ......................................................................1842
9.14.1 IF ... ELSE ... ENDI structure...........................................1843
9.14.2 REPEAT ... UNTIL structure ............................................1843
9.14.3 WHILE ... ENDW structure..............................................1844
9.14.4 CASE branch ...................................................................1844
9.15 Linking Files...................................................................................1846
9.15.1 USES Statement (USES) .................................................1847
9.15.2 GLOBAL statement (GLOBAL)........................................1848
9.15.3 EXTERN Statement (EXTERN) ........................................1848
9.16 PLC Modules..................................................................................1849
9.16.1 Markers, bytes, words, and double words......................1849
9.16.2 Number conversion.........................................................1852
9.17 Python............................................................................................1856
10 Data Interfaces......................................1857
10.1 Introduction...................................................................................1857
10.1.1 Principles of data transfer................................................1858
10.1.2 Data transfer check: Handshaking...................................1862
10.2 The Ethernet Interface of the iTNC..............................................1863
10.3 Connecting the iTNC to the Network .........................................1864
10.3.1 Settings at the iTNC ........................................................1864
10.4 Protection Against Data Tampering............................................1893
10.5 The USB Interface of the iTNC.....................................................1894
10.6 iTNC Serial Data Interfaces ..........................................................1899
10.6.1 General information.........................................................1899
10.6.2 RS-232-C/V.24 interface ..................................................1899
10.7 Configuration of Interfaces ..........................................................1902
10.7.1 Control characters ...........................................................1902
10.7.2 Selection of interfaces and operating modes..................1903
10.7.3 Configuration of interfaces..............................................1903
10.8 Data Transmission Protocols .......................................................1907
10.8.1 Selection of transmission protocols ................................1907
10.8.2 Standard communications protocol.................................1908
10.8.3 Communications protocol with block check character....1910
10.8.4 LSV2 transmission protocol.............................................1913
10.9 Saving and Loading Files .............................................................1914
10.10 Data Transfer by PLC ....................................................................1916
10.10.1 Settings ...........................................................................1916
10.10.2 PLC modules...................................................................1917
10.11 External Programming .................................................................1929

18 HEIDENHAIN Technical Manual iTNC 530 HSCI
11 iTNC 530 and Windows........................1931
11.1 General information and important notes .................................1931
11.2 IPC 6341—Industrial PC with Windows 7 ...................................1931
12 Error messages .....................................1943
12.1 DSP/NC error messages...............................................................1943
12.2 iTNC Error Messages during Data Transfer................................1944
12.3 Error messages of the file system...............................................1945
13 Subject Index ........................................1947

July 2013 1.1 General information 19
1 Update Information
1.1 General information
Update Information for the iTNC 530 HSCI 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 HSCI Technical Manual.
The Technical Manual and each Update Information are saved in the
HEIDENHAIN HESIS-Web including Filebase on the Internet, where
registered users can access them at http://portal.heidenhain.de.
Registered users of the HEIDENHAIN HESIS-Web including Filebase on the
Internet receive an e-mail notification when a new Update Information
appears.
This version of the Technical Manual includes all Update Information
documents of the iTNC 530 up to and including number 37, meaning that the
contents of this Technical Manual for the iTNC 530 HSCI correspond to the
scope of functions of software version 60642x-03.

20 HEIDENHAIN Technical Manual iTNC 530 HSCI