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