HEIDENHAIN MANUALPLUS 620 User manual

Technical Manual
MANUALplus 620
NC Software
548 328-04
January 2012

January 2012 3
Contents
1 Update Information No. 1........................19
1.1 Overview............................................................................................19
1.2 NC Software 548 328-02...................................................................19
1.2.1 Important notes on updating software .................................19
1.2.2 Description of the new functions..........................................26
1 Update Information No. 2........................37
1.1 Overview............................................................................................37
1.2 NC Software 548 328-03...................................................................37
1.2.1 Important notes on updating software .................................37
1.2.2 Description of the new functions..........................................39
1 Update Information No. 3........................47
1.1 Hardware ...........................................................................................47
1.1.1 UEC 11x controller unit with inverter and PLC I/O................47
1 Update Information No. 4........................51
1.1 Overview............................................................................................51
1.1.1 Released service packs.........................................................51
1.1.2 Released NC software..........................................................51
1.2 NC Software 548 328-03...................................................................51
1.3 NC Software 548 328-04...................................................................52
1.3.1 Important change made in the technical manual ..................52
1.3.2 Important notes on updating software .................................53
1.3.3 Description of the new functions..........................................57
1.4 Hardware ...........................................................................................78
1.4.1 CMA-H SPI module for analog axes......................................78

4 HEIDENHAIN Technical Manual MANUALplus 620
2 Introduction...............................................79
2.1 Meaning of the Symbols Used in this Manual...............................79
2.2 Proper and Intended Operation.......................................................79
2.3 Trained Personnel .............................................................................79
2.4 General Information..........................................................................80
2.4.1 HSCI interface.......................................................................83
2.5 Component Overview of MANUALplus 620..................................84
2.5.1 MC main computer, CFR memory card and SIK...................84
2.5.2 SIK (System Identification Key).............................................86
2.5.3 CC 61xx controller units........................................................86
2.5.4 UEC 11x controller unit with integrated inverter and PLC ....87
2.5.5 PLC input/output systems with HSCI interface ....................89
2.5.6 SPI expansion modules.........................................................93
2.5.7 PSL 13x low-voltage power supply unit................................94
2.5.8 MB 620T machine operating panel.......................................96
2.5.9 HSCI adapter for PLB 6001 OEM-specific machine
operating panel .....................................................................97
2.5.10 Handwheels..........................................................................98
2.5.11 Key symbols........................................................................101
2.5.12 Touch probes ......................................................................106
2.5.13 Other accessories...............................................................109
2.5.14 Documentation ...................................................................110
2.6 Brief Description..............................................................................111
2.6.1 Specifications for MANUALplus 620 ..................................111
2.6.2 User functions.....................................................................117
2.6.3 Software options.................................................................122
2.6.4 Accessories.........................................................................123
2.7 Software ..........................................................................................125
2.7.1 Designation of the software ...............................................125
2.7.2 PLC software ......................................................................125
2.7.3 Additional control loops or software options ......................126
2.7.4 Configurations.....................................................................136
2.7.5 Coordinate system of the lathe...........................................137
2.7.6 NC software exchange on the MANUALplus 620 ..............137
2.7.7 Installing a service pack ......................................................143
2.7.8 Reversing a software update..............................................144
2.7.9 Special features of the software.........................................146
2.7.10 Firmware update on HSCI devices .....................................147
2.7.11 Monitoring hardware changes ............................................149
2.7.12 Data backup ........................................................................149
2.8 Software Releases ..........................................................................150
2.8.1 NC software 548 328-xx .....................................................150

January 2012 5
3 Mounting and Electrical Installation.....151
3.1 General Information........................................................................151
3.1.1 Safety precautions ..............................................................151
3.1.2 Degrees of protection.........................................................152
3.1.3 Electromagnetic compatibility.............................................152
3.1.4 ESD protection....................................................................153
3.2 Environmental Conditions .............................................................155
3.2.1 Storage and operating temperatures ..................................155
3.2.2 Heat generation and cooling ...............................................157
3.2.3 Limit values for ambient conditions....................................158
3.2.4 Installation elevation ...........................................................158
3.2.5 UEC 11x (FS) mounting position.........................................159
3.2.6 MC 6110T mounting position .............................................160
3.2.7 CC 61xx, UV xxx, UM xxx, UE 2xx B(D) mounting position161
3.2.8 PLB 6xxx mounting position ...............................................162
3.3 Overview of Components ..............................................................163
3.4 HSCI..................................................................................................168
3.4.1 Introduction.........................................................................168
3.4.2 Topology .............................................................................170
3.4.3 HSCI interface.....................................................................171
3.5 MANUALplus 620 Connection Overview......................................172
3.5.1 MC 6110T main computer..................................................172
3.5.2 CC 6106 ..............................................................................173
3.5.3 CC 6108 ..............................................................................174
3.5.4 CC 6110 ..............................................................................175
3.5.5 UEC 11x..............................................................................176
3.5.6 PLB 62xx.............................................................................177
3.5.7 PLB 61xx.............................................................................177
3.5.8 PLD-H and PLA-H I/O modules...........................................178
3.6 Supply Voltages in the HSCI System............................................180
3.6.1 Current consumption of the HSCI components..................182
3.6.2 X90: +24 V NC output of the UxC 11x (FS).........................183
3.6.3 X101: NC power supply ......................................................184
3.6.4 Power supply of the CC 61xx .............................................185
3.6.5 PSL 13x low-voltage power supply unit..............................189
3.7
MS 110 / MS 111 Installation Kit for Double-Row Configuration ....199
3.7.1 General information ............................................................199
3.7.2 Double-row configuration....................................................200
3.7.3 Connection overview ..........................................................202
3.8 UxC 11x (FS): Power Supply and Motor Connection...................206
3.8.1 UEC 11x (FS).......................................................................206
3.9 UxC 11x (FS): Meaning of the LEDs...............................................212
3.10 Power Supply for PLC Outputs......................................................214
3.11 Power Supply for PLB 6xxx (FS)....................................................216
3.12 Meaning of the LED on PLB 6xxx ..................................................217
3.13 Power Supply for Control-Is-Ready Signal...................................217
3.14 Drive Controller Enable ..................................................................218

6 HEIDENHAIN Technical Manual MANUALplus 620
3.15 Digital PLC Inputs/Outputs............................................................219
3.15.1 UxC 11x (FS): Digital PLC inputs/outputs............................228
3.16 Analog PLC Inputs/Outputs...........................................................235
3.17 PROFIBUS Connection....................................................................237
3.18 Configuring the PLC Inputs/Outputs with IOconfig ....................238
3.19 Buffer Battery ..................................................................................241
3.20 Encoder Connections .....................................................................242
3.20.1 General information ............................................................242
3.20.2 Position encoder input .......................................................243
3.20.3 Speed encoder input .........................................................246
3.21 Adapters for Encoder Signals ........................................................250
3.22 Connecting the Motor Power Modules (Only CC 61xx) ..............254
3.23 Analog Nominal Value Output ......................................................255
3.23.1 CMA-H 04-04-00 – Pin layout..............................................257
3.24 Touch Probe Systems.....................................................................260
3.25 Data Interfaces ................................................................................265
3.25.1 USB interface (USB 2.0)......................................................268
3.26 MB 620T Machine Operating Panel...............................................269
3.27
HSCI Adapter for PLB 6001 OEM-Specific Machine Operating Panel ....278
3.28 Handwheel Input.............................................................................287
3.28.1 HR 410 portable handwheel ...............................................287
3.28.2 HR 130 panel-mounted handwheel ....................................289
3.28.3 HRA 110 handwheel adapter..............................................290
3.29 CML 110 Capacitor Module............................................................292
3.30 Connecting Cables: Specifications ................................................294
3.31 Dimensions......................................................................................295
3.31.1 MC 6110T ...........................................................................296
3.31.2 MB 620T .............................................................................297
3.31.3 CC 6106 ..............................................................................298
3.31.4 CC 6108 / CC 6110 .............................................................299
3.31.5 UEC 11x (FS).......................................................................300
3.31.6 PL 6xxx (FS) ........................................................................301
3.31.7 PLB 6001(FS) ......................................................................302
3.31.8 PSL 130...............................................................................303
3.31.9 PSL 135...............................................................................304
3.31.10 MS 11x................................................................................305
3.31.11 Adapter block for the data interface....................................306
3.31.12 USB hub..............................................................................307
3.31.13 Line-drop compensator.......................................................308
3.31.14 Handwheels........................................................................308
3.31.15 Touch probes ......................................................................311
3.31.16 CML 110 .............................................................................318
3.31.17 USB hub for operating panel...............................................318
3.32
HSCI Connection Overview of the MANUALplus 620 with CC 61xx .....319
3.33
HSCI Connection Overview of the MANUALplus 620 with UEC 11x .....320

January 2012 7
3.34 Grounding Diagram for MANUALplus 620 with Modular
HEIDENHAIN Inverter System .......................................................321
3.35 Basic Circuit Diagram for MANUALplus 620 ................................322
3.36 Cable Overview for MANUALplus 620 with UEC 11x – Basic
Configuration...................................................................................323
3.37 Cable Overview for MANUALplus 620 with CC 610x – Basic
Configuration...................................................................................324
3.38 Cable Overview for HEIDENHAIN Inverter System......................325
3.39 Cable Overview for MANUALplus 620 – Accessories ..................326
4 Machine Parameters...............................327
4.1 General Information........................................................................327
4.2 The "Machine Parameters" Mode of Operation...........................329
4.2.1 Calling the configuration editor ...........................................329
4.2.2 Entering and changing machine parameters.......................331
4.2.3 Accessing machine parameters via MP numbers...............342
4.2.4 Managing configuration files...............................................345
4.2.5 Sorting file content..............................................................346
4.2.6 Attribute information...........................................................347
4.2.7 Access protection / Options................................................350
4.2.8 Update rules........................................................................351
4.2.9 Removing syntax errors......................................................362
4.2.10 Resetting the update version..............................................362
4.2.11 Backup of parameters.........................................................363
4.2.12 Resetting system settings..................................................364
4.3 User Parameters..............................................................................365
4.3.1 Configuration of the user parameters.................................366
4.3.2 Example: .............................................................................372
4.3.3 XML commands for creating the layout files......................374
4.4 The KeySynonym Function............................................................377
4.5 Allocation of Configuration Data ..................................................379
4.6 Structure of a Parameter File.........................................................380
4.7 Machine-Parameter Subfiles..........................................................383
4.7.1 Syntax of machine-parameter subfile .................................383
4.7.2 Activating the machine-parameter subfile ..........................384
4.7.3 Displaying/editing data records in the configuration editor .387
4.8 Reading or Changing Machine Parameters via PLC Modules.....389
4.9 Switching Parameter Sets .............................................................398
4.10 List of Machine Parameters ...........................................................408
4.10.1 "System" group....................................................................408
4.10.2 "Channels" group.................................................................490
4.10.3 "Axes" group........................................................................510
4.10.4 KeySynonym.......................................................................582
4.10.5 Aggregates..........................................................................583
4.10.6 ProcessingData...................................................................595

8 HEIDENHAIN Technical Manual MANUALplus 620
5 Modules and PLC Operands ..................599
5.1 Overview of Modules......................................................................599
5.2 Overview of the PLC Operands......................................................604
5.2.1 PLC operands of the General Data group ...........................604
5.2.2 PLC operands of the Operating Mode Group group...........606
5.2.3 PLC operands of the Machining Channels group................607
5.2.4 PLC operands of the Axis group .........................................609
5.2.5 PLC operands of the Spindle group ....................................611
6 Configuring the Axes and Spindle ........613
6.1 Machine Structure ..........................................................................613
6.1.1 Adapting the MANUALplus 620 to the machine.................613
6.1.2 Definition of axes................................................................614
6.2 Configuration of Machining Channels ..........................................617
6.2.1 Configuring a machining channel........................................617
6.2.2 Traversing the reference marks..........................................621
6.2.3 Returning to the contour/block scan...................................622
6.3 Configuration of Axes.....................................................................624
6.3.1 Axis designations and coordinates......................................626
6.3.2 Programmable axes ............................................................628
6.3.3 Physical axes.......................................................................631
6.3.4 Kinematic properties of axes ..............................................641
6.3.5 Manually operated axis (counter axis).................................643
6.4 Encoders ..........................................................................................645
6.4.1 Type of position encoder ....................................................645
6.4.2 Signal period of encoders ...................................................648
6.4.3 Distance-coded reference marks ........................................654
6.4.4 Connecting the encoders, PWM output on the CC 61xx....656
6.4.5 Connecting the encoders to the UEC 11x ..........................661
6.4.6 Defining the traverse direction............................................663
6.4.7 Encoder monitoring.............................................................665
6.5 Analog Axes.....................................................................................669
6.5.1 Central drive........................................................................670
6.6 Reading and Writing Axis Information .........................................671
6.6.1 Reading axis information.....................................................671
6.6.2
Writing axis information—activating and deactivating axes .....678
6.7 Traverse Ranges..............................................................................688
6.8 Lubrication Pulse.............................................................................690
6.9 PLC Axes ..........................................................................................692
6.9.1 Hirth coupling......................................................................702
6.10 Axis Error Compensation ...............................................................705
6.10.1 Backlash compensation ......................................................707
6.10.2 Linear axis error compensation...........................................711
6.10.3 Nonlinear axis error compensation .....................................713
6.10.4 Compensation of thermal expansion ..................................721
6.10.5 Compensation of static friction...........................................723
6.10.6 Compensation of sliding friction .........................................724

January 2012 9
6.11 Machine Kinematics (As of NC Software 548328-03) ..................727
6.11.1 Configuring the machine kinematics...................................730
6.11.2 Preconfigured subkinematics..............................................739
6.11.3 Standard kinematic models.................................................742
6.11.4 Finding/activating kinematics through the PLC...................744
6.11.5 Axis mirroring on lathes (as of NC software 548328-03) ....746
6.12 Machine Kinematics (Up to NC Software 548 328-02) ................747
6.12.1 Configuration of the machine kinematics ...........................748
6.12.2 Definition of the transformation with vectors.....................758
6.12.3 Axis mirroring for lathes......................................................761
6.13 Parallel Axes ....................................................................................762
6.14 Synchronized Axes (Option 24) .....................................................764
6.14.1 Gantry axes.........................................................................765
6.14.2 Master-slave torque control................................................775
6.14.3 Brake test for synchronized axes........................................784
6.15 Reference Marks..............................................................................789
6.15.1 Definition.............................................................................789
6.15.2 Traversing the reference marks..........................................790
6.15.3 Traversing the reference marks..........................................794
6.15.4 Defining the process of traversing the reference marks ....797
6.15.5 "Traverse Reference Points" operating mode .....................804
6.16 The Control Loop ............................................................................808
6.16.1 Block diagram of control loop .............................................808
6.16.2 Relation between jerk, acceleration, velocity and distance 809
6.16.3 Nominal position value filter................................................811
6.16.4 Look-ahead..........................................................................825
6.16.5 Interpolator..........................................................................838
6.16.6 Position controller ...............................................................839
6.16.7 Activating and deactivating position control loops..............848
6.16.8 Feed-rate enable .................................................................852
6.16.9 Speed controller..................................................................853
6.16.10 Filters in the speed controller and position controller
when using the CC 61xx and CC 424 .................................857
6.16.11 Filter order for separate low-pass filter in the speed
controller on the CC 61xx and CC 424: ..............................861
6.16.12 Peculiarities in weakened-field operation with CC 61xx
and CC 424 .........................................................................862
6.16.13 Active damping of low-frequency oscillations.....................864
6.16.14 Acceleration feedforward control........................................866
6.16.15 IPC, holding torque, following error in the jerk phase.........869
6.16.16 HSCI: switching drives on and off, enabling the drive
controller.............................................................................874
6.16.17 Current controller ................................................................885
6.16.18
Braking the drives for an emergency stop and a power failure ....890
6.16.19 Power and torque limiting...................................................894
6.16.20 Controller parameters for manual traverse .........................901
6.16.21 Controller parameters for analog axes................................902
6.16.22 Controller parameters for analog axes................................913
6.16.23 Weakened field operation...................................................924
6.16.24 Motor with wye/delta switchover .......................................936
6.16.25 Speed-dependent switching of the PWM frequency..........938
6.16.26 TRC – Torque Ripple Compensation ...................................941
6.16.27 Torsion compensation.........................................................944

10 HEIDENHAIN Technical Manual MANUALplus 620
6.17 Monitoring Functions .....................................................................946
6.17.1 Monitoring the drives..........................................................946
6.17.2 Position monitoring.............................................................948
6.17.3 Movement monitoring ........................................................953
6.17.4 Standstill monitoring ...........................................................955
6.17.5 Positioning window.............................................................956
6.17.6 Monitoring of the power supply unit ..................................959
6.17.7 Temperature monitoring .....................................................962
6.17.8 I2t monitoring......................................................................965
6.17.9 Momentary utilization of drive motors................................977
6.17.10 Status of HEIDENHAIN hardware and software.................979
6.17.11 Motor brake ........................................................................983
6.17.12 Emergency stop monitoring................................................989
6.17.13
Monitoring functions when using the CC 61xx and CC 424 ........996
6.18 Spindles ...........................................................................................998
6.18.1 Configuring spindles ...........................................................998
6.18.2 Spindle in position feedback control .................................1000
6.18.3 Spindle in speed control....................................................1009
6.18.4 Filtering the acceleration values........................................1014
6.18.5 Controlling the spindle ......................................................1015
6.18.6 Switching the operating modes ........................................1029
6.18.7 Analog spindle with unipolar motor ..................................1032
6.18.8 Spindle synchronism.........................................................1033
6.18.9 Spindle of the kinematics model
(as of NC software 548 328-03)........................................1036
6.18.10 Spindle of the kinematics model
(until NC software 548 328-02).........................................1037
6.18.11 Gear shifting......................................................................1038
6.18.12 Tapping .............................................................................1039
6.18.13 C-axis operation ................................................................1040
6.18.14 Volts-per-hertz control mode.............................................1042
6.19 Configuring the Controller Unit and Drive Motors....................1044
6.19.1 Specifications of CC 61xx / UEC 1xx ................................1044
6.19.2 Structure of the CC 61xx and UEC 11x controller units....1046
6.19.3 PWM frequencies with the CC 61xx ................................1048
6.19.4
PWM frequency with INDRAMAT "POWER DRIVE" inverters ... 1050
6.19.5 PWM frequency with SIEMENS "SIMODRIVE" inverters .1050
6.19.6 Comparison of the CC 61xx and CC 424 controller units..1053
6.19.7 Configuring the drive motor..............................................1055
6.19.8 Field orientation ................................................................1058
6.19.9
Determining the field angle with the CC 61xx und CC 424 ........ 1061
6.20 Commissioning .............................................................................1072
6.20.1 Tables for power modules, supply modules and motors..1072
6.20.2 Field orientation ................................................................1084
6.20.3 Preparation........................................................................1084
6.20.4 Commissioning of digital axes ..........................................1089
6.20.5 Commissioning of analog axes .........................................1104
6.20.6 Configuring the nominal position value filter and
look-ahead parameters......................................................1124
6.20.7 Commissioning the digital spindle ....................................1140

January 2012 11
6.21 Integrated Oscilloscope................................................................1145
6.21.1 Fundamentals ...................................................................1145
6.21.2 Preparing a recording........................................................1147
6.21.3 Recording signals..............................................................1151
6.21.4 Analyzing the recording.....................................................1154
6.21.5 Saving and loading recordings ..........................................1157
6.21.6
Circular interpolation test with the integrated oscilloscope ... 1158
6.21.7 Configuring the colors of the oscilloscope display............1159
6.22 Diagnosis with the Online Monitor (OLM) .................................1162
6.22.1 Introduction.......................................................................1162
6.22.2 Using the OLM .................................................................1163
6.22.3 Screen layout ....................................................................1165
6.22.4 Group of NC axes..............................................................1168
6.22.5 Group of spindle commands.............................................1188
6.22.6 Group of NC channels.......................................................1190
6.22.7 Hardware group ................................................................1196
6.22.8 Group of drive commands ................................................1209
6.22.9 Auxiliary group ..................................................................1210
6.22.10 PLC group .........................................................................1216
6.22.11 Queue trace ......................................................................1219
6.22.12 Frequent causes of error...................................................1221
7 Machine Interfacing..............................1223
7.1 Display and Operation..................................................................1223
7.1.1 Unit of measurement for display and operation................1223
7.1.2 Conversational language...................................................1225
7.1.3 Expanded menu structure.................................................1228
7.1.4 Access rights to NC files...................................................1230
7.1.5 Code numbers ..................................................................1230
7.1.6 Programming station mode ..............................................1233
7.1.7 Operating modes / control operation in the operating
mode group.......................................................................1236
7.1.8 Control operation in the machining channel......................1241
7.1.9 Error messages and log files.............................................1254
7.1.10 TURNguide – context-sensitive help system
(user documentation)........................................................1278
7.2 Machine Display in the Dashboard..............................................1287
7.2.1 Assigning dashboards to the operating modes.................1289
7.2.2 Configuring dashboards ....................................................1292
7.3 PLC Soft Keys ................................................................................1307
7.3.1 Soft-key resource file........................................................1308
7.4 Switching the Control On/Off......................................................1313
7.4.1 Powering up the control....................................................1313
7.4.2 Shutting down the control ................................................1317
7.5 Keystroke Simulation ...................................................................1325
7.5.1 Control keyboard...............................................................1325
7.5.2 Machine operating panel...................................................1331

12 HEIDENHAIN Technical Manual MANUALplus 620
7.6 Electronic Handwheel...................................................................1333
7.6.1 Serial handwheel...............................................................1333
7.6.2 Handwheel at position encoder input ...............................1339
7.6.3 Traverse per handwheel revolution...................................1344
7.6.4 Assigning a handwheel to an axis.....................................1345
7.6.5 HR 410 portable handwheel .............................................1348
7.6.6 HR 150 panel-mounted handwheels with HRA 110
handwheel adapter ...........................................................1350
7.7 Override .........................................................................................1352
7.7.1 Override devices...............................................................1352
7.7.2 Override functions ............................................................1354
7.7.3 Compensation for potentiometers....................................1360
7.8 PLC Inputs/Outputs ......................................................................1361
7.8.1 Diagnosis of the external PL.............................................1361
7.8.2 24 V– switching input/outputs .........................................1365
7.8.3 Analog inputs ....................................................................1368
7.8.4 Analog outputs..................................................................1371
7.9 Operating Times and System Times...........................................1373
7.9.1 Measuring operating times...............................................1373
7.9.2 System time......................................................................1379
7.10 Touch Probe...................................................................................1381
7.10.1 Tool measurement ...........................................................1384
7.11 Additional Parameters for Lathes................................................1388
7.11.1 Coordinate system of the lathe.........................................1388
7.11.2 Linear axes........................................................................1389
7.11.3 Spindles ............................................................................1391
7.11.4 C axis ................................................................................1393
7.11.5 Tailstock and steady rest ..................................................1395
7.11.6 Tool carriers ......................................................................1396
7.11.7 Tool holders (mounts) .......................................................1400
7.11.8 Transfer of data to the PLC...............................................1404
7.11.9 Conversions ......................................................................1408
7.11.10 Global settings ..................................................................1408
7.11.11 Settings for cycles ............................................................1418
7.11.12 Settings for smart.Turn operating mode...........................1419
7.11.13 Settings for the simulation................................................1422
7.11.14 User parameters ...............................................................1427
7.12 Configuration of the Lathe...........................................................1428
7.12.1 Coordinate system............................................................1428
7.12.2 Settings for linear axes .....................................................1429
7.12.3 Settings for spindles .........................................................1430
7.12.4 Driven tool.........................................................................1432
7.12.5 Settings for the C axis.......................................................1434
7.12.6 Configuring the Y axis.......................................................1439
7.12.7 Configuring parallel axes...................................................1446
7.12.8 Activating gantry axes.......................................................1452
7.12.9 Configuring rear-side machining .......................................1455
7.12.10 Traversing to a fixed stop (G916) and sleeve
monitoring (G930) .............................................................1464
7.12.11 Configuring the tool carrier ...............................................1470
7.12.12 Expert programs ...............................................................1476
7.12.13 Manual programs..............................................................1478

January 2012 13
8 PLC Programming.................................1481
8.1 PLC Functions................................................................................1481
8.1.1 The API 3.0 symbolic memory interface...........................1482
8.1.2 HEIDENHAIN PLC basic program.....................................1486
8.1.3 Selecting the PLC programming mode of operation.........1487
8.1.4 PLC main menu ................................................................1487
8.1.5 File management ..............................................................1489
8.1.6 The API DATA function.....................................................1490
8.1.7 The WATCH LIST function................................................1491
8.1.8 The TABLE function..........................................................1493
8.1.9 The TRACE function..........................................................1495
8.1.10 The COMPILE function.....................................................1497
8.1.11 The EDIT function .............................................................1498
8.1.12 Diagnostic functions .........................................................1501
8.1.13 Bus diagnosis....................................................................1502
8.2 PLC Compiler.................................................................................1509
8.2.1 Configuration file for the PLC compiler.............................1509
8.2.2 Conditional compilation.....................................................1514
8.3 Configuring PLC Input/Output Systems.....................................1516
8.4 Operands........................................................................................1518
8.4.1 Overview of operands.......................................................1518
8.4.2 Operand addressing (byte, word, double word)................1521
8.4.3 Timers and counters ........................................................1522
8.4.4 Fast PLC inputs.................................................................1532
8.5 Data Organization.........................................................................1534
8.5.1 Data organization on the CFR memory card .....................1534
8.5.2 Data organization on the hard disk....................................1536
8.5.3 Compressing graphic files.................................................1537
8.5.4 Configuring the displayed drives and directories in
the file manager................................................................1538
8.5.5 PLC system files ...............................................................1540
8.6 M Functions (M Strobe)................................................................1548
8.6.1 Assigning M functions to the machining channels ...........1548
8.6.2 Configuration of M functions ............................................1549
8.6.3 Overview of M functions of the MANUALplus 620..........1558
8.7 S Function (S Strobe) ...................................................................1560
8.7.1 Assigning S functions to the machining channels ............1560
8.7.2 Configuration of S function ...............................................1561
8.8 T Functions (T Strobe)..................................................................1574
8.8.1 Assigning T functions to the machining channels.............1574
8.8.2 Configuration of T functions..............................................1575
8.9 Alias Functions (Alias Strobe).....................................................1582
8.9.1 Assigning alias functions to the machining channels........1582
8.9.2 Configuration of alias functions.........................................1583
8.10 Python Settings (Option 46) ........................................................1585
8.11 User-Defined Cycles......................................................................1588

14 HEIDENHAIN Technical Manual MANUALplus 620
8.12 Tables.............................................................................................1589
8.12.1 Table types of the MANUALplus 620 ...............................1590
8.12.2 Creating a new table type.................................................1593
8.12.3 Defining the path for OEM tables.....................................1605
8.12.4 Symbolic names for tables................................................1605
8.12.5 Editing tables via the PLC ................................................1606
8.12.6 Access to tables via SQL commands ...............................1621
8.12.7 PLC modules for the SQL statements..............................1635
8.13 Data Transfer NC => PLC, PLC => NC..........................................1654
8.13.1 Introduction.......................................................................1654
8.13.2 Data transfer NC program => PLC ...................................1654
8.13.3 Data transfer machine parameters => PLC......................1657
8.14 Program Creation..........................................................................1659
8.14.1 ASCII editor.......................................................................1659
8.14.2 Program format.................................................................1659
8.14.3 Program structure.............................................................1660
8.15 Command Set................................................................................1661
8.15.1 Overview...........................................................................1661
8.15.2 LOAD (L) ...........................................................................1664
8.15.3 LOAD NOT (LN) ................................................................1666
8.15.4 LOAD TWO’S COMPLEMENT (L–)...................................1668
8.15.5 LOAD BYTE (LB)...............................................................1669
8.15.6 LOAD WORD (LW) ...........................................................1669
8.15.7 LOAD DOUBLE WORD (LD).............................................1670
8.15.8 ASSIGN (=)........................................................................1670
8.15.9 ASSIGN BYTE (B=) ...........................................................1671
8.15.10 ASSIGN WORD (W=)........................................................1672
8.15.11 ASSIGN DOUBLE WORD (D=).........................................1672
8.15.12 ASSIGN NOT (=N).............................................................1673
8.15.13 ASSIGN TWO’S COMPLEMENT (=–)...............................1673
8.15.14 SET (S) ..............................................................................1674
8.15.15 RESET (R)..........................................................................1675
8.15.16 SET NOT (SN) ...................................................................1676
8.15.17 RESET NOT (RN)...............................................................1677
8.15.18 AND (A).............................................................................1678
8.15.19 AND NOT (AN)..................................................................1680
8.15.20 OR (O)...............................................................................1682
8.15.21 OR NOT (ON)....................................................................1684
8.15.22 EXCLUSIVE OR (XO).........................................................1686
8.15.23 EXCLUSIVE OR NOT (XON)..............................................1688
8.15.24 ADDITION (+)....................................................................1690
8.15.25 SUBTRACTION (–) ............................................................1691
8.15.26 MULTIPLICATION (X) .......................................................1692
8.15.27 DIVISION (/).......................................................................1693
8.15.28 REMAINDER (MOD).........................................................1694
8.15.29 INCREMENT (INC) ............................................................1695
8.15.30 DECREMENT (DEC)..........................................................1695
8.15.31 EQUAL TO (==) ................................................................1696
8.15.32 LESS THAN (<) .................................................................1697
8.15.33 GREATER THAN (>)..........................................................1698
8.15.34 LESS THAN OR EQUAL TO (<=)......................................1699
8.15.35 GREATER THAN OR EQUAL TO (>=) ..............................1700
8.15.36 NOT EQUAL (<>)..............................................................1701

January 2012 15
8.15.37 AND [ ] (A[ ])......................................................................1702
8.15.38 AND NOT [ ] (AN[ ])...........................................................1704
8.15.39 OR [ ] (O[ ])........................................................................1704
8.15.40 OR NOT [ ] (ON[ ]).............................................................1704
8.15.41 EXCLUSIVE OR [ ] (XO[ ])..................................................1704
8.15.42 EXCLUSIVE OR NOT [ ] (XON[ ]).......................................1704
8.15.43 ADDITION [ ] (+[ ]).............................................................1705
8.15.44 SUBTRACT [ ] (–[ ])............................................................1706
8.15.45 MULTIPLY [ ] (x[ ]).............................................................1706
8.15.46 DIVIDE [ ] (/[ ]) ...................................................................1706
8.15.47 REMAINDER [ ] (MOD[ ])..................................................1706
8.15.48 EQUAL TO [ ] (==[ ]) .........................................................1707
8.15.49 LESS THAN [ ] (<[ ]) ..........................................................1708
8.15.50 GREATER THAN [ ] (>[ ])...................................................1708
8.15.51 LESS THAN OR EQUAL TO [ ] (<=[ ]) ...............................1708
8.15.52 GREATER THAN OR EQUAL TO [ ] (>=[ ]) .......................1708
8.15.53 NOT EQUAL [ ] (<>[ ]).......................................................1708
8.15.54 SHIFT LEFT (<<) ...............................................................1709
8.15.55 SHIFT RIGHT (>>).............................................................1710
8.15.56 BIT SET (BS)......................................................................1710
8.15.57 BIT CLEAR (BC) ................................................................1711
8.15.58 BIT TEST (BT)....................................................................1712
8.15.59 PUSH DATA ONTO THE DATA STACK (PS).....................1713
8.15.60 PULL DATA FROM THE DATA STACK (PL)......................1714
8.15.61 PUSH LOGIC ACCUMULATOR ONTO THE
DATA STACK (PSL)...........................................................1714
8.15.62 PUSH WORD ACCUMULATOR ONTO THE
DATA STACK (PSW) .........................................................1715
8.15.63 PULL LOGIC ACCUMULATOR FROM THE
DATA STACK (PLL) ...........................................................1715
8.15.64 PULL WORD ACCUMULATOR FROM THE
DATA STACK (PLW)..........................................................1716
8.15.65 UNCONDITIONAL JUMP (JP)...........................................1716
8.15.66 JUMP IF LOGIC ACCUMULATOR = 1 (JPT) ....................1717
8.15.67 JUMP IF LOGIC ACCUMULATOR = 0 (JPF) ....................1718
8.15.68 CALL MODULE (CM)........................................................1718
8.15.69 CALL MODULE IF LOGIC ACCUMULATOR = 1 (CMT) ...1718
8.15.70 CALL MODULE IF LOGIC ACCUMULATOR = 0 (CMF) ...1719
8.15.71 END OF MODULE, END OF PROGRAM (EM) .................1720
8.15.72
END OF MODULE IF LOGIC ACCUMULATOR = 1 (EMT) ... 1720
8.15.73
END OF MODULE IF LOGIC ACCUMULATOR = 0 (EMF) ... 1720
8.15.74 LABEL (LBL)......................................................................1720
8.16 INDEX Register (X Register).........................................................1721
8.17 Commands for String Processing................................................1723
8.18 LOAD String (L) .............................................................................1725
8.19 ADD String (+) ...............................................................................1725
8.20 STORE String (=) ...........................................................................1725
8.21 OVERWRITE String (OVWR) ........................................................1726
8.22 EQUAL TO Command for String Processing (==) ......................1727
8.23 LESS THAN Command for String Processing (<).......................1727
8.24 GREATER THAN Command for String Processing (>)...............1727

16 HEIDENHAIN Technical Manual MANUALplus 620
8.25 LESS THAN OR EQUAL TO Command for
String Processing (<=) ..................................................................1728
8.26 GREATER THAN OR EQUAL TO Command for
String Processing (>=) ..................................................................1728
8.27 NOT EQUAL Command for String Processing (<>)....................1729
8.28 Modules for string processing.....................................................1730
8.29 Submit Programs..........................................................................1733
8.30 Calling the Submit Program (SUBM)..........................................1734
8.31 Interrogating the Status of a Submit Program (RPLY)..............1734
8.32 Canceling a Submit Program (CAN)............................................1735
8.33 Cooperative Multitasking.............................................................1737
8.33.1 Starting a parallel process (SPAWN).................................1737
8.33.2 Control of events ..............................................................1737
8.34 Constants Field (KF)......................................................................1744
8.35 Program Structures ......................................................................1745
8.35.1 IF ... ELSE ... ENDI structure.............................................1746
8.35.2 REPEAT ... UNTIL structure..............................................1746
8.35.3 WHILE ... ENDW structure ...............................................1747
8.36 CASE Branch..................................................................................1748
8.37 Linking Files...................................................................................1749
8.38 USES Statement (USES)..............................................................1750
8.39 GLOBAL Statement (GLOBAL) ....................................................1751
8.40 EXTERN Statement (EXTERN).....................................................1751
8.41 PLC Modules..................................................................................1752
8.41.1 Markers, bytes, words, and double words .......................1752
8.41.2 Number conversion...........................................................1755

January 2012 17
9 Data Interfaces......................................1759
9.1 Introduction...................................................................................1759
9.2 The Ethernet Interface..................................................................1760
9.3 HSCI interface................................................................................1761
9.4 The USB Interface of the Control (USB 2.0) ...............................1763
9.5 The Serial Interface of the Control ..............................................1766
9.5.1 RS-232-C/V.24 interface....................................................1766
9.5.2 RS-422/V.11 interface .......................................................1769
9.6 Configuring the Serial Interface...................................................1771
9.6.1 Control characters.............................................................1771
9.6.2 Configuration of interfaces................................................1772
9.7 Data Transmission Protocols .......................................................1783
9.7.1 Standard communications protocol ..................................1783
9.7.2 Communications protocol with block check character .....1785
9.7.3 LSV2 transmission protocol ..............................................1788
9.8 Saving and Loading Files .............................................................1789
9.9 Configuring the Control for TeleService 2.0 ...............................1790
9.10 The Transfer Mode of Operation .................................................1793
9.10.1 Selective parameter backup..............................................1794
9.11 Data Transfer by PLC ....................................................................1795
9.11.1 PLC modules.....................................................................1795
10 Index ......................................................1807

18 HEIDENHAIN Technical Manual MANUALplus 620

January 2012 1.2 NC Software 548 328-02 19
1 Update Information No. 1
1.1 Overview
1.2 NC Software 548 328-02
1.2.1 Important notes on updating software
Please remember the following important information when updating the
software versions listed below:
MANUALplus 620: 548 328-01 to 548 328-02
Moving the EnDat axes to known positions before the update:
A function for monitoring the SRAM contents for consistency is introduced
with the new NC software. After the software update, all EnDat axes will
therefore display the error message S-RAM contents of axis are invalid.
At the same time, the control will display a dialog box for confirmation, in
which the current (the displayed) position of the axis is compared with the
physical (switch-off) position.
Move the axes to known positions before the update.
Write down the switch-off positions.
After the control has booted with the new software for the first time,
confirm the positions of the EnDat axes.
Note
If you are using linear encoders with EnDat interface or motor encoders
with EnDat interface for position measurement on your machine, you must
carry out the following step.
Note
HEIDENHAIN recommends:
Making a backup of the control (e.g. with TNCbackup) before updating the
NC software.
Saving your current machine configuration. The configuration editor (DATA
BACKUP soft key) can be used for this purpose.
If you later want to undo the software update and return to the previous
software version, you need the saved configuration data of the old version!
Note
Please perform the update of the NC software as described in the Technical
Manual in Chapter 2 "NC Software Exchange".
Note
Be sure to remember the important information about the software update,
which is provided on the following pages.

20 HEIDENHAIN Technical Manual MANUALplus 620
Checking and saving new machine parameters:
After having installed the new NC software and rebooted the control, you
must check and confirm the new machine parameters. The code number
dialog box appears on the screen:
Enter the MP code number 95148 and confirm your entry with the ENT key.
Press the UPDATE RULES soft key.
Check the listed update rules. Each entry in the list stands for a new
parameter that was added to the system by the update.
Exit the UPDATE RULES with the END soft key.
Press the CONFIG DATA soft key.
Before the configuration editor opens, an informational window is displayed,
reporting the removal of the CfgRestorePosition machine parameter. Press
the NEXT soft key.
All new machine parameters are marked with a red exclamation point in the
configuration editor. The control indicates if certain machine parameters are
faulty. Please ignore these messages for the time being.
Important step: Press the SAVE soft key
The Configuration data changed dialog box opens. Press the SAVE soft key
again. The new machine parameters are now automatically saved in the
*.cfg files.
Press the END soft key and exit the Machine Parameter operating mode by
pressing the END soft key again.
The control then continues booting.
Note
The definition file of the symbolic programming interface API 3.0 has been
expanded. The step described below must be taken for the PLC program
to be compiled successfully after the update.